World-Class Coating Consultants

BG GROUP OF PAINT & COATING CONSULTANTS

Corrosion Management | Surface Protection | Digital Engineering Solutions

🌐 bgcoating.com 📞 +91 99258 10408 📍 Surat, Gujarat, India

🖌️

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Paint Calculators

WFT · DFT · Coverage · Cost

📐

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Surface Area

Pipe · Tank · Vessel · Plate

💎

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Abrasive Consumption

Garnet · Copper Slag

🧂

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Salt Contamination

Bresle · ISO 8502-9

👑

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Executive Coating — PRO

28 PRO modules incl. Bid Comparison

Quick Access

Most-used calculators

📐

Coverage

TC & PS spread rate (m²/L)

🧮

WFT Range

Min & Max WFT from DFT

📏

DFT

Dry film thickness from WFT

🔩

Surface Area

Pipe · Tank · Vessel m²

💎

Abrasive

Garnet & Copper Slag (kg)

🧂

Salt Test

Bresle ISO 8502-9 + temp

👑

Executive PRO

Volume Solids verification suite

Industry Insights

Engineering reference

🛡️

Common Paint Systems

Inorganic Zinc Silicate75 µm

Epoxy Intermediate100 µm

High-Build Epoxy125 µm

Polyurethane Topcoat50 µm

📏

Typical DFT Ranges

Primer Coat40–75 µm

Intermediate100–150 µm

Finish / Topcoat50–80 µm

Coal Tar Epoxy200 µm

💎

Abrasive Factors

Garnet · SA 2.520 kg/m²

Garnet · SA 3.025 kg/m²

Copper Slag · SA 2.530 kg/m²

Copper Slag · SA 3.035 kg/m²

🧂

Salt Test Limits

Standard (general)≤ 20 mg/m²

Immersion service≤ 10 mg/m²

High-spec offshore≤ 5 mg/m²

MethodISO 8502-9

All Calculators

Tap any tool to begin

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🧮

WFT Range Calculation

Min & Max WFT from DFT range

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📏

DFT Calculation

Dry Film Thickness from WFT

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📐

Paint Coverage

TC & PS Spread Rate (m²/L)

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🧪

Paint Consumption

Total litres for surface area

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💥

Blast Loss

Dead Volume paint loss

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⚗️

Mixing Ratio

Part A & B volumes

→

💰

Cost Per Area

Full project costing

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🔩

Pipe Area

Inside / outside surface m²

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🛢️

Tank Area

Shell, roof & bottom m²

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⚖️

Structure Weight-Wise

Surface area from tonnage

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🔲

Plate Area

Both sides + thickness faces

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🫙

Dished End Area

Hemi / Semi-Ellip / Tori head

→

🏭

Vessel / Equipment

Complete vessel area

→

💎

Abrasive Consumption

Garnet + Copper Slag (kg)

→

🧂

Salt Contamination

ISO 8502-9 + temp correction

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📋

Volume Solids — TDS Verify

DFT × Coverage ÷ 10 vs TDS

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⚖️

Volume Solids — Density

WS% × Wet ÷ Dry density

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🧫

Volume Solids — Laboratory

ASTM D2697 / ISO 3233

→

📊

Paint Reconciliation

Theoretical vs actual consumption

→

💹

Coating Life Cycle Cost

Total ownership cost · ₹/m² · ₹/yr

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🪨

Abrasive Size vs Blast Profile

Predict anchor profile · ISO 8503

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♻️

Abrasive Recycling

Recovery rate · efficiency · makeup

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🌀

Dust Collector Capacity

CFM · filter area · fan motor · model

→

🏗️

Surface Area & Weight

Steel sections · paint · abrasive · BOQ

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📏

DFT Acceptance — SSPC-PA 2

Spot 80/120% rule · area average

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📐

DFT Acceptance — ISO 19840

Correction value · readings · status

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⚡

Holiday Test Voltage

ASTM G62 formula · NACE SP0188 table

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🧲

Corrosion Rate

Weight / thickness loss · remaining life

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🩺

Coating Life Prediction

Health index · condition · recoat year

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🧵

TSA Wire Consumption

Wire kg · efficiency · procurement

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📦

TSA Area Coverage

m² per available wire quantity

→

🎯

TSA Deposition Efficiency

Deposited ÷ consumed · rating

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🔎

TSA Thickness Verify

Achieved µm from deposited weight

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⏱️

TSA Productivity

m²/hr · kg/hr · per operator

→

💰

TSA Cost

Material + labour + sealer · ₹/m²

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🧱

PFP Material Consumption

Area × thickness × density + wastage

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🔥

PFP Thickness — Fire Rating

UL 1709 · Hp/A · critical temp

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⚗️

PFP Density Verification

ASTM E605 — actual vs specified

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🕸️

Mesh Quantity

Rolls · overlap · procurement

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🧾

PFP Cost

Full project cost · ₹/m² · breakdown

→

🩹

PFP Repair Quantity

Damaged area · repair material · %

→

🛒

Paint Procurement Quantity

Multi-coat · containers · reserve

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🏆

Bid Tab & Comparison

Up to 10 bids · scores · charts

📋

Quick Reference — Common Paint Systems

Click any row to auto-fill the Coverage calculator

Paint Type	VS%	DFT µm	TC m²/L	Loss%	PS m²/L
Inorganic Zinc Silicate	75%	75	10.00	20%	8.00
Epoxy Zinc Primer	65%	60	10.83	25%	8.13
Epoxy Intermediate	80%	100	8.00	20%	6.40
High-Build Epoxy	85%	125	6.80	20%	5.44
Polyurethane Topcoat	60%	50	12.00	25%	9.00
Coal Tar Epoxy	70%	200	3.50	25%	2.63
Amine-Cured Epoxy	90%	150	6.00	20%	4.80
Alkyd Primer	45%	40	11.25	15%	9.56

Paint Calculators

7 Paint & Coating Calculators

🧮

WFT Range Calculation

Min & Max WFT from DFT range

P-1

Min DFT µm

µm

Max DFT µm

µm

Volume Solids %

Thinner %

Paint Name optional

WFT Range Result

WFT Minimum

—µm

From Min DFT

WFT Maximum

—µm

From Max DFT

📝 Input Data (Provided by User)

Paint Name—

Min DFT—

Max DFT—

VS%—

Thinner—

Application Range: Use WFT between — µm to achieve target DFT.

