Calculation Tool for

Electric Arc Welding

Version 3.0, Last Updated: November 1, 2011 YS, JA, & ZI

This page contains necessary instructions that will help you use this calculator to estimate the amount of priority substances and other
chemicals that are manufactured, processed, otherwise used (MPO) and released during welding

How to use this 1. Click on the "Input-Output" Tab

calculator:
2. Fill out the appropriate amounts in the yellow boxes
3. Scroll down to view the Output Summary
Input summary: 1. Select the type of welding electrodes or wires used.
2. Enter the quantity of each welding electrode or wire used.
Output summary:
This table gives you the estimated quantity of ChemTRAC priority substances this process manufactured,
processed, otherwise used and released for the reporting year.
Other processes: If your facility has other activities or sources that MPO or release priority substances (chemicals), then you need to calculate the amo

Total MPO and Once you have your estimates for all the activities or processes, enter the amounts of MPO and release of each
Releases: substance from each process into the "Calculation of Totals" calculator (available at www.toronto.ca/chemtrac) to
determine if you need to report.

Before you start make - the quantity (in kilograms) of welding electrode
sure you have: - the type of welding electrode and wire used during the reporting year
Note: some of these may not apply to your facility
 Version 3.0, Last Updated: November 1, 2011 YS, JA, & ZI

Instructions • This page gathers information related to welding at your facility and shows the estima
manufactured, processed, otherwise used (MPO) or released
You are • Please provide all the information requested in the yellow cells. If a section does not a
here Input/Output blank.
• To determine if you need to report, add the amounts shown in the Output Summary tab
from other processes or sources, if any, in your facility. Then you need to compare the t
• You may use the Calculation of Totals spreadsheet to calculate the totals.
Calculations
Please complete the INPUT table below
INPUT
References
Welding Process

Shielded Metal Arc: SMAW (Stick)

Select

Select

Select

Select

Select

Select

Select

Select

Select

Select

Select

Select

Emission Control:

If your facility operates emission control equipment to control the release of c

please provide the equipment control efficiency (please consult your supplier

OUTPUT SUMMARY (Only ChemTRAC priority substances)

 ChemTRAC Priority Substances
Chromium, non-hexavalent, and its compounds
Chromium VI (hexavalent), and its compounds
Manganese, and its compounds
Nickel, and its compounds
Lead, and its compounds
Particulate Matter 2.5 (PM2.5)
1
Definitions available on References tab
 YS, JA, & ZI

ing at your facility and shows the estimated amounts of priority substances
O) or released
n the yellow cells. If a section does not apply to your facility, leave it

mounts shown in the Output Summary table to any other MPOs or releases
facility. Then you need to compare the total to the reporting thresholds.
dsheet to calculate the totals.

Input Quantity
Select Electrode or Wire Used
(kg/yr)
SMAW E11018 0
Select 0
Select 0
Select 0
Select 0
Select 0
Select 0
Select 0
Select 0
Select 0
Select 0
Select 0
Select 0

ntrol equipment to control the release of contaminants, 0%

efficiency (please consult your supplier)

mTRAC priority substances)

 Quantity (kg/yr)
Otherwise
Manufactured1 Processed1 Used1 Released to Air1
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
 Unit Converson Help

1 pounds = 0.4536 kg
1 ounces = 0.02835 kg
1 grams = 0.001 kg
1 tons (US) = 907.18474 kg
1 tons (UK) = 1016.0469 kg
1 tonnes (metric) = 1000 kg
 Summary of Calculations
Version 3.0, Last Updated: November 1, 2011 YS, JA, & ZI

Instructions • This page provides detailed calculations based on the information provided in the In
calculations and an assessment of emission factor data quality.
Input/Output • If you have site specific emission factors you may use them in the table below. If yo
emission factor ensure that the units have been converted accordingly.

ChemTRAC Substances
You are here Calculations Chromium, non-hexavalent, and its compounds
Chromium VI (hexavalent), and its compounds
References Manganese, and its compounds
Nickel, and its compounds
Lead, and its compounds
Particulate Matter 2.5 (PM2.5)(2)
Other Substances
Cobalt Compounds
Particulate Matter (PM)
Particulate Matter 10 (PM10)
n/a - Not Applicable

Note (1): Where a contaminant is not expected to be present in the welding rod, but a
estimated, the Quantity Used was assumed to be equal to the Release, and this numbe
Mass Reporting Threshold.

