Welding Cost Calculator — Electrode, Labour & Power
Estimate total welding cost from filler/electrode consumption, arc-on time, labour rate, machine power draw, and shielding gas — get an instant cost breakup.
Calculator
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Electrode/filler cost: ₹1125.00
Labour cost: ₹1200.00
Power cost: ₹194.40
Gas cost: ₹3888.00
Total welding cost: ₹7048.14
Formula
Electrode Cost = Filler Metal Required (kg) × Filler Cost (₹/kg). Labour Cost = Arc-on Time (hr) × Labour Rate (₹/hr). Power Cost = Machine Rating (kW) × Duty Cycle (%) × Arc-on Time (hr) × Electricity Rate (₹/kWh). Gas Cost = Gas Flow Rate (L/min) × Arc-on Time (min) × Gas Cost (₹/L). Total Welding Cost = (Electrode + Labour + Power + Gas Cost) × (1 + Overhead %).
Example calculation
A fabrication job uses 2.5 kg of filler wire at ₹450/kg, 6 hours of arc-on time at a fully-loaded welder rate of ₹200/hr, a 6 kW welding machine at 60% duty cycle on ₹9/kWh power, and 12 L/min of shielding gas at ₹0.9/L, with 10% overhead: Electrode = 2.5×450 = ₹1,125. Labour = 6×200 = ₹1,200. Power = 6×0.6×6×9 = ₹194.4. Gas = 12×(6×60)×0.9 = ₹3,888. Subtotal = ₹6,407.4 → with 10% overhead ≈ ₹7,048.
Engineering notes
Arc-on time is not the same as total job time — factor in fit-up, grinding, positioning, and inspection separately when quoting a full fabrication job rather than just the weld itself; arc-on time is typically only 20–40% of a welder's total shift on complex fabrication work. Duty cycle matters for power cost because a welding machine draws its rated current only while actually striking an arc, not for the full arc-on session — a 60% duty cycle means the machine draws power roughly 60% of the arc-on time, the rest being positioning between passes. Shielding gas consumption varies significantly by process (MIG/MAG typically 10–20 L/min, TIG typically 5–15 L/min) and joint accessibility — always confirm the process before estimating gas cost. For AMC or fabrication contract quoting, add a consumables allowance (grinding discs, wire brushes, PPE) on top of this cost as a percentage overhead.
When to use this calculator
- Quoting fabrication or structural welding jobs before submitting a tender or proposal
- Estimating AMC/repair welding cost for plant maintenance budgeting
- Comparing MIG vs TIG vs stick welding cost for a given job based on consumable and labour differences
- Sanity-checking a fabrication contractor's quote by rebuilding the cost bottom-up
Frequently asked questions
- How do you calculate welding cost?
- Total Welding Cost = Electrode/Filler Cost + Labour Cost + Power Cost + Shielding Gas Cost, then add an overhead percentage for consumables (grinding discs, PPE) and margin. Electrode cost = kg of filler used × cost per kg. Labour cost = arc-on hours × fully-loaded hourly rate. Power cost = machine kW rating × duty cycle × hours × electricity rate.
- What is duty cycle in welding cost calculation?
- Duty cycle is the percentage of a time period a welding machine can operate at its rated output before it needs to cool. A 60% duty cycle at 10 minutes means the machine welds for 6 minutes and rests for 4 in every 10-minute cycle. For cost calculation, multiply machine kW rating by duty cycle (not 100%) to avoid overstating actual power draw during arc-on time.
- How much filler/electrode does a welding job typically use?
- Consumption depends on weld size, joint type, and process — as a rough planning figure, MIG/MAG welding typically deposits 1.5–3 kg of wire per hour of arc-on time at typical industrial settings, while stick (SMAW) electrode consumption is usually estimated per linear metre of weld and joint volume. Always get an actual consumption rate from the WPS (Welding Procedure Specification) or a trial run for accurate quoting.
- What is arc-on time vs total welding job time?
- Arc-on time is only the duration the arc is actually struck and metal is being deposited. Total job time also includes fit-up, tack welding, repositioning, grinding, and inspection — arc-on time is often just 20–40% of a welder's total shift on complex fabrication work. Cost estimates based only on arc-on time will understate true job cost unless fit-up/finishing labour is added separately.
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