📏

DFT Calculation

Dry Film Thickness from WFT, VS% and Thinner

P-2

WFT µm

µm

Volume Solids %

Thinner %

Paint Name optional

DFT Result

Dry Film Thickness

—µm

📝 Input Data (Provided by User)

Paint Name—

WFT—

VS%—

Thinner—

Effective VS%—

📐

Paint Coverage

Theoretical & Practical Spread Rate (m²/Litre)

P-3

DFT µm

µm

Volume Solids %

Application Loss %

20%

0% brush15–25% airless30–50% spray

Paint Name optional

▸ Optional Quantity Estimator

Area m²

m²

Coats

cts

Coverage Result

Theoretical (TC)

—m²/L

Practical (PS)

—m²/L

📝 Input Data (Provided by User)

Paint Name—

DFT—

VS%—

Loss—

🧪

Paint Consumption

Total litres for surface area at given DFT

P-4

Surface Area m²

m²

DFT µm

µm

Volume Solids %

Application Loss %

20%

Paint Name optional

Consumption Result

Paint Required (Practical)

—L

TC Consumption

—L

PS Coverage

—m²/L

📝 Input Data (Provided by User)

Paint Name—

Area—

DFT—

VS%—

Loss—

💥

Paint Loss Due to Blasting Roughness

Dead Volume paint loss from abrasive blasting

P-5

Surface Area m²

m²

Blasting Roughness Rz µm

µm

Volume Solids %

Paint Name optional

Blast Loss Result

Paint Loss (Dead Volume)

—Litres

DVC Coefficient

—

Per 100 m²

—L

📝 Input Data (Provided by User)

Paint Name—

Area—

Rz—

VS%—

⚗️

Paint Mixing Ratio

Exact Part A & B volumes from any ratio

P-6

Ratio A parts

Ratio B parts

Total Volume L

Paint Name optional

Mixing Result

Volume Part A

—L

Volume Part B

—L

📝 Input Data (Provided by User)

Paint Name—

Ratio A:B—

Total Volume—

Part A%—

Part B%—

💰

Paint Cost Per Area

Full project costing with thinner

P-7

Surface Area m²

m²

DFT µm

µm

Volume Solids %

Thinner %

Loss %

Paint Price ₹/L

₹

Thinner Price ₹/L

₹

Paint Name optional

Cost Result

Total Project Cost

—

Paint + Thinner combined

Cost / m²

—

Paint Qty

—L

Thinner Qty

—L

PS Coverage

—m²/L

📝 Input Data (Provided by User)

Paint Name—

TC Coverage—

Paint Cost—

Thinner Cost—

Surface Area

6 Surface Area Calculators

🔩

Pipe Surface Area Calculator

Inside, outside and thickness face areas

A-1

Pipe Length mm

Inside Diameter mm

Thickness mm

Quantity nos.

nos

Item Name optional

Pipe Area Result

Inside Area (Total)

—m²

Outside Area (Total)

—m²

In + Out Combined

—m²

Thickness Ends

—m²

📝 Input Data (Provided by User)

Item Name—

Inside Dia—

Outside Dia (calc)—

Length—

Thickness—

Quantity—

🛢️

Tank Surface Area Calculator

Shell, roof, bottom inside & outside areas

A-2

Tank Height m

Inside Diameter m

Thickness mm

Quantity nos.

nos

Item Name optional

Tank Area Result

Total Inside + Outside Area

—m²

Shell Inside

—m²

Shell Outside

—m²

📝 Input Data (Provided by User)

Item Name—

Height—

Inside Dia—

Thickness—

Bottom+Roof (In+Out)—

Quantity—

⚖️

Structure Weight-Wise Area

Surface area estimation from tonnage (editable rates)

A-3

Standard Norms (Editable): UltraLight=35 · Light=30 · Medium=25 · Heavy=20 · UltraHeavy=15 m²/tonne

UL Tonnage t

UL Rate m²/t

m²/t

Light Tonnage t

Light Rate m²/t

m²/t

Medium Tonnage t

Medium Rate m²/t

m²/t

Heavy Tonnage t

Heavy Rate m²/t

m²/t

UH Tonnage t

UH Rate m²/t

m²/t

Structure Area Result

Total Surface Area

—m²

Total Tonnage

—t

Avg m²/Tonne

—m²/t

📝 Input Data (Provided by User) — Per Category

🔲

Plate Surface Area Calculator

Both sides + 4 thickness faces for plate quantities

A-4

Length m

Width m

Thickness mm

Quantity nos.

nos

Item Name optional

Plate Area Result

Total Surface Area

—m²

One Side

—m²

Both Sides

—m²

📝 Input Data (Provided by User)

Item Name—

Length—

Width—

Thickness—

Thickness Side Area—

Quantity—

🫙

Dished End Surface Area

Hemispherical, Semi-Ellipsoidal & Torispherical head area

A-5

Head Type

Inside Diameter m

Depth/Height (Tori) m

Thickness mm

Quantity nos.

