Helsel-Coating Lifetime Costs Final
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Transcript of Helsel-Coating Lifetime Costs Final
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Calculating Coating Lifetime Costs
Presented by:Jayson L. Helsel, P.E.
KTA-Tator, Inc.
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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
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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”
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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
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Coating Systems - Atmospheric
• Most common systems for atmospheric exposure
• Surface preparation requirementBlast cleaning or hand/power tool
cleaning
• Minimum dry film thickness• Service environments
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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
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Coating Systems - Atmospheric
• Service environment definition
C2: Low
“Atmospheres with low levels of pollution; mostly rural areas”
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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)”
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Coating Systems - Atmospheric• Service environment definition
C5-I: Very High, Industry
“Industrial areas with high humidity and aggressive atmosphere”
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Coating Systems - Atmospheric
• Service environment definition
C5-M: Very High, Marine
“Coastal and offshore areas with high salinity”
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Coating Systems - Immersion
• Most common systems for immersion service
• Surface preparation requirementAbrasive blast cleaning
• Minimum dry film thickness• Service environments
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Coating Systems - Immersion
• Service environments Potable water Fresh waterSalt water
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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
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Practical Service Life
• Time until 5 to 10% coating breakdown occurs (SSPC-Vis 2 Rust Grade 4)
• Active rusting of the substrate is evident
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Rust Grade 4 & 5 – General Rusting
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Rust Grade 4 & 5 – Spot Rusting
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Rust Grade 4 & 5 – Pinpoint Rusting
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Typical Maintenance Painting Sequence
• Original Painting• Spot Touch-Up and Repair• Maintenance Repaint
Spot prime and full overcoat
• Full RepaintTotal coating removal and replacement
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Typical Maintenance Painting Sequence
• Spot Touch-Up and RepairThe first time coating repairs are made Intended to be completed at the
“Practical Life” (from Tables 1A or 1B)
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Typical Maintenance Painting Sequence
• Maintenance RepaintEstimated to be the “Practical Life” plus
33% • e.g. “P” x 1.33
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Typical Maintenance Painting Sequence
• Full RepaintExpected to occur at the year of
“Maintenance Repaint” plus 50% of the “Practical Life” • e.g. Maintenance Repaint year + [“P” x 0.5]
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Maintenance Painting Example
• Service Environment: C3• Surface Preparation: Abrasive Blast
Cleaning• Coating system: 2 coat epoxy • “P” life = 12 years
Spot touch up @ 12 yearsMaintenance repaint @ 16 yearsFull repaint @ 22 years
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Cost Data
• Current material costs• Current shop painting costs• Current field painting costs
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Cost Data
• Current material costsDFTTheoretical cost per sq ftPractical sprayPractical brush/roller
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Cost Data
• Current shop painting costsSurface prep cost per sq ftPaint application cost per sq ftHot dip galvanizing costCost multipliers
• Size of job• Member size for galvanizing
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Cost Data
• Current field painting costsSurface prep cost per sq ftPaint application cost per sq ftCost multipliers
• Size of job• Complexity of structure• Existing conditions
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Cost Comparisons
• Shop vs. FieldShop abrasive blast cleaning and
priming approximately half of field cost (minimum of 250 tons of steel)
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Cost Comparisons
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Cost Comparisons
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Cost Comparisons • Shop applied inorganic zinc vs. hot
dipped galvanizing75,000 to 125,000 sq ft steelModerate service environment (C3)35 year structure life4% inflation & 7% interest
• Initial cost of galvanizing 43% greater• Life cycle cost for galvanizing 15%
less
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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
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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
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Economic Analysis
• For each coating system:Timing and number of painting
operationsCost of each painting operations Carry out for projected life of structure
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Economic Analysis
• Present value analysisFor each painting operation calculate:
• Current cost• Net future value• Net present value
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Present Value Analysis
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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 lifeRepresents coating lifetime or life cycle cost
i = interest, n = structure life
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Life Cycle Cost
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Life Cycle Cost
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Summary
• Coating system selectionSurface preparation and service
environmentDetermines “Practical” life
• Material costs• Shop or field preparation and
application• Economic analysis• Life cycle cost