How Can You Reduce Costs in Your Construction Operation? | MillerWelds

How Can You Reduce Costs In Your Welding Operation?

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Outdated equipment can drive up construction welding costs. Learn how new welding technology can save your operation money.
Welder on construction site adjusting settings on ArcReach feeder

Welding costs and construction efficiency 

Is traditional welding equipment driving up costs in your construction operation? 

When considering whether to buy new equipment, it can be easy to dismiss the idea based on purchase price alone. But if you’re not taking into account the total cost of ownership — including maintenance, labor and unplanned downtime costs — you’re probably greatly overestimating your return on sticking with outdated equipment.

Your current equipment is likely costing you in ways that don’t just show up on your P&L. Learn how XMT® 650 ArcReach® Systems can save your operation money across the board.

Added expenses: 

  • Control cables 

Systems that require a control cable for weld communication between the feeder and the power source waste money. Operators using the XMT 650 with ArcReach power source and ArcReach 16 wire feeder can change processes and polarity right at the feeder — without the need for a control cable.


Eliminating the control cable keeps operators at the weld joint so they are more efficient. It also reduces cable inventory and the associated maintenance expenses for repair or replacement. Control cables are easily damaged, which increases the total cost of ownership. Control cables typically cost about $1,000 for 100 feet, and some jobsites may require 300 feet or more of control cable between the power source and feeder. In addition, these cables are often repaired after one year and replaced after two years.


  • Separate gouging power source 

When operations have separate power sources dedicated to gouging — whether you rent or buy — it increases expenses and decreases efficiency. Renting a gouging power source typically costs about $650 per month for each machine. 

XMT 650 ArcReach Systems deliver integrated gouging at the wire feeder. Eliminating the need for a separate gouging power source can save thousands of dollars over the life of each project. The system also provides the ability to change from welding to gouging with the push of a button at the feeder. 


  • Homemade mobility solutions

Added work and hassle to assemble a sled or cart for welding equipment that’s used on your jobsite or in your shop takes up valuable support staff time and also adds costs for the supplies. 

XMT 650 ArcReach Systems are available with two options that improve portability and save time. The field sled has rollers that make it easy to pull the ArcReach 16 wire feeder across pan decking. The shop cart option with caster wheels and handle makes it easy to transport the wire feeder across the shop and under I-beams, thanks to its low profile. 

These mobility solutions come preassembled and ready to use right out of the box — eliminating cart or sled custom design and assembly, so operators are ready to weld in minutes with an ArcReach 16 wire feeder. 


  • Time spent on process changes

Walking back to the power source to make process or parameter changes adds to your labor costs. This lost time for a few trips per day can add up to $11,250 per year, per welder. 

ArcReach technology eliminates this costly scenario, since operators get full control of process, polarity and parameter changes at the point of use, increasing their efficiency. 


  • Inadequate equipment

Using equipment that isn’t built for harsh environments can result in damage that increases your total cost of ownership. It likely requires you to increase your fleet size — and budget — to have spare equipment on hand for when a machine goes down.

XMT 650 ArcReach Systems include a power source and feeder that are rugged and durable, so the equipment lasts. The IP23 rating, Wind Tunnel Technology™ and Fan-On-Demand™ technology all mean the equipment can withstand harsh elements and keep performing. 

Get next-level cost savings 

XMT 650 ArcReach Systems let you minimize downtime and maximize productivity, all while improving operator safety and ensuring that operators are producing high-quality welds. Learn more about the cost-saving benefits of these systems here.