nos

Item Name optional

Dished End Result

Inside Surface Area

—m²

Outside Surface Area

—m²

📝 Input Data (Provided by User)

Item Name—

Head Type—

Inside Dia—

Thickness—

Quantity—

🏭

Vessel / Equipment Surface Area

Complete vessel — shell, dished ends, skirt + extras

A-6

Shell Length m

Shell Inside Dia m

Shell Thickness mm

Quantity nos.

nos

Skirt Length m

Skirt Inside Dia m

Skirt Thickness mm

Extra External %

Extra Internal %

Extra Skirt %

Item Name optional

Vessel Result

Entire Vessel Surface Area

—m²

Pressure Boundary (In)

—m²

Pressure Boundary (Out)

—m²

Skirt Inside

—m²

Skirt Outside

—m²

📝 Input Data (Provided by User)

Item Name—

Shell L × ID × T—

Quantity—

Abrasive Consumption

Abrasive Consumption Calculator

Garnet & Copper Slag consumption — switch using the tabs below.

💎

Abrasive Consumption Calculator

@ 7 kg/cm² pressure · Venturi Nozzle · BG Group Rates

ABR

Garnet Consumption · 7 kg/cm² blast pressure · Venturi nozzle (BG Group standard)

Surface Condition / Scale	Sweep	Commercial
Zero Scale / Flash Rust Only
Mild Scale / New Steel / Thin Coating (<25 µm)	N/A
Heavy Scale / 1× Heat Treated / Thin Coating (<90 µm)	N/A	N/A
Very Heavy Scale / Multi Heat Treated / Thick Coating (>90 µm)	N/A	N/A

Enter the surface area (m²) in any applicable cell. Cells marked N/A are not applicable for that blast quality / scale combination.

Garnet Result

Total Garnet Required

—Kg

📝 Input Data (Areas Provided by User in m²)

Copper Slag Consumption · 7 kg/cm² blast pressure · Venturi nozzle (BG Group standard)

Surface Condition / Scale	Sweep	Commercial
Zero Scale / Flash Rust Only
Mild Scale / New Steel / Thin Coating (<25 µm)	N/A
Heavy Scale / 1× Heat Treated / Thin Coating (<90 µm)	N/A	N/A
Very Heavy Scale / Multi Heat Treated / Thick Coating (>90 µm)	N/A	N/A

Enter the surface area (m²) in any applicable cell. Cells marked N/A are not applicable for that blast quality / scale combination.

Copper Slag Result

Total Copper Slag Required

—Kg

📝 Input Data (Areas Provided by User in m²)

Salt Contamination

Salt Contamination Test (ISO 8502-9)

Online salt contamination test with temperature correction factor — BG Group / Horiba method.

🧂

Online Salt Contamination Test

ISO 8502-9 · Temperature Correction · Pass/Fail Verdict

ISO 8502-9

Instrument optional

Project Name optional

Blank Conductivity µS/cm

µS/cm

DM Water Volume ml

Surface Conductivity µS/cm

µS/cm

Acceptable Limit mg/m²

mg/m²

Steel Temperature

Salt Result

Measured (at test temp.)

—mg/m²

Corrected @ 25°C Ref ✓

—mg/m²

Measured (µg/cm²)

—µg/cm²

Corrected (µg/cm²) ✓

—µg/cm²

📝 Input Data (Provided by User)

Instrument—

Project—

Blank Conductivity—

Surface Conductivity—

DM Water Volume—

Steel Temperature—

Net Conductivity—

Temp Factor—

Limit—

Executive Coating Calculation – PRO

Advanced Verification & Validation Suite · Standards-Aligned Engineering Modules

👑

EXECUTIVE COATING CALCULATION – PRO

For Paint Manufacturers · QA/QC · AMPP/NACE Inspectors · Consultants · EPC · Procurement · Laboratories · Asset Owners

Modular · Expanding

📋

Method 1 — TDS Verification

Cross-check the manufacturer's Product Data Sheet: VS% = DFT × Coverage ÷ 10

PRO · VS-1

DFT (from TDS) µm

µm

Theoretical Coverage m²/L

m²/L

Published Volume Solids % · optional

Product Name optional

Formula: Volume Solids (%) = ( DFT × Theoretical Coverage ) ÷ 10 · Example: 125 µm × 5.6 m²/L ÷ 10 = 70%

Volume Solids Result

Calculated Volume Solids

—%

—

Published VS (TDS)

—%

Difference

—%

Deviation

—%

📝 Input Data (Provided by User)

Product Name—

DFT—

Theoretical Coverage—

Validation Criteria: Difference < ±2% → PASS · 2–5% → REVIEW · > 5% → FAIL. Engineering verification only — not a substitute for ASTM D2697 / ISO 3233 laboratory testing.

⚖️

Method 2 — Density Verification

Paint-manufacturing method: VS = Weight Solids × Wet Density ÷ Dry Film Density

PRO · VS-2

Weight Solids %

Wet Paint Density kg/L · ASTM D1475

kg/L

Dry Film Density kg/L

kg/L

Published Volume Solids % · optional

Product Name optional

Formula: VS% = Weight Solids × ( Wet Density ÷ Dry Film Density ) · Example: 0.80 × 1.60 ÷ 1.80 = 71.1%

Volume Solids Result

Calculated Volume Solids

—%

—

Published VS (TDS)

—%

Difference

—%

Deviation

—%

📝 Input Data (Provided by User)

Product Name—

Weight Solids—

Wet Density—

Dry Film Density—

🧫

Method 3 — Laboratory Verification

ASTM D2697 / ISO 3233 — most accurate: gravimetric weights + measured dry film volume

