Welding Table — BOM & Cut List
Mobile welding table sized for gates, fences and other fabricated metalwork. Rolls on levelling casters, brakes, and sits down solid on foot pads for work.
CAD: /exports/WeldingTable.FCStd + .step on the CAD box. Fully parametric — every dimension below is driven from the Params spreadsheet in the document.
Specification
| Work surface | 3000 × 1500 mm |
| Working height | 900 mm to top of plate |
| Top | PL 10, overhanging the frame 50 mm all round |
| Material | S350 throughout |
| Frame | RHS 80×40×3, legs 80 mm dimension along the table length |
| Shelf | SHS 50×50×3 at 250 mm off the floor, 3 mm chequer deck |
| Feet | 4 × Ø125 levelling caster, total-lock brake |
| Mass | 643 kg empty · 157 kg per caster |
The 50 mm plate overhang is the feature that makes it a gate table — C-clamps and toggle clamps grip anywhere on the perimeter with nothing in the way underneath.
Bill of materials
| # | Assy | Description | Qty | Material | Cut mm | kg |
|---|---|---|---|---|---|---|
| 1 | Top | Top plate | 1 | PL 10 S350, 3000 × 1500 | — | 353.2 |
| 2 | Frame | Leg | 4 | RHS 80×40×3 | 725 | 15.5 |
| 3 | Frame | Frame rail — long | 2 | RHS 80×40×3 | 2740 | 29.3 |
| 4 | Frame | Frame rail — end | 2 | RHS 80×40×3 | 1320 | 14.1 |
| 5 | Frame | Frame rail — cross | 4 | RHS 80×40×3 | 1320 | 28.2 |
| 6 | Shelf | Shelf rail — long | 2 | SHS 50×50×3 | 2740 | 23.3 |
| 7 | Shelf | Shelf rail — end | 2 | SHS 50×50×3 | 1320 | 11.2 |
| 8 | Shelf | Shelf rail — intermediate | 2 | SHS 50×50×3 | 2800 | 23.8 |
| 9 | Shelf | Shelf deck, 4 corners notched 80×40 | 1 | PL 3 chequer, 2900 × 1400 | — | 107.3 |
| 10 | Running gear | Caster mount plate | 4 | PL 10 S350, 180 × 120 | — | 6.8 |
| 11 | Running gear | Levelling caster Ø125, total-lock, ≥250 kg | 4 | bought-in | — | 30.8 |
| 12 | Running gear | Bolt M12×40 + nut + 2 washers, gr 8.8 | 16 | bought-in | to suit caster PCD | — |
| TOTAL | 643.4 |
Masses are catalogue values — EN 10219 section weights and durbar including the raised pattern. The CAD geometry says 628 kg; the 15 kg gap is almost entirely the chequer pattern, which the model treats as flat plate. Use 643 kg for ordering and lifting.
Item 12 is a placeholder quantity — caster bolt patterns vary by make. Confirm PCD and hole size against what you actually buy, or delete it entirely if you weld the casters to the mount plates.
Raw material to order — 655 kg
| Material | Hungarian | Form | Off | kg |
|---|---|---|---|---|
| RHS 80×40×3 S350 | Zártszelvény 80×40×3 | 6 m bar / 6 m-es szál | 3 | 96.1 |
| SHS 50×50×3 S350 | Zártszelvény 50×50×3 | 6 m bar / 6 m-es szál | 3 | 76.5 |
| PL 10 S350 | Lemez 10 | 3000 × 1500 sheet / tábla | 1 | 353.2 |
| PL 3 chequer | Cseppmintás lemez 3 | 3000 × 1500 sheet / tábla | 1 | 119.2 |
| PL 10 S350 | Lemez 10 | drop ~400 × 300 / maradék | 1 | 9.4 |
The top is a stock sheet
3000 × 1500 is a standard mill plate size, so the top needs no cutting at all.
Single 353 kg piece
The top sheet needs a forklift or crane at both the merchant and your end. Confirm delivery and offload before paying for it.
Cutting plan
6 m bars, 3 mm kerf, 20 mm end trim per bar.
RHS 80×40×3 — 3 bars, 91% used
| Bar | Cuts | Offcut |
|---|---|---|
| 1 | 2 × 2740 (frame long) | 494 |
| 2 | 2 × 1320 (end) + 2 × 1320 (cross) | 688 |
| 3 | 2 × 1320 (cross) + 4 × 725 (leg) | 422 |
SHS 50×50×3 — 3 bars, 76% used
| Bar | Cuts | Offcut |
|---|---|---|
| 1 | 2 × 2800 (shelf intermediate) | 374 |
| 2 | 2 × 2740 (shelf long) | 494 |
| 3 | 2 × 1320 (shelf end) | 3334 |
The third SHS bar is only a quarter used. If the merchant cuts to length, ask for 2 × 6 m plus one 2.7 m instead — saves ~42 kg of steel you’d otherwise pay for and store.
Layout
- Cross rails at 645 / 1218 / 1782 / 2346 from the left edge → 524 mm clear plate span
- Shelf intermediate rails at 500 / 950 across the width → 400 mm clear deck span
- Frame footprint 2900 × 1400, legs at the outer corners
- Legs 725 mm (not 720 — the top went from 15 mm to 10 mm and the height stayed at 900)
Engineering checks
| Check | Result |
|---|---|
| Frame sag, 300 kg workpiece | 1.64 mm = span/1674 (limit span/360) |
| Frame stress | 36 MPa = 10% of fy |
| Local plate dip, 200 kg point load | 0.34 mm |
| Leg utilisation | 1.0% of squash capacity |
| Caster load | 157 kg empty, 232 kg with 300 kg workpiece |
The frame relies on the top being welded to it
Bare, the long rails would sag 7 mm. The 1.64 mm figure assumes composite action between the rails and the 10 mm top — which needs the plate stitch-welded down. Do not just lay it on.
Decisions worth remembering
Leg orientation — 80 mm along the table’s length. Puts the leg’s stiff axis in the plane with the longer, more flexible beam span (2740 vs 1320), and leaves the front and back faces flush with the 40 mm rails so nothing protrudes inboard on the two sides you stand at.
S350 buys nothing here. Stiffness is set by E = 210 GPa, identical for every structural steel grade. The higher yield is margin on a design running at 10%. If it’s S350GD it’s pre-galvanised — grind the zinc back at every weld prep and ventilate properly.
10 mm top instead of 15 mm. Saved 177 kg. Counter-intuitively the frame sags less, because losing plate mass took more load off than it took stiffness away. The real cost is heat: a 10 mm top has a third less thermal mass and is more prone to warping. Skip-weld it down in a balanced alternating sequence, 40–50 mm stitches at ~300 mm centres — do not run continuous beads.
Shelf intermediates were a defect fix, not a feature. The 3 mm deck originally spanned 1300 mm between the shelf side rails with nothing underneath and would have visibly sagged under a gas bottle. Two intermediates bring it to 400 mm.
Open items
- Confirm caster PCD before ordering item 12 fasteners
- Consider expanded mesh instead of the 3 mm chequer deck — takes ~90 kg out of the table and lets slag fall through instead of pooling
- Optional: a 5th cross rail tightens plate support from 524 to 430 mm for one extra 1320 mm cut and ~7 kg, if the 10 mm top proves heat-sensitive in use
- It will not fit through a standard doorway at 1500 mm wide — build it where it lives