Heat Exchanger, Coil & Radiator Manufacturing worked example

Tube Length Usage at 61% usable tube yield: a worked example

This worked example runs the tube length usage numbers for a tougher week than the baseline: 61% usable tube yield instead of the typical 85%. Estimate tube footage required for coils, radiators, condensers, evaporators, oil coolers, or tube bundles from tube count, cut length, and usable yield.

The inputs for this scenario

  • Number of tubes required for the build: 500 tubes (held at the documented default)
  • Finished cut length per tube: 8 ft (held at the documented default)
  • Usable tube yield (good footage after scrap): 61 % (the input this scenario stresses; the baseline uses 85)

Working through the calculation

  • The calculation starts from the formula this tool documents: Required tube footage = tubes required × cut length per tube ÷ usable tube yield.
  • Required tube footage works out to 6,557 ft at these inputs, and this is the headline figure for the scenario.
  • Theoretical tube footage works out to 4,000 ft at these inputs.
  • Tube loss allowance works out to 2,557 ft at these inputs.
  • Usable tube yield works out to 61 % at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where usable tube yield sits at 85% and the headline result is 4,706 ft, this scenario comes in 39.34% above the baseline at 6,557 ft.
  • Use it when releasing a coil-stock purchase order or kitting material for a production run from a tube count and cut length. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Required tube footage: 6,557 ft (headline result)
  • Theoretical tube footage: 4,000 ft
  • Tube loss allowance: 2,557 ft
  • Usable tube yield: 61 %

Run it with your numbers

  • To rerun this with your own numbers, open the live Tube Length Usage calculator, set usable tube yield to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.