【鋼構(gòu)知識(shí)】鋼結(jié)構(gòu)防腐的生命周期成本

《工業(yè)防護(hù)涂料的生命周期成本》

本文來源：

澳大利亞一家鍍鋅廠的技術(shù)手冊(cè)。該公司把這本技術(shù)手冊(cè)做成了公開的網(wǎng)頁格式，既可以在線瀏覽，也可以下載。雖然本文沒有明說，但是字里行間都是一句潛臺(tái)詞：鍍鋅是鋼結(jié)構(gòu)最好的防腐方案；

防腐相關(guān)文章：

【鋼構(gòu)知識(shí)】淺析鋼結(jié)構(gòu)的防腐問題

【行業(yè)知識(shí)】鋼橋梁的長效防腐涂裝

【鋼構(gòu)知識(shí)】鋼結(jié)構(gòu)涂料與涂裝技術(shù)

【鋼構(gòu)知識(shí)】鋼結(jié)構(gòu)防腐處理

【行業(yè)知識(shí)】用鋼結(jié)構(gòu)做住宅，腐蝕真的是問題嗎？

【鋼構(gòu)知識(shí)】不銹鋼為何也生銹？不銹鋼知識(shí)詳解

【鋼構(gòu)知識(shí)】鋼橋梁的長效防腐涂裝

【行業(yè)知識(shí)】耐候鋼應(yīng)用是橋梁建設(shè)必然趨勢(shì)（專訪中國工程院院士柯偉）

【鋼構(gòu)知識(shí)】英國耐候鋼鋼橋技術(shù)之一

【鋼構(gòu)知識(shí)】英國耐候鋼鋼橋技術(shù)之二

Industrial Galvanizers Corporation (IGC) operates nine galvanizing plants around Australia, ranging in size from large structural galvanizing facilities to specialised small plants designed to process small parts.

工業(yè)鍍鋅公司(IGC)在澳大利亞運(yùn)營著九個(gè)鍍鋅廠，規(guī)模從大型結(jié)構(gòu)鍍鋅設(shè)備到專門加工小零件的小型工廠。

The Australian Galvanizing Division has galvanized in excess of 2.5 million tonnes of steel products in Australia since its first plant was commissioned in 1965 and is recognized for its ability to handle complex and difficult projects, as well as routine contracts.

自1965年第一家工廠投產(chǎn)以來，澳大利亞鍍鋅部門已經(jīng)在澳大利亞鍍鋅了超過250萬噸的鋼鐵產(chǎn)品，并因其處理復(fù)雜和困難項(xiàng)目以及日常合同的能力而得到認(rèn)可。

This experience has been collated in the Specifiers Design Manual, to assist those involved in the design of steel products and projects to better understanding the galvanizing process and allow the most durable and cost-effective solutions to be delivered to these products and projects. 

這一經(jīng)驗(yàn)已被整理在《設(shè)計(jì)手冊(cè)》中，以幫助那些參與鋼材產(chǎn)品和項(xiàng)目設(shè)計(jì)的人員更好地理解鍍鋅過程，并為這些產(chǎn)品和項(xiàng)目提供最持久和最具成本效益的解決方案。

本文是節(jié)選的該技術(shù)手冊(cè)第22章。

The concept of life cycle costing is not a new one. Standards Australian produced its first AS/ NZS Standard in 1999 ; AS/NZS 4536 - Life cycle costing – An application guide.

In any life-cycle costing assessment, the initial cost of the coating is an important component in doing any long-term cost analysis, as is the need to determine the likely maintenance free life of the coating and the future costs of maintenance.

生命周期成本計(jì)算并不是一個(gè)新概念。澳大利亞標(biāo)準(zhǔn)協(xié)會(huì)于1999年首次制定了AS/ NZS標(biāo)準(zhǔn);AS/NZS 4536 -生命周期成本計(jì)算應(yīng)用指南。在任何生命周期成本評(píng)估中，涂層的初始成本是進(jìn)行任何長期成本分析的一個(gè)重要組成部分，同樣需要確定涂層可能的免維護(hù)壽命和未來的維護(hù)成本。

A bit of History

Protective coating costs on most projects are a relatively small component of the total project cost; typically less than 2%. On a major steel project containing, say, 1000 tonnes of structural steel, the cost of a basic protective coating system may be in the order of $500/tonne, a high performance coating system may be $1000/tonne, and a special super-durable specification may cost $1500/tonne.

