CALCULATIONS

and FORMULAS GUIDE for

PAINTS and COATINGS

INDEX

Page

HowtoSpecifyBlasting.1
Abrasive/ProfileComparativeChart.2
ReductioninSolidsContentbyAddingThinner..3
VolumeofThinnerRequiredtoThin%Shown4
WetFilmThicknessRequirements..5
TheoreticalCoverageinSquareFeet..6
CoatingCoverageCalculations7
AbrasiveConsumptionperHour8
ExamplesofAbrasiveCleaningRates.9
ExamplesofCleaningProductionRates9
PressureLossinAirLine.............1011
CommonlyUsedFormulasandCalculations.12
EstimatingSquareFootageinVariousShapes.1314

1116E.ScottAve.WichitaFalls,TX76308(940)7679912www.excaliburpaint.com

HOW TO SPECIFY BLASTING

Your coating supplier will always designate the degree of surface preparation required for his materials.
The three basic standards used to describe surface preparation are: Steel Structure Painting Council
(SSPC) "Surface Preparation Specifications", the National Association of Corrosion Engineers Standards
(N.A.C.E.) and the Swedish Pictoral Standards. Their basic definitions are:

SSPC

SWEDISH*

DESCRIPTION

N/A

Removal of oil, grease, dirt, soil and

contaminants by cleaning with solvent,
vapor,alkali,emulsionorsteam.

St2

Removal of loose rust, loose mill scale and

loose paint by hand chipping, scraping,
sandingandwirebrushing.

N/A

St3

Removal of loose rust, loose mill scale and

loose paint by power tool chipping,
descaling, sanding, wire brushing and
grinding.

SP5,WhiteMetalBlast
Cleaning

Sa3

Removal of all visible rust, mill scale, paint

andforeignmatterbyblastcleaning.

SP6,CommercialBlast
Cleaning

Sa2

Blast cleaning until at least two thirds of

each square inch is free of all visible
residues.

SP7,BrushOffBlast
Cleaning

Sa1

Blast cleaning of all except tightly adhered

residuesofmillscale,rustandcoatings.

SP1,SolventCleaning

SP2,handToolCleaning

SP3,PowerTool
Cleaning

NACE

N/A

N/A

Complete removal of rust and mill scale by

acid pickling, duplex pickling or electrolytic
pickling.

SP8,Pickling

SP10,NearWhiteBlast
Cleaning

Sa2

Blast cleaning until at least 95% of each

square inch is free of all visible rust, mill
scale,paintandforeignmatter.

SP1187T,PowerTool
CleaningtoBareMetal

N/A

N/A

Removal of all visible rust, mill scale, paint

and foreign matter using power tools and
producingaminimumprofileof1mil.

ABRASIVE / PROFILE COMPARATIVE CHART

The following chart should be used only for approximating the abrasive size required to
obtain a specified anchor pattern. The standard metal used to obtain these results was hot
rolled steel with tightly adhering mill scale. The resulting depth of anchor pattern will vary
with the method used for measuring depths as well as any one of numerous other
variables (type and hardness of steel, thickness of mill scale, degree of cleaning specified,
etc.) This information can be used for centrifugal wheel as well as pressure blasting.
Pressure blasting should be done using 90-100 psi nozzle pressure. The depth of anchor
pattern used in this chart is an average and not a minumum of maximum depth obtainable.
Consult local abrasive suppliers for specific technical data.

1MilProfile

1.5MilProfile

30/60MeshSilicaSand
G80SteelGrit
S110SteelShot*
80MeshGarnet
100AluminumOxide
Clemtex#4
BlackBeauty3060

16/35MeshSilicaSand
G50SteelGrit
S170SteelShot*
36MeshGarnet
50GritAluminumOxide
Clemtex#3
BlackBeauty3060

2MilProfile

2.5MilProfile

16/35MeshSilicaSand
G40SteelGrit
S230SteelShot*
36MeshGarnet
36GritAluminumOxide
Clemtex#3
BlackBeauty2040

8/35MeshSilicaSand
G40SteelGrit
S280SteelShot*
16MeshGarnet
24GritAluminumOxide
Clemtex#2
BlackBeauty2040

3MilProfile
8/20MeshSilicaSand
G25SteelGrit
S330or390SteelShot*
16MeshGarnet
16GritAluminumOxide
Clemtex#2
BlackBeauty1240
*Steel shot alone will not give a good angular pattern and should be used in combination with steel
gritforbestresults.

