Refractories, Furnace Linings & Foundry Consumables worked example

Anchor Count at 65% crew and equipment uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop crew and equipment uptime to 65%, then walk the calculation through step by step. Anchor count capacity estimates how many refractory anchors — the metal studs, V-anchors or ceramic anchors that hold castable and gunning mix to the shell — a crew can actually install and pass during a shutdown.

The inputs for this scenario

  • Anchors welded per work cycle: 4 units / cycle (held at the documented default)
  • Work cycles available in the outage: 480 cycles (held at the documented default)
  • Crew and equipment uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass weld yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross anchor count capacity = units per cycle × available cycles.
  • Good output capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross capacity works out to 1,920 units at these inputs.
  • Uptime loss works out to 672 units at these inputs.
  • Yield loss works out to 37.44 units at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where crew and equipment uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 27.78% below the baseline at 1,211 units.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to crew and equipment uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes a steady welding rate; congested overhead work, tight geometry or pre-heat requirements can push the real per-cycle rate well below the input.

Results at a glance

  • Good output capacity: 1,211 units (headline result)
  • Gross capacity: 1,920 units
  • Uptime loss: 672 units
  • Yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Anchor Count calculator, set crew and equipment uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.