A Houston process piping shop used IronKit to generate a bid for a water treatment facility expansion. The scope covered 3 t and 4 t Sch 40 carbon steel pipe spools — 38 butt weld joints, 8 socket weld connections, and miscellaneous flanged connections. IronKit counted the weld joints by size and process, generated the material take-off from nominal pipe sizes and flange weights, and produced a clean $31,200 bid.
Frequently Asked Questions
How does IronKit count weld joints for process piping?
IronKit takes the pipe sizes and quantities you enter and calculates the number of butt weld joints by counting the number of spools and fittings. 3 t and 4 t spools typically have one joint per spool end, plus joint connections between spools. The calculator applies estimated weld time per joint size and process (SMAW, GTAW, GMAW) to build the labor estimate.
Why separate shop spool fabrication from field erection?
Process piping shops often do their fabrication in the shop (controlled environment, better quality) and then send field welders to the site for erection. Shop rates and field rates are different, and shop fabrication hours are more predictable. Separating them lets the customer see exactly where the cost is — and lets the shop owner track shop vs. field margin.
What is the difference between Sch 40 and Sch 80 for material takeoff?
Wall thickness. Sch 40 has thinner walls than Sch 80 at the same diameter, so it ts lighter and cheaper per foot. Sch 80 is used for higher pressure service. IronKit calculates pipe weight per foot using ASME B36.10M dimensions — automatically adjusts the material cost based on the schedule you specify.
Can IronKit handle stainless and chrome-moly pipe too?
Yes — specify the material (304/316 stainless, P91 chrome-moly) and IronKit adjusts the material cost, weld process, and labor rate. Chrome-moly requires GTAW root + SMAW fill (no GMAW or FCAW), and the weld time is significantly higher due to the preheat and post-weld requirements.