Note (2): As per the NPRI toolbox, PM2.5 can be estimated to be 75% of PM10 emis

Process

Select
Shielded Metal Arc: SMAW (Stick)
Gas Metal Arc: GMAW (MIG)
Flux Cored Arc: FCAW
Submerged Arc: SAW
Gas Tungsten Arc: GTAW (TIG)
Other Consumable Electrode/Wire Process
Non-Consumable Electrode (ex. GTAW)
 Process
2
1
1
1
1
1
1
1
1
1
1
1
1

Electrode

1 Select
2 Shielded Metal Arc Electrode
3 SMAW E11018
4 SMAW E308
5 SMAW E310
6 SMAW E316
7 SMAW E410
8 SMAW E6010
9 SMAW E6011
10 SMAW E6012
11 SMAW E6013
12 SMAW E7018
13 SMAW E7024
14 SMAW E7028
15 SMAW E8018
16 SMAW E9015
17 SMAW E9018
18 SMAW ECoCr
19 SMAW ENi-Cl
20 SMAW ENiCrMo
21 SMAW ENi-Cu-2
22 SMAW 14Mn-4Cr
23 Other SMAW Electrode(3)(8)
24 Gas Metal Arc Wire
25 GMAW E308L
26 GMAW E70S
27 GMAW ER1260
28 GMAW ER5154
29 GMAW ER5356
30 GMAW ER316
31 GMAW ENiCrMo
32 GMAW ERNiCu
33 Other GMAW Wire(3)(8)
34 Flux Cored Arc Electrode
35 FCAW E110
36 FCAW E11018
37 FCAW E308LT
38 FCAW E316LT
39 FCAW E70T
40 FCAW E71T
41 Other FCAW Electrode(3)(8)
42 Submerged Arc Electrode
43 SAW EM12K
44 Other SAW Electrode(3)(8)
45 Other Consumable Electrode/Wire(3)
46 Non-Consumable Electrodes (ex. GTAW) (5)(6)

Summary

Electrode
Shielded Metal Arc Electrode
Gas Metal Arc Wire
Flux Cored Arc Electrode
Submerged Arc Electrode
Other Consumable Electrode Wire
All Gas Tungsten Arc Welding
Note (3) - PM Emission factor taken as 1% of electrode consumption as per MOE Pu
Note (4) - Emissions from all other electrodes or wires were calculated following the
Note (5) - PM Emission factor taken as 1% of wire consumption as per County of San
Note (6) - The amount of all ChemTRAC substances found in the base metal being w
Note (7) - Chromium (VI), cobalt, and lead or not expected to be present in significan
Note (8) - Generic emission factors of "other" consumable electrodes in each process
amounts in a single type of electrode, but is in other cases more conservative than the

Sample Calculations:

If 400 kg of SMAW E11018 is used, and a filter with 85% control efficiency is in
Manganese used =
=
=
Particulate matter emission rate =
=
=
YS, JA, & ZI
n the information provided in the Input table. It also provides sample
data quality.
ay use them in the table below. If you choose to insert your own
nverted accordingly.

Quantity (kg/yr)
Otherwise Released to
CAS # Manufactured Processed Used Air
n/a 0.0 0.0 0.0 0.0
n/a 0.0 0.0 0.0 0.0
n/a 0.0 0.0 0.0 0.0
n/a 0.0 0.0 0.0 0.0
n/a 0.0 0.0 0.0 0.0
n/a 0.0 0.0 0.0 0.0

n/a 0.0 0.0 0.0 0.0

n/a 0.0 0.0 0.0 0.0
n/a 0.0 0.0 0.0 0.0

be present in the welding rod, but an emission is

equal to the Release, and this number was compared to the

estimated to be 75% of PM10 emissions

 Electrode Quantity (kg/yr)
3 0
1 0
1 0
1 0
1 0
1 0
1 0
1 0
1 0
1 0
1 0
1 0
1 0

Electrode/Wire Nominal Composition

Consumption (wt%)
(kg/yr)
Mn Cr Ni Cr(VI)(7) Co(7) Pb(7)

