Refractories, Furnace Linings & Foundry Consumables worked example

Lining Wear Rate at 68% target thickness-retention rate: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop target thickness-retention rate to 68%, then walk the calculation through step by step. Lining Wear Rate expresses how much of a furnace's refractory has been consumed as a percentage of what was installed, giving foundry and steel-shop maintenance teams a single number to trend across a campaign.

The inputs for this scenario

  • Lining thickness lost this campaign: 8 mm (held at the documented default)
  • Original installed lining thickness: 250 mm (held at the documented default)
  • Target thickness-retention rate: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

  • The calculation starts from the formula this tool documents: Lining Wear Rate rate = affected amount ÷ total amount.
  • Rate works out to 3.2 % at these inputs, and this is the headline figure for the scenario.
  • Gap to target works out to 64.8 points at these inputs.
  • Affected count works out to 8 count at these inputs.
  • Total count works out to 250 count at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where target thickness-retention rate sits at 95% and the headline result is 3.2 %, this scenario lands almost exactly on the baseline at 3.2 %.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to target thickness-retention rate, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. A single wear percentage averages the whole measured zone — it hides the local hot spot or slag-line groove that actually decides when you reline, so always pair it with worst-point readings.

Results at a glance

  • Rate: 3.2 % (headline result)
  • Gap to target: 64.8 points
  • Affected count: 8 count
  • Total count: 250 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Lining Wear Rate calculator, set target thickness-retention rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.