Precast Concrete & Modular Construction Manufacturing worked example

Precast Defect Repair Cost at 98% defects repairable in-plant: a worked example

What does the result look like when defects repairable in-plant reaches 98%? The full calculation is worked below with real intermediate numbers. A quality lead uses it to size the cost of patching honeycomb, bug holes, and edge spalls on a casting run before the units ship to the jobsite.

The inputs for this scenario

  • Panels flagged for surface repair: 18 panels (unchanged)
  • Patch & finishing labor per panel: 65 $/panel (unchanged)
  • Defects repairable in-plant: 98 % (raised for this scenario; the documented default is 85)
  • Mobilized repair crew setup: 120 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total repair cost = flagged panels x labor per panel x in-plant repair rate + crew setup) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,267 $ for total precast defect repair cost, the number this scenario is built around.
  • At this operating point the engine returns 70.37 $ / piece for precast defect repair cost per unit.
  • At this operating point the engine returns 1,147 $ for variable precast defect repair cost.
  • At this operating point the engine returns 120 $ for fixed precast defect repair cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where defects repairable in-plant sits at 85% and the headline result is 1,115 $, this scenario comes in 13.65% above the baseline at 1,267 $.
  • A figure at this level is achievable when defects repairable in-plant is genuinely sustained, not just peaked for a shift. It assumes flagged panels are repairable in-plant at the entered rate and does not price scrapped panels or field rework, so batches with structural rejects that must be recast are understated.

Results at a glance

  • Total precast defect repair cost: 1,267 $ (headline result)
  • Precast defect repair cost per unit: 70.37 $ / piece
  • Variable precast defect repair cost: 1,147 $
  • Fixed precast defect repair cost adder: 120 $

Run it with your numbers

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

Last reviewed 2026-05-12.