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Thread: How many inches of weld per roll of wire?

  1. #1
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    How many inches of weld per roll of wire?

    So speaking of the licncoln 71 elite outer shield, how many inches or feet of weld could I expect to get from one roll of .045 wire? Assuming I'm running single pass 5/16 filet welds

    Im trying to calculate how many rolls I'll need for a large upcoming job.

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    Re: How many inches of weld per roll of wire?

    I calculated I'll need to do 6,500 ft of 5/16 filet weld


    That's crazy, over a mile

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    Re: How many inches of weld per roll of wire?

    The manufacturers typically put pounds or percentage of wire used.
    I calculated the amount of weld then weight weld. Then use the percentage given.

    Do what I did made chart with 3/16, 1/4" , 3/8" , 1/2" & 3/4" filet welds.

    Dave

    Quote Originally Posted by MetalMan23 View Post
    So speaking of the licncoln 71 elite outer shield, how many inches or feet of weld could I expect to get from one roll of .045 wire? Assuming I'm running single pass 5/16 filet welds

    Im trying to calculate how many rolls I'll need for a large upcoming job.

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    Re: How many inches of weld per roll of wire?

    I bet Dave has a calculator handy for that. There is even time calc for it. Real good jobber/supplier could help. Might be time for another machine or 2? These kind of things interest me a little,,, details available? Seems I saw something from Lincoln had chart for material and time???
    Last edited by Sberry; 08-10-2022 at 09:32 AM.

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    Re: How many inches of weld per roll of wire?

    I'm pricing a large job, it's a bunch of w10x12 I- beams fabricated, almost 800 parts need to be made with about 100 inches of weld each




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    Re: How many inches of weld per roll of wire?

    The wire sold by pound.

    This may help for 5/16 filet welded 0.6 inch³ per foot of welded.
    Weight of steel per 1³: is 0.2833 pound.
    So your weld weight is 0.6 x 0.2833 =0.16998 pound per foot of weld.

    But there was and fluxcore is about 85% metal the rest is slag.

    Best to say 70% for wire
    0.16998 pound ÷ 70%= amount of wire need for the job is per foot of welded need is 0.24 pounds.

    So your can with 30 pound roll will welded 125 feet.
    Typically I would get more than 125 feet but for pricing it safer.

    Dave

    Quote Originally Posted by MetalMan23 View Post
    I calculated I'll need to do 6,500 ft of 5/16 filet weld


    That's crazy, over a mile

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    Re: How many inches of weld per roll of wire?

    In the shop then? I dont remember what power supply you had? From the line and machines?

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    Re: How many inches of weld per roll of wire?

    I'll definitely be getting at least one more welder, if not 2 to get the job done

    I have the esab mm280



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    Re: How many inches of weld per roll of wire?

    Could simply figure it a 4 ft # for estimation then. n 1500, maybe 1600# This might be tempting to look at motor drive?

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    Re: How many inches of weld per roll of wire?

    So I would need 52 rolls of wire, only $9,500 not bad

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    Re: How many inches of weld per roll of wire?

    Quote Originally Posted by MetalMan23 View Post
    I calculated I'll need to do 6,500 ft of 5/16 filet weld


    That's crazy, over a mile

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    Are you using a 33lb spool, or 60lb coil?
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    Re: How many inches of weld per roll of wire?

    Quote Originally Posted by Oscar View Post
    Are you using a 33lb spool, or 60lb coil?
    Probably 30lb spool

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    Re: How many inches of weld per roll of wire?

    Sounds like a lot if wire need.
    8 foot of welded timed 800 parts
    6,400 feet x 0.24 pounds or 1,536 pounds of wire need, 51 rolls need if using 30 pound rolls

    Dave

    Quote Originally Posted by MetalMan23 View Post
    I'm pricing a large job, it's a bunch of w10x12 I- beams fabricated, almost 800 parts need to be made with about 100 inches of weld each




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    Re: How many inches of weld per roll of wire?

    But then again I've never welded this much before, if there's a better way, or better equipment to get it done, I'm all ears, I was thinking of buying another 300amp mig welder and having 2 guys welding full time, anything wrong with that idea?



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    Re: How many inches of weld per roll of wire?

    Might be better to have a guy doing all the cutting fit up and another guy welding continuously? Production line style.
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    Re: How many inches of weld per roll of wire?

    Quote Originally Posted by Roert42 View Post
    Might be better to have a guy doing all the cutting fit up and another guy welding continuously? Production line style.
    I was thinking 2 guys welding, and 2 helpers

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    Re: How many inches of weld per roll of wire?

    Might be able to work 1 helper for 2 machines too. Have Dave help u calc the time too. I know you are expert builder but this is about production and often 2 different things, the handling is going to be as big a deal as the welding. What line power do you have? This can effect the new machine as power supply and equipment for 3 ph can be had. Scott V has used all this stuff and could guide to an economical model inverter. Do you do the cutting or they come ready?

