Refractories, Furnace Linings & Foundry Consumables worked example

Patch Repair Cost at 92% billable share of patch work: a worked example

Push billable share of patch work up to 92% and the picture changes. This example computes every intermediate figure at that operating point. Use it when patch repair cost in refractories, furnace linings and foundry consumables is being put through a refractories, furnace linings and foundry consumables weighted-cost review.

The inputs for this scenario

  • Number of patch repairs performed: 100 units (unchanged)
  • Refractory material and labor cost per patch: 45 $ / unit (unchanged)
  • Billable share of patch work (capture factor): 92 % (raised for this scenario; the documented default is 80)
  • Fixed mobilization and setup cost: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Patch Repair Cost cost = quantity × rate × capture factor + fixed cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,390 $ for weighted cost, the number this scenario is built around.
  • At this operating point the engine returns 43.9 $ / piece for per piece value.
  • At this operating point the engine returns 4,140 $ for captured value.
  • At this operating point the engine returns 250 $ for fixed adjustment.

How this compares with the baseline

  • Against the tool's baseline example, where billable share of patch work sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • It sums variable patch cost (quantity x rate x capture factor) with a one-time fixed cost and then divides the total by quantity for a per-patch figure. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Weighted cost: 4,390 $ (headline result)
  • Per piece value: 43.9 $ / piece
  • Captured value: 4,140 $
  • Fixed adjustment: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.