Adhesives, Sealants & Industrial Bonding calculator

Bond Rework Exposure Calculator

Estimate the direct cost of repairing assemblies already identified for bond rework. Enter the repair count, measured labor time, loaded rate, consumables and one-time setup.

What this calculator does

  • Estimate the labor, consumables and teardown budget for known assemblies requiring bond repair.

Formula used

  • Repair hours = assemblies × person-minutes per repair ÷ 60
  • Repair labor cost = repair hours × loaded hourly rate
  • Consumables cost = assemblies × consumables per repair
  • Rework budget = repair labor + consumables + teardown and setup

Inputs explained

  • Assemblies Requiring Rework: Confirmed assemblies on the bond repair work order.
  • Repair Labor per Assembly: Measured operator minutes for one repair, including retest.
  • Loaded Labor Rate: Repair labor cost per person-hour from your cost ledger.
  • Repair Consumables per Assembly: Adhesive, cleaner and replacement consumables used in one repair.
  • Teardown and Setup Cost: One-time teardown and repair setup for the work order.

How to use the result

  • Best suited to containment repair planning, repair versus replacement budgeting.
  • Excludes repeat failures, replacement assemblies and unattended cure occupancy. Does not establish whether a bonded assembly is repairable.

Current U.S. benchmarks

  • The producer price index for industrial chemicals stands at 336.006 (BLS, Aug 2026), up 13.3% from a year earlier. Quotes priced off last quarter's material cost miss this move.
  • The U.S. has 11,391 plastics and rubber products establishments employing about 815,988 workers (Census County Business Patterns, 2023).

Common questions

  • Why is there no rework probability? The input is a confirmed repair count. Applying a probability to assemblies already needing repair understates the planned workload.
  • Does repair time include removing old adhesive? Yes, include removal, preparation, rebonding and attended retesting in the measured person-minutes for one repair.
  • What if a repair attempt fails? Price a further attempt or replacement separately. This estimate assumes the entered work instruction requires one repair attempt per assembly.
  • Can I compare this with scrapping the batch? Yes, after adding any omitted costs consistently. Consider recoverable component value, replacement work and the qualification of the proposed repair.

Last reviewed 2026-10-01.