Abrasive Blasting, Shot Peening & Surface Prep worked example

Blast Rework Cost at 25% expected fraction of area needing rework: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop expected fraction of area needing rework to 25%, then walk the calculation through step by step. Estimate rework dollars from affected area, reblast/recoat cost per square foot, expected affected percentage, and inspection or remobilization cost.

The inputs for this scenario

  • Total coated area at risk of rework: 600 sq ft (held at the documented default)
  • Reblast and recoat cost per area: 4.25 $ / sq ft (held at the documented default)
  • Expected fraction of area needing rework: 25 % (the input this scenario stresses; the baseline uses 35)
  • Inspection and remobilization fixed cost: 450 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Expected rework subtotal = potential rework area × reblast/recoat cost × expected affected area.
  • Total rework cost works out to 1,088 $ at these inputs, and this is the headline figure for the scenario.
  • Expected cost per sq ft works out to 1.81 $ / sq ft at these inputs.
  • Expected rework subtotal works out to 638 $ at these inputs.
  • Inspection/remobilization cost works out to 450 $ at these inputs.

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 18.99% below the baseline at 1,088 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to expected fraction of area needing rework, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 1,088 $ (headline result)
  • Expected cost per sq ft: 1.81 $ / sq ft
  • Expected rework subtotal: 638 $
  • Inspection/remobilization cost: 450 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Blast Rework Cost calculator, set expected fraction of area needing rework to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.