在大多數(shù)工程項(xiàng)目中，保護(hù)層成本占工程總成本的比例相對(duì)較小;一般少于2%。對(duì)于一個(gè)包含1000噸結(jié)構(gòu)鋼的大型鋼鐵項(xiàng)目，一個(gè)基本的防護(hù)涂層系統(tǒng)的成本可能是500美元/噸，一個(gè)高性能的涂層系統(tǒng)可能是1000美元/噸，一個(gè)特殊的超級(jí)耐用規(guī)格可能是1500美元/噸。

This equates to an additional project cost of $500,000 - $1,500,000. If a project accountant applied a net present value analysis to this in the 1980’s, when interest rates exceeded 15% and company taxation was well over 40%, the option of using the cheaper coating and expensing accelerated maintenance costs would seem a sound financial decision.

這等于一個(gè)額外項(xiàng)目費(fèi)用$50萬至$ 150萬。如果一個(gè)項(xiàng)目會(huì)計(jì)在20世紀(jì)80年代將凈現(xiàn)值分析應(yīng)用于此，當(dāng)時(shí)利率超過15%，公司稅收遠(yuǎn)遠(yuǎn)超過40%，選擇使用更便宜的涂層和花費(fèi)加速維護(hù)成本似乎是一個(gè)明智的財(cái)務(wù)決策。

However, in the 21st Century, company tax is only 30% and interest rates are lower, so the Tax Office no longer subsidises maintenance costs to the same degree. In addition, expensed maintenance costs hit the balance sheet at a level that exceeds any interest benefits from the original saving.

然而，在21世紀(jì)，公司稅只有30%，利率更低，所以稅務(wù)局不再對(duì)維修費(fèi)用給予同樣程度的補(bǔ)貼。此外，支出的維護(hù)成本在資產(chǎn)負(fù)債表上所占的比例超過了原始儲(chǔ)蓄的利息收益。

Also, the labour costs of the 1980’s did not include the on-costs of superannuation, higher workers compensation and other statutory obligations for employers. Nor were the WH&S and environmental obligations anything like they are today.

此外，80年代的勞動(dòng)力成本不包括退休金、更高的工人補(bǔ)償和雇主的其他法定義務(wù)。WH&S和環(huán)境責(zé)任也與今天不同。

It is thus very difficult to foretell the distant future for the purposes of life-cycle costing for protective coatings, and conditions in 2035 will have changed as much in that 25-year cycle as they did between 1950, 1975 and 2000.

因此，要預(yù)測防護(hù)涂層的壽命周期成本，預(yù)測遙遠(yuǎn)的未來是非常困難的。在這25年的周期內(nèi)，2035年的條件變化將與1950年、1975年和2000年之間的情況一樣大。

The other reality faced by asset owners, particularly of infrastructure assets, is that their service life is often far longer that originally anticipated. Many power distribution and transport structures are now well over 50 years old and are subject to numerous maintenance cycles to maintain their functionality.

資產(chǎn)所有者(尤其是基礎(chǔ)設(shè)施資產(chǎn))面臨的另一個(gè)現(xiàn)實(shí)是，他們的使用壽命往往比最初預(yù)期的長得多。許多電力分配和運(yùn)輸結(jié)構(gòu)現(xiàn)在已經(jīng)有50多年的歷史了，需要進(jìn)行大量的維護(hù)來維護(hù)它們的功能。

The other issue with maintenance coatings is that they add very little value to a business. They make no contribution to efficiency or productivity.

維護(hù)涂層的另一個(gè)問題是，它們對(duì)企業(yè)的價(jià)值貢獻(xiàn)很小。他們對(duì)效率和生產(chǎn)率沒有貢獻(xiàn)。

For this reason, the selection of an appropriate protective coating system for steel, be it paint, galvanizing, or a combination of both should be based on the performance of the coating over time rather than its initial cost.

因此，選擇合適的鋼鐵防護(hù)涂層系統(tǒng)，無論是油漆、電鍍還是兩者的結(jié)合，都應(yīng)該基于涂層的長期性能，而不是它的初始成本。

Factors in the Cost of a Coating

涂層的成本因素

Australian Standards such as AS/NZS 2312:2002 – Guide to the protection of iron and steel against atmospheric corrosion contains comprehensive guidelines related to coating selection versus environmental condition to provide an estimated service life for a range of coating systems.

澳大利亞標(biāo)準(zhǔn)，如/NZS 2312:2002—《鋼鐵抗大氣腐蝕保護(hù)指南》，包含了有關(guān)涂層選擇與環(huán)境條件的綜合指南，為各種涂層系統(tǒng)提供了估計(jì)的使用壽命。

Material Selection

材料選擇

The choice between materials of construction will usually be a `steel versus concrete decision’, with a proportion of projects being a composite of both.