0 2.5% 3.0% n/a n/a n/a

0 2.5% 22.5% 11.0% n/a n/a n/a
0 2.5% 22.5% 11.0% n/a n/a n/a
0 2.5% 22.5% 11.0% n/a n/a n/a
0 2.5% 22.5% 11.0% n/a n/a n/a
0 1.2% 0.0% 0.0% n/a n/a n/a
0 1.2% 0.0% 0.0% n/a n/a n/a
0 1.2% 0.0% 0.0% n/a n/a n/a
0 1.2% 0.0% 0.0% n/a n/a n/a
0 1.6% 0.0% 0.0% n/a n/a n/a
0 1.3% 0.0% n/a n/a n/a
0 1.6% 0.0% 0.0% n/a n/a n/a
0 3.0% 0.0% 3.0% n/a n/a n/a
0 3.0% 0.0% 4.0% n/a n/a n/a
0 3.0% 0.0% 4.0% n/a n/a n/a
0 1.0% 28.5% 13.5% n/a n/a n/a
 0 2.5% 1.0% 85.0% n/a n/a n/a
0 1.3% 22.8% 58.0% n/a n/a n/a
0 2.3% 35.0% 60.0% n/a n/a n/a
0 14.0% 4.0% 0.0% n/a n/a n/a
0 2.6% 9.5% 14.4% n/a n/a n/a
0 n/a n/a n/a
0 2.0% 22.0% 11.5% n/a n/a n/a
0 2.0% 0.0% 0.0% n/a n/a n/a
0 0.0% 0.0% 0.0% n/a n/a n/a
0 1.0% 0.0% n/a n/a n/a
0 0.1% 0.1% 0.0% n/a n/a n/a
0 2.0% 22.0% 11.5% n/a n/a n/a
0 1.3% 22.8% 58.0% n/a n/a n/a
0 2.3% 35.0% 60.0% n/a n/a n/a
0 1.3% 14.6% 17.6% n/a n/a n/a
0 n/a n/a n/a
0 5.0% 0.0% 5.0% n/a n/a n/a
0 2.5% 3.0% n/a n/a n/a
0 1.5% 19.5% 10.0% n/a n/a n/a
0 1.5% 18.5% 12.5% n/a n/a n/a
0 3.0% 0.0% 0.0% n/a n/a n/a
0 3.0% 0.0% 0.0% n/a n/a n/a
0 2.8% 7.6% 5.1% n/a n/a n/a
0 n/a n/a n/a
0 1.0% 0.0% 0.0% n/a n/a n/a
0 1.0% 0.0% 0.0% n/a n/a n/a
0 2.2% 9.8% 12.7% n/a n/a n/a
0 0% 0% 0% n/a n/a n/a

Total Quantity Quantity Used (kg/yr)

Used (kg/yr) Mn Cr Ni Cr(VI)(5) Co(5) Pb(5)
0 0 0 0 n/a n/a n/a
0 0.00 0.00 0.00 n/a n/a n/a
0 0 0 0 n/a n/a n/a
0 0 0 0 n/a n/a n/a
0 0 0 0 n/a n/a n/a
0 0 0 0 n/a n/a n/a
ctrode consumption as per MOE Publication #3614e03 page 92 and individual metal emission factors taken from 2004 NPRI To
wires were calculated following the procedures listed US EPA AP 42 Section 12.9 "Electric Arc Welding"
e consumption as per County of San Diego APCD Emission Factor Tables: Tungsten Inert Gas Welding (TIG), Electrode: Uns
ces found in the base metal being welded must be considered in the threshold calculations for GTAW welding.
expected to be present in significant quantities (>1%)
nsumable electrodes in each process are estimated using the average contaminant emission factor for each process. This approach
er cases more conservative than the NPRI's recommend generic emission factors for consumable electrodes

r with 85% control efficiency is installed:

Total weld rod used (kg) X % of Manganese in Generic Rod
400 kg/yr X 2.5%
10 kg/yr
Total weld rod used (kg/yr) X Emission Factor (g/kg) X 1 kg/1000 g X (100%-control efficiency (%))
400 kg/yr X 16.4 g/kg X 1 g/1000 kg X (100% - 85%)
0.984 kg/yr
 Emission Factor g/kg Data
(grams of fume emitted per kg of weld rod or electrode consumed) Quality
PM10 Rating Cr Cr(VI) Co Mn Ni Pb Rating

16.40 C 1.380 C
10.80 C 0.393 0.359 0.001 0.252 0.043 D
15.10 C 2.530 1.880 2.200 0.196 0.024 C
10.00 C 0.522 0.332 0.544 0.055 D
13.20 D 0.685 0.014 C
25.60 B 0.003 0.001 0.991 0.004 B
38.40 C 0.005 0.001 0.998 0.005 C
8.00 D
19.70 B 0.004 0.001 0.945 0.002 B
18.40 C 0.006 0.001 1.030 0.002 C
9.20 C 0.001 0.629 C
18.00 C 0.013 0.846 0.162 C
17.10 C 0.017 0.030 0.051 C
17.00 D
16.90 C 0.212 0.783 0.013 C
27.90 C
 18.20 C 0.039 0.890 C
11.70 C 0.420 0.043 0.247 C
10.10 C 0.212 0.423 C
81.60 1.390 23.200 1.710 C
10.00 0.424 0.643 0.001 2.047 0.261 0.093

