Abrasive Blasting, Shot Peening & Surface Prep worked example

Blast Cost per Square Foot at 72% chargeable yield factor: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop chargeable yield factor to 72%, then walk the calculation through step by step. Estimate total surface prep cost and cost per square foot from blast area, variable prep cost, chargeable factor, and fixed setup cost.

The inputs for this scenario

  • Surface prep area: 2,500 sq ft (held at the documented default)
  • Variable blast cost rate: 2.75 $ / sq ft (held at the documented default)
  • Chargeable yield factor: 72 % (the input this scenario stresses; the baseline uses 100)
  • Setup and mobilization cost: 650 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable prep subtotal = surface prep area × variable prep cost × chargeable yield factor.
  • Total prep cost works out to 5,600 $ at these inputs, and this is the headline figure for the scenario.
  • Cost per square foot works out to 2.24 $ / sq ft at these inputs.
  • Variable prep subtotal works out to 4,950 $ at these inputs.
  • Setup/mobilization cost works out to 650 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where chargeable yield factor sits at 100% and the headline result is 7,525 $, this scenario comes in 25.58% below the baseline at 5,600 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to chargeable yield factor, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. A single variable rate assumes uniform profile and access; tight geometry, scaffolding, or heavy mill scale can push real cost well above the estimate.

Results at a glance

  • Total prep cost: 5,600 $ (headline result)
  • Cost per square foot: 2.24 $ / sq ft
  • Variable prep subtotal: 4,950 $
  • Setup/mobilization cost: 650 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Blast Cost per Square Foot calculator, set chargeable yield factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.