The Benefits of Using Dual-Operator Diesel Welding Machines

21 Feb 2024

Traditionally, most diesel welding machines are designed to be operated by a single welder. With advancement in technology, it is now not uncommon to see dual-operator diesel welding machines (dual welder) in the market. Simply put, a dual welder is designed with two welding outputs and can be used by two welders simultaneously in the jobsite. For jobsites that require welders to work in close proximities, a dual welder can deliver significant benefits.

Here are 5 key benefits of using dual welders

1. Lower upfront costs. It is usually always cheaper to purchase a dual welder compared to two single-operator diesel welding machines. This directly translates to a lower cost per welding arc. In addition, the shipping costs is lower for a dual welder.
2. Lower fuel costs. Most welding contractors must pay for the cost of diesel. With a large fleet of diesel welding machines, the cost of diesel can quickly add up. Dual welders can allow for fuel savings. For example, if two welders were to operate two Big Blue® 600X CC single operator welding machines at 150amps each, the fuel consumption is approximately 5.68 litres/hour. On the other hand, if two welders were to operate one Big Blue® 700X Duo Pro (dual welder) at 150amps each, the fuel consumed is 3.79 litres/hour. This translates to a 33% fuel savings.
3. Lower maintenance costs. All diesel welding machines must undergo routine maintenance to ensure they perform at optimal levels in the field. The schedule for routine maintenance is largely dependent on the engine run time (hours). Dual welders will result in lower maintenance costs because there are fewer machines to maintain. This means lower parts costs, inventory costs and labour costs.
4. Lower warehousing and transportation costs. A dual welder has a smaller footprint than two single-operator diesel welders. This directly impacts warehousing space and cost. For welding contractors that work in expansive jobsites that require the welding machines to be set up and moved multiple times during the day or week, dual welders can help save on transportation costs.
5. Reduced jobsite clutter and noise pollution. For cramped jobsites, it may not be feasible to accommodate multiple single-operator diesel welders. In such situations, dual welders can be employed to minimize jobsite clutter. Additionally, a dual welder will run quieter compared to two single-operator diesel welders, resulting in a reduction in noise pollution on the jobsite.

Minimizing equipment on-site, while maintaining or boosting productivity, enables welding contractors to quickly realize the ROI of these dual-operator diesel welding machines.

2 additional tips to consider before taking the plunge

1. Before purchasing a dual welder, request for a welding demo. Ask one welder to start welding from one of the outputs. After 10 seconds, ask the second welder to start welding from the second output. After another 10 seconds, ask the first welder to stop the arc. The second welder can stop the arc shortly after the first welder has stopped. Speak to both welders to understand if they experienced any arc interference or arc instability issues. The same test should be carried out again, except this time, the second welder should use the auxiliary power of the dual welder to run common jobsite tools such as grinders. Always choose a dual welder that delivers two independent and stable welding arcs.
2. In most jobsites, Stick and TIG welding are still the most common processes used in Southeast Asia. However, some welding contractors want to improve jobsite productivity and are looking at FCAW and MIG processes when welding in the field. For such instances, look for dual welders that offer multiprocess welding capabilities. This gives you more flexibility in the field, as well as opportunities to improve jobsite productivity.

Want to know more about the dual welder options from our Miller® Big Blue® product line, reach out to us at SGOffice@MillerWelds.com