REDUCTION IN SOLIDS CONTENT BY ADDING THINNER

(THINNER ADDED)

Original
Solids
Contentof
Material
Before
Adding
Thinner

2%

5%

7%

100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25

98
93
88
83
78
74
69
64
59
54
49
44
39
34
29
24

95
90
86
81
76
71
67
62
57
52
48
43
38
33
29
24

93
89
84
79
75
70
65
61
56
51
47
42
37
32
28
23

10% 12% 15% 17% 20% 25% 30% 35%

91
86
82
77
73
68
64
59
55
50
46
41
36
31
27
23

89
85
80
76
71
67
63
58
54
49
45
40
36
31
27
22

87
83
78
74
70
65
61
57
52
48
44
39
35
30
26
22

85
81
77
73
68
64
60
56
51
47
43
38
34
30
26
21

83
79
75
71
67
63
59
54
50
46
42
37
33
29
25
21

80
76
72
68
64
60
56
52
48
44
40
36
32
28
24
20

77
73
69
65
62
58
54
50
46
42
39
35
31
27
23
19

74
70
67
63
59
56
52
48
44
41
37
33
30
26
22
19

Solids
Content
After
Thinner

VOLUME OF THINNER REQUIRED

TO THIN PERCENTAGE SHOWN
1GallonKit
%
2
5
7
10
12
15
17
20
25
30
35

Oz.
2.6
6.5
9.0
12.8
15.4
19.2
21.8
25.6
32.0
38.4
44.8

5GallonKit
Liter
0.08
0.19
0.27
0.38
0.46
0.57
0.64
0.76
0.95
1.14
1.32

%
2
5
7
10
12
15
17
20
25
30
35

5LiterKit
%
2
5
7
10
12
15
17
20
25
30
35

Liter
0.10
0.25
0.35
0.50
0.60
0.75
0.85
1.00
1.25
1.50
1.75

Oz.
13.0
32.5
45.0
64.0
77.0
96.0
109.0
128.0
160.0
192.0
224.0

Liter
0.40
0.95
1.35
1.90
2.30
2.85
3.20
3.80
4.75
5.70
6.60

20LiterKit
Oz.
3.5
8.5
12.0
17.0
20.5
25.5
29.0
34.0
42.5
50.5
59.0

%
2
5
7
10
12
15
17
20
25
30
35

Liter
0.4
1.0
1.4
2.0
2.4
3.0
3.4
4.0
5.0
6.0
7.0

Oz.
14.0
34.0
48.0
68.0
82.0
102.0
116.0
136.0
170.0
202.0
236.0

WET FILM THICKNESS REQUIREMENTS

Required Dry Film Thickness (Mils)

%
100
95
90
85
80
Solids
75
Contentof
70
Material
65
After
60
Thinning
55
50
45
40
35
30
25

10

11

12

13

14

15

16

17

2.0
2.1
2.2
2.4
2.5
2.7
2.9
3.1
3.3
3.6
4.0
4.4
5.0
5.7
6.7
8.0

3.0
3.2
3.3
3.5
3.8
4.0
4.3
4.6
5.0
5.5
6.0
6.7
7.5
8.6
10.0
12.0

4.0
4.2
4.4
4.7
5.0
5.3
5.7
6.2
6.7
7.3
8.0
8.9
10.0
11.4
13.3
16.0

5.0
5.3
5.6
5.9
6.3
6.7
7.1
7.7
8.3
9.1
10.0
11.1
12.5
14.3
16.7

6.0
6.3
6.7
7.1
7.5
8.0
8.6
9.2
10.0
10.9
12.0
13.3
15.0
17.1

7.0
7.4
7.8
8.2
8.8
9.3
10.0
10.8
11.7
12.7
14.0
15.6
17.5

8.0
8.4
8.9
9.4
10.0
10.7
11.4
12.3
13.3
14.6
16.0
17.8

9.0
9.5
10.0
10.6
11.3
12.0
12.9
13.9
15.0
16.4
18.0

10.0
10.5
11.1
11.8
12.5
13.3
14.3
15.4
16.7
18.2

11.0
11.6
12.2
12.9
13.7
14.6
15.7
16.9
18.3

12.0
12.6
13.3
14.1
15.0
16.0
17.1
18.5

13.0
13.7
14.4
15.3
16.3
17.3
18.6

14.0
14.7
15.6
16.5
17.5
18.7
20.0

15.0
15.8
16.7
17.7
18.8
20.0
21.4

16.0
16.8
17.8
18.8
20.0
21.3
22.9

17.0
17.9
18.9
20.9
21.3
22.7
24.3

Note:Dryfilmthicknessesareminimum.Noallowanceismadeforevaporationofsolventsduringapplication.

