Weld Repair Estimator
A qualitative tool to estimate the relative time and cost of repairing common welding imperfections. Understand the high price of "doing it wrong the first time."
The Hidden Costs of Weld Repair
In welding, the cheapest weld is the one you only do once. A weld repair is always significantly more expensive than the original weld. The process involves multiple, time-consuming steps: identifying the defect, removing it (usually by grinding or arc gouging), preparing the area, re-welding, and re-inspecting. This calculator demonstrates how different defects have vastly different repair costs.
Why are Cracks the Most Expensive?
A crack is the most severe defect. Repairing it isn't simple. You must grind out the entire crack, often making sure to "chase" it to its very ends. Then, the area must be inspected with methods like Magnetic Particle Testing (MPT) or Dye Penetrant Testing (DPT) to ensure the crack is fully removed before re-welding can even begin. This is why the cost and time factor for a crack is so much higher than for a minor issue like a slag inclusion.