Newbie Spray Question

[PPSABoyce]

I want to spray alum wire with a Metco 12 standard gearing with acet. I am spraying a pipe with a 58" OD that is 10ft long. I estimated the weight of required material to be about 30# if it was done perfect so I doubled the expected usage for error. My partner argues that it will be around 150# to complete the job. I used the Metco book as a guide but may be calculating it wrong. Any suggestions on what the total weight would be?

[MichiganMan]

I suspect that you may be calculating wrong, but it depends on how thick you are building the coating (30# would be a pretty thin coating). Assuming this is a cathodic protection coating I would arc spray it rather than flame if the customer allows and you have the equipment available.

Calculating by the book will often give you substantially more material than you will actually need, but how thick do you need the coating to be?

[PPSABoyce]

I suspect that you may be calculating wrong, but it depends on how thick you are building the coating (30# would be a pretty thin coating). Assuming this is a cathodic protection coating I would arc spray it rather than flame if the customer allows and you have the equipment available.

Calculating by the book will often give you substantially more material than you will actually need, but how thick do you need the coating to be?

I'm sorry I ment to include that in the beginning. The depth should be .013".

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I calculated:
Area (in2) 22582.88
Volume (in3) 293.57744
Time (hours) 2.446478667
Weight (lbs) 29.357744

Using these terms from the Metco Book:

Speed (in3/Hour) Col 15 120
Consumption of Wire/Hour Col 11 12
Consumption of Oxygen/HourCol 12 83
Consumption of Acet/Hour Col 13 40

[Jim Weber]

I suspect that you may be calculating wrong, but it depends on how thick you are building the coating (30# would be a pretty thin coating). Assuming this is a cathodic protection coating I would arc spray it rather than flame if the customer allows and you have the equipment available.

Calculating by the book will often give you substantially more material than you will actually need, but how thick do you need the coating to be?

I'm sorry I ment to include that in the beginning. The depth should be .013".

---

I calculated:
Area (in2) 22582.88
Volume (in3) 293.57744
Time (hours) 2.446478667
Weight (lbs) 29.357744

Using these terms from the Metco Book:

Speed (in3/Hour) Col 15 120
Consumption of Wire/Hour Col 11 12
Consumption of Oxygen/HourCol 12 83
Consumption of Acet/Hour Col 13 40

Hi PPSABoyce,

I checked your numbers and your estimates are correct for the amount wire needed, however you may be a bit optimistic on the spraying speed. Realistically, you can spray 1/8" aluminum in the 8-10# per hour range, so figure it will take you nearly 4 hours to spray it with 1/8" wire. If you can switch to 3/16" wire you would cut that time in half. Also make certain you don't use 0 temper arc wire, as that too will slow you down. For flame spray aluminum use H18 temper wire.

Regards,

Jim Weber