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
L
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
Covered
Electrodes
Stainless
Steel
Products
Solid Wire
& Rod
Products
ESAB
TIG & MIG
Wires
Cored
Wire
Products
Submerged
Arc
Products
Hard-
surfacing
Products
Calculations
Filler Metals
ASTM
Steels
Conversion
Tables
Filler Metal
Consumption
StubLoss
Correction
Electrode/Wire
Consumption
Weld Metal Cost
Worksheet
Weight/Foot
Weld Metal
Weight/Meter
Weld Metal
1.039  (1.546)
(1.674)
1.125   
(1.503)
1.010
(2.659)
1.787
(4.076)
 2.739
(2.527)
1.698