Paint Consumption Calculations Guide
Paint Consumption Calculations Guide
CALCULATIONS OF PAINT Often there is a lot of confusion when paint consumption is going to be
CONSUMPTION calculated. The various paint manufacturers arrive at different volumes, and
thereby also different costs, when giving quotations for a specific job. It is not
possible to find the true coating costs without a uniform method of calculating.
The following requisites are necessary for calculating the correct quantity and
coating costs:
3. Number of coats
5. Method of application
7. Loss factor
Percent Volume Solids Percent volume solids is the volume percentage of solid material in the coating.
(% VS) The remaining volume percentage consists of volatile solvents or thinners (see
also chapter 4 “What is paint?”). The solids are the film forming portion of the
coating that will remain on the surface after drying or curing. Percent volume
solids is the only true basis for calculating paint volumes required. Solids
content quoted by weight is a figure that for most coatings and applications is
meaningless. The percent volume solids is found in the technical data sheet
(TDS), but can also be found or verified by standardised tests.
Dry Film Thickness (DFT) The dry film thickness (DFT) of an applied coating can be determined if the
percent volume solids (% VS) and the wet film thickness (WFT) are known.
This information can be obtained from the manufacturer’s Technical Data
Sheets. The equation for calculating the dry film thickness is:
Example 1:
A coating is to be applied at wet film thickness of 250 microns, and the volume
solid is 50 percent. The equation becomes:
Wet film thickness (WFT) The wet film thickness can be determined if the percent volume solids (%VS)
and the dry film thickness (DFT) are known. This information can also be
obtained from the manufacturers Technical Data Sheets. The equation for
calculating the WFT is:
Example 2:
A coating is to be applied at a dry film thickness of 100 microns, and the volume
solid is 65%.
The coating must be applied in a WFT of 154 microns since 35% of the paint is
solvents that will evaporate.
Wet film thickness after If the coating is thinned 20% to adjust the viscosity for application the solid by
thinning volume will change, it decreases. The new volume percent solids can be
calculated or found in a table.
Example 3:
If one litre of a coating with 65% volume solid is thinned 20%, the total volume
of the coating will increase to 1.2 litres. The new percentage by volume of solid is:
The new WFT, to get a DFT of 100 microns after adding 20%, is:
The coating must be applied in a WFT of 185 microns, since 46% of the paint
in the tin is solvents that evaporate.
Example 4:
Another way of calculating the new WFT after thinning is given by the formula:
New WFT: DFT x (100 + % added thinner) = 100 microns x 120 = 185 microns
% VS 65%
Theoretical spreading rate The theoretical spreading rate (m2/litre) is the area covered by one litre of paint
of a coating for a given dry film thickness. Thus, the spreading rate can be determined if the
percent volume solid and the desired dry film thickness are known. The
equation for calculation is:
Consumption of paint, The theoretical consumption of a coating can be determined if the area (m2), the
theoretical value percent volume solid (% VS) and the desired dry film thickness (DFT) are
known. The equation to get the theoretical consumption is:
The constant 10 is a correction factor for the different units included in the
formula and derives from the following:
First, let us calculate the paint consumption in m3. Here we have to include the
correlation factor for transforming from metres to microns. We know
that 1 m = 1.000.000 microns, and get the following equation:
However, we would like to order the paint in litres and not in m3. Then, we have
to convert by introducing that 1 m3 = 1000 litres, and we get the equation:
Paint consumption in litre = area (m2 ) x DFT (microns) x 100% x 1000 l/m 3
% VS x 1 000 000 microns/m
[continued]
Paint DFT % VS
Epoxy mastic 200 microns 85
Polyurethane topcoat 50 microns 50
Paint consumption The above example assumes that there is no loss of paint during the job and that
with loss every drop of paint is applied to the surface. In a real situation some of the paint
will be lost:
• The coating may miss target due to strong wind, very complex geometry
of the structure or by poor application technique.
• Some material will be left in the pump, the tins or in the container.
• Dead volume
Such paint losses are usually in the range of 25–40%, but may accumulate to as
high as 50% of the total theoretical volume. Loss of paint must always be
included when the total paint consumption is calculated. Further, it is important
to calculate the volume of paint to order in the correct manner. If the theoretical
amount of paint needed is 100 litres and the loss is 40%, only 60% of the actually
paint is left on the surface after painting. The loss factor is 0.6. The equation for
calculation is:
[continued]
Paint consumption with Blast cleaning will increase the surface roughness and thereby increase the
Loss- and Dead Volume surface area. The roughness will depend on the abrasive used. However, the
factor
consequence is that more paint is needed to cover the increased area. The ‘dead
volume’ is the amount of paint needed to fill in for the roughness (profile) on
the blast cleaned steel (from the bottom to the top of the valley). The amount of
paint (l/m2) needed to fill in the roughness is indicated below:
The equation for calculating the paint consumption, including loss and dead
volume is:
Total paint consumption (litre): Area (m2 ) x dead volume (l/m 2) x 100
% VS x loss factor
NB! The “dead volume” factor only affects the paint consumption for the
primer or the first coat of a paint system.
[continued]
As Epoxy mastic is used as a first coat we have to include the dead volume:
The total need for Epoxy mastic is: 39 litres + 196 litress = 235 litres.
As the dead volume will have no influence on the topcoat the volume of the
Polyurethane is the same as in example 6:
Summary of formulae
Solid by Vol. (% VS) = DFT x 100
WFT
Cost/m2 = Cost/ltr.
(Theoretical) m2/ltr.