PRO · VS-3

Weight of Empty Dish g

Dish + Wet Paint g

Dish + Dry Film g · after full cure

Wet Paint Density kg/L · ASTM D1475

kg/L

Measured Dry Film Volume cm³ · D2697/ISO 3233

cm³

Published Volume Solids % · optional

Product / Lab Reference optional

Calculation Steps: ① Wet Wt = (Dish+Wet) − Dish ② Dry Wt = (Dish+Dry) − Dish ③ Non-Volatile % = Dry ÷ Wet × 100 ④ Wet Volume = Wet Wt ÷ Density ⑤ VS% = Dry Film Volume ÷ Wet Volume × 100

Laboratory Volume Solids Result

Volume Solids (Lab)

—%

—

Weight Solids (NV%)

—%

Wet Paint Volume

—cm³

Dry Film Density

—kg/L

📝 Input Data (Provided by User)

Product / Lab Ref—

Empty Dish—

Dish + Wet Paint—

Dish + Dry Film—

Wet Paint Weight—

Dry Film Weight—

Wet Density—

Dry Film Volume (Measured)—

Published VS (TDS)—

📊

Paint Reconciliation Calculator

Theoretical requirement vs actual issued / consumed / returned — savings, excess & financial impact

PRO · PR-1

A · Project Information

Project Name optional

Client optional

Contractor optional

Paint Manufacturer optional

Paint Product optional

Coat Number optional

Report Date optional

B · Surface & Specification

Surface Area Painted m²

m²

Specified DFT µm

µm

Volume Solids %

Loss Factor % · default 15

Number of Coats for this reconciliation

nos

C · Material Issue Details

Opening Stock L

Paint Received L

Total Paint Available auto

Paint Issued to Site L

Paint Returned to Store L

Unused Paint in Container L

Rejected Paint L

Spillage / Wastage L

Thinner Issued L · optional

D · Optional — Density & Cost

Paint Density kg/L · optional

kg/L

Paint Cost ₹/L · optional

₹/L

Reconciliation Result

Paint Variance

—L

—

Variance

—%

—

Consumption Efficiency

—%

Material Utilization

—%

Theoretical Requirement

—L

Practical Requirement (incl. loss)

—L

Actual Paint Consumed

—L

Total Actual (incl. losses)

—L

Paint Wasted (Spillage+Rejected)

—L

Financial Impact

—

Material Flow

Theoretical vs Actual

Issued Paint Breakdown

📝 Project Material Summary

Classification: ±0–5% Excellent Control · ±5–10% Acceptable · ±10–15% Needs Review · >15% Investigate | References: ISO 12944 · ISO 19840 · SSPC PA Guide · ASTM D3276 · ASTM D4414 · AMPP GPP · NORSOK M-501 · PMBOK Material Control

💹

Coating Life Cycle Cost (LCC) Calculator

Total Cost of Ownership over asset design life — initial + inspection + maintenance + repair + recoating

PRO · LCC-1

A · Project Information

Project Name optional

Asset Name optional

Client optional

Location optional

Environment (ISO 12944) C1–CX / Im1–Im4

Coating System Name optional

B · Asset Details

Surface Area m²

m²

Design Life of Asset years

yrs

Expected Coating Service Life years

yrs

Recoating Cycles blank = auto

nos

C · Initial Coating Cost (₹)

Paint Material Cost

₹

Surface Preparation Cost

₹

Labour Cost

₹

Equipment Cost

₹

Scaffolding Cost

₹

Inspection Cost (initial QA/QC)

₹

Other Costs

₹

D · Maintenance Details

Inspection Interval years

yrs

Inspection Cost per Visit

₹

Routine Maintenance Interval years

yrs

Routine Maintenance Cost

₹

Repair Interval years

yrs

Repair Cost per Event

₹

Major Recoating Cost per event

₹

E · Economic Factors (optional)

Inflation Rate %/yr

Discount Rate %/yr · enables NPV

Escalation Rate %/yr

F · Optional Cost Elements (₹)

Production Shutdown Cost per recoat event

₹

Access Cost

₹

Waste Disposal Cost

₹

Environmental Compliance Cost

₹

Safety Management Cost

₹

Life Cycle Cost Result

Total Life Cycle Cost

—

Annual Coating Cost

—/yr

LCC per m²

—/m²

NPV (Discounted)

—

Initial Coating Cost

—

Inspections (— cycles)

—

Routine Maint. (— cycles)

—

Repairs (— events)

—

Recoating (— cycles)

—

Shutdown + Optional Costs

—

Life Cycle Cost Breakdown

Cost Timeline — Cumulative Expenditure by Year

Maintenance Schedule Timeline

⚖️ Comparative Analysis — up to 3 systems

No systems added yet. Calculate a coating system above, then click “Add This System to Comparison”. Repeat with different inputs for System B / C.

📝 Life Cycle Cost Analysis Summary

References: ISO 12944 · ISO 55000 (Asset Management) · AMPP Guidelines · NORSOK M-501 · API RP 652 / RP 651 / API 653 · SSPC Guides · Whole Life Cost / LCC / TCO principles. Note: The lowest initial coating cost is not always the lowest total ownership cost.

