Formula No.

Theoretical spreading rate :

Volume Solids (%) x 10

------------------------------- = m2/litre
DFT (m)

1
 Formula No.2

Practical consumption :

Area m2) x CF
----------------------------------- = litre
Theoretical Spearing Rate

Where CF is the Consumption Factor always > 1)

2
Formula No.3

1
Loss factor = -------
CF

3
 Formula No.4

100% - loss %
Loss factor = ------------------
100

Example : if the loss % is 45% then the loss factor is 0,55

Corresponding to a consumption factor of 1.8

4
 Formula No.5

Area m2) x DFT

Litres of paint = -----------------------------------------------
10 x Volume Solids %) x loss factor

5
 Formula No.6

DFT x 100% + % thinning)

WFT = -------------------------------------
Volume Solids %)

6
 Formula No.7

Area m2) x “dead volume” l/ m2) x 100%

Total “Dead Volume” = -------------------------------------------------------
Volume Solids %) x loss factor

Relationship between Rz and “dead volume”:

Rz : 30 45 60 75 90 105 micron
“Dead Volume” : 0,02 0,03 0,04 0,05 0,06 0,07 l/m2.

Note : The “dead volume” is only calculated for the first coat in a paint system

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 PAINT CONSUMTION

The dry film thickness DFT) of an applied coating can be

determined if the percentage of the volume solids % solids) and
the wet film thickness WFT) are known. This information can be
obtained from the Manufacturer’s Published Product Data Sheets.

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 Case 1

 A WFT of 200 micron has been applied on a steel structure. The percentage of the volume
solids of this paint is 60%. Determine the DFT.
 A percentage of the volume solids of 60 indicates that the other 40% are solvents that will
evaporate. If a WFT of 200 micron is applied, 40% of the WFT will evaporate and what is
left is the DFT. The DFT is equal to 120 micron.

WFT x 100% solids

DFT = --------------------------
100%

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 Case 2

 A DFT of 100 micron is to be applied on a steel structure. The percentage of the

volume solids of the paint is 50. Determine the WFT.
 The paint must be applied in a WFT of 200 micron since 50% of the paint is solvents
that will evaporate.

DFT x 100%
WFT = -----------------
% solids

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 Case 3

 Often, the paint operator will have to adjust the viscosity of the paint by thinning
the paint. This will of course affect the necessary DFT as well as the WFT of the
paint.
 A DFT of 75 micron is to be applied on a steel structure. The percentage of the
volume solids of the paint is 50 and the paint has been thinned 20%. Determine
the DFT.
 The paint must be applied in a WFT of 180 micron.

DFT x 100 + % thinning)

WFT = ----------------------------------
% solids

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You could also determine the percentage of the volume solids after thinning the paint by 20%. To
do so, the simplest way is to base the calculation on 1 litre of paint.

If 1 litre of paints is thinned by 20%, the volume of the paint will be increased to 1,2 litres. The
ratio of the old percentage of the volume solids to the new volume of the paint is the new
percentage of volume solids.

Old percentage by volume solids

New percentage of volume solids = -----------------------------------------
New volume of paint

50%
= -------- = 41,7%
1,2

DFT x 100% 75 x 100

WFT = ------------------ = ------------ = 180 micron
% solids 41,7
What other information do we need in order to calculate the amount of paint that should be
ordered for a project?
In order to calculate the approximate amount of paint, the following must be known or estimated:
 the surface area of the construction
 the appearance of the construction
 the surface roughness of the structure
 the WFT or the DFT
 the number of coats of each paint
 the percentage of the volume solids of the each
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 Case 4

The outside of a tank, an area of 500 m2, is to be painted. The following paint
system is to be applied by airless spray:

Paint DFT % solids

Zinc epoxy 25 micron 70%

Epoxy high build 100 micron 50%
Polyurethane topcoat 50 micron 50%

Assuming there is no loss of paint during application, calculate the amount of paint
that must be ordered.

13
 Area m2) x DFT micron)
Litres of paint = -----------------------------------
10 x solids %)

500 m2 x 25 micron
Zinc epoxy = --------------------------- = 18 litres
10 x 70

500 m2 x 100 micron

Epoxy high build = ---------------------------- = 100 litres
10 x 50

500 m2 x 50 micron
Polyurethane topcoat = --------------------------- = 50 litres
10 x 50

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 Case 5
As in case 4, the outside of a tank, an area of 500 m2 is to be painted. The following paint system is to be applied by
airless spray :

Paint DFT % solids

Zinc epoxy 25 micron 70%

Epoxy high build 100 micron 50%
Polyurethane topcoat 50 micron 50%

 There is a loss of paint of 40% during application. What is the amount of paint to be ordered?
 When calculating loss of paint during application, it is important to make the calculation the correct way. If you have
calculated the amount of paint needed to be 100 litres and the loss is 40%, only 60% of the paint is actually left on the
construction after painting.

 The correct amount of paint to be ordered will be:

100 litres x 100 100 litres

------------------- or ------------ = 167 litres
60 0,6

0,6 is the loss factor.

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 Area m2) x DFT micron)
Litres of paint = -------------------------------------
10 x solids %) x loss factor

Amount of the paint ordered :

500 m2 x 25 micron
Zinc epoxy = --------------------------- = 30litres
10 x 70 x 0,6

500 m2 x 100 micron

Epoxy high build = ---------------------------- = 167 litres
10 x 50 x 0,6

500 m2 x 50 micron
Polyurethane topcoat = --------------------------- = 84 litres
10 x 50 x 0,6

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 Case 6
 After creating a surface profile by blast cleaning, the surface area of the steel has been
increased and additional primer has to be ordered. How much more paint depends on the
surface roughness?
 Most frequently used coefficient between roughness and dead volume.

Roughness determined “Dead volume”

As a mean of Rz micron) the amount of paint needed to fill up the
roughness l/m2)

30 0,02
45 0,03
60 0,04
75 0,05
90 0,06

Area m2) x “dead volume” l/m2) x 100%

“Total dead volume” = ------------------------------------------------------
% Solids x loss factor

The “dead volume” is only a factor, which effects the primer coat of the paint system.
Please also see section R 15b in the Coating Adviser’s Handbook.
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 STANDARDS

Standards are used to get consensus in understanding among persons. Standards are also used to ensure a common
basis for technical matters and it is this last point that will be discussed in this paper.
We have different types of standards:
ISO Standards : which are valid for most countries in the world i.e. those countries who are members of the
ISO organization).
CEN Standards : which are valid among the CEN European member countries.
National Standards : which are only valid within one country.
Industrial Standards : which are only valid for a specific industry.
Company Standards : which are only valid for one company or company group.
The above list has been made in priorities, which means that the ISO standards overrule the others.
Standards member countries of ISO as well as the CEN Standards have agreed to adapt all ISO and CEN standards
as joint ISO/CEN National Standards after the former two types have been in force for a period of twelve months.
By using standards – especially technical ones – we get the benefit of reducing misunderstandings. For instance,
specification writing is facilitated as reference to standards will eliminate the need for long and detailed descriptions.
Therefore, we used standards as much as possible in specifications, technical data sheets, application instructions,
etc. To establish a technical basis for items like steel preparation, surface treatment, quality of abrasives, etc.
At the moment, we have a few international standards, which deals with paint properties and paint application,
however, both ISO and especially CEN are working on this and several standards are in the process of being issued.
In various countries there are several National Standards covering generic types of paint.

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