Welding Cost Calculator
Job inputs
Fields start empty. Enter your own values, or load the worked example to see how it works.
Each pass travels the full weld length.
Clock hours for the crew.
Clock hours for the crew.
Advanced options: welders, other costs, overhead, markup
Assumes welding work can be divided evenly among workers. All entered welders are assumed to be on the clock during setup and cleanup.
Markup, not profit margin. 25% markup = 20% margin.
Enter your values (or load an example) to see results. Fix any highlighted inputs.
How to read the result
- Arc time is the time the arc is actually running: total weld travel divided by travel speed. It assumes continuous welding at your travel speed.
- Total job time is elapsed clock time: arc time shared across welders, plus setup and cleanup.
- Labor hours are paid person-hours: total job time × number of welders.
- Job cost is labor + consumables + gas + other costs + overhead. It is your cost, before markup.
- Quote appears only when you enter a markup. It is job cost plus markup.
Real jobs include time the arc isn't running: repositioning, changing rod or wire, chipping slag, inspection. This calculator does not add a hidden factor for that. Put that time into setup or cleanup so you can see it.
Formula
Total weld travel = weld length × passes
Arc time (h) = total weld travel ÷ travel speed ÷ 60
(length converted to in or mm to match speed per minute)
Job time (h) = arc time ÷ welders + setup time + cleanup time
Labor hours = job time × welders
Labor cost = job time × labor rate × welders
Direct cost = labor cost + consumables + gas + other costs
Overhead = direct cost × overhead %
Job cost = direct cost + overhead
Cost per ft (m) = job cost ÷ weld length (joint length, not × passes)
Quote = job cost × (1 + markup %)
Profit = quote − job cost
Margin = profit ÷ quote
= markup % ÷ (1 + markup %)Welder count is applied once. The calculator assumes welding work can be divided evenly among workers, so more welders shorten elapsed arc time but the total arc labor-hours stay the same. All entered welders are assumed to be on the clock during setup and cleanup.
Markup vs. profit margin
Markup is a percentage of cost. Margin is a percentage of the selling price. A 25% markup on $100 of cost gives a $125 quote and $25 profit. That profit is 20% of the quote, so the margin is 20% (0.25 ÷ 1.25). This calculator asks for markup and shows the matching margin.
Worked example
50 ft of joint, 2 passes, 10 in/min, 2 h setup, 1 h cleanup, 1 welder at $45/h, $40 consumables, $25 gas, 15% overhead, 25% markup.
Weld travel = 50 ft × 12 × 2 = 1,200 in Arc time = 1,200 ÷ 10 ÷ 60 = 2 h Job time = 2 + 2 + 1 = 5 h Labor cost = 5 × $45 × 1 = $225 Direct cost = 225 + 40 + 25 = $290 Overhead = 290 × 0.15 = $43.50 Job cost = $333.50 → shown as $334 Quote = 333.50 × 1.25 = $416.88 → shown as $417 (20% margin)