Handbook - Calculations

4 Electrode or Welding Wire Consumption Horizontal Fillet Welds Pounds/Foot (Kilos/meter) of Electrode or Wire

Fillet Size

Weld Metal

Required per Lineal Foot or (Meter) of Weld

in. (mm)

Required

SMAW-Stick GMAW-Solid FCAW-Gas Metal Cored

lbs/ft (kg/m)

Electrodes Wires Shielded Wires

1/8

(3.2)

.027

(.040)

.043

(.064)

.028

(.042)

.032

(.048)

.029

(.043)

3/16

(4.7)

.060

(.089)

.097

(.144)

.063

(.094)

.070

(.104)

.065

(.097)

1/4

(6.3)

.106

(.158)

.171

(.254)

.112

(.167)

.125

(.186)

.115

(.171)

5/16

(7.9)

.166

(.247)

.268

(.399)

.175

(.260)

.195

(.290)

.180

(.268)

3/8

(9.5)

.239

(.356)

.385

(.573)

.252

(.375)

.282

(.420)

.260

(.387)

1/2 (12.7)

.425

(.632)

.686 (1.020)

.447

(.665)

.50

(.744)

.462

(.688)

5/8 (15.8)

.664

(.988) 1.071 (1.594)

.699 (1.040)

.781 (1.162)

.722 (1.074)

3/4 (19.1)

.956 (1.423) 1.542 (2.295)

1 (25.4)

2.0 (2.976) 1.846 (2.747)

L L Electrode Consumption (cont’d.) Square Butt Joint Weld Metal Stick Electrodes Joint Dimensions - Inches (m m ) Required Required T B A lbs/ft (kg/m ) lbs/ft (kg/m ) 3/16 (4.7) 1/16 (1.6) 3/8 (9.5) .093 (.138) .150 (.223) 1/16 (1.6) .115 (.171) .185 (.275) 1/4 (6.3) 7/16 (11.1) 3/32 (2.4) .142 (.211) .229 (.341) 1/16 (1.6) .137 (.204) .220 (.327) 5/16 (7.9) 1/2 (12.7) 3/32 (2.4) .165 (.245) .266 (.396) 1/16" A B T