Refractories, Furnace Linings & Foundry Consumables worked example

Brick Count at 99% crew and equipment uptime during relining: a worked example

This scenario runs the brick count calculation on the strong side: 99% crew and equipment uptime during relining, with every other input held at its documented default. Use it when brick count in refractories, furnace linings and foundry consumables is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Refractory bricks laid per install cycle: 4 units / cycle (unchanged)
  • Available brick-laying cycles in the campaign: 480 cycles (unchanged)
  • Crew and equipment uptime during relining: 99 % (raised for this scenario; the documented default is 90)
  • First-pass brick placement yield (no cracks or rejects): 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross brick count capacity = units per cycle × available cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 units for good output capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 units for gross capacity.
  • At this operating point the engine returns 19.2 units for uptime loss.
  • At this operating point the engine returns 57.02 units for yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where crew and equipment uptime during relining sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • Use it when planning a furnace, ladle, or kiln reline to convert a nominal laying rate into a realistic good-brick count for ordering and scheduling. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Good output capacity: 1,844 units (headline result)
  • Gross capacity: 1,920 units
  • Uptime loss: 19.2 units
  • Yield loss: 57.02 units

Run it with your numbers

  • Every input above is editable in the live Brick Count calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.