16. Calculations and conversions.

Table of content.

Section Title Page

16.1 Calculation of paint consumption 16.2

16.1.1 Percent volume solids (% VS) 16.2
16.1.2 Dry film thickness (DFT) 16.2
16.1.3 Wet film thickness (WFT) 16.3
16.1.4 Wet film thickness after thinning 16.3
16.1.5 Theoretical spreading rate of a coating 16.4
16.1.6 Consumption of paint, theoretical value 16.4
16.1.7 Paint consumption with loss 16.5
16.1.8 Paint consumption with loss and dead volume factor 16.6
16.1.9 Summary of formulas 16.7

16.2 Conversion tables 16.8

16.3 Conversion factors for different units 16.11

16. Calculations and conversions.

16.1. Calculations of paint consumption.
Often there is a lot of confusion when paint consumption is going to be 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:

1. Percent volume solids of the products.

2. Dry film thickness recommended.
3. Number of coats.
4. Surface area and condition of area to be coated.
5. Method of application.
6. Cost per litre paint.
7. Loss factor

16.1.1. Percent Volume Solids, (% VS).

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Percent volume solids is the volume percentage of solid material in the coating. The
remaining volume percentage consists of volatile solvents or thinners (See also “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.

16.1.2. 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:

Dry Film Thickness, DFT : WFT x % VS

100 %

WFT = Wet film thickness in microns

% VS = Percent volume solids

Example 1:
A coating is to be applied at wet film thickness of 250 microns, and the percent
volume solid is 50 percent. The equation becomes:

DFT = 250 microns x 50 % VS = 125 microns

100 %

16.1.3. 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:

Wet Film Thickness, WFT = DFT x 100 %

% VS

Example 2:
A coating is to be applied at a dry film thickness of 100 microns. The percent volume
solid is 65 %.

WFT = 100 microns x 100 % = 153,9 microns microns

65 % VS

The coating must be applied in a WFT of 154 microns since 35% of the paint is
solvents that will evaporate.

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16.1.4. Wet film thickness after thinning.

If the coating is thinned 20 % to adjust the viscosity for application the solid by
volume will change, it decreases. The new volume percent solids can be calculated or
found in a table (See tables in section 16.2).

Example 3:
If one litre of a coating with 65 percent 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:

% VS after thinning: % VS prior to thinning = 65 % VS = 54 % VS

New volume of paint 1,2 litres

The new WFT, to get a DFT of 100 microns after adding 20%, is:

New WFT : 100 microns x 100 % = 185 microns

54 % VS

The coating must be applied in a WFT of 185 microns, since 46 % of the paint in the
tin is solvents that evaporates.

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 % VS

See also the Table in section 16.3: “Solids content after thinning”.

16.1.5. Theoretical spreading rate of a coating.

The theoretical spreading rate (m2/litre) is the area covered by one litre of paint 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:

Theoretical spreading rate, m2/litre = % VS x 10

DFT

How to arrive at the constant 10 is shown in section 16.1.6.

16.1.6. Consumption of paint, theoretical value.

The theoretical consumption of a coating can be determined if the area (m 2), the

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percent volume solid (% VS) and the desired dry film thickness (DFT) are known.
(Practical consumption is given in sections 16.1.7. and 16.1.8.). The equation to get
the theoretical consumption is:

Paint consumption = area (m2) x WFT (microns)

or

Paint consumption = Area (m2) x DFT = litre of paint

10 x % VS

as WFT (microns) = DFT (microns) x 100%

% V.S.

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 m 3. 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:

Paint consumption in m3 = area (m2) x DFT (microns) x 100 %

% V.S. x 1 000 000 microns/m

However, we would like to order the paint in litres and not in m 3. Then, we have to
convert by introducing that 1 m3 = 1000 litre, and we get the equation:

Paint consumption in litre = area (m2) x DFT (microns) x 100 % x 1000 l/m3
% V.S. x 1 000 000 microns/m

giving the formula as above:

Paint consumption is = area x DFT

% V.S. x 10

Example 5:
The outside of a tank is to be painted. The total area is 500 m 2. The following paint
system is to be applied by airless spray:

Paint DFT % V.S.

Epoxy mastic 200 microns 85 %
Polyurethane topcoat 50 microns 50 %

How much paint do we need theoretically for the job?

Epoxy mastic : 500 m2 x 200 microns = 117,7 litre

10 x 85 % VS

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 Polyurethane topcoat: 500 m2 x 50 microns = 50 ,0 litre
10 x 50 % VS

16.1.7. Paint consumption with loss.

The above example assumes that there is no loss of paint during the job and that 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.
 Overspray due to 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: See section 16.1.8.

