Abrasive Blasting, Shot Peening & Surface Prep worked example

Blast Rework Cost at 40% expected fraction of area needing rework: a worked example

What does the result look like when expected fraction of area needing rework reaches 40%? The full calculation is worked below with real intermediate numbers. you need to quantify the cost exposure of rejected surface prep or a likely reblast area

The inputs for this scenario

  • Total coated area at risk of rework: 600 sq ft (unchanged)
  • Reblast and recoat cost per area: 4.25 $ / sq ft (unchanged)
  • Expected fraction of area needing rework: 40 % (raised for this scenario; the documented default is 35)
  • Inspection and remobilization fixed cost: 450 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Expected rework subtotal = potential rework area × reblast/recoat cost × expected affected area) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,470 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 2.45 $ / sq ft for expected cost per sq ft.
  • At this operating point the engine returns 1,020 $ for expected rework subtotal.
  • At this operating point the engine returns 450 $ for inspection/remobilization cost.

How this compares with the baseline

  • Against the tool's baseline example, where expected fraction of area needing rework sits at 35% and the headline result is 1,343 $, this scenario comes in 9.5% above the baseline at 1,470 $.
  • A figure at this level is achievable when expected fraction of area needing rework is genuinely sustained, not just peaked for a shift. It uses a single expected affected-area percentage; actual failures cluster and may trigger full-section redo or schedule penalties not captured by a simple area fraction, so it estimates direct rework cost only.

Results at a glance

  • Total rework cost: 1,470 $ (headline result)
  • Expected cost per sq ft: 2.45 $ / sq ft
  • Expected rework subtotal: 1,020 $
  • Inspection/remobilization cost: 450 $

Run it with your numbers

  • Every input above is editable in the live Blast Rework Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.