建筑材料的選擇通常是“鋼與混凝土的選擇”，有一部分項(xiàng)目是兩者的組合。

The decision may be based on familiarity of a designer of working with one material or another, the form of the structure, its location and most importantly, its installed cost.

這個(gè)決定可能是基于設(shè)計(jì)師對(duì)一種或另一種材料的熟悉程度，結(jié)構(gòu)的形式，它的位置，最重要的是，它的安裝成本。

While the protective coating costs are a relatively small component of the total projects cost, they can be a significant proportion of the structural steel cost. In addition, steel simply cannot be used (with a few exceptions) without protective coatings and these coatings will have a defined life that will determine future maintenance costs.

雖然保護(hù)層成本在工程總成本中所占的比例相對(duì)較小，但在結(jié)構(gòu)鋼成本中所占的比例很大。此外，沒有防護(hù)涂層，鋼就不能使用(少數(shù)例外)，這些涂層的使用壽命將決定未來的維護(hù)成本。

While steel and fabrication costs are volatile, benchmark costs obtained in mid-2012 indicate that the cost components are approximately as follows for standard medium structural steel:

雖然鋼材和制造成本波動(dòng)較大，但2012年年中獲得的基準(zhǔn)成本表明，標(biāo)準(zhǔn)中結(jié)構(gòu)鋼的成本組成大致如下:

Medium structural steel cost: $1200/t

中等結(jié)構(gòu)鋼材成本:$1200/t

Fabrication cost: $3000 - $5000/t

制造成本:3000 - 5000美元/噸

Coating Costs for new Steelwork

鋼結(jié)構(gòu)的涂料成本

The cost of coating new steelwork is made up of a number of factors. These are:

The type of steel – size, shape, section.鋼的型號(hào)-尺寸、形狀、截面。

The quantity of steel鋼材數(shù)量

The location of the project with respect to the coating provider, the fabricator and the site.關(guān)于涂料供應(yīng)商、制造商和現(xiàn)場的項(xiàng)目位置。

The regional cost of labour地區(qū)勞動(dòng)力成本

The material cost (paint components/zinc/ chemicals)材料成本(油漆成分/鋅/化學(xué)品)

The cost of surface preparation (abrasive blasting/chemical/mechanical)表面處理成本(噴砂/化學(xué)/機(jī)械)

The cost of application – number of coats, plant capability, processing time應(yīng)用成本-涂層數(shù)量，工廠能力，處理時(shí)間

Logistic costs – inspection, loading, transport, erection物流成本-檢驗(yàn)，裝載，運(yùn)輸，安裝

Post erection costs – remediation of handling damage, on-site completion安裝后費(fèi)用-處理損壞的補(bǔ)救，現(xiàn)場完成。

For applied coatings (paint, metallising) the surface area of the steelwork and the complexity of the fabrication will be the most significant factors influencing the cost. Logically, thin steel sections with high surface area per tonne will absorb more labour and materials than heavy structural sections.

對(duì)于應(yīng)用涂層(油漆、金屬化)，鋼結(jié)構(gòu)的表面積和制造的復(fù)雜性將是影響成本的最重要因素。從邏輯上講，每噸高表面積的薄型鋼將比重型鋼吸收更多的勞動(dòng)力和材料。

For example, a 3 mm thick steel section has a surface area per tonne of over 80 m2, while a 10 mm section has a surface area of 25 m2 per tonne.

例如，3毫米厚的鋼截面每噸的表面積超過80平方米，而10毫米厚的鋼截面每噸的表面積為25平方米。

For process-applied coatings (hot dip and continuous galvanizing, powder coating), material costs and fixed costs are important, making the profitability of these processes very volume sensitive.

對(duì)于工藝應(yīng)用的涂層(熱浸鍍和連續(xù)鍍鋅、粉末涂料)，材料成本和固定成本非常重要，這使得這些工藝的利潤對(duì)產(chǎn)量非常敏感。

Typical Material Costs

典型的材料成本

Many of the materials incorporated in coatings are traded as commodities with supply and demand affecting prices above and beyond normal inflationary variations. The following indicative prices are for generic materials used in coating in mid-2008, in commercial quantities

涂料中包含的許多材料都是作為商品進(jìn)行交易的，其供求關(guān)系對(duì)價(jià)格的影響超出了正常的通脹波動(dòng)范圍。以下指示性價(jià)格是2008年年中用于涂料的一般材料的商業(yè)價(jià)格

Paint Coatings

The true material cost of paint coatings is determined by how much of what is in the can ends up on the steel surface. This is determined by the volume solids in the paint, the applied thickness of the coating and the coating efficiency (over-spray losses).

