Refractories, Furnace Linings & Foundry Consumables worked example

Cost Per Lining Job at 58% usable material fraction after waste: a worked example

Suppose usable material fraction after waste falls to 58%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Cost per lining job is the fully loaded price to install a complete refractory lining — the delivered material, the portion actually placed after rebound and waste, plus fixed setup and dry-out charges.

The inputs for this scenario

  • Refractory volume installed: 100 units (held at the documented default)
  • Installed cost per unit volume: 45 $ / unit (held at the documented default)
  • Usable material fraction after waste: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed job setup and dry-out cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Cost Per Lining Job cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where usable material fraction after waste sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • Computes the total cost of a refractory lining job as installed volume times unit cost times the usable material fraction, plus a fixed setup and dry-out cost, with a per-unit breakdown. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Cost Per Lining Job calculator, set usable material fraction after waste to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.