Thermal Spray, Hardfacing & Wear Coatings worked example

Masking Labor Cost at 58% effective masking coverage factor: a worked example in thermal spray, hardfacing & wear coatings

Here is what the math looks like when conditions slip. We hold every other input steady and drop effective masking coverage factor to 58%, then walk the calculation through step by step. Masking labor is one of the most under-estimated cost drivers in thermal spray and hardfacing work, where every bore, thread, keyway and sealing face has to be shielded from overspray before the gun ever fires.

The inputs for this scenario

  • Parts masked per batch: 100 units (held at the documented default)
  • Loaded masking labor rate per part: 45 $ / unit (held at the documented default)
  • Effective masking coverage factor: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed masking material setup cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Masking Labor Cost 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 effective masking coverage factor sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to effective masking coverage factor, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. The coverage factor is a single blended multiplier; it does not model part-to-part complexity differences, so mixed-geometry batches should be split and run separately.

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 Masking Labor Cost calculator, set effective masking coverage factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.