WetFilm
Thickenss
Required

Example:
Matl.=70%
Solids
DFT=6mils
WetFilm=
8.6mils

THEORETICAL COVERAGE IN SQUARE FEET PER U.S. GALLON

Required Dry Film Thickness Per Coat (Mils)

%
100
95
90
85
80
75
Solids
70
Contentby
65
Volume
60
55
50
45
40
35
30
25

10

11

12

13

14

15

16

1604
1524
1444
1363
1283
1203
1123
1043
962
882
802
772
642
561
481
401

802
762
722
682
642
602
561
521
481
441
401
361
321
281
241
201

535
511
481
455
428
401
374
348
321
294
267
241
214
187
160
134

401
381
361
341
321
301
281
261
241
221
201
181
160
140
120
100

321
305
289
273
257
241
225
209
193
176
160
144
128
112
96
80

267
254
241
227
214
201
187
174
160
147
134
120
107
94
80
67

229
218
206
195
183
172
160
149
138
126
115
103
92
80
69
57

201
191
181
170
160
150
140
130
120
110
100
90
80
70
60
50

178
169
160
152
143
134
125
116
107
98
89
80
71
62
54
45

160
152
144
136
128
120
112
104
96
88
80
72
64
56
48
40

146
139
131
124
117
109
102
95
88
80
73
66
58
51
44
37

135
127
120
114
107
100
94
87
80
74
67
60
54
47
40
33

123
117
111
105
98
92
86
80
74
68
62
55
49
43
37
31

115
109
104
98
92
86
80
75
69
63
58
52
46
40
35
29

107
102
96
91
86
80
75
70
64
59
54
48
43
37
32
27

100
95
90
85
80
75
70 Theoretical
CoveragePer
65
Gallon
60
55
50
45
40
35
30
25

COATING COVERAGE CALCULATIONS

TheoreticalCoverage
(onsmoothsurface)

= TheoreticalCoverage

PracticalCoverage

Consumption

ft/U.S.gal =

%SBV/100x1604
dft(mils)

m/1 =

%SBV/100x1000
dft(micronsn)

TheoreticalCoveragex%Loss
100

Area(ftorm)
PracticalCoverage(gallonsorliters)

FilmThickness
WettoDry:

wftx%SBV
100

DrytoWet:

dftx100
%SBV

%SolidsbyVolumeandwetfilmthicknessadjustmentsduetothinning
W

=
A
W
X
Y
Z

=
=
=
=
=

X
1+Y

adjustedWFTrequiredforthinnedmaterial
adjusted%solidsbyvolumeduetothinning
originalmaterials%solidsbyvolume
%thinneradded
requireddryfilmthickness

Z
W

ABRASIVE CONSUMPTION PER HOUR

and

AIR CONSUMPTION IN CUBIC FEET PER MINUTE

Pressure at Nozzle
Orifice
Size
3/16"
(5mm)
1/4"
(6mm)
5/16"
(8mm)
3/8"
(10mm)
7/16"
(11mm)
1/2"
(13mm)
5/8"
(16mm)
3/4"
(19mm)

60PSI

70PSI

80PSI

90PSI

100PSI

30
171
7
54
312
12
89
534
20
126
764
28
170
1032
38
224
1336
50
356
2140
80
504
3056
112

33
196
7.5
61
354
13.5
101
604
22.5
143
864
32
194
1176
43.5
252
1512
56
404
2422
90
572
3456
127

38
216
8.5
68
408
15
113
672
25.5
161
960
36
217
1312
48.5
280
1680
62.5
452
2690
100
644
3840
143

41
238
9.5
74
448
16.5
126
740
28
173
1052
38.5
240
1448
53.5
309
1856
69
504
2973
112
692
4208
154

45
264
10
81
494
18
137
812
30.5
196
1152
44
254
1584
56.5
338
2024
75
548
3250
122
784
4608
175

Air(CFM)
Sand(lb/hr)
H.P.*
Air
Sand
H.P.
Air
Sand
H.P.
Air
Sand
H.P.
Air
Sand
H.P.
Air
Sand
H.P.
Air
Sand
H.P.
Air
Sand
H.P.

*ElectricmotorhorsepowerrequiredtoproductindicatedC.F.M.

EXAMPLES OF ABRASIVE CLEANING RATES

Abrasive
SilicaSand
16/40Mesh
CrushedFlint
12/30Mesh
Staurolite
50/100Mesh
CoalSlag
16/40Mesh
CopperSlag
16/40Mesh
*Garnet36
Grit
*Aluminum
Oxide36Grit
*G40Steel
Grit

Abrasive
Consumption

Production
Rate

Comments

2.6lbs./sq.ft.

