This paper is an update to “Expected Service Life and Cost Considerations for Maintenance and New
Construction Protective Coating Work” co-authored by J. L. Helsel, M. F. Melampy, K. Wissmar for NACE
Corrosion 2006.
Designed to assist the coatings engineer or specifier in identifying candidate protective coating systems
for specific industrial environments, this paper provides: 1) commonly used generic coating systems in
typical service environments, 2) service life for each, 3) current material costs, 4) current field and shop
painting costs, and 5) guidelines for calculating approximate installed costs of the systems. Guidelines for
developing long-term life-cycle costs and number of paintings for the expected life of the structure are
included. The basic elements of economic analysis and justification are addressed together with guidance on
the preparation of a Present Value Analysis. Worksheets and examples are provided to aid the reader in the
proper use of the information.
Updates to the paper also include additional information related to metallizing, updated cost data, and the
inclusion of new coating systems.