Abrasive Blasting, Shot Peening & Surface Prep calculator
Blast Nozzle Wear Cost Calculator
Nozzle wear increases air demand, lowers pressure, and changes media velocity. This calculator turns nozzle life into a job cost so estimators can include boron carbide, tungsten carbide, or ceramic nozzle wear instead of hiding it in overhead.
What this calculator does
- Build the cost of nozzle wear from blast hours, wear cost per hour, duty factor, and inspection or changeout cost.
- a blasting estimator needs to recover nozzle replacement and inspection cost on abrasive jobs with heavy hours
- Returns the nozzle wear dollars to include in a job or monthly consumables review.
Formula used
- Nozzle wear subtotal = billable blast hours × nozzle wear rate × loaded blast duty
- Nozzle wear cost = subtotal + inspection/changeout cost
Inputs explained
- Billable blast hours: undefined
- Nozzle wear rate: undefined
- Loaded blast duty: undefined
- Inspection/changeout cost: undefined
How to use the result
- Use it when abrasive type, high pressure, or long blast hours make nozzle life a real cost driver.
- Actual life depends on media hardness, pressure, bore size growth, impact damage, and whether operators replace nozzles before performance falls off.
Common questions
- How do I calculate wear rate? Divide nozzle purchase cost by expected usable blast hours for that nozzle material and abrasive.
- Why track nozzle wear separately? A worn nozzle can consume more CFM and slow cleaning, so the cost is both the part and the productivity loss it creates.
- Should I enter 100% duty? Use 100% for continuous blasting. Lower it if the nozzle is only active part of the paid job hours.
- Does this include compressor energy? No. Use the energy cost calculator for compressor kWh; this page isolates nozzle consumable cost.
Last reviewed 2026-05-12.