275ft/hr.

1milprofile
dusty

3.6lbs./sq.ft.

161ft/hr.

3mils

3.1lbs./sq.ft.

291ft/hr.

1milprofile
smoothsurface

3.2lbs./sq.ft.

230ft/hr.

2milprofile

3.1lbs./sq.ft.

262ft/hr.

2milprofile

*3.6lbs./sq.ft.

213ft/hr.

*3.1lbs./sq.ft.

275ft/hr.

*5.5lbs./sq.ft.

184ft/hr.

1milprofile
verylittledust
1milprofile
verylittledust
2milprofile
nodust

*Theseabrasivesarenormallyreused
Newlyfabricatedsteelusinga3/8"I.D.orificenozzleand100psitoaSSPCSP10
nearwhitecondition.

EXAMPLES OF CLEANING PRODUCTION RATES

1.
2.
3.
4.
5.
6.
7.

Method

ProductionRate

SSPCSP1
SSPCSP2
SSPCSP3
SSPCSP5
SSPCSP6
SSPCSP7
SSPCSP10

500ft/hour
250300ft/hour
100ft/hour
1000ft
2500ft
5200ft
1500ft

AbrasiveUsed
1gal/hour
4units/day
2units/day
10,000lbs.
8,000lbs.
7,000lbs.
12,500lbs.

Pera3personcrewdayonlightlyrustedsteel,using30/40meshmediumhardness
abrasive,3/8"orificenozzleat80psi.

PRESSURE LOSS IN HOSE

Lubrication Only at Tool - No Line Lubricator
HoseLength
and
InsideDiameter

50Feet

3/4"

50Feet

1"

50Feet

1"

50Feet

1"

cfm
Free
Air
60
80
100
120
140
160
180
200
220
120
150
180
210
240
270
300
330
360
390
420
450
200
250
300
350
400
450
500
550
600
650
700
750
800
300
400
500
600
700
800
900
1000
1100
1200
1300

LinePressurepsig
60

80

100

3.1
5.3
8.1

2.4
4.2
6.4
9.0
12.0

2.0
3.5
5.2
7.4
9.9
12.7

2.7
4.1
5.8
7.7

2.1
3.2
4.6
6.1
7.9
9.8
12.0

2.4
3.7
5.2
7.0
8.9

2.1
3.7
5.6
8.0

120

150

200

300

2.9
4.5
6.3
8.4
10.8
13.6
16.6

2.4
3.6
5.1
6.9
8.9
11.1
13.5
16.2

1.8
2.8
3.9
5.3
6.8
8.5
10.5
12.4

1.2
1.9
2.7
3.6
4.6
5.8
7.1
8.4

2.6
3.5
4.5
5.6
6.9
8.2
9.7
11.3
13.0
14.8

2.0
2.7
3.4
4.3
5.3
6.3
7.4
8.7
10.0
11.4

1.3
1.8
2.3
2.9
3.6
4.3
5.0
5.9
6.8
7.7

2.3
3.1
4.0
5.0
6.2
7.4
8.7
10.2
11.7
13.3
15.0

1.8
2.4
3.1
3.9
4.7
5.7
5.7
7.8
9.0
10.2
11.5

1.2
1.6
2.1
2.6
3.2
3.9
4.6
5.3
6.1
6.9
7.8

2.5
3.6
4.9
6.3
7.8
9.5
11.4
13.6
15.8

1.9
2.8
3.7
4.8
6.0
7.3
8.8
10.4
12.1

1.3
1.9
2.5
3.2
4.1
4.9
6.0
7.1
8.3

2.7
3.8
4.0
6.5
8.1
9.9
11.8
13.9

2.3
3.2
4.3
5.5
6.9
8.4
10.0
11.9
13.8
15.9

2.9
4.1
5.5
7.0
8.8
10.8

2.4
3.4
4.5
5.8
7.3
8.9
10.7
12.6
14.6

2.0
2.9
3.8
4.9
6.2
7.6
9.1
10.7
12.4
14.3

2.9
4.4
6.3
8.5
10.9

2.4
3.7
5.2
7.0
9.0
11.2
13.6

2.0
3.1
4.4
5.9
7.7
9.5
11.6
14.0

PRESSURE LOSS IN HOSE - cont.

