Back to Basics

As previously discussed in earlier modules, paints and coatings are made of

volatile and non-volatile components.

The volatile component is the solvent used in the coating for application
purposes only.

The non-volatile components consist primarily of the binder and pigment and
do not evaporate.

This is specified by the paint supplier as ‘Volume Solids’ and is given as a

percentage of the total volume.

Due to environmental legislation, there are requirements to produce coatings

with a higher level of non-volatile components.

The coatings which contain high volatile contents are predominately, primers
and topcoats.
Spreading Rate

To calculate the spreading rate, you require the (non volatile components)
volume solids of the coating, which is found on the product data sheet and
the specified dry film thickness.

Using the formula:- (Metric)

Theoretical spreading rate, m²/litre = 10 x solid by vol % divided by the dry

film thickness

An example could be a coating with 65% volume solids and a specified dry
film thickness of 125 microns (5 mils).

65 x 10 = 650 ÷ 125 = 5.2

So the theoretical spreading rate is 5.2m²/litre (TSR = 5.2m²/litre).

This assumes no practical waste.

The US Measure would be:

Volume Solids (%) x 16.04/DFT (mils) which will give the theoretical coverage
in sqft/US gallon

208.52 sqft/US gallon

Practical Waste

Practical waste comes in a number of ways including:

 Mixing of paint
 Overspray
 Rough pitted surfaces
 High surface profile
 Porous surfaces
 Spillages
 Theft
 Paint left in or on application equipment

Flatter and bigger surfaces will have the least paint wastage while locations
with small and awkward configurations will have the most Paint wastage.
Paint Wastage

Paint wastage on a flat location with a relatively smooth surface such as the
outside of a vessel could be 20-30%. Whereas paint wastage on a small
diameter pipe could be as high as 60-70%

Paint wastage is also affected by the method of application, conditions during

application and specification criteria.

Deducting the paint wastage (based on assessment) from the theoretical

spreading rate (TSR) will give you the anticipated practical spreading rate
(PSR).

Practical spreading rate is calculated as TSR x (100% - wastage%) = PSR. For

example for a relatively smooth surface with an estimated wastage of 25% and
a TSR of 5.2m2/ litre the PSR can be calculated as PSR = 5.2m2/ litre x (100% -
25%) = 5.2 x 75% = 3.90m² / litre.

For USA the equivalent would be 208.52 sqft/US gallon x 75% = 156.39
sqft/US Gallon.
Calculating the Area of Plate

If the surface illustrated is 10 metres (33 feet) long and 3 metres (9.8 feet) wide
the area can be determined by multiplying the length by the width (30 sq
metres or 323.4 sq feet).

If both sides are coated then the surface area would be double.

Assuming the theoretical paint coverage of 5.2m² per litre then 11.53 litres of
paint will be required to cover both sides of the plate.

Taking into account approx 25% paint wastage, the practical coverage will be
3.9m² per litre.

The paint requirement will then be 15.38 litres.

Therefore 30m² per side = 60m²

Therefore 60m² / 3.9m² per litre = 15.38 litres

US Coverage

60m2 = 645 square feet / 156.39 sqft/US gallon practical spreading rate = 4.12
US gallon
Calculating the Area of Plate

For ease of calculation, the surface area illustrated in Figure 1 can be divided
into two separate shapes or Areas in order to calculate the total area as
detailed in Figure 2.

9 metres x 4 metres = 36m²

5 metres x 4 metres = 20m²

Total 56m² or 112m² both sides

or

29.5 feet x 13.1 feet = 386.5 sq feet

16.4 feet x 13.1 feet = 214.8 sq feet

Total = 601.3 sq feet or 1202.6 sq feet both sides

Calculating the Area of an I-Beam

A steel I-beam is essentially three steel plates welded together to create the
shape.

The beams may have stiffeners but there are also steel plate sections.
Therefore we can use the same formula for length and width.

An I-beam has top and bottom plates that are positioned horizontally. These
are called flanges.

The vertical steel plate that connects the top and bottom flanges is called the
web.