油漆涂料的實(shí)際材料成本是由罐內(nèi)的材料在鋼表面的含量決定的。這是由涂料中固體顆粒的體積、涂層的厚度和涂層效率(過噴損失)決定的。

Low volume solids will result in higher losses due to solvent evaporation. Simple solid structures (beams, tanks) will experience higher coating efficiencies that open structures (pipe work and trusses)

由于溶劑蒸發(fā)，體積小的固體顆粒會(huì)造成較大的損失。簡單的實(shí)體結(jié)構(gòu)(梁、罐)將獲得比開口結(jié)構(gòu)(管道和桁架)更高的涂層效率。

One litre of paint, applied to a wet film thickness of 100 microns will theoretically cover 10 m2 of surface. In practice, the same paint applied to a dry film thickness of 100 microns, to medium structural steel by airless spray will cover approximately 5 m2.

一公升的油漆，適用于100微米的濕膜厚度，理論上將覆蓋10平方米的表面。在實(shí)踐中，同樣的涂料應(yīng)用于100微米的干膜厚度，通過無空氣噴涂到中等結(jié)構(gòu)鋼材上將覆蓋約5平方米。

All paint suppliers have product safety data sheets for each of their paints. These documents list technical specifications for the paint, including volume solids, recommendations for wet and dry film thickness requirements and theoretical coverage.

所有油漆供應(yīng)商都有各自油漆的產(chǎn)品安全數(shù)據(jù)表。這些文件列出了涂料的技術(shù)規(guī)格，包括固體體積、干膜和濕膜厚度要求的建議和理論覆蓋范圍。

In addition to the paint cost, most solvent-based spray applied coatings require the addition of thinners, (typically around 30% by volume) which becomes a component of the paint material cost.

除了涂料成本外，大多數(shù)基于溶劑型的噴涂涂料還需要添加稀釋劑(通常體積約為30%)，這成為涂料材料成本的一個(gè)組成部分。

An important point to note is that the paint cost is a relatively small proportion of the applied system cost. Based on a typical practical coverage rate of $5.00/m2, the cost differential between a basic industrial epoxy or urethane and a high performance urethane or polysiloxane is in the order of $3.00-$4.00/m2.

需要注意的重要一點(diǎn)是，涂料成本占應(yīng)用系統(tǒng)成本的比例相對(duì)較小。根據(jù)典型的實(shí)際覆蓋率為$5.00/m2，基本工業(yè)環(huán)氧樹脂或聚氨酯與高性能聚氨酯或聚硅氧烷之間的成本差異約為$3.00-$4.00/m2。

The most significant single cost in paint coatings is surface preparation. Abrasive blasting is almost mandatory to ensure acceptable performance for industrial paint systems.

涂料中最重要的單項(xiàng)成本是表面處理。噴砂幾乎是強(qiáng)制性的，以確保工業(yè)涂料系統(tǒng)的可接受的性能。

Fabricated steelwork is usually abrasive blasted with chilled iron shot, in a chamber that allows recovery and recycling of the blasting media. Abrasive blasting standards are defined in Australian Standard AS 1627.4. Class 2 ? Blast is most commonly specified for industrial coating, with Class 3 (the highest level) being a requirement for specialised coatings such as zinc metal spray.

預(yù)制鋼結(jié)構(gòu)通常是在一個(gè)允許爆破介質(zhì)的回收和循環(huán)利用的腔體中，用冷硬鐵噴丸進(jìn)行磨料噴砂。噴砂標(biāo)準(zhǔn)在澳大利亞標(biāo)準(zhǔn)中定義為1627.4。指定類2?爆炸是最常見的工業(yè)涂料,與3班(最高級(jí)別)被要求專業(yè)涂料如鋅金屬噴霧。

Abrasive blasting costs vary regionally, but generally fall in the $15.00 - $20.00/m2 range. Large automated blasting facilities using wheelabrador equipment to process columns, beams and plates can significantly reduce this cost.

噴砂成本因地區(qū)而異，但一般在$15.00 - $20.00/m2范圍內(nèi)。大型自動(dòng)化爆破設(shè)施使用輪對(duì)爆破設(shè)備來處理柱、梁和板可以大大降低成本。

Where galvanized coatings are to be painted, Class 1 or whip blasting is generally specified. This involves using less aggressive media such as garnet or illmentite, at typical cost ranging from $10.00 - $15.00/m2, depending on the complexity of the fabrication.

如果要噴涂鍍鋅涂層，一般規(guī)定為1級(jí)或起爆。這包括使用不太激進(jìn)的媒體，如石榴石或illmentite，典型的成本從$10.00到$15.00/m2不等，這取決于制造的復(fù)雜性。

Chemical preparation (pickling, phosphating) is rarely used as a method of preparing fabricated steel for painting, and is confined to process applied coatings such as powder coating and galvanizing.

