Calculating Coating

Lifetime Costs
Presented by:
Jayson L. Helsel, P.E.
KTA-Tator, Inc.

Learning Outcomes
Completion of this webinar will enable the
participant to:
Define various service environments
Identify suitable coating systems for intended
service
Describe a typical maintenance painting sequence
Calculate installed cost for coating systems
Perform economic analysis
Calculate coating lifetime cost

History
Based on Expected Service Life and Cost
Considerations for Maintenance and New
Construction Protective Coating Work,
presented at NACE Corrosion 2008
Data from survey of contractors and
coating manufacturers
Data presented in SSPC Painting Manual
Volume 1, Good Painting Practice, Chapter
10.2, Comparative Painting Costs

Coating System Data

Commonly used coating systems
For typical service environments

Service life estimates

Time until 5-10% coating breakdown
For practical maintenance sequence

Current material costs

Current shop painting costs
Current field painting costs

Coating Systems Atmospheric

Most common systems for
atmospheric exposure
Surface preparation requirement
Blast cleaning or hand/power tool
cleaning

Minimum dry film thickness

Service environments

Coating Systems Atmospheric

Service environments per ISO 129442, Classification of Environments
C2: Low
C3: Medium
C5-I: Very High, Industry
C5-M: Very High, Marine

Coating Systems Atmospheric

Service environment definition
C2: Low
Atmospheres with low levels of
pollution; mostly rural areas

Coating Systems Atmospheric

Service environment definition
C3: Medium
Urban and industrial atmospheres,
moderate sulfur dioxide pollution;
coastal areas with low salinity

Production rooms with high humidity

and some air pollution (e.g., food
processing plants, laundries, breweries,
dairies)

Coating Systems Atmospheric

Service environment definition
C5-I: Very High, Industry
Industrial areas with high humidity and
aggressive atmosphere

Coating Systems Atmospheric

Service environment definition
C5-M: Very High, Marine
Coastal and offshore areas with high
salinity

Coating Systems Immersion

Most common systems for immersion
service
Surface preparation requirement
Abrasive blast cleaning

Minimum dry film thickness

Service environments

Coating Systems Immersion

Service environments
Potable water
Fresh water
Salt water

Hot Dip Galvanizing

Service life for 4 mils minimum
(American Galvanizers Association)
Mild (rural) = 68 Years
Moderate (industrial) = 33 Years
Severe (heavy industrial) = 21 Years

Practical Service Life

Time until 5 to 10% coating
breakdown occurs (SSPC-Vis 2 Rust
Grade 4)
Active rusting of the substrate is
evident

Rust Grade 4 & 5 General

Rusting

Rust Grade 4 & 5 Spot

Rusting

Rust Grade 4 & 5 Pinpoint

Rusting

Typical Maintenance
Painting Sequence
Original Painting
Spot Touch-Up and Repair
Maintenance Repaint
Spot prime and full overcoat

Full Repaint
Total coating removal and replacement

Typical Maintenance
Painting Sequence
Spot Touch-Up and Repair
The first time coating repairs are made
Intended to be completed at the
Practical Life (from Tables 1A or 1B)

Typical Maintenance
Painting Sequence
Maintenance Repaint
Estimated to be the Practical Life plus
33%
e.g. P x 1.33

Typical Maintenance
Painting Sequence
Full Repaint
Expected to occur at the year of
Maintenance Repaint plus 50% of the
Practical Life
e.g. Maintenance Repaint year + [P x 0.5]

Maintenance
Painting Example
Service Environment: C3
Surface Preparation: Abrasive Blast
Cleaning
Coating system: 2 coat epoxy
P life = 12 years
Spot touch up @ 12 years
Maintenance repaint @ 16 years
Full repaint @ 22 years

Cost Data
Current material costs
Current shop painting costs
Current field painting costs

Cost Data
Current material costs
DFT
Theoretical cost per sq ft
Practical spray
Practical brush/roller

Cost Data
Current shop painting costs
Surface prep cost per sq ft
Paint application cost per sq ft
Hot dip galvanizing cost
Cost multipliers
Size of job
Member size for galvanizing

Cost Data
Current field painting costs
Surface prep cost per sq ft
Paint application cost per sq ft
Cost multipliers
Size of job
Complexity of structure
Existing conditions

Cost Comparisons
Shop vs. Field
Shop abrasive blast cleaning and
priming approximately half of field cost
(minimum of 250 tons of steel)

Cost Comparisons

Cost Comparisons

Cost Comparisons
Shop applied inorganic zinc vs. hot
dipped galvanizing
75,000 to 125,000 sq ft steel
Moderate service environment (C3)
35 year structure life
4% inflation & 7% interest

Initial cost of galvanizing 43% greater

Life cycle cost for galvanizing 15% less

Economic Analysis
Net Future Value (NFV)
How much will it cost, in inflated dollars
in the year scheduled?
NFV = Current Cost [(1 + i)n]
i = inflation, n = years

Economic Analysis
Net Present Value (NPV)
The present worth of the inflated cost (in
monies today invested at current
interest rates)
NPV = NFV (1/ [(1 + i)n] )
i = interest, n = years

Economic Analysis
For each coating system:
Timing and number of painting
operations
Cost of each painting operations
Carry out for projected life of structure

Economic Analysis
Present value analysis
For each painting operation calculate:
Current cost
Net future value
Net present value

Present Value Analysis

Economic Analysis
Average Equivalent Annual Cost (AEAC)
Converts entire stream of present and future
costs to a present worth (NPV)
Distributes that sum in equal annual
amounts over the structures life
Represents coating lifetime or life cycle cost

i = interest, n = structure life

Life Cycle Cost

Life Cycle Cost

Summary
Coating system selection
Surface preparation and service
environment
Determines Practical life

Material costs
Shop or field preparation and application
Economic analysis
Life cycle cost