5.40 C 0.524 0.001 0.346 0.184 C

5.20 A 0.001 0.001 0.318 0.001 A
20.50 D 0.004 D
24.10 D 0.010 0.034 D
51.00 1.000 U
3.20 C 0.528 0.010 0.245 0.226 D
3.90 C 0.353 0.070 1.250 B
2.00 C 0.001 0.022 0.451 C
10.00 0.203 0.010 0.001 0.291 0.422

20.80 D 0.002 2.020 0.112 D

57.00 D 0.969 0.704 0.102 C
9.10 C
8.50 B 0.970 0.140 0.590 0.093 B
15.10 B 0.004 0.891 0.005 B
12.20 B 0.002 0.001 0.662 0.004 B
10.00 0.389 0.140 0.001 0.973 0.063

0.05 C
10
10 0.0002 0.0002 0.0002 0.0002 0.0002 0.0002
10 0.000033 0.000033 0.000033 0.000033 0.000033 0.000033

Quantity Released (g/yr)

PM10 Cr Cr(VI) Co Mn Ni Pb
0 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000
0 0.000 0.000 0.000 0.000 0.000 0.000
ctors taken from 2004 NPRI Toolbox Guidance document 4.2 Guidance for the Reporting of Welding Activities.

Welding (TIG), Electrode: Unspecified

AW welding.
for each process. This approach reduces the impact of emission factors where a contaminant is present in higher
electrodes

l efficiency (%))
Activities.
 Instructions

Input/Output

Calculations

You are
here
References
References
Version 3.0, Last Updated: November 1, 2011 YS, JA, & ZI

This page provides all the reference information for the emission factors and assumptions used in the Calculations sp
Click on the links below to view the source documents.

Emission factors and an assessment of their data quality are provided in Environment Canada's 2008 NPRI Toolbox
Spreadsheet for Electric Arc Welding
http://www.ec.gc.ca/inrp-npri/9C8F5570-19B6-4E37-97DB-290D4CE28153/electirc_arc_welding_e_04_02_2009.xl
the US EPA AP-42 "Electric Arc Welding", Section 12.19, 1995
http://www.epa.gov/ttn/chief/ap42/ch12/final/c12s19.pdf
Air Pollution Control District County of San Diego APCD Emission Factor Tables: Tungsten Inert Gas Welding (TI
Electrode: Unspecified
http://www.sdapcd.org/toxics/emissions/welding/t99.pdf
Indiana Department of Environmental Management, Office of Air Quality
Generic compositions for the following electrodes are based on welding datasheets published by the America
Society:
SMAW E6010
SMAW E6011
SMAW E6012
SMAW E6013
SMAW E7018
SMAW E7024
SMAW E7028
SMAW ECoCr
SMAW ENi-Cl
SMAW ENiCrMo
SMAW ENi-Cu-2
GMAW ENiCrMo
GMAW ERNiCu
FCAW E308LT
FCAW E316LT
Datasheets are available at:
https://www.awspubs.com/
Generic compositions of other SMAW electrodes were calculated using Material Safety Data Sheets for each of th
types with published emission factors.
Generic compositions of Other (Consumable) electrodes were estimated as the average composition for each c
present in the defined consumable electrodes (SMAW, GMAW, FCAW, SAW)
Generic compositions of other GMAW, other FCAW, SAW, and Other (Non-Consumable) electrodes are based on L
Electric compositions provided on
http://www.mylincolnelectric.com/Catalog/lecobrowse.aspx?locale=4105
Generic compositions of GMAW, FCAW, SAW, and Other (Non-Consumable) electrodes are based on Hobart Broth
Canada compositions provided on

http://www.hobartcanada.com/product_info.asp

Definitions1
Manufacture - To produce, prepare or compound a priority substance and includes the conincidental production of a priority.
as a by-product.
Process - The preparation of a priority substance, after its manufacture, for commercial distribution and includes the preparati
substance in the same physical state or chemical form as that received by the facility, or preparation which produces a change i
state or chemical form.

Otherwise Use - Any use, disposal or release of a priority substance at a facility that does not fall under the definitions of "m
or "process." This includes the use of the priority substance as a chemical processing aid, manufacturing aid or some other use.
Release - The emission or discharge of a priority substance, whether intentional, accidental or coincidental, from a facility into
environment.

1 For details refer to the Environmental Reporting and Disclosure Bylaw available at the ChemTRAC website.

Copyright (C) 2010, City of Toronto

This tool is provided solely as an aid, and the City of Toronto makes no representation or warranty as to its applica
your facility or to your obligation to comply with the Environmental Reporting and Disclosure Bylaw (Municipal C
Chapter 423). It is the responsibility of each facility owner or operator to take the necessary steps to ensure compli
the bylaw.