Welding Cost Calculator — Arc Time, Labor & Consumables
Who this is for: For fabrication shops and mobile welders quoting by the job — especially the ones who quote by feel and discover the truth at invoice time.
Weld length, travel speed and shop rate in — get arc time, labor, consumables and the price for the run.
Quick answer: Welding price = (length ÷ travel speed) arc time × shop rate + setup + consumables. A 60-inch MIG run at 18 IPM = 3.3 arc-min; +20 min setup at $60/h = $23.30 labor + $7.20 filler/gas ≈ $30.53. Quote finishing separately. The calculator splits every line.
Fit, clamp, tack
| Arc time | Length ÷ travel speed (MIG 15–25 IPM) |
|---|---|
| Welder rate | $45–85/h shop · $75–150 mobile call |
| Consumables | MIG ≈ $0.07–0.20/in · TIG SS $0.30+/in |
| Example | 60" @ 18 IPM + 20 min setup = $30.53 |
| Rule | Setup & finishing are separate lines |
| Status | Quotes use standard shop math: machine-hour rate × cycle time + materials + setup amortization. SFM/chipload figures are conservative HSS starting points (carbide runs 3–4× SFM). Compiled September 2026 — estimates for budgeting; real quotes come from the shop that runs the job. |
How do you price welding work?
Arc time drives it: weld length ÷ travel speed = minutes under the arc. Manual MIG on carbon steel travels 15–25 IPM on typical joints; TIG runs slower (5–12 IPM). Arc time ÷ 60 × shop rate ($45–85/h for welders) is the labor line; filler wire and shielding gas add $0.07–0.30 per inch depending on joint and process; setup (fitting, clamping, positioning) is charged like any machining setup. Example: a 60-inch run at 18 IPM = 3.3 arc minutes + 20 min setup at $60/h = $23.30 labor + $7.20 consumables ≈ $30.53 — and that's before grinding, inspection and the markup that keeps the lights on.
Common uses
- Quoting bracket and frame welds by the run
- Comparing MIG vs TIG cost on the same joint
- Checking a mobile-welding minimum call against real time
- Teaching apprentices why 'it's just a quick bead' isn't