化學(xué)制劑(酸洗、磷化)很少被用作制備涂漆用鋼的方法，而且僅限于粉末涂料和鍍鋅等工藝應(yīng)用涂料。

Powder coating costs are usually charges on a `window area’ basis rather than surface area, as the area the item takes up on the powder coating line is the main factor in its cost of processing. For standard grades of polyester powder, powder coating costs are typically $15.00 - $20.00/m2, although large quantities of uniform manufactured product that can be loaded to high line efficiencies can be powder coated at lower cost.

粉末涂料的成本通常是按“窗口面積”而不是按表面積計(jì)算的，因?yàn)楫a(chǎn)品在粉末涂料生產(chǎn)線上所占的面積是其加工成本的主要因素。對(duì)于標(biāo)準(zhǔn)等級(jí)的聚酯粉末，粉末涂料的成本通常為$15.00 - $20.00/m2，盡管大量的均勻生產(chǎn)的產(chǎn)品可以裝載到高生產(chǎn)線效率，也可以以較低的成本粉末涂料。

With all costs included (labour, overheads, margins) indicative industrial painting costs for commonly specified systems are:

包括所有成本(人工、間接費(fèi)用、毛利率)后，一般指定系統(tǒng)的指示性工業(yè)油漆成本為:

Basic wire brush/Class1 blast and ROZP prime ---> $12.00/m2基本鋼絲刷/Class1 blast和ROZP prime -> $12.00/m2

Class 2 ? blast + inorganic zinc primer ---> $25.00/m2類2?爆炸+無機(jī)富鋅底漆- - - > 25.00美元/平方米

Class 2 ? blast + inorganic zinc primer + epoxy topcoat ---> $35.00/m2類2?爆炸+無機(jī)富鋅底漆+環(huán)氧面漆- - - > 35.00美元/平方米

Class 2 ? blast + inorganic zinc primer + urethane ---> $45.00/m2類2?爆炸+無機(jī)富鋅底漆+聚氨酯- - - > 45.00美元/平方米

NOTE: These are indicative average prices only and will vary regionally and depending on the design of the items being painted.

注:這些只是指示性平均價(jià)格，并將根據(jù)地區(qū)和項(xiàng)目的設(shè)計(jì)而有所不同。

Galvanized Coatings

The parameters governing the cost of galvanized coatings are quite different to those determining paint costs.

決定鍍鋅板成本的參數(shù)與決定涂料成本的參數(shù)有很大的不同。

Continuously applied galvanized coatings applied to sheet, wire and tube are applied in facilities with high capital and operating cost, with large volumes of steel being able to be processed very efficiently.

鍍鋅板、線材、管材連續(xù)涂敷鍍鋅板是一種資金和運(yùn)營成本都很高的設(shè)備，大量的鋼材可以被高效地加工。

For this reason, the galvanized coating cost component of these products is relatively small and driven by the material (zinc) cost. In addition, these technologies apply relatively thin zinc coatings – usually less than 30 microns per side for a material cost of about $0.75/m2 of surface.

因此，這些產(chǎn)品的鍍鋅板成本組成相對(duì)較小，受材料(鋅)成本的驅(qū)動(dòng)。此外，這些技術(shù)適用于相對(duì)較薄的鋅涂層——通常每面不到30微米，材料成本約為0.75美元/平方米。

Hot dip galvanized coatings applied to fabricated steelwork are priced on the basis of the tonnage that can be processed through the galvanizing bath. Surface area is thus not as significant in galvanizing costs. Thin sections that can be loaded into galvanizing jigs at high loading density will attract a relatively low galvanizing cost, while 3-D structural fabrications containing heavy universal sections may be more costly to process.

用于裝配式鋼結(jié)構(gòu)的熱浸鍍鋅涂層的價(jià)格是根據(jù)鍍鋅槽處理的噸位來定的。因此，表面面積是不顯著鍍鋅成本。能夠以高負(fù)載密度加載到鍍鋅夾具中的薄片將會(huì)吸引相對(duì)較低的鍍鋅成本，而包含重型通用截面的三維結(jié)構(gòu)制造的加工成本可能會(huì)更高。

Hot dip galvanized coatings are almost always costed on a $./tonne basis. Typical galvanizing costs per tonne will range from $650/tonne for heavy, simple elements such as columns and beams in large project quantities, to $1500/tonne for light fabrications. Items requiring double-end dipping will usually attract a premium cost and small one-off fabrications (boat trailers, wrought iron, anchors etc) for non-account customers will be charged around $2000-$2500/tonne.

