Renewable Energy, Solar & Wind Manufacturing worked example

Tower Fabrication Cost at 99% sound weld yield: a worked example

This scenario runs the tower fabrication cost calculation on the strong side: 99% sound weld yield, with every other input held at its documented default. A tower shop uses it to price a multi-section tubular tower order before committing rolling and welding capacity.

The inputs for this scenario

  • Steel Plate Tonnage: 180 tons (unchanged)
  • Fabrication Cost per Ton: 1,450 $/ton (unchanged)
  • Sound Weld Yield: 99 % (raised for this scenario; the documented default is 96)
  • Tooling and Setup Charge: 35,000 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total = plate tonnage x fab cost/ton x sound weld yield% + tooling charge) to the inputs above produces each figure below.
  • At this operating point the engine returns 293,390 $ for total tower fabrication cost, the number this scenario is built around.
  • At this operating point the engine returns 1,630 $ / piece for tower fabrication cost per unit.
  • At this operating point the engine returns 258,390 $ for variable tower fabrication cost.
  • At this operating point the engine returns 35,000 $ for fixed tower fabrication cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where sound weld yield sits at 96% and the headline result is 285,560 $, this scenario comes in 2.74% above the baseline at 293,390 $.
  • Use it when quoting tower sections, setting weld-repair targets, or comparing a rolling or welding process change against yield. 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

  • Total tower fabrication cost: 293,390 $ (headline result)
  • Tower fabrication cost per unit: 1,630 $ / piece
  • Variable tower fabrication cost: 258,390 $
  • Fixed tower fabrication cost adder: 35,000 $

Run it with your numbers

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

Last reviewed 2026-05-12.