Such paint losses are usually in the range of 25 – 40 %, but may accumulate to as
high as 50 percent 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:

Volume paint with loss: Area (m2) x DFT (microns) = litre

10 x % VS x loss factor

Example 6:
The same figures as for Example 5 are used, but now a loss of 40% (loss factor of
0.6) is included. The correct amount of paint to order will be:

Epoxy mastic: 500 (m2) x 200 microns = 196 litres

10 x 85 % VS x 0,6

Polyurethane topcoat: 500 (m2) x 50 microns = 83 litres

10 x 50 % VS x 0,6

16.1.8. Paint consumption with Loss- and Dead Volume factor

Blast-cleaning will increase the surface roughness and thereby increase the surface
area. The roughness will depend on the abrasive used. However, the 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:

Surface Roughness Dead volume

Mean of Ry (microns) (l/m2)

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 30 0,02
45 0,03
60 0,04
75 0,05
90 0,06
105 0,07

The equation for calculating the paint consumption, including loss and dead volume
is:

Total paint consumption (litre): Area (m2) x dead Volume (l/m2) x 100
% VS x loss factor

NB! The “dead volume” is only a factor which effect the paint consumption for the
primer or the first coat of a paint system.

Example 7:
Here example 6 is taken one step further. The loss is 40%. The surface of 500 m 2 is
blast-cleaned to Sa 2 ½ with a roughness of 60 microns. A roughness of 60 microns
gives a dead volume of 0,04 l / m2 (see table above).

The paint consumption with loss, calculated in example 6, is:

Epoxy mastic: 500 (m2) x 200 microns = 196 litres

10 x 85% VS x 0,6

As Epoxy mastic is used as a first coat we have to include the dead volume:

Dead volume: 500 (m2) x 0,04 (l/m2) x 100 = 39 litres

85 % VS x 0,6

The total need of Epoxy mastic is: 39 litres + 196 litres = 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:

Polyurethane topcoat 500 (m2) x 50 microns = 83 litres

10 x 50 % VS x 0,6

16.1.9. Summary of formulas.

Solid by Vol. (% VS) = DFT x 100

Wet film

Wet film in µm (WFT) = DFT x 100

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 %VS

Dry film in µm (DFT) = WFT x % VS

100

Theoretical spreading rate. = % VS x 10

(m2 / ltr) DFT (µm)

Cost/m2 = Cost / ltr.

(Theoretical) m2 / ltr.

Cost/m2 = DFT x cost / ltr.

(Theoretical) 10 x %VS

Consumption (litre) = DFT x area (m2)

10 x %VS

Consumption = DFT x area (m2)

with loss 10 x %VS x loss factor

Dead volume = Area (m2 ) x dead volume (l/m2) x 100

% VS x loss factor

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16.2. Conversion tables

Table 16.2.1.
Loss in % and corresponding loss factor

Loss in % Loss factor

40 % loss 0,6
30 % loss 0.7
20 % loss 0.8
10 % loss 0.9

Table 16.2.2.
Dead volume as function of surface roughness.

Roughness in microns Dead volume, l / m2

30 0,02
45 0,03
60 0,04
75 0,05
90 0,06
105 0,07

Table 16.2.3.
Volume solids (%VS) after thinning.

Solid Thinner added

% 2% 5% 7% 10% 12% 15% 17% 20% 25% 30% 35%
100 98 95 93 91 89 87 85 83 80 77 74
95 93 90 89 86 85 83 81 79 76 73 70
90 88 86 84 82 80 78 77 75 72 69 67
85 83 81 79 77 76 74 73 71 68 65 63
80 78 76 75 73 71 70 68 67 64 62 59
75 74 71 70 68 67 65 64 63 60 58 56
70 69 67 65 64 63 61 60 59 56 54 52
65 64 62 61 59 58 57 56 54 52 50 48
60 59 57 56 55 54 52 51 50 48 46 44
55 54 52 51 50 49 48 47 46 44 42 41
50 49 48 47 46 45 44 43 42 40 39 37
45 44 43 42 41 40 39 38 37 36 35 33
40 39 38 37 36 36 35 34 33 32 31 30
35 34 33 32 31 31 30 30 29 28 27 26
30 29 29 28 27 27 26 26 25 24 23 22
25 24 24 23 23 22 22 21 21 20 19 19

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 Table 16.2.4.
Wet Film Thickness Requirements as function of % volume solids (% VS)

% VS Dry Film Thickness (Microns)

50 75 100 125 150 175 200 225 250
100 50 75 100 125 150 175 200 225 250
95 53 80 105 132 158 184 211 237 263
90 56 83 111 139 167 194 222 250 278
85 59 88 118 147 177 206 235 265 294
80 63 94 125 156 188 219 250 281 313
75 67 100 133 167 200 233 267 300 333
70 71 107 143 179 214 250 286 321 357
65 71 115 154 192 231 269 308 346 385
60 83 125 167 208 250 292 333 375 417
55 91 136 182 227 273 318 364 409 455
50 100 150 200 250 300 350 400 450
45 111 167 222 278 333 389 444
40 125 188 250 313 375 438
35 143 214 286 357 429
30 167 250 333 417
25 200 300 400

% VS Dry Film Thickness (Microns)

275 300 325 350 375 400 425 450 475
100 275 300 325 350 375 400 425 450 475
95 290 342 352 368 395 421 447 473 500
90 306 361 361 389 417 444 472 500 528
85 324 382 382 412 441 471 500 530 560
80 344 406 406 438 469 500 531 562 593
75 367 433 433 467 500 533 567 600 633
70 393 464 464 500 536 571 607 643 679
65 423 462 500 539 577 615 654 692 731
60 458