Stiffeners are vertical plates that are connected to the top and bottom flanges
and to the web.
Calculating the Area of I Beam

To determine the total area of the I-beam, follow the basic steps:

1. Measure the length and width of one of the flanges and calculate the
area of one of the surfaces by multiplying the length by the width.
2. Multiply step 1 by four, you may need to review the thickness of the
flange. This is generally small and not usually calculated unless the
thickness is significant.
3. Measure the length and width of the web and calculate the area by
multiplying the length times the width.
4. Multiply step 3 by 2.
5. Measure stiffeners in a similar fashion.
Calculating the Area of an I Beam

Alternative Methods of Calculation

1. The area of an I beam can be calculated by measuring the perimeter of

the exposed beam (both sides of the top flange i.e. = 2 x 300mm + 2 x
500mm + 2 x 300mm).
2. To calculate the total area multiply this by the length. Perimeter = 2.2
mtrs x length of 2 mtrs = 4.4 sq mtrs
3. Measure the length and width of a stiffener and calculate the area of
one of the sides by multiplying the length by the width.
4. Multiply step 3 by 2.

Note; 1mm = 0.0393700787 inches

Calculating the Area of a Cylinder

The area of a cylinder or tank can be calculated if the circumference of one

end (roof) can be determined and if the area of the side walls can be
calculated.

The side walls of a tank area created by bending flat steel sheets to create a
circle, so the formula to calculate the areas of the side walls are the same
formula to calculate the area of the plate.

We will use an example (metric) of a ground storage tank 40 metres high with
a roof diameter of 30 meters.

N.B. Circumference is defined as the enclosed boundary of a curved geometric

figure and normally related to a circle.
Calculating the Area of a Cylindrical Storage Tank

The circumference (C) of the tank is the perimeter at the base.

Calculated using the formula:

C = Pi x diameter

Pi = 3.14

The diameter (d) is the length from either side of the perimeter base,
intersecting the middle.

If the diameter of the roof is 30 metres, the circumference is 3.14 x 30 metres

or 94.2 metres.

To determine the radius (r) of the roof, divide the diameter by 2 or measure
from the perimeter to the middle of the base.

r = 30 ÷ 2 = 15 metres.

To determine the area (A) of the flat roof use the formula for a circle.

Area = Pi x r² = 3.14 x (15 x 15) = 706.5m².

The surface area of the vertical sides is determined by multiplying the height
of the tank shell by the circumference. So if the height is 40m...

Area of Sides = 40 x 94.2 = 3768m²

Calculating the Area of a Pipe

The surface area of a pipe can be calculated by knowing the circumference of

the pipe (calculated using the same formula used to determine the
circumference of a circle) and the length of a pipe.

The circumference is multiplied by the length of the pipe to determine the

total area (in m² or sq ft).

Area of a pipe = C x L

We will use an example (metric) of a pipe which has a 0.6 metre outside
diameter and is 12 metres long.

C = 3.14 x d (diameter).

If the diameter of the pipe is 0.6 metres, the circumference is 3.14 x 0.6 or 1.9
metres.

To determine the surface area of the exterior of the pipe, multiply the length
by the circumference.

12 metres x 1.9 = 22.8m²

Calculating Volume

There may be a requirement to estimate the total volume of liquid that a tank
or vessel can hold.

The volume of a box is calculated using the formula:

V = L x W x H, where
L = Length
W = Width
H = Height

If the box is 3 feet long, 2 feet wide and 4 feet high, the volume inside the box
is:

3 x 2 x 4 = 24 cubic feet or

900mm long, 600mm wide x 1200mm high, the volume inside the box is:

0.90m x 0.60m x 1.20m = 0.65 cubic metres

Calculating Volume

The volume of a cylinder can be calculated by determining the surface area of

the roof and multiplying by the height.

Note, this is the same approach for the box as previous because of the
formula (3 feet x 2 feet x 4 feet) = (base x height).

In the case of a cylinder, the surface area of the roof is determined by the
formula pi x r² as discussed previously with the result multiplied by the height
of the tank.

