Estimation of Pipe Paint Quantity

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Paint Quantity Estimator

Pipe NPD :
Required Dry Film Thickness (DFT) Microns :
60
Length of Pipe :
4.34
Percentage of Solids in Paint :
60
Percentage Loss While Painting :
10
Theoretical Paint Quantity
Liters : 0.017
Gallons : 0.0046
Cubic Meters : 0
Actual Paint Quantity Including Losses
Liters : 0.019
Gallons : 0.0051
Cubic Meters : 0
Explanation
Required paint quantity for painting of a pipe depends on following factors :

Pipe Diameter.
Length of Pipe.
Required Dry Film Thickness (DFT).
Percentage of Solids content in a given paint.
Wastage of paint during painting which is based on type of painting method used.
Wet Paint Thickness
When paint is applied to pipe, it is in wet condition with volatile organic compounds. When it dries, all
volatile components goes away leaving only solids component behind. So to achieve particular dry
film thickness, higher thickness of wet film is required is is calculated as :

Wet Film Thickness (WFT) = DFT/Fraction of Solids.

Theoretical Paint Quantity

Theoretical Paint quantity is calculated by multiplying total surface area to be painted with wet film
thickness.

Theoretical Paint Quantity = Surface Area X WFT.

Wastage
During painting process, some amount of paint gets wasted which depends on method of paint
application. Typical wastage percentages are :

Brush or Roller Painting : 10%.

Airless Spray Painting : 20%.
Conventional Spray Painting : 30%
So, we have to add wastage to calculated paint quantity to get actual paint quantity.

Actual Paint Quantity = Theoretical Paint Quantity / Fraction of Solids in Paint.

Example Calculation
Pipe of nominal pipe diameter 10″ to be painted with Inorganic Zinc Silicate Coating with solids
percentage of 60%. Required dry film thickness is 70 microns. Method of application is conventional
Spray Painting. Calculate amount of paint required for length of 100 meters.

Pipe Dia in mm (D) = 10″ X 25.4 = 254mm.

Length of Pipe (L) = 100 meters = 100000 mm.
Surface area of pipe for one meter (A) = Pi X D = 3.141 X 254 = 0.797814 Sq. MM. (It is not necessary
to take actual pipe outside diameter from pipe data tables. Difference is negligible.)
Total Surface Area = A X L = 797.814 X 10000 0= 79781400 Sq.MM.
Required Dry Film Thickness (DFT) = 70 microns = 0.07 mm.
Fraction of Solids in Paint (S) = Solids Percent/100 = 60/100 = 0.6
Welt Film Thickness (WFT) = (DFT/S) = 0.07/0.6 = 0.1167 mm.
Theoretical volume of paint required = Total Surface Area X WFT = 79781400 X 0.1167 = 9310489
Cubic MM. = 9.310489 Liters.
For conventional spray painting method, estimated wasted is around 30%. So only 70% paint gets
used for actual painting. So amount of actual paint required is theoretical paint quantity divided by
fraction of actual paint usage.
Actual Paint Volume = Theoretical Paint Volume/0.7 = 9.310489/0.7 = 13.3 Liters.