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Weld consumable weight calculator

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Free tool · Welding

Weld consumable weight calculator

Enter joint type, thickness, angle, root gap and weld length; cross-section area, weld metal weight and the electrode/wire needed at the given efficiency are calculated instantly. Everything runs in your browser.

Also available in: Türkçe · العربية

Cross-section area– mm²
Weld metal– kg
Electrode / wire needed– kg

V: A = (t−f)² × tan(α/2) + g × t + cap · X: A = 2 × ((t−f)/2)² × tan(α/2) + g × t + 2 caps · Fillet: A = z²/2 + cap · Cap ≈ 2/3 × face width × h · Weight = A × L × ρ · Consumable = weight ÷ efficiency

Deposition efficiency is the share of purchased consumable that ends up in the weld (stub ends, spatter, slag, cutting losses). Values are typical ranges; if you have your own measurement, overwrite the field. The result is the net quantity for the weld only; add a waste allowance for stock.

For information only; the WPS, the drawing and supplier data govern. The final assessment rests with the responsible welding engineer.

Let the app keep your welding recordsThe Welding module offers WPS checks, welder qualification tracking, inspection records and PDF reports for your audit file.
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Curious?

Why is the cap (reinforcement) included?The weld face finishes slightly above the plate surface and that excess is weld metal too. A 1–3 mm cap can be 10–20 % of the total weight on thick plate, so leaving it out understates consumption.
Where do the efficiency values come from?From the typical deposition efficiency ranges published by consumable manufacturers: 60–70 % for stick electrodes because of stub ends and slag, 90–97 % for solid wire, 80–90 % for flux-cored wire and close to 99 % for submerged arc. If your specification or supplier gives another value, change the field.
Does this work for multi-pass welds?Yes; the cross-section area does not depend on the number of passes. If there is interpass grinding or back gouging, the removed metal is deposited again; adding 5–10 % for back gouging on X grooves is common.
How do I get kg per metre?Enter a weld length of 1 m; the weight shown is then kg/m. Quotes and stock plans use this value as a multiplier. The ERP side of the app links this calculation to the work order and deducts it from stock.