🪨

Abrasive Size & Blast Profile Calculator

Predict achievable anchor profile from abrasive type, grade, pressure & operating parameters — ISO 8503 / ASTM D4417

PRO · ABP-1

A · Project Information

Project Name optional

Client optional

Structure / Equipment optional

B · Abrasive Selection

Abrasive Type

Abrasive Grade / Mesh Size

C · Operating Parameters

Blast Pressure bar at nozzle

bar

Nozzle Diameter mm

Nozzle Type

Stand-off Distance mm

Blast Angle ° to surface

Surface Condition

Steel Hardness optional

D · Specified Target Profile (optional — enables warnings)

Target Profile — Min µm

µm

Target Profile — Max µm

µm

Predicted Blast Profile

Expected Surface Profile

—µm

—

Classification

—

Abrasive Consumption

—kg/m²

—

Blasting Productivity

—m²/hr

—

Recommended DFT Range

—

ISO 19840 Profile Correction (add to DFT)

—

Extra Paint due to Profile (dead volume)

—

Adjustment Factors Applied

Abrasive Grade vs Typical Profile Chart (µm) — selected grade highlighted

📝 Blast Profile Analysis Summary

References: ISO 8501 (Cleanliness) · ISO 8503 (Profile) · ASTM D4417 · SSPC-SP Series · AMPP/NACE Surface Prep Guidelines. Note: Predicted values are engineering estimates — always verify profile on site with replica tape or stylus gauge per ASTM D4417 / ISO 8503-5.

♻️

Abrasive Recycling Calculator

Recovery rate · recycling efficiency · reusable quantity · waste generation · fresh makeup — ISO 11124 / ISO 11126

PRO · ARC-1

A · Project Information

Project Name optional

Client optional

Structure / Equipment optional

B · Abrasive Details

Abrasive Type

Number of Recycling Cycles completed so far

nos

C · Operating Inputs

Total Fresh Abrasive Charged kg

Total Recovered Abrasive kg

Waste Collected kg

Dust Collected kg

Rejection Percentage % of recovered

Abrasive Cost ₹/kg · optional

₹/kg

Surface Area Blasted m² · optional

m²

Recycling Performance Result

Recycling Efficiency

—%

—

Recovery Rate

—%

—

Waste Percentage

—%

—

Fresh Makeup Required

—kg

—

Fresh Charged

—kg

Recovered

—kg

Reusable

—kg

Rejected

—kg

Waste + Dust

—kg

Consumption

—

Fresh Abrasive Cost (Makeup)

—

Estimated Cost Saving vs Expendable Use

—

Abrasive Mass Balance

Fresh Charge Distribution

Actual vs Expected (Database Benchmark)

📝 Recycling Analysis Summary

Performance Classification: >95% Excellent · 90–95% Very Good · 80–90% Good · 70–80% Fair · <70% Poor (Investigation Required) | References: ISO 11124 (Metallic) · ISO 11126 (Non-Metallic) · ISO 8504 · AMPP/SSPC Surface Prep · NACE/AMPP Good Blasting Practices

🌀

Dust Collector System Capacity Calculator

Required airflow · filter area · fan motor · recommended collector model — ACGIH / OSHA / NFPA

PRO · DCC-1

A · Project Information

Project Name optional

Client optional

Blast Room Name optional

B · Blast Room Details

Blast Room Length m

Blast Room Width m

Blast Room Height m

C · Operating Parameters

Number of Blast Nozzles

nos

Nozzle Diameter mm

Compressor Capacity total CFM available

CFM

Blast Pressure bar

bar

Face Velocity m/min · typ. 18–25

m/min

Air Changes per Hour typ. 30–60 ACH

ACH

D · Dust Collection Parameters

Dust Loading g/m³ · optional

g/m³

Filter Cleaning System

Safety Factor % · typ. 10–20

Est. System Static Pressure mm WG · for fan sizing

mmWG

Dust Collector Sizing Result

Recommended Collector Capacity

—CFM

—

Required Airflow (before SF)

—CFM

—

Recommended Filter Area

—m²

—

Fan Motor Rating

—

Blast Room Volume

—m³

Airflow by ACH

—

Airflow by Face Velocity

—

Nozzle Air Demand

—

Governing Basis

—

Airflow Requirement — Design Basis Comparison

Dust Collector Model Selection (Internal Database)

📝 Dust Collector Sizing Summary

Classification: >110% of required = Excellent · 100–110% = Recommended · 90–100% = Acceptable · <90% = Undersized (Upgrade Required) | References: ACGIH Industrial Ventilation Manual · OSHA 29 CFR 1910 · ISO 11124 / 11126 · AMPP/SSPC · NFPA Dust Collection Guidelines

🏗️

Structure Surface Area & Weight Calculator

Steel sections database + formulas — area · weight · paint · abrasive · treatment cost · BOQ

PRO · SAW-1

A · Project Information

Project Name optional

Client optional

Structure Name optional

Drawing Number optional

B · Section Selection

Section Type

Section Size database: m²/m · kg/m

Length m

Quantity nos

nos

C · Paint System & Rates (optional)

Paint System primer / mid / finish

Total DFT µm · optional

µm

Paint Coverage m²/L practical

m²/L

Abrasive Consumption kg/m²

kg/m²

Paint Cost ₹/L

₹/L

Blasting Rate ₹/m²

₹/m²

Painting Rate ₹/m²

₹/m²

Surface Area & Weight Result

Total Surface Area

—m²

—

Total Steel Weight

—MT

—

Weight-to-Area Ratio

—kg/m²

—

Paint Quantity

—L

—

Abrasive Requirement

—

Paint Cost

—

Blasting Cost

—

Painting Cost

—

Total Surface Treatment Cost

—

📋 Project BOQ — accumulate multiple items

No items yet. Calculate each member (beams, columns, bracing, pipe…) and click “Add This Item to BOQ” to build the structure take-off.

📝 Area & Weight Summary

References: ISO 12944 · SSPC-PA Guide · AMPP GPP · AISC Steel Manual · IS 808 · EN 10025 · AS/NZS Sections. Database values (m²/m · kg/m) from standard structural section tables; formula items use ρ = 7,850 kg/m³.

