Abrasive Blasting, Shot Peening & Surface Prep worked example

Blast Nozzle Wear Cost at 65% loaded blast duty factor: a worked example

Suppose loaded blast duty factor falls to 65%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Build the cost of nozzle wear from blast hours, wear cost per hour, duty factor, and inspection or changeout cost.

The inputs for this scenario

  • Billable on-blast hours: 36 hr (held at the documented default)
  • Nozzle wear cost rate: 3.5 $ / hr (held at the documented default)
  • Loaded blast duty factor: 65 % (the input this scenario stresses; the baseline uses 90)
  • Inspection and changeout cost: 25 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Nozzle wear subtotal = billable blast hours × nozzle wear rate × loaded blast duty.
  • Nozzle wear cost works out to 107 $ at these inputs, and this is the headline figure for the scenario.
  • Cost per blast hour works out to 2.97 $ / hr at these inputs.
  • Wear subtotal works out to 81.9 $ at these inputs.
  • Changeout cost works out to 25 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where loaded blast duty factor sits at 90% and the headline result is 138 $, this scenario comes in 22.76% below the baseline at 107 $.
  • It computes total nozzle wear cost over a job by applying a per-hour wear rate to duty-adjusted blast hours, then adding the inspection/changeout cost. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Nozzle wear cost: 107 $ (headline result)
  • Cost per blast hour: 2.97 $ / hr
  • Wear subtotal: 81.9 $
  • Changeout cost: 25 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Blast Nozzle Wear Cost calculator, set loaded blast duty factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.