Lubrication Only at Tool - No Line Lubricator
LinePressurepsig

HoseLength
and

cfm
Free

InsideDiameter

Air

60

600
800
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
1000
1500
2000
2500
3000
3500
4000
4500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
5000
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000

1.9
3.2
5.0
7.0
9.3

50Feet

2"

50Feet

2"

50Feet

3"

25Feet

4"

1.7
3.7
6.5
10.0

2.5
3.9
5.5
7.5
9.8

1.9
2.7
3.6
4.7
5.9
7.2
8.7

80

100

2.5
3.9
5.5
7.4
9.6
12.1

2.1
3.2
4.5
6.1
7.9
9.9
12.2
14.6

2.9
5.1
7.9
11.2

2.4
4.2
6.5
9.3
12.4

2.0
3.6
5.5
7.9
10.6
13.7

2.5
3.6
4.9
6.3
7.9
9.6
11.5
13.6

2.1
3.1
4.1
5.3
6.7
8.2
9.8
11.5
13.5
15.6

2.0
3.0
4.4
5.9
7.6
9.6
11.7

2.1
2.8
3.7
4.6
5.7
6.8
8.1
9.4

1.7
2.3
3.0
3.8
4.7
5.6
6.7
7.8
9.0

120

150

200

300

2.7
3.8
5.2
6.7
8.4
10.4
12.5
14.7

2.2
3.1
4.2
5.5
6.9
8.5
10.2
12.0
14.1
16.2

1.7
2.4
3.2
4.2
5.3
6.5
7.8
9.2
10.8
12.4

1.1
1.6
2.2
2.8
3.6
4.4
5.3
6.3
7.3
8.5

2.9
4.5
6.4
8.7
11.2
14.0

2.2
3.4
4.9
6.6
8.6
10.7

1.5
2.3
3.3
4.5
5.8
7.3

2.5
3.4
4.4
5.5
6.7
8.0
9.4
11.0
12.7
14.5

1.9
2.6
3.3
4.2
5.1
6.1
7.2
8.4
9.8
11.1

1.3
1.7
2.3
2.8
3.5
4.2
4.9
5.7
6.6
7.6

2.1
2.6
3.2
3.9
4.6
5.4
6.2
7.1
8.0
9.1

1.2
1.6
2.0
2.5
3.0
3.5
4.1
4.8
5.4
6.2
6.9

2.0
2.6
3.2
4.0
4.8
5.7
6.6
7.6
8.7
9.8

COMMONLY USED FORMULAS for CALCULATING SURFACE AREA

Squares and Rectangles

a The areas of a square and of a
rectangle are obtained by multiplying the
length of one side
by the length of the other, i.e.
square = a x a

rectangle = a x b
a

Cubes

a
a

A cube has 6 sides that are all identical

squares. To calculate the total surface
area, multiply 6 by the
square of the length (a) of one of the
sides i.e.
6 x a x a

Spheres

The surface area of a sphere is

3.1416 multiplied by the square of
the diameter i.e.
3.1416 x d x d

L
d

Pipes
The surface area of a pipe is 3.1416
multiplied by the diameter (d) and by the
length (L) i.e.
3.1415 x d x L

L
R
d

Cylindrical Tanks
The surface area consists of the
cylindric shell plus the top and
bottom area i.e.
3.1416 x d x L + 2 x (3.1416 x R x R)

ESTIMATING SQUARE FOOTAGE IN VARIOUS SHAPES

Cylinder
a. Determine area of both ends of cylinder
(circles) by multiplying 3.1416 times the
radius (in feet) squared.
b. Determine area of side of cylinder by
multiplying circumference (in feet) times
height (in feet).
c. Add square feet of both ends to square
feet of side for total square feet of
cylinder.

Cone
a. Determine area of base by multiplying
3.1416 times the radius (in feet)
squared.
b. Determine the area of the side of the
cone by multiplying circumference of
base (in feet) times one-half of the slant
height (in feet).
c. Add the square foot area of the base to
the square foot area of the cone side for
total square foot area.

Triangle
Multiply the base measurement (in feet)
times one-half the altitude (in feet).

Circle
To determine the square footage of the area
of a circle, multiply 3.1416 times the radius (in
feet) squared.

Circumference
To determine the circumference of a circle,
multiply 3.1416 times the diameter (twice the
radius).

Square or Rectangle
Multiply the base measure (in feet)
times the height (in feet).

Estimating Square Footage from Tonnage

Many times structures will have unusual shapes or be too difficult to
accurately measure. In such instances, if the tonnage and
thickness of the steel can be determined, fairly accurate estimates
of area can be determined from the table below.

Thickness
of Steel
(inches)
Square
Foot Area
Per Ton

1/8

3/16

1/4

5/16

800

533

400

3/8

1/2

5/8

3/4

7/8

1-1/2

320

267

200

160

133

114

100

67

50