Tank, Vessel & Pressure Equipment Fabrication worked example

Weld Consumable Cost at 58% deposition efficiency factor: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop deposition efficiency factor to 58%, then walk the calculation through step by step. Weld Consumable Cost estimates what the filler metal, shielding gas and flux for a tank or pressure vessel job actually cost, adjusted for deposition efficiency.

The inputs for this scenario

  • Weld filler consumed: 100 units (held at the documented default)
  • Delivered cost per unit of filler: 45 $ / unit (held at the documented default)
  • Deposition efficiency factor: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed gas and flux charge: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Weld Consumable Cost cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where deposition efficiency factor sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to deposition efficiency factor, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. Efficiency varies sharply by process and position; a single factor cannot capture SAW versus out-of-position SMAW, so set it per process for tight estimates.

Results at a glance

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Weld Consumable Cost calculator, set deposition efficiency factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.