Welding & Fabrication worked example

Arc-On Time at 11% setup, repositioning, and minor-stop allowance: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop setup, repositioning, and minor-stop allowance to 11%, then walk the calculation through step by step. Estimate arc-on time from total weld length, travel speed, and a setup and handling allowance.

The inputs for this scenario

  • Total weld length to deposit: 600 in (held at the documented default)
  • Weld travel speed: 18 in / min (held at the documented default)
  • Setup, repositioning, and minor-stop allowance: 11 % (the input this scenario stresses; the baseline uses 15)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base arc-on time = total weld length to deposit ÷ weld travel speed.
  • Required arc-on time at the booth works out to 37 min at these inputs, and this is the headline figure for the scenario.
  • Base arc-on time works out to 33.33 min at these inputs.
  • Setup, reposition, and minor-stop allowance works out to 11 % at these inputs.
  • Weld travel speed works out to 18 pieces / min at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where setup, repositioning, and minor-stop allowance sits at 15% and the headline result is 38.33 min, this scenario comes in 3.48% below the baseline at 37 min.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to setup, repositioning, and minor-stop allowance, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It is a single-pass estimate — multi-pass welds, tacking, grinding, and inter-pass cleaning are not included and must be added separately for thick joints.

Results at a glance

  • Required arc-on time at the booth: 37 min (headline result)
  • Base arc-on time: 33.33 min
  • Setup, reposition, and minor-stop allowance: 11 %
  • Weld travel speed: 18 pieces / min

Run it with your numbers

  • To rerun this with your own numbers, open the live Arc-On Time calculator, set setup, repositioning, and minor-stop allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.