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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

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calculating coating lifetime costs

Calculating Coating Lifetime Costs

Presented by:

Jayson L. Helsel, P.E.

KTA-Tator, Inc.

learning outcomes
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
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
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
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 atmospheric1
Coating Systems - Atmospheric
  • Service environments per ISO 12944-2, “Classification of Environments”
    • C2: Low
    • C3: Medium
    • C5-I: Very High, Industry
    • C5-M: Very High, Marine
coating systems atmospheric2
Coating Systems - Atmospheric
  • Service environment definition
    • C2: Low“Atmospheres with low levels of pollution; mostly rural areas”
coating systems atmospheric3
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 atmospheric4
Coating Systems - Atmospheric
  • Service environment definition
    • C5-I: Very High, Industry“Industrial areas with high humidity and aggressive atmosphere”
coating systems atmospheric5
Coating Systems - Atmospheric
  • Service environment definition
    • C5-M: Very High, Marine“Coastal and offshore areas with high salinity”
coating systems immersion
Coating Systems - Immersion
  • Most common systems for immersion service
  • Surface preparation requirement
    • Abrasive blast cleaning
  • Minimum dry film thickness
  • Service environments
coating systems immersion1
Coating Systems - Immersion
  • Service environments
    • Potable water
    • Fresh water
    • Salt water
hot dip galvanizing
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
Practical Service Life
  • Time until 5 to 10% coating breakdown occurs (SSPC-Vis 2 Rust Grade 4)
  • Active rusting of the substrate is evident
typical maintenance painting sequence
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 sequence1
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 sequence2
Typical Maintenance Painting Sequence
  • Maintenance Repaint
    • Estimated to be the “Practical Life” plus 33%
      • e.g. “P” x 1.33
typical maintenance painting sequence3
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
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
Cost Data
  • Current material costs
  • Current shop painting costs
  • Current field painting costs
cost data1
Cost Data
  • Current material costs
    • DFT
    • Theoretical cost per sq ft
    • Practical spray
    • Practical brush/roller
cost data2
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 data3
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
Cost Comparisons
  • Shop vs. Field
    • Shop abrasive blast cleaning and priming approximately half of field cost (minimum of 250 tons of steel)
cost comparisons3
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
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 analysis1
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 analysis2
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 analysis3
Economic Analysis
  • Present value analysis
    • For each painting operation calculate:
      • Current cost
      • Net future value
      • Net present value
economic analysis4
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 structure’s life
    • Represents coating lifetime or life cycle cost

i = interest, n = structure life

summary
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