熱浸鍍鋅涂料的價(jià)格幾乎都是a美元。/噸。典型的鍍鋅成本從每噸650美元到1500美元不等，如大型工程中使用的柱和梁等重而簡單的構(gòu)件。需要雙頭浸洗的物品通常會(huì)收取額外費(fèi)用，而非帳戶客戶的小型一次加工(拖架、熟鐵、錨等)，每公噸收費(fèi)約為$2000至$2500。

The cost per square metre for hot dip galvanizing reduces quite significantly as sections become thinner. The following examples illustrate this:

熱鍍鋅的成本每平方米相當(dāng)顯著減少了截面變薄。下面的例子說明了這一點(diǎn):

Medium structural steel – 10 mm average thickness

中等結(jié)構(gòu)鋼- 10毫米平均厚度

Galvanizing cost: $700/tonne

鍍鋅成本:700美元/噸

Surface area per tonne: 25 m2/tonne

Cost/m2: $28/m2

每噸表面積:25平方米/噸

成本/ m2: 28美元/平方米

Light fabrications - 3 mm average section thickness

輕加工- 3毫米平均截面厚度

Galvanizing cost $1500/tonne

Surface area per tonne: 85 m2/tonne

Cost/m2: $18.00/m2

鍍鋅成本1500美元/噸

每噸表面積:85平方米/噸

成本/ m2: 18.00美元/平方米

A fringe benefit of hot dip galvanizing, because it is an immersion process, is that all internal surfaces of hollow sections are coated uniformly. This may be an advantage or disadvantage, as the external surface area of a hollow section is only half that of an open section of the same section thickness.

熱鍍鋅的一個(gè)附帶好處是，由于它是一種浸鍍工藝，所有空心型材的內(nèi)表面都得到了均勻的涂層。這可能是一個(gè)優(yōu)點(diǎn)，也可能是一個(gè)缺點(diǎn)，因?yàn)榭招慕孛娴耐獗砻婷娣e只有相同截面厚度的開口截面的一半。

Another fringe benefit of hot dip galvanizing compared to both paint coatings and continuously galvanized coatings is that the applied coating thickness almost always in excess of Australian Standard requirements.

與油漆涂層和連續(xù)鍍鋅涂層相比，熱鍍鋅的另一個(gè)附加好處是涂層厚度幾乎總是超過澳大利亞標(biāo)準(zhǔn)要求。

This is a bonus for the customer, as additional zinc pick-up on steelwork cannot be accurately predicted by the galvanizer, as it is influenced by the surface condition, section thickness and chemistry of the steel. It can add $50-$100/tonne to the galvanizer’s material costs, with the added bonus for the customer of the extra zinc adding proportionately to the service life of the coating.

這對(duì)客戶來說是一個(gè)額外的好處，因?yàn)殄冧\器不能準(zhǔn)確地預(yù)測鋼結(jié)構(gòu)上額外的鋅含量，因?yàn)樗艿戒摰谋砻鏃l件、截面厚度和化學(xué)成分的影響。它可以增加50- 100美元/噸的鍍鋅材料成本，與客戶額外的鋅按比例添加到涂層的使用壽命額外的獎(jiǎng)金。

The Realties of Future Maintenance

未來維護(hù)的現(xiàn)實(shí)

Where maintenance coating is required on an infrastructure or industrial project, the real cost experienced in 2008 would not have been even considered 25 year ago.

如果一個(gè)基礎(chǔ)設(shè)施或工業(yè)項(xiàng)目需要維護(hù)涂層，那么在25年前，2008年的實(shí)際成本甚至不會(huì)被考慮在內(nèi)。

The major cost factors impacting on maintenance costs include:

影響維修成本的主要成本因素包括:

Access

Containment

OH&S Management

Productivity

It is worth looking at each of these factors in more detail.

值得更詳細(xì)地研究這些因素。

1. Access

It is now mandatory in most jurisdictions in Australia to use scaffolding systems when working at heights. Ladders and trestles are no longer acceptable for commercial coating contractors.

在澳大利亞的大多數(shù)司法管轄區(qū)，在高處工作時(shí)必須使用腳手架系統(tǒng)。梯子和支架不再被商業(yè)涂料承包商所接受。

The cost of erecting, hiring and dismantling scaffolding is a major component of any maintenance coating operation. Since the introduction of more stringent safety requirements on residential building sites, few houses are now built that do not require scaffolding to be erected during their construction. While this is not directly connected to the life-cycle costing of industrial coatings, it is worth noting that the value of the residential scaffolding market in Australia now exceeds $250 million annually.