Formula used:

WFT = DFT without thinning x 100 %

% VS

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 Table 16.2.5.
Relation between dewpoint, air temperature and relative humidity

Air Dew point in °C at a relative humidity of:

Temp.
°C 50% 55% 60% 65% 70% 75% 80% 85% 90%
5 -4.1 -2.9 -1.8 -0.9 0.0 0.9 1.8 2.7 3.6
6 -3.2 -2.1 -1.0 -0.1 0.9 1.8 2.8 3.7 4.5
7 -2.4 -1.3 -0.2 0.8 1.8 2.8 3.7 4.6 5.5
8 -1.6 -0.4 0.8 1.8 2.8 3.8 4.7 5.6 6.5
9 -0.8 0.4 1.7 2.7 3.8 4.7 5.7 6.6 7.5
10 0.1 1.3 2.6 3.7 4.7 5.7 6.7 7.6 8.4
11 1.0 2.3 3.5 4.6 5.6 6.7 7.6 8.6 9.4
12 1.9 3.2 4.5 5.6 6.6 7.7 8.6 9.6 10.4
13 2.8 4.2 5.4 6.6 7.6 8.6 9.6 10.6 11.4
14 3.7 5.1 6.4 7.5 8.6 9.6 10.6 11.5 12.4
15 4.7 6.1 7.3 8.5 9.5 10.6 11.5 12.5 13.4
16 5.6 7.0 8.3 9.5 10.5 11.6 12.5 13.5 14.4
17 6.5 7.9 9.2 10.4 11.5 12.5 13.5 14.5 15.3
18 7.4 8.8 10.2 11.4 12.4 13.5 14.5 15.4 16.3
19 8.3 9.7 11.1 12.3 13.4 14.5 15.5 16.4 17.3
20 9.3 10.7 12.0 13.3 14.4 15.4 16.4 17.4 18.3
21 10.2 11.6 12.9 14.2 15.3 16.4 17.4 18.4 19.3
22 11.1 12.5 13.8 15.2 16.3 17.4 18.4 19.4 20.3
23 12.0 13.5 14.8 16.1 17.2 18.4 19.4 20.3 21.3
24 12.9 14.4 15.7 17.0 18.2 19.3 20.3 21.3 22.3
25 13.8 15.3 16.7 17.9 19.1 20.3 21.3 22.3 23.2
26 14.8 16.2 17.6 18.8 20.1 21.2 22.3 23.2 24.2
27 15.7 17.2 18.6 19.8 21.1 22.2 23.2 24.3 25.2
28 16.6 18.1 19.5 20.8 22.0 23.2 24.2 25.2 26.2
29 17.5 19.1 20.5 21.7 22.9 24.1 25.2 26.2 27.2
30 18.4 20.0 21.4 22.7 23.9 25.1 26.2 27.2 28.2

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16.3. Conversion factors for different units.

You have Multiply by To obtain

Length
Inches 0.0254 Meters
mm 25.4 mils
Feet 0.305 Meters
Fathoms 6 Feet
Fathoms 120 Cable Length
Feet 6.085 Nautical Mile
Feet 5.280 Statute Mile
Cable Length 7.5 Mile
Yards 0.914 Meters
Miles 1609 Meters
Miles 1.609 Kilometres
Millimetres 0.03937 Inches
Centimetres 0.3937 Inches
Meters 39.37 Feet
Meters 1.094 Miles
Area
Sq. Inches 6.45 Sq. Centimetres
Sq. Feet 0.0929 Sq. Meters
Sq. Yards 0.936 Sq. Meters
Sq. Centimetres 0.155 Sq. Inches
Sq. Meters 10.764 Sq. Feet
Sq. Meters 1.186 Sq. Yards
Sq.Inches 645.137 Sq. millimetres
Sq.Feet 0.0929 Sq. Metres
Volume
Litres 0.2642 Gallons (US)
Litres 0.22 Gallons (Imp.)
Gallons (US) 3.78 Litres
Imp. Gallons 1.20 Gallons (US)
Imp. Gallons 4.55 Litres
US Gallons 0.833 Gallons (Imp.)
Cubic Meters 35.314 Cubic Feet
Weight
Kilograms 2.40262 Lbs. Avoirdupois
Kilo per Meter 0.67196 Lbs. per Foot
Ounces 28.3495 Grammes
Pounds 0.45359 Kilograms
Density
Kilo per Cu.Meter 0.06243 Lbs. per Cwt.Ft.
Sq.Ft./USGal. 0.0246 Sq.M./Litre
Sq.Ft./USGal. 0.112 Sq.M./Imp. Gal.
.

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Various
Kilo per Meter 0.67196 Lbs. per Foot
Sq.Ft./USGal. 0.0246 Sq.M./Litre
Sq.Ft./USGal. . 0.112 Sq.M./Imp. Gal.
Sq.M./Litre 40.76 Sq.Ft./US Gal.
Sq.M./Imp.Gal. 8.97 Sq.Ft./USGal.
Sq.M./Kilo 4.9 x Wt./Gal Sq.Ft./US Gal.

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