Weld Repair Rate Calculator
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Weld Repair Rate Calculator
Total Welds Inspected (Quantity or Length)
Total Defective/Rejected Welds
Average Cost per Repair (Optional)
Please enter valid positive numbers. Defective welds cannot exceed total welds.
Calculate Repair Rate
Total Inspected:
0
Defective Count:
0
Acceptance Rate:
0%
Repair Rate:
0%
Quality Status:
Estimated Rework Cost:
$0.00
About Weld Repair Rate Calculations
The Weld Repair Rate (often referred to as the rejection rate) is a critical Key Performance Indicator (KPI) in welding quality control, pipeline construction, and structural steel fabrication. It measures the percentage of welds that fail Non-Destructive Testing (NDT) and require rework or repair.
Monitoring this metric helps project managers and quality assurance (QA) teams identify issues with welding procedures, welder skill levels, or material quality. A lower repair rate indicates higher efficiency and lower project costs.
How to Calculate Weld Repair Rate
There are two primary methods for calculating the repair rate, depending on the project specifications (e.g., ASME, API 1104, or AWS D1.1):
By Weld Count: Useful for structural steel or piping where discrete joints are counted.By Linear Length: Often used in pipeline construction or tank fabrication where long seams are welded.
The standard formula used by this calculator is:
Repair Rate (%) = (Total Defective Welds ÷ Total Welds Inspected) × 100
Industry Benchmarks
While acceptable repair rates vary by industry and code, general benchmarks include:
Excellent: Less than 2% (Typical for automated welding or highly skilled teams).Acceptable: 2% to 5% (Common industry standard).Concerning: 5% to 10% (Requires investigation into process parameters).Critical: Above 10% (Immediate work stoppage and procedure requalification often required).
Cost Implications of Welding Repairs
Repairing a weld is significantly more expensive than the original weld. Costs include:
Direct Labor: Grinding out the defect and re-welding.NDT Costs: The repair must be re-inspected (often requiring more stringent methods).Schedule Delays: Rework can hold up hydro-testing or painting.Material Waste: Consumables and base metal degradation.
Use the "Average Cost per Repair" field in the calculator above to estimate the direct financial impact of current quality levels.
function calculateWeldStats() {
// 1. Get DOM elements
var totalInput = document.getElementById('totalWelds');
var defectiveInput = document.getElementById('defectiveWelds');
var costInput = document.getElementById('avgRepairCost');
var errorMsg = document.getElementById('inputError');
var resultContainer = document.getElementById('resultContainer');
var displayTotal = document.getElementById('displayTotal');
var displayDefective = document.getElementById('displayDefective');
var displayAcceptance = document.getElementById('displayAcceptance');
var displayRate = document.getElementById('displayRate');
var qualityStatus = document.getElementById('qualityStatus');
var displayCost = document.getElementById('displayCost');
var costRow = document.getElementById('costRow');
// 2. Parse values
var total = parseFloat(totalInput.value);
var defective = parseFloat(defectiveInput.value);
var cost = parseFloat(costInput.value);
// 3. Validation Logic
var isValid = true;
if (isNaN(total) || total <= 0) {
isValid = false;
}
if (isNaN(defective) || defective total) {
isValid = false;
}
if (!isValid) {
errorMsg.style.display = 'block';
resultContainer.style.display = 'none';
return;
}
// 4. Reset Error
errorMsg.style.display = 'none';
// 5. Calculate Rates
var repairRate = (defective / total) * 100;
var acceptanceRate = 100 – repairRate;
// 6. Calculate Cost (if provided)
if (!isNaN(cost) && cost > 0) {
var totalCost = defective * cost;
displayCost.innerHTML = '$' + totalCost.toLocaleString(undefined, {minimumFractionDigits: 2, maximumFractionDigits: 2});
costRow.style.display = 'flex';
} else {
costRow.style.display = 'none';
}
// 7. Update DOM with results
displayTotal.innerText = total.toLocaleString();
displayDefective.innerText = defective.toLocaleString();
displayRate.innerText = repairRate.toFixed(2) + '%';
displayAcceptance.innerText = acceptanceRate.toFixed(2) + '%';
// 8. Determine Status/Color logic
qualityStatus.className = 'status-badge'; // reset classes
if (repairRate <= 3.0) {
qualityStatus.innerText = "Excellent";
qualityStatus.classList.add('status-good');
displayRate.style.color = "#28a745";
} else if (repairRate <= 7.0) {
qualityStatus.innerText = "Acceptable";
qualityStatus.classList.add('status-warning');
displayRate.style.color = "#e67e22";
} else {
qualityStatus.innerText = "Critical / High";
qualityStatus.classList.add('status-bad');
displayRate.style.color = "#dc3545";
}
// 9. Show Results
resultContainer.style.display = 'block';
}