How much does it cost · welding
Short answer: the cost of a weld is calculated from the mass of metal to deposit. Divided by the deposition rate of the process, it gives the arc time; divided by the duty cycle, that time becomes the welder’s real time. In semi-automatic MIG/MAG, the arc is on only about 45% of the time (source: TWI, 10 June 2016): that is why labour makes most of the price.
By the RFQdecoder team · updated 27 September 2026
For an equal-leg fillet weld with leg z, the theoretical cross-section is z² ÷ 2, without reinforcement.
| Process | Typical | Range |
|---|---|---|
| Stick electrode (MMA) | about 25% | 15 to 40% |
| Semi-automatic MIG/MAG | about 45% | 15 to 60% |
| Automatic MIG/MAG | about 90% | 50 to 100% |
| Semi-automatic flux-cored (FCAW) | about 40% | 15 to 55% |
| Mechanised submerged arc (SAW) | about 40% | 40 to 90% |
Source: TWI, “What typical duty cycles are achieved when arc welding?”, 10 June 2016. The duty cycle is the share of time during which the arc is on.
| Process | Deposition rate | Consumption factor |
|---|---|---|
| Stick electrode (MMA) | 0.4 to 5.5 kg/h | 1.5 |
| MAG solid wire | 0.6 to 12 kg/h | 1.05 |
| Flux-cored (FCAW) | 1 to 15 kg/h | 1.2 |
| Submerged arc, single wire | 3 to 16 kg/h | 1.02 |
| TIG | 1.1 |
Deposition rates: TWI, Job Knowledge 97, 20 October 2015. Consumption factor (metal bought ÷ metal deposited): TWI, Job Knowledge 96, 20 October 2015.
Example values: 4 mm fillet weld over 2 m, steel, semi-automatic MAG at 2 kg/h deposition, 45% duty cycle, welder at €60/h, wire at €3/kg.
| Item | Calculation | Result |
|---|---|---|
| Weld cross-section | 4 × 4 ÷ 2 | 8 mm² |
| Deposited metal per metre | 8 mm² × 1 m × 7.85 g/cm³ | 62.8 g/m |
| Deposited metal | × 2 m | 126 g |
| Arc time | 126 g ÷ 2 kg/h | 3.77 min |
| Welder time | 3.77 min ÷ 45% | 8.37 min |
| Labour | 8.37 min × €60/h | €8.37 |
| Wire | 126 g × 1.05 = 132 g × €3/kg | €0.40 |
In this example, labour is about 95% of the cost of the weld, excluding gas and energy. Saving on preparation, positioning and rework pays far more than saving on wire.
Travail-Industrie (in French) publishes a day rate of €180 to €450 excl. VAT for a qualified freelance welder in France, and €200 to €350 in steel construction and heavy industry (accessed 27 September 2026). A shop hourly rate adds the welding station, gas, energy and overheads: see the machine hour rate calculator.
Start from the weld length and its cross-section: that gives the mass of metal to deposit. Divided by the deposition rate of the process, it gives the arc time. Divided by the duty cycle, it gives the welder’s real time, which is multiplied by the hourly rate. Then add wire, gas and energy.
It is the share of time during which the arc is actually on. TWI puts it around 45% for semi-automatic MIG/MAG and 25% for stick welding: the rest of the time goes to preparing, positioning, removing slag or changing electrodes.
TWI gives 0.6 to 12 kg of weld metal per hour for MAG, 0.4 to 5.5 kg/h for stick electrodes and 1 to 15 kg/h for flux-cored wire, depending on diameter, current and position.
Because weld metal is cheap per kilo, while the welder spends more time preparing than welding. In the example on this page, labour is about 95% of the cost of the weld.
Travail-Industrie publishes a day rate of €180 to €450 excl. VAT for a qualified freelance welder in France, and €200 to €350 in steel construction and heavy industry.
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