📏

DFT Acceptance Calculator — SSPC-PA 2

Spot measurements · 80% / 120% rule · area average · multi-area project acceptance

PRO · QA-1

Project Name optional

Client optional

Structure Name optional

Inspection Area e.g. Area A

Specified DFT µm

µm

Max Spot Limit % of spec · default 120

Spot Measurements µm · each spot = avg of 3 gauge readings · comma / space separated

SSPC-PA 2 Criteria: No spot < 80% of specified DFT · No spot > 120% (unless specification permits) · Average of spots ≥ Specified DFT (minimum 5 spots per ~10 m² area recommended)

SSPC-PA 2 Acceptance Result

Area Average DFT

—µm

—

Min / Max Allowed

—

80% / max % of specified

Lowest Spot

—µm

—

Highest Spot

—µm

—

Spot Readings vs Limits

🗂 Project Acceptance — multiple areas (A, B, C…)

No areas added yet. Evaluate each inspection area (A, B, C…) and add it here for the overall project acceptance.

📝 Inspection Summary

References: SSPC-PA 2 / AMPP SSPC-PA 2 · ISO 12944. Gauge calibration and base-metal-reading adjustment per SSPC-PA 2 Appendix; number of spots per area as specified.

📐

DFT Acceptance Calculator — ISO 19840

Correction value (CV) for surface profile · individual readings · average vs NDFT

PRO · QA-2

Project Name optional

Client optional

Specified DFT (NDFT) µm

µm

Correction Value (CV) µm · ISO 19840: fine 10 · medium 25 · coarse 40

µm

Maximum DFT µm · optional (ISO default ≤ 3 × NDFT)

µm

Measured DFT Readings µm · comma / space separated

ISO 19840 Criteria: Individual readings ≥ (NDFT − CV) · Arithmetic mean ≥ NDFT · Readings should not exceed the specified maximum (default guidance 3 × NDFT). Note: gauge readings are taken over the blast profile; CV compensates for profile influence.

ISO 19840 Acceptance Result

Average DFT

—µm

—

Minimum Acceptable

—µm

NDFT − CV

Lowest Reading

—µm

—

Highest Reading

—µm

—

Readings vs Limits

📝 Inspection Summary

References: ISO 19840 · ISO 12944. Correction Value depends on surface profile / measuring instrument and shall be entered per project specification (typical: fine +10 µm · medium +25 µm · coarse +40 µm).

⚡

Holiday Detection Voltage Calculator

High-voltage spark test — ASTM G62 formula & NACE/AMPP SP0188 lookup

PRO · QA-3

Project Name optional

Coating Type

DFT µm

µm

Preferred Method

Holiday Test Voltage Result

Recommended Test Voltage

—kV

—

ASTM G62 Formula

—

SP0188 Table Value

—

Interpolated from lookup table

Thickness

—mil

—

Voltage vs DFT — both methods, your point marked

📝 Test Parameters Summary

References: ASTM D5162 · ASTM G62 · NACE/AMPP SP0188. Always confirm the test voltage against the coating manufacturer's data sheet and project specification before testing. For DFT ≤ 500 µm consider low-voltage wet-sponge testing (ASTM D5162 Type I, typically 9–90 V).

🧲

Corrosion Rate Calculator

Weight-loss (ASTM G1/G31/G102) & thickness-loss methods · remaining life · inspection interval

PRO · CE-1

Project Name optional

Method

Initial Weight g

Final Weight g

Exposure Time

Specimen Area cm²

cm²

Metal Density g/cm³ · steel 7.85

g/cm³

Remaining Life (optional — API 570 / 510 / 653)

Current Wall Thickness mm · for remaining life

Minimum Required Thickness mm · t-min / retirement

Formulas: Weight loss — CR (mm/y) = 87.6 × W(mg) ÷ (D × A × T hours) · Thickness loss — CR = (t₀ − t) ÷ years · Remaining Life = (t − t·min) ÷ CR · mpy = mm/y × 39.37

Corrosion Rate Result

Corrosion Rate

—mm/yr

—

Corrosion Rate (mpy)

—mpy

Total Metal Loss

—

Remaining Life

—yrs

—

Thickness Remaining

—

Recommended Inspection Interval

—

📝 Corrosion Analysis Summary

Severity: <0.05 Excellent · 0.05–0.10 Low · 0.10–0.50 Moderate · 0.50–1.00 High · >1.00 mm/yr Severe | References: ASTM G1 · G31 · G102 · NACE SP0775 · AMPP · API 570 / 510 / 653

🩺

Coating Life Prediction Calculator

Health index from ISO 4628 findings · condition factor · adjusted remaining life · recoat year

PRO · CE-2

A · Project & Coating Information

Project Name optional

Structure Name optional

Environment (ISO 12944)

Coating System optional

Total DFT µm

µm

Year Applied

Design Life years

yrs

Current Age years · blank = auto from year applied

yrs

B · Inspection Findings (ISO 4628)

Rusting % of area · ISO 4628-3

Blistering ISO 4628-2 · 0 = none

Cracking ISO 4628-4

Flaking ISO 4628-5

Chalking ISO 4628-6

Adhesion Result ASTM D4541 / D3359

Holiday Test optional

C · Maintenance History

Number of Repairs

nos

Number of Touch-ups

nos

Major Recoating Performed?