V = pi x r² x H

R = Radius of the tank

H = Height of the tank

Cont......
Calculating Volume

If the diameter of the tank is 18 metres then the Radius is calculated to be 9

metres (diameter ÷ 2) and the height of the tank is 10 metres, the volume that
the tank will hold (in litres) is calculated as:

Pi x r² x h
= 3.14 x (9 metres²) x 10 metres = 2543 cubic metres.

To convert cubic metres into litres of fresh water, multiply by 1000 (1 m³ =

1000 litres)

Therefore the volume that the tank can hold is 2,543,000 litres.
Converting Temperature

Temperature can be expressed in degrees Fahrenheit (°F) or in degrees Celsius

(°C).

The Fahrenheit scale is the scale where the boiling point is 212°F and the
freezing point of water is 32°F. Under standard atmospheric conditions.

The Celsius scale is the metric version of the Fahrenheit scale where the
boiling point of water is 100° and the freezing point of water is 0° under
standard atmospheric condition.

The range from freezing to the boiling point is:

1. Fahrenheit 32° to 212° = 180°F

2. Centigrade 0° to 100° = 100°C

Therefore 1 degree Centigrade is equal to 1.8 degrees Fahrenheit

= 1°C = 1.80°F
Converting Temperature

The easiest form of conversion is a conversion chart which is readily available.

Calculation

If the temperature in °F is known and needs to be converted to °C, the

following formula can be used:

Example

Converting 80°F into Centigrade

°C = (°F – 32°) ÷ 1.80

= (80-32) ÷ 1.80
= 48 ÷1.80
= 26.67°C

If the temperature in °C is known and needs to be converted to °F, the

following formula can be used: °F = (1.80 x °C) + 32 °F

Example

Converting 5°C to Fahrenheit

°F = (1.8 x 5 °C) + 32 °F
= (9) + 32
= 41°F
Microns and Mil

The terms micron (metric) and mils (British imperial) are often referred to in
the coating industry, specifying for coating thickness and surface profile
measurement.

One mil is equivalent to 0.001 inch and one micrometer is equivalent to 0.001
millimetre.

The term micrometer is abbreviated as micron.

There are 25.4 microns in a mil.

To convert from mils to microns, the value in mils is multiplied by 25.4.

To convert from micron to mils, the value in microns is divided by 25.4.

Basic Conversion Factors

There are a number of basic conversion factors of use to the global coatings
industry.

 There are 3.79 litres in 1 US Gallon

 There are 29.6 millilitres in 1 Ounce
 There are 1000 millilitres in 1 Litre
 There are 128 ounces in 1 US Gallon
 There are 4.546 litres in 1 UK Gallon
 There are 10.76 sq ft in 1 sq metre
 There are 35.31 cubic ft in 1 cubic metre
 There are 220 UK Gallons in 1 cubic metre
 There are 3.28 ft in 1 metre
Useful Definitions

Volume solids = Volume of non-volatile components. Usually found on the

product data sheet

Dry Film Thickness = The thickness of cured coatings

Practical Wastage = the amount of paint lost during the application process.

Circumference = The boundary line of an object (e.g. circle)

Circumference is defined as the enclosed boundary of a curved geometric

figure and normally related to a circle.

Diameter = the length of a straight line segment that passes through the
centre from one side to the other of a circle.

Radius = the length of a straight line that joins the centre of a circle with any
point of its circumference or half the diameter

Volume = the capacity of a three-dimensional object.

Useful Formulas

Theoretical spreading rate, m² per ltr = 10 x solid by Vol % divided by the Dry
film in microns

Practical Spread Rate = TSR x (100 % - wastage%) = PSR

Area of a plate = length x width

Pi = 3.14

Circumference = Pi x diameter

Radius = diameter ÷ 2

Area of circle= pi x r²

Cylinder surface area of the sides = height x circumference

Volume box = length x width x height

Volume Cylinder = pi x r² x H

°F = (1.80 x °C) + 32 °F

°C = (°F – 32°) ÷ 1.80

Microns = mil x 25.4

Mils = Microns divided by 25.4

Summary

In this unit, we have reviewed the volatile and non-volatile components of a

coating, items of practical paint wastage and calculating the surface area of
various structures.

Basic calculations and formulas have been discussed.