Protective Coatings Application

Coverage

© Copyright 2016 Fitz-Coatings Ltd

 Coverage

Objective
To understand how paint coverage is calculated. To gain basic knowledge of theoretical and practical
spreading rate of paints and coatings. The Paint coverage rate is essential for:

Tendering a contract.
Ordering the correct quantity of coating material.
Using the correct volume of coating material.

Paint Quantities
Getting the correct paint quantities is essential, especially on
projects where there is a tight program of works such as a ship
dry dock or where the coating program effects other trades such
as construction works.

In this training unit, we will be reviewing the coverage calculations

for protective coatings taking into consideration the theoretical and
practical aspects of a project.

Paint Coverage
In the protective coatings industry, virtually every job is different,
the variables include;

The skill of the operative

The method of application
The surface and surface condition ie after existing coatings
are removed there may be more pitting in the steel etc
The configuration of the surface
Environmental conditions can change daily such as wind etc
Access may also change or not quite be as originally
expected

The contractor has to make a number of factors into consideration

at an early stage.

Spreading Rates
To calculate the coating spreading rate you will require the
following information:

The volume solids.

The specified dry film thickness.

Both these items will be found on the product data sheets.

Also, check the paint specification for the recommended dry film
thickness as this may differ from the product data sheets.

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 Paint Drying
This simple animation demonstrates paint applied to a surface.

Once applied, the solvents are released to leave a solid film which
dries and cures.

This animation does not detail the condition of the substrate such
as rough, porous, pitted etc or wastage such as overspray,
thickness variation etc.

Wet Film Thickness Gauge

It is important that operatives understand the principles of wet
film thickness compared to dry film thickness and the use of
a wet comb.
It is important that operatives use the wet film comb when
applying coatings.
The applicator must know the required wet and dry film
thickness which will be found on the product data sheets.
The volume solids will also be on the product data sheet.

Dry Film Thickness Gauge

This animation is a simple demonstration on the use of a dry film
thickness gauge in use.

The principle to the process is 'electromagnetic induction'.

Some very sophisticated types of gauges are available which can

be linked to computers via Bluetooth etc.

The animation demonstrates a digital type gauge.

Other Considerations
Not all coatings are applied with the volume solids and wet and dry
rules applied or detailed in the data sheets.

Decorative products:

Supplier's information for decorative products is usually sq.m

per litre or sq.ft per gallon depending upon the type of surface.

Specialist products:

Specialist flooring etc. This could be calculated as kg per

sq.m or pounds per sq.ft and calculation of specific gravity is
required

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 Volume Solids
Examples of how volume solids are calculated for a coverage at a
specific dry film thickness:

Example One

Volume solids is 60: 60 x 10 = 600 /100 Microns Dry film

thickness (4 mil) = 6m2 /Litre (64.5 sq.ft)

Example Two

Volume solids is 75: 75 x 10 = 750 /150 microns Dry film

thickness (6 mil) = 5m2 /litre (54 sq.ft)

Both examples based on theoretical spreading rates only.

Practical Spreading Rate

Guidelines to consider for practical spreading rates:

Overspray - this will depend upon the type of equipment and

application conditions.
The complex geometry of the substrate.
Wind, temperature or distance from the spray gun to the
substrate.
Minimum film thicknesses.
Wastage - general.
The roughness of surface - porous, pitted etc.

Note: Paint wastage can vary between 30-70% depending upon

the configuration of the structure etc.

Surface Condition
The degree of surface irregularities only become clear after surface
preparation has been conducted.

Abrasive blast cleaning increases the surface area of a surface,

however, this surface area can increase two or three times more
on a pitted and rusted surface.

This will dramatically increase the coating consumption as the

coating will have to fill all the pits etc.

Paint Mixing
Paint wastage is also possible when mixing paints.

Residue is often left in the cans and containers and overspill is

possible when using a mechanical mixer.

As much as five percent wastage can be found during the mixing

of products, especially two-part products as illustrated.

On large jobs, this can add up to a lot of wasted material and

additional cost.

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 Paint Mixing -General Wastage
Although the paint can may only look like they have a light coat
left to the inside of the paint can, it can add up to approx 5%
without considering any other loss.

Large paint containers are more economical and often used in

large painting facilities, shipyards etc.

Paint Application
You will always find a level of paint wastage when applying
coatings.

This wastage can be managed to some extent by correct

equipment, pressures, tips, trained applicators etc.

Even the simplest of structures will have edges etc and it will be
difficult not to overspray this area as illustrated.

Some structures can be very complex and the method of

application must be carefully selected.

Paint Wastage
Paint wastage is also possible when applying paints in a light
breeze or in windy conditions.

The paint droplets can travel for miles! (kilometers)

Do not apply coatings during windy conditions.

Also, do not spray paint from a distance and do not stretch or

overreach.

Ensure you have reasonable access.

Note; As a general rule the maximum wind speed at which

coatings should be applied is 15 miles per hour (24 kilometers per
hour)

Dry Film Thickness

The specification may also determine paint wastage by default.

If the specification specifies a 'minimum' dry film thickness

additional paint will be used.

An average dry film thickness is therefore often specified or a

specific calculation or standard such as SSPC-PA2.

Check the painting specification for the exact details on how to

check the dry film thickness.

Paint Application
Additional paint loses can be found when coating porous or rough
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 surfaces.

This animation demonstrates coatings being applied to a rough

surface. Paint will be lost in the troughs and additional paint will be
required to cover the peaks.

Conduct a test piece to assess the level of paint loss and

coverage in general.

Airless Spray Equipment

On some large projects the spray equipment has to be placed
away from the work-face (work location), this may also be a safety
requirement.

Spray lines of 20-100 metres (65-330 feet) are commonly found in

on some projects.

There can be between 10-25 litres (2.6-6.6 US Gallon) of paint in

the line so it is important to calculate when you start pushing
solvent through the paint line, otherwise, you will flush the paint at
the end of the task and also have to remove the hazardous waste.

Summary
In this training unit, we have reviewed paint coverage. We have
reviewed the importance of getting the paint quantities correct and
the reasons for practical losses that will be found on every type of
painting contract.

Losses include;

Paint Mixing
Surface configuration
Poor application
Losses in the spray equipment
Rough and porous surfaces
Overspray etc

© Copyright 2016 Fitz-Coatings Ltd Page 5