Coating Life Prediction Result

Adjusted Remaining Life

—yrs

—

Coating Health Index

—%

—

Design / Age / Remaining

—

years

Estimated Recoating Year

—

Coating Health Index

Service Life Timeline

📝 Coating Condition Summary

Health Classification: 90–100% Excellent · 75–90% Good · 60–75% Fair · 40–60% Poor · <40% Critical | References: ISO 12944-1/-9 · ISO 4628 · AMPP · NORSOK M-501 · API RP 652 / RP 651

🧵

TSA Wire Consumption Calculator

Aluminium wire required for specified thickness — ISO 2063 · SSPC-CS 23.00 · AWS C2.18

PRO · TSA-1

Project optional

Surface Area m²

m²

Specified TSA Thickness µm

µm

Wire Diameter mm · for length estimate

Aluminium Density g/cm³

g/cm³

Deposition Efficiency % · typical 60–70

Material Loss / Contingency % · optional

Wire Consumption Result

Actual Wire Required

—kg

—

Theoretical Al Weight

—kg

Coating Volume

—L

Procurement Quantity

—kg

—

Wire per m²

—

Estimated Wire Length

—

📝 Summary

References: ISO 2063-1/-2 · AMPP/NACE SP0198 · SSPC-CS 23.00 · AWS C2.18 · ISO 14919 (wire)

📦

TSA Area Coverage Calculator

Maximum area achievable from available wire stock

PRO · TSA-2

Available Wire Quantity kg

TSA Thickness µm

µm

Deposition Efficiency %

Aluminium Density g/cm³

g/cm³

Required Area m² · optional — for remaining wire

m²

Coverage Result

Total Coverage Area

—m²

—

Wire Consumption per m²

—kg/m²

Remaining Wire

—kg

—

Material Utilization

—%

—

📝 Summary

🎯

TSA Deposition Efficiency Calculator

Key TSA performance indicator — deposited ÷ consumed × 100

PRO · TSA-3

Wire Consumed kg

Coating Weight Deposited kg

Deposition Efficiency Result

Deposition Efficiency

—%

—

Material Loss

—kg

—

📝 Summary

Rating: >70% Excellent · 60–70% Good · 50–60% Average · <50% Poor | ISO 2063 · AWS C2.18 · AMPP Good Thermal Spray Practice

🔎

TSA Thickness Calculator

Achieved thickness from deposited weight — production control & QA verification

PRO · TSA-4

Surface Area m²

m²

Deposited Aluminium Weight kg

Aluminium Density g/cm³

g/cm³

Specified Thickness µm · optional — for pass/fail

µm

Thickness Verification Result

Calculated TSA Thickness

—µm

—

Thickness Deviation

—%

—

📝 Summary

⏱️

TSA Productivity Calculator

Production efficiency — m²/hr · kg/hr · per operator · daily output

PRO · TSA-5

Surface Area Completed m²

m²

Working Hours

hrs

Number of Operators

nos

Wire Consumption kg · optional

Shift Length hrs · for daily output

hrs

Productivity Result

Productivity

—m²/hr

—

Wire Consumption Rate

—kg/hr

Operator Productivity

—m²/op/hr

Estimated Daily Output

—m²/day

—

📝 Summary

💰

TSA Cost Calculator

Total TSA application cost & ₹/m² — budgeting and estimation

PRO · TSA-6

Surface Area m²

m²

Wire Consumption kg

Wire Cost ₹/kg

₹/kg

Labour Cost ₹

₹

Equipment Cost ₹

₹

Consumable Cost ₹ · gas, grit, PPE

₹

Sealer Cost ₹

₹

Overhead % · optional

TSA Cost Result

Total Project Cost

—

Cost per m²

—/m²

Material (Wire) Cost

—

Procurement Quantity

—kg

incl. 5% contingency

Cost Breakdown

📝 Summary

🧱

PFP Material Consumption Calculator

Area × thickness × density (or yield) + wastage — UL 1709 · ASTM E119 · EN 13381

PRO · PFP-1

Project optional

Structure optional

PFP Material optional

Surface Area m²

m²

Required Thickness mm

Material Density kg/m³ · wet applied

kg/m³

Material Yield kg/mm/m² · optional — overrides density

Wastage %

Material Cost ₹/kg · optional

₹/kg

PFP Material Result

Total Procurement Quantity

—kg

—

Material Required (Net)

—kg

Wastage Quantity

—kg

Cost / m²

—

Material vs Wastage

📝 Detail Table

References: UL 1709 · ASTM E119 · EN 13381 · BS 476 · ISO 834 · API 2218 · Project Specification

🔥

PFP Thickness Calculator — Fire Rating

Required thickness from fire rating · section factor Hp/A · critical steel temperature

PRO · PFP-2

Fire Rating

Steel Section Factor Hp/A (m⁻¹) or W/D basis · ref. 180

m⁻¹

Critical Steel Temperature °C · UL 1709 base 538

°C

Material Type

Applied / Proposed Thickness mm · optional — compliance check

Note: Base thickness table (editable database, cementitious @ Hp/A 180, 538 °C) is adjusted for section factor, critical temperature and material type. Final thickness shall always be confirmed against the manufacturer's certified/listed thickness tables (UL / EN 13381 assessment) for the actual section.

Required Thickness Result

Required Thickness

—mm

—

Fire Rating

—min

Section Factor / Crit. Temp

—

Compliance Status

—

Fire Rating vs Required Thickness (your parameters)

📝 Detail Table

References: UL 1709 · ASTM E119 · BS 476 · EN 13381 · ISO 834 · API 2218

⚗️

PFP Density Calculator

Applied density vs manufacturer specification — ASTM E605 / E736

PRO · PFP-3

Sample ID optional

Sample Weight g

Sample Volume cm³

cm³

Specified Density kg/m³ · manufacturer minimum

kg/m³

Density Verification Result

Actual Density

—kg/m³

—

Specified Density

—kg/m³

Difference

—%

—

📝 Detail Table

Acceptance: ≥ 100% of specified = PASS · 90–100% = REVIEW · < 90% = FAIL | ASTM E605 · ASTM E736 · UL Guidelines

