This paper is a significant update to “Costing Considerations for Maintenance and New Construction Coating Work”1 on protective coating costing and selection co-authored by M. F. Melampy, M. P. Reina and K. R. Shields in 1998.
Designed to assist the coatings engineer or specifier in identifying suitable protective coating systems for specific industrial environments, this paper provides guidelines for calculating approximate installed costs of coating systems, expected coating service lives for each system identified, and methods for determining the most cost-effective systems to use. The effect of maintenance sequences on long-term costs and system performance is also reviewed.
Significant updates to the 1998 paper include streamlining the number of coating systems to better correspond with systems most commonly used today, a simplification of service environments to correspond with ISO classifications, and a more practical coating maintenance schedule. Included in the paper are 1) most commonly used generic coating systems in typical service environments, 2) service life for each, 3) current material costs, and 4) current field and shop painting costs.
Guidelines for developing long-term life-cycle costs and number of paintings for the expected life of the structure are included. The basic elements of economic analysis and justification are addressed together with guidance on the preparation of a Present Value Analysis. Worksheets and examples are provided to aid the reader in the proper use of the information.
Keywords: protective coatings, life-cycle costs, coating selection, coating system life, containment costs, industrial maintenance, maintenance painting costs, industrial environments, corrosive, solvent-free, metallizing, galvanizing, Present Value Analysis, installed coating costs.