安裝、租用和拆除腳手架的費(fèi)用是任何維護(hù)涂層操作的主要組成部分。由于對(duì)住宅建筑工地實(shí)施了更嚴(yán)格的安全規(guī)定，現(xiàn)在很少有房屋在建造過程中不需要搭建腳手架。雖然這與工業(yè)涂料的生命周期成本沒有直接聯(lián)系，但值得注意的是，澳大利亞住宅腳手架市場的價(jià)值現(xiàn)在每年超過2.5億美元。

On industrial projects, much larger scaffolding systems may be required to provide the needed access for maintenance.

在工業(yè)項(xiàng)目中，可能需要更大的腳手架系統(tǒng)來提供所需的維護(hù)訪問。

In assessing the likely maintenance costs, access factors can be applied to life cycle costing models to more accurately estimate costs on a specific structure.

在評(píng)估可能的維護(hù)成本時(shí)，可以將訪問因子應(yīng)用于生命周期成本計(jì)算模型，從而更準(zhǔn)確地估計(jì)特定結(jié)構(gòu)的成本。

It is possible to classify structures for assessing access issues. The following is an example:

可以對(duì)評(píng)估訪問問題的結(jié)構(gòu)進(jìn)行分類。以下是一個(gè)例子:

Level 1 – Simple structure to 15 m. Maintenance able to continue while structure is operational. Easy access for scaffolding or lifts.一級(jí)-簡單結(jié)構(gòu)，高度15米。結(jié)構(gòu)運(yùn)行時(shí)可以繼續(xù)進(jìn)行維護(hù)。方便腳手架或升降機(jī)。

Level 2 – Simple structure 15-30 m. Greater scaffolding requirements. Maintenance able to be done while structure operational.二級(jí)-簡單結(jié)構(gòu)，高15-30米。更大的腳手架要求。能夠在結(jié)構(gòu)運(yùn)行時(shí)進(jìn)行維護(hù)。

Level 3 – Simple structure over 30 m. Specialised external access required. Operating requirements of other plant and equipment must be considered.三級(jí)-簡單結(jié)構(gòu)，高度30米以上。需要特殊的外部訪問。必須考慮其他工廠和設(shè)備的操作要求。

Level 4 – Complex structure to 15 m. Internal and external access required. Operating requirements of other plant and equipment must be considered.四級(jí)-復(fù)雜結(jié)構(gòu)，高度15米。需要內(nèi)部和外部訪問。必須考慮其他工廠和設(shè)備的操作要求。

Level 5 – Complex structure 15 – 30 m. Internal and external access required. Staging at each level may be required. Operating requirements of other plant and equipment must be considered.5級(jí)-復(fù)雜結(jié)構(gòu)，15 - 30米。需要內(nèi)部和外部訪問?？赡苄枰诿總€(gè)級(jí)別上進(jìn)行分段。必須考慮其他工廠和設(shè)備的操作要求。

Level 6 – Complex structure over 30 m. Staged internal and specialised external access required. Operating requirements of other plant and equipment must be considered.6級(jí)- 30米以上的復(fù)雜結(jié)構(gòu)。需要階段性的內(nèi)部和特殊的外部訪問。必須考慮其他工廠和設(shè)備的操作要求。

2. Containment

Like access, containment costs will vary with the complexity of the requirements for containment. As with access, models can be developed to classify containment levels and factor in the costs of containment for a specific containment requirement.

與訪問一樣，控制成本也會(huì)隨著控制需求的復(fù)雜性而變化。與訪問一樣，可以開發(fā)模型來對(duì)容器級(jí)別進(jìn)行分類，并考慮特定容器需求的容器成本。

An example of classification of containment factors is as follows:

包容因子分類的一個(gè)例子如下:

None – No recovery of residues or paint.沒有-沒有回收殘留物或油漆。

Level 4 (Minimum) – For abrasive blast cleaning only – air penetrable walls, flexible framing, open entryways and natural air flow.4級(jí)(最低)-僅用于噴砂清理-可穿透空氣的墻壁、柔性框架、敞開的入口和自然氣流。

Level 3 (Moderate) – For abrasive blast cleaning – air penetrable walls, rigid or flexible framing, partially sealed entryways and joints, exhaust air filtration.3級(jí)(中等)-用于磨料噴砂清理-空氣可穿透的墻壁，剛性或柔性框架，部分密封的入口和接頭，排氣過濾。

Level 2 (High) – For abrasive blast cleaning – air impenetrable walls rigid or flexible framing, fully sealed joints, airlock entryways, negative air flows and exhaust air filtration.2級(jí)(高)-用于磨料噴砂清理-空氣不透壁，剛性或柔性框架，全密封接頭，氣閘入口，負(fù)氣流和排氣過濾。

A good example of high-level containment is the maintenance painting program undertaken on under-road steelwork on the Sydney Harbour Bridge, which also incorporates very complex staging and access systems.

