Cost considerations
There are multiple anticorrosive systems that serve to protect structures. These systems have different materials characteristics, numbers of layers to apply, methods of application, surface requirements, etc.
All these differences make it difficult to assess the total cost of the part you are coating. The main points to consider are listed below.
1. Coating Material
Costs related to coating material depend on the following key points:
- Density of the material
- Layer thickness you will apply
- Number of layers you have to apply
- Cost of the coating products
When evaluating liquid coating, the dry content and the number of layers should be taken into consideration.
2. Metallic substrate
The cost of the metallic substrate depends on the quality and source of the metal. Depending on its composition, it may be better suited to resisting corrosion but also more expensive.
The impact of the choice of metal on the many other factors (energy consumption, surface treatment) should not be neglected.
Conversely, the benefits and performance of the coating materials should be considered to avoid selecting an inappropriate metallic substrate at the design stage. By selecting an effective coating system, you may make savings by improving substrate quality and performance.
3. Surface treatment
Surface treatment requirements vary depending on the coating system you select and substrate you use. Depending on the requirements, cost will be different. Chemical surface treatment will involve the cost of chemicals and involve waste treatment and mechanical treatment as well as requiring more manpower and incurring greater materials costs.
4. Energy
Energy will play an important part in the total cost of your powder coating system, depending on the substrate you use.
Degassing metal substrates requires a step to heat the uncoated substrate to avoid subsequent degassing issues.
Multilayer systems require multiple curing cycles between the different layers you apply.
Depending on the powder technology you use (e.g., Thermoplastic vs Thermosetting), different oven temperatures and heating times will be required, affecting energy consumption and cost.
Depending on your oven type and changes in variations in energy prices, the appropriate selection of coating materials will strongly impact on this part of your total cost.
5. Labour
Having qualified persons prepare the surface and apply the coating is a key part of the coating process. Depending on the labour time required to apply a coating system, labour costs can be significant.
Multilayer systems need more hours of labour and reduce productivity.
Robust coating systems enable optimisation and standardisation of your process and avoid the need for reworking.
Stability and applicability avoid wasting time due to the impact of uncontrollable parameters (e.g, air humidity).
Non-hazardous coating systems not emitting VOCs, like powder coating, will avoid additional costs required to protect your employees.
6. Maintenance costs & life span
Depending on the target life span of the parts you are coating, choosing the adequate coating system will avoid possible maintenance and the need to re-coat throughout their full life cycle. Parallel costs related to maintenance (dismantling/re-assembly/closure periods) have to be considered to avoid choosing a coating more attractive in terms of price but less robust/efficient/protective, requiring multiple maintenance operations during the life cycle of the items coated.
Maintenance may be needed due to parts you have designed/built/coated being used in un-recommended conditions or because of accidental damage. Selecting a coating system that allows for repairs in situ may avoid the significant costs of dismantling and re-assembly.
If you want to determine the cost of your project in detail, please contact your local sales engineer. We can help you define the different cost factors and guide you to the best coating solution for you.
Protection and expected performance will vary according to the design of the part to be painted, the quality of the surface pretreatment and application and thickness of the coating system, as well as the maintenance program of the coated surfaces. This information is given as an indication. It is based on our experience and does not constitute a commitment or any form of guarantee on our part.