Calculator
Example data table
| Project | Pattern | Run length | Joints | Sides | Weld model | Size | Estimated weld length | Estimated weight |
|---|---|---|---|---|---|---|---|---|
| Trellis frame corners | Continuous | 60 cm | 8 | Both | Fillet (equal) | 4 mm | 9.60 m | 0.60 kg |
| Raised bed brackets | Stitch | 40 cm | 12 | One | Fillet (unequal) | 4×3 mm | 1.80 m | 0.09 kg |
| Gate latch repair | Continuous | 80 mm | 2 | One | Groove (square) | 3×4 mm | 0.16 m | 0.01 kg |
Formula used
- Continuous: L_effective = L_run
- Stitch: L_effective = (floor(L_run / P) × L_stitch) + min(L_stitch, remainder)
- Total: L_total = L_effective × joints × sides
- Fillet equal legs: A = 0.5 × a²
- Fillet unequal legs: A = 0.5 × a × b
- Square groove: A ≈ thickness × bead_width
- Custom: A = user input (mm²)
- V = A × L_total × passes
- W_net = V × density and W = W_net × (1 + allowance%)
- Arc_minutes = (L_total / travel_speed) × passes
- Total_minutes = Arc_minutes + (setup_per_joint × joints)
- Cost = (W × filler_cost) + (hours × labor_rate) + overhead%
How to use this calculator
- Pick your input length unit for all measurements.
- Set run length and how many joints repeat that seam.
- Choose continuous or stitch weld pattern for your build.
- Select a weld model that matches your joint geometry.
- Enter passes, travel speed, and setup time estimates.
- Add allowance and costs to estimate total spend quickly.
- Press Calculate, then export CSV or PDF if needed.
Weld length planning for garden metalwork
Garden frames, trellises, gates, and raised-bed supports often fail first at joints. Estimating weld length before cutting steel helps you size consumables, schedule work, and avoid rushed tack-ups that crack after weather cycles. Measure the weld run on one side, then scale by joint count and sides welded. For repeat builds, save your inputs, compare variants, and confirm that the calculated weld length matches your cut list before striking an arc outdoors in cold weather.
Continuous versus stitch seams
Continuous welds maximize stiffness and sealing, useful for load paths and thin tubing where movement is unwanted. Stitch welds reduce heat input and distortion, ideal for long runs on light sections. The calculator converts stitch length and pitch into an effective welded distance.
Reading weight and allowance outputs
Weld metal weight is derived from cross‑section area, total length, and number of passes, then adjusted with an allowance. The allowance covers starts, stops, spatter, and occasional rework. For outdoor garden builds, a 5–15% range is common when fit-up is good. Choose the weld model that best matches your joint: fillet for angles, groove for butt seams, or a custom area.
Using time estimates to plan sessions
Arc time is based on travel speed, while setup time captures clamping, squaring, cleaning, and repositioning. Splitting a project into short sessions can improve accuracy: complete all similar joints together, then grind and paint as a batch. This reduces tool changes and keeps measurements consistent.
Cost notes for small fabrication jobs
The cost section combines filler use and labor, then adds overhead for power and consumables. If you are comparing designs, keep rates fixed and change only geometry. You can quickly see how doubling sides, increasing passes, or switching to stitch welds affects budget and total time.
FAQs
1) What should I enter for travel speed?
Use a realistic welding travel speed for your process and position. If you do not know it, time a short test bead and convert length per minute. Faster speeds reduce arc time but can reduce bead size.
2) How do I choose one side or both sides welded?
Select one side for typical fillet joints on brackets and tabs. Choose both sides when you will weld both faces of the joint for strength or symmetry. Both sides doubles the total weld length.
3) Does weld metal weight equal filler wire weight?
It is an estimate of deposited weld metal, based on joint area and length. Actual wire use can be higher due to spatter and inefficiency. The allowance percentage helps bridge that gap for practical planning.
4) Why is stitch weld length lower than the run length?
Stitch welds are discontinuous. The tool calculates how many stitches fit along the run based on pitch, then multiplies by stitch length. The gaps between stitches are not welded, so effective length is lower.
5) Can I work in inches or feet?
Yes. Pick inches or feet as the input unit and enter all geometry in that unit. The calculator converts internally, then reports total weld length in feet for imperial inputs, and meters for metric inputs.
6) What allowance percent is sensible for garden work?
For clean fit-up on new steel, 5–10% is often enough. For rusty repairs, awkward positions, or many restarts, use 10–15%. If you are learning, start higher and refine after a few projects.