Clutch welding plays a key role in steel sheet piling works, particularly when a watertight or structurally continuous wall is required. It involves welding the interlocks—commonly known as clutches—of adjacent sheet piles. Based on site experience collected by the author during ongoing work on a recent marine project, this article provides a practical reference for daily output rates and cost expectations under standard conditions.
In optimal conditions—where access is not restricted, weather is stable, and material supply is uninterrupted—a good, self-employed welder is capable of producing approximately 60 metres of clutch weld per day. This equates to 30 linear metres of clutch length, as both sides of the interlock require welding. This rate reflects best-case scenarios with efficient crane support, clean steel, and minimal interruptions.
The cost for hiring a self-employed welder directly to the company is generally between £250 and £300 per day, depending on location, qualifications, and terms. These welders usually provide their own tools and personal protective equipment. If the work is subcontracted through a specialist welding firm or agency, the cost typically rises to around £400 per day, which includes labour, overheads, transport, and basic consumables.
In terms of equipment, clutch welding to sheet piles requires a high-output diesel-powered welding machine. While standard daily hire rates for such machines (300 Amp diesel or super-silenced diesel welder/generators) range between £113 and £148, larger contractors often negotiate these rates down by approximately 50%. In practice, this brings the daily hire cost to around £55 to £75, depending on supplier terms and the length of the hire period. These rates exclude fuel and consumables such as rods or gas.
For planning and programming purposes, it is essential to remember that the 60 metres per day figure assumes consistent production without delays. Access restrictions, excessive crane waiting time, windy conditions, or non-standard pile profiles can reduce output significantly. It is advisable to carry out trials in early stages of the programme and monitor progress against the plan, especially on large or sensitive infrastructure projects.
This guidance is intended as a realistic benchmark for estimating time and cost in steel sheet piling projects involving clutch welding, and reflects the actual site productivity achieved under favourable conditions.
The following table summarises the productivity and cost data referenced in the article:
| Item | Unit | Value / Range |
| Clutch weld output (best case) | m of weld per day | 60 m |
| Equivalent linear clutch length | m per day | 30 m |
| Welder (self-employed) | £ per day | £250 – £300 |
| Welder (subcontractor) | £ per day | £400 |
| Diesel welding machine (retail hire) | £ per day | £113 – £148 |
| Diesel welding machine (negotiated hire) | £ per day | £55 – £75 |