Renewable Energy, Solar & Wind Manufacturing worked example

Blade Repair Cost at 98% reworkable defect share: a worked example

What does the result look like when reworkable defect share reaches 98%? The full calculation is worked below with real intermediate numbers. A service manager uses it to price a leading-edge or laminate repair before dispatching a composite crew.

The inputs for this scenario

  • Repair Labor Hours: 60 hours (unchanged)
  • Loaded Labor Rate: 135 $/hr (unchanged)
  • Reworkable Defect Share: 98 % (raised for this scenario; the documented default is 85)
  • Mobilization and Cure Cost: 6,500 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total = labor hours x loaded rate x reworkable share% + mobilization and cure cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 14,438 $ for total blade repair cost, the number this scenario is built around.
  • At this operating point the engine returns 241 $ / piece for blade repair cost per unit.
  • At this operating point the engine returns 7,938 $ for variable blade repair cost.
  • At this operating point the engine returns 6,500 $ for fixed blade repair cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where reworkable defect share sits at 85% and the headline result is 13,385 $, this scenario comes in 7.87% above the baseline at 14,438 $.
  • A figure at this level is achievable when reworkable defect share is genuinely sustained, not just peaked for a shift. It assumes the reworkable share is known up front; hidden delamination, weather standdowns, or a repair that escalates to a full section replacement can push actual cost well beyond the estimate.

Results at a glance

  • Total blade repair cost: 14,438 $ (headline result)
  • Blade repair cost per unit: 241 $ / piece
  • Variable blade repair cost: 7,938 $
  • Fixed blade repair cost adder: 6,500 $

Run it with your numbers

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

Last reviewed 2026-05-12.