Spray Orifice Atlas Atlas ARO Devilbiss Devilbiss Exit Exit Graco Graco Graco Graco Kremlin Lautom Lautom Lautom Nordson Spraying Spraying Wagner Wagner Wagner
angle Copco Copco standard standard insert standard insert standard RAC RAC FF air mix standard insert tip maxi tip systems system quick blastaway standard
standard insert tip nozzle nozzle tip nozzle TC tip RC nozzle nozzle 741- 741- 742- TC Roto clean change nozzle RC TC
25° 0.013” 6803-1325 6804-1325 TC 1325 213-033 201-233 213-033 233 163-313 216-313 09/043 741-20033 741-233 000904 25025 3G 0999213 0080213 0090213
25° 0.015” 6803-1525 6804-1525 TC1525 215-038 201-238 215-038 238 163-315 216-315 206-056 14/093 741-238 742-83215 25033 3H 0999215 0080215 0090215
25° 0.017” 6803-1725 6804-1725 217-043 201-243 217-043 243 167-317 216-317 205-949 001404
25° 0.018” 6803-1825 6804-1825 TC1825 163-319 216-319 206-183 163-318 741-20045 002004 25050 3J 0999218 0080218
40° 0.013” 6803-1340 6804-1340 TC1340 413-033 201-433 413-033 433 163-413 216-413 205-882 09/113 741-40033 741-433 742-88413 000906 40025 4G 0999413 0080413 0090413
40° 0.015” 6803-1540 6804-1540 TC1540 415-038 201-438 415-038 438 163-415 216-415 205-809 14/113 741-40038 741-438 742-88415 40033 4H 0999415 0080415 0090415
40° 0.017” 6803-1740 6804-1740 417-043 201-443 417-043 443 163-417 216-417 205-883 741-443 742-88417 001406 40044
40° 0.018” 6803-1840 6804-1840 TC1840 163-419 216-419 206-092 163-418 741-40045 741-445 40050 4J 0999418 0080418 0090418
40° 0.021” 6803-2140 6804-2140 TC2140 421-053 201-453 421-053 453 163-421 216-421 205-952 20/113 741-40053 741-453 742-88421 002006 40067 4K 0999421 00880421 0090421
40° 0.023” 6803-2340 6804-2340 423-058 201-458 423-058 458 163-423 216-423 205-815 741-40058 741-458 741-88423 003006 40080 4A
65° 0.013” 6803-1365 6804-1365 TC1365 613-033 201-633 613-033 633 163-713 216-613 205-906 09/133 741-60033 741-633 742-88613 050135 65025 6G 0999613 0080613 0090613
65° 0.015” 6803-1565 6804-1565 TC1565 615-038 201-638 615-038 638 163-715 216-615 205-803 14/133 741-60038 741-638 742-88615 65033 6H 0999615 0080615 0090615
65° 0.017” 6803-1765 6804-1765 617-043 201-643 617-043 643 163-717 216-617 205-783 741-60043 65044
65° 0.018” 6803-1865 6804-1865 TC1865 163-719 216-619 205-823 163-718 741-60045 741-645 742-88618 050145 65050 6J 0999618 0080618 0090618
65° 0.021” 6803-2165 6804-2165 TC2165 621-053 201-653 621-053 653 163-721 216-721 205-829 20/133 741-60053 741-653 742-88621 65067 6K 0999621 0080621 0090621
65° 0.023 6803-2365 6804-2365 623-058 201-658 623-058 658 163-723 216-723 206-240 741-65058 741-658 742-88623 002010 65080 6A
65° 0.025” 6803-2565 6804-2565 TC2565 625-063 201-663 625-063 663 163-725 216-725 205-830 741-65063 741-663
65° 0.026” 6803-2665 6804-2665 TC2665 163-276 741-60066 741-666 742-88626 003010 6501 6L 0999626 0080626 0090626
65° 0.027” 6803-2765 6804-2765 627-068 201-668 627-068 668 163-727 216-627 206-317 741-668
65° 0.031” 6803-3165 6804-3165 TC3165 631-078 201-678 631-078 678 163-731 216-631 206-447 65015 6M 0999631 0080631 0090631
65° 0.035” 6803-3565 6804-3565 635-089 201-689 635-089 689 163-735 216-635 205-963 006812 6502 6N 0999636 0080636 0090636
65° 0.043” 6803-4365 6804-4365 TC4365 643-109 201-6109 643-109 6109 163-743 205-754 741-65107 741-6107 6503 6O 0999643 0080643 0090643
65° 0.047” 6803-4765 6804-4765 647-119 201-6119 647-119 6119 163-747 216-645 205-825 741-6119
65° 0.052” 6803-5265 6804-5265 TC5265 163-753 205-746 741-6132 6504 6P 0999552 0080552 0090552
80° 0.017” 6803-1780 6804-1780 817-043 201-843 817-043 843 163-817 216-817 205-826 741-843
80° 0.018” 6803-1880 6804-1880 TC1880 163-819 216-819 205-807 163-818 741-80045 741-845 742-88818 050147 80050 8J 0999818 0080818 0090818
80° 0.021” 6803-2180 6804-2180 TC2180 821-053 201-853 821-053 853 163-821 216-821 205-722 20/173 741-80053 741-853 742-88821 050157 80067 8K 0999821 0080821 0090821
80° 0.023” 6803-2380 6804-2380 823-058 201-858 823-058 858 163-823 206-240 741-80058 80080 8A
80° 0.025” 680-2580 6804-2580 825-063 201-863 825-063 863 163-825 205-032 741-80063 741-863 003014
80° 0.026” 6803-2680 6804-2680 TC2680 163-827 216-827 205-968 163-826 741-80066 741-866 742-88826 8001 8L 0999826 0080826 0090826