高水平遏制的一個(gè)很好的例子是對(duì)悉尼港大橋上的地下鋼結(jié)構(gòu)進(jìn)行的維護(hù)噴漆項(xiàng)目，該項(xiàng)目也包含非常復(fù)雜的階段和入口系統(tǒng)。

Where lead based paints are concerned, additional environmental management systems may be required to monitor local soil and water system during the remediation activities.

在涉及含鉛油漆時(shí)，可能需要額外的環(huán)境管理系統(tǒng)來監(jiān)測當(dāng)?shù)赝寥篮退到y(tǒng)的修復(fù)活動(dòng)。

3. WH&S Management職業(yè)健康

Worker safety is now the first priority in any business and where heights are involved, stringent requirements for personal safety equipment are mandatory. Industrial manslaughter laws apply in many Australian States, and while managers should not need the threat of such legislation to care for the welfare of their workers, it is an indication that the most stringent risk assessments must be applied to any hazardous activity.

工人安全現(xiàn)在是任何行業(yè)的第一要?jiǎng)?wù)，在涉及高度的地方，對(duì)個(gè)人安全設(shè)備的嚴(yán)格要求是強(qiáng)制性的。工業(yè)過失殺人法適用于澳大利亞的許多州，雖然經(jīng)理們不應(yīng)該需要這種立法的威脅來關(guān)心他們的工人的福利，但這表明，最嚴(yán)格的風(fēng)險(xiǎn)評(píng)估必須適用于任何危險(xiǎn)的活動(dòng)。

Certified safety equipment is mandatory when working at height, and approved safety harnessing and attachment systems have to be provided by contractors. Other Workcover regulations related to working in enclosed spaces places further onus on employers to ensure that no cost-cutting shortcuts are taken in the provision of maintenance coating services.

在高空作業(yè)時(shí)，必須配備合格的安全設(shè)備，承包商必須提供經(jīng)批準(zhǔn)的安全控制和連接系統(tǒng)。與在封閉空間內(nèi)工作有關(guān)的其他工作覆蓋規(guī)定進(jìn)一步規(guī)定了雇主的責(zé)任，以確保在提供維護(hù)涂層服務(wù)時(shí)不采取任何削減成本的捷徑。

4. Productivity生產(chǎn)力

Each of the above factors will have an impact on productivity. With new steelwork, labour costs represent about 75-80% of the coating cost. For on-site maintenance, the labour cost component is far greater and for this reason material costs (paint costs) are less significant and more expensive surface tolerant paints will have little impact on the overall costs of a maintenance project, and represent better value given the expectation of higher levels of performance.

以上每一個(gè)因素都會(huì)對(duì)生產(chǎn)力產(chǎn)生影響。新鋼鐵廠的勞動(dòng)力成本約占涂層成本的75-80%。現(xiàn)場維護(hù),勞動(dòng)力成本組件是更大,為此材料成本(油漆成本)寬容更重要和更昂貴的表面油漆對(duì)維修項(xiàng)目的總成本,并代表更好價(jià)值的期望更高水平的性能。

Surface preparation is the most labour-intensive part of the process. Surfaces may be contaminated with soluble salts so may require water washing/ blasting prior to mechanical removal of the rusted surface or failed paint coating.

表面處理是整個(gè)過程中勞動(dòng)強(qiáng)度最大的部分。表面可能被可溶性鹽污染，因此在機(jī)械去除生銹表面或失效的油漆涂層之前，可能需要水洗/爆破。

As a guide, the cost per square metre for maintenance coating a rusted steel structure may be 5-10 times the cost of applying an equivalent coating to new steelwork.

作為指導(dǎo)，每平方米生銹鋼結(jié)構(gòu)的維護(hù)涂層成本可能是新鋼結(jié)構(gòu)的5-10倍。

Summary

 總結(jié)

Regardless of the protective coating used, there is a strong case, particularly in the present environment of low interest rates and decreasing company taxes, to use the longest life coatings available commensurate with the design life of the asset.

This may mean more stringent inspection with applied coatings, the use of QA certified applicators or the insistence in a coating performance guarantee from the supplier to better manage the risk and avoid the inevitable and more costly than expected future maintenance costs.

無論使用何種防護(hù)涂層，都有充分的理由使用與資產(chǎn)的設(shè)計(jì)壽命相稱的最長壽命涂