🕸️

Mesh Quantity Calculator

Reinforcement mesh for cementitious / epoxy PFP — rolls, overlap & procurement

PRO · PFP-4

Surface Area to Reinforce m²

m²

Mesh Roll Width m

Mesh Roll Length m

Overlap % · typical 10

Wastage % · cutting & profiles

Mesh Cost ₹/roll · optional

₹

Mesh Quantity Result

Rolls Required

—rolls

—

Mesh Quantity (Procurement)

—m²

Overlap Area

—m²

Mesh Utilization

—%

—

📝 Detail Table

🧾

PFP Cost Calculator

Complete PFP project cost — material to inspection · ₹/m²

PRO · PFP-5

Surface Area m²

m²

Material Cost ₹

₹

Labour ₹

₹

Equipment ₹

₹

Scaffolding ₹

₹

Mesh ₹

₹

Primer ₹

₹

Topcoat ₹

₹

Inspection ₹

₹

Overheads %

PFP Cost Result

Total Project Cost

—

Cost per m²

—/m²

Material Share

—%

Cost Distribution

📝 Detail Table — Cost Head · Amount · %

🩹

PFP Repair Quantity Calculator

Repair material from damaged area & repair thickness — maintenance estimation

PRO · PFP-6

Repair Location optional

Total PFP Area m²

m²

Damaged Area m²

m²

Repair Thickness mm

Material Density kg/m³

kg/m³

Material Yield kg/mm/m² · optional

Wastage %

Material Cost ₹/kg · optional

₹/kg

Repair Quantity Result

Repair Material (Procurement)

—kg

—

Repair Percentage

—%

—

Material Cost

—

Remaining Intact PFP

—m²

—

📝 Detail Table

🛒

Paint Procurement Quantity Calculator

Multi-coat system — paint per coat · containers · reserve · total procurement cost

PRO · BID-1

A · Project Data

Project Name optional

Client / Structure optional

Surface Area m²

m²

Transfer Efficiency % · airless ~ 70–90

Application Loss %

Procurement Reserve % · contingency stock

B · Coating System (DFT = 0 skips a coat)

Coat 1 — Primer product · optional

DFT µm · 0 = skip coat

µm

Volume Solids %

Unit Price ₹/L · optional

₹/L

Packing Size

Coat 2 — Intermediate product · optional

DFT µm · 0 = skip coat

µm

Volume Solids %

Unit Price ₹/L · optional

₹/L

Packing Size

Coat 3 — Finish product · optional

DFT µm · 0 = skip coat

µm

Volume Solids %

Unit Price ₹/L · optional

₹/L

Packing Size

Coat 4 — Stripe Coat product · optional

DFT µm · 0 = skip coat

µm

Volume Solids %

Unit Price ₹/L · optional

₹/L

Packing Size

Stripe Area % of total area

Procurement Result

Total Procurement Quantity

—L

—

Total Paint Requirement

—L

Total Containers

—packs

Total Procurement Cost

—

Detail Table — Coat · DFT · Coverage · Paint · Procurement · Packs

📝 Summary

References: ISO 12944 · NORSOK M-501 · AMPP/SSPC Guidelines · API RP 652/651 · Project Paint Specification

🏆

Multi-Manufacturer Bid Comparison

Compare up to 10 bids — technical & commercial scoring · badges · interactive charts

PRO · BID-2

A · Common Project Basis (shared by all bids)

Surface Area m²

m²

Application Loss %

Score Weighting Technical : Commercial

B · Enter Bid (then “Add Bid” — repeat up to 10)

Manufacturer

Custom Manufacturer / Bid Name if Custom…

Product / Coating System optional

Total System DFT µm

µm

Volume Solids (system avg) %

Unit Price ₹/L

₹/L

Paint Quantity L · blank = auto from DFT/VS/area

VOC g/L

g/L

Expected Service Life years

yrs

Technical Compliance % vs spec

Warranty years

yrs

Packing Size

Drying / Recoat optional text

Application Method optional

Final Bid Comparison Dashboard

No bids yet. Fill Section B and click “Add Bid to Comparison” for each manufacturer (up to 10).

Interactive Comparison Table

Graphical Dashboard

Scoring: Technical = compliance 50% + service life 25% + volume solids 15% + low VOC 10% (normalised across bids) · Commercial = low cost/m² 60% + low lifecycle ₹/yr 40% · Overall per selected weighting. References: ISO 12944 · NORSOK M-501 · AMPP/SSPC · API RP 652/651 · Project Specification.

📚

Reference Standards & Smart Classification

Standards basis for volume solids verification

REF

Primary Standards
• ASTM D2697 — Volume Nonvolatile Matter of Coatings
• ISO 3233 — % Volume of Non-Volatile Matter
• ASTM D2369 — Volatile Content
• ASTM D1475 — Density of Liquid Coatings
Engineering References
• ISO 12944 · SSPC PA Guide · AMPP Good Painting Practice · NORSOK M-501

Volume Solids Classification
• > 90% — Solvent Free Coating
• 80–90% — Ultra High Solids
• 70–80% — High Solids
• 60–70% — Medium High Solids
• 50–60% — Conventional Industrial
• 35–50% — Low Solids
• < 35% — Very Low Solids

Note: This module provides engineering verification and consistency checks using internationally accepted coating equations. It does not replace ASTM / ISO laboratory testing.

🚀 PRO Roadmap — Upcoming Verification Modules:
VOC Calculator · Weight Solids Calculator · PVC (Pigment Volume Concentration) · CPVC (Critical PVC) · Density Calculator · Spreading Rate Verification · WFT / DFT Verification · Transfer Efficiency Calculator
The PRO architecture is modular — each new calculator plugs into this section, building toward a complete Paint Formulation & Coating Engineering Verification Suite.