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  21. #18
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    Re: How many inches of weld per roll of wire?

    The 10 large for the wire doesnt sound like a terrible deal. I dont know anything about the wire at all, what kind of current range we gonna need on the top end, this obviously be flat so a guy can turner up.

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    Re: How many inches of weld per roll of wire?

    a couple helpers for sure. Some of this might depend on the shop, is there room to stage 2 stations and keep weld continious while fitting and removing finished pieces? You need to do the rest of the work while the welding is going on. The work u do now has production aspect but this might be a little different with so much material.

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    Re: How many inches of weld per roll of wire?

    Phil, if you are buying a new welder, I would consider the new Millermatic 355 if you don't go with a separate power supply and a feeder. I love the display on that welder. Having pulse will give you the ability to run metal core wires out of position. If your on a budget, you can probably find the older 350P machines on the cheap.

    But on the other hand an XMT350 with a separate feeder will give you more flexibility (i.e., you can do stuff like carbon arc gouging with it), but will run you more money I think.
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    Re: How many inches of weld per roll of wire?

    According to Lincoln, it's a 33lb spool instead of 30lb, and if you use their 87% efficiency it comes out to ~39 rolls, not 52 (168 linear feet of weld per 33lb spool). Might want a few extra rolls of course, but I don't think Lincoln's specs/stats are off, seeing as how they are a premier supplier of filler metal. Is that the only wire that is spec'd out to use? Can you switch to a metal-core wire? You can get near 97% efficiency, and the deposition rate is approx 16 lb/hr vs 11.4 lb/hr of the OuterShield Elite. 35 rolls metal-core vs 39 of Outershield Elite, 70 hrs of welding with metal core vs 101 hours with OuterShield Elite. No post-welding slag removal, just small silica islands here and there. The main drawback is metal-core is flat/horizontal only, unless you have a pulsed-spray capable power source to be able to go out-of-position.
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    Re: How many inches of weld per roll of wire?

    Well if I land this job, I will be able to buy whatever machine I want

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  27. #23
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    Re: How many inches of weld per roll of wire?

    I did some jobs last couple weeks, as we got started early on we said,,, we gotta stop right here and work this out we got to far to go to be doing fixes and not have it right and the stop paid off 5x with ) finiosh when were were done. I really watch this when I send any kind of common labor because they wont even back the truck up close, will carry every piece. Takes 5 minutes to toss them on or an hour. They are oblivious to this. I often get back far enopugh people dont see me wqatching so to speak and then I come back and move the tables or the trucks or both, or the cords, hang up cords and lines.
    Way back I hired on and the point was to spruce it upo and make it glide a little, on the second day I got the gang stopped moving the machines and benches around. The guy is about to blow a gasket and I just walk to my lunchbox,,, he starts after me,,,, I said simply,,, you hired someone to fix this and now you wanna keep limping on,,,, my work is done here. We finally come to a deal but sheet, shut down for a day and double the job next 4 weeks.

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    Re: How many inches of weld per roll of wire?

    I went to one this spring, the help had it right and told me when we went in to the back,,, I am trying to tell my boss. I look around, he is right. I suggest a couple things to the boss who is a great guy but college boy manager with 20 yrs experience and he look me straight in the eye before I can even finish about stopping the bleeding for cheap and free how they are aware and they know the inventory is depleting but they cot a plan and they gonna sort this and that, they know despite the obvious hemorrhage on the floor. v
    Went to another wanted some opinion but they got all the answers before we get there. It had been sold and they kept the old owners as managers which is the main problem they had as it was.

  29. #25
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    Re: How many inches of weld per roll of wire?

    Quote Originally Posted by Oscar View Post
    According to Lincoln, it's a 33lb spool instead of 30lb, and if you use their 87% efficiency it comes out to ~39 rolls, not 52 (168 linear feet of weld per 33lb spool). Might want a few extra rolls of course, but I don't think Lincoln's specs/stats are off, seeing as how they are a premier supplier of filler metal. Is that the only wire that is spec'd out to use? Can you switch to a metal-core wire? You can get near 97% efficiency, and the deposition rate is approx 16 lb/hr vs 11.4 lb/hr of the OuterShield Elite. 35 rolls metal-core vs 39 of Outershield Elite, 70 hrs of welding with metal core vs 101 hours with OuterShield Elite. No post-welding slag removal, just small silica islands here and there. The main drawback is metal-core is flat/horizontal only, unless you have a pulsed-spray capable power source to be able to go out-of-position.
    I don't have to use any specific wire, I can use whatever I want, if metal cored is the way to go, for over 6000 ft of weld, I'll go with that.

    Could I get a power source and run 2 feeders off it?

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