Abrasive Blasting, Shot Peening & Surface Prep calculator
Abrasive Blast Rework Event and Expected-Cost Calculator
Price one possible rework event from its reworked area and accepted rate, then weight it by probability. Enter area, rate, labor and operating cost per active hour, fixed event cost and event probability.
What this calculator does
- Full cost of one rework event, kept separate from its probability-weighted expected exposure for quoting.
Formula used
- Active rework hours = reworked area ÷ accepted rework rate
- Labor cost = active hours × labor cost per active hour
- Operating cost = active hours × operating cost per active hour
- Expected exposure = (labor + operating + fixed event cost) × probability % ÷ 100
Inputs explained
- Area Reworked If Event Occurs: Expected affected area for one defined rework event.
- Accepted Rework Blast Rate: Accepted area per active hour under restricted rework.
- Labor Cost per Active Hour: Rework crew size times the loaded labor rate.
- Operating Cost per Active Hour: Media and compressor cost for one active rework hour.
- Fixed Event Cost: Setup, mobilization, waste and inspection cost per event.
- Probability of This Rework Event: Evidence-based event probability for the planning population.
How to use the result
- Best suited to quote contingency evidence, corrective action business case, rework reserve planning.
- Does not price schedule penalties or lost customer value unless entered as fixed cost. Expected value does not describe worst-case cash need. Correlated rework modes need a broader risk model.
Current U.S. benchmarks
- As of Sep 2026, average hourly earnings in U.S. manufacturing are $30.21 (BLS), up 3.4% from a year earlier. Burdened shop rates typically run 1.3 to 1.8 times earnings once benefits and overhead are loaded.
Common questions
- Why show two costs? If rework occurs, the full event cost is spent. Expected exposure is the probability-weighted amount used to plan across uncertain work.
- Should probability include severity? No. Probability is occurrence likelihood. Consequence is represented by the full event cost and by any separately governed risk limits.
- Can I add schedule impact? Add a defensible incremental cost to the fixed event cost or model schedule impact separately. Do not hide it inside the probability.
- What if several rework modes can occur together? Model the dependency explicitly, because summing independent expected values can understate correlated events and their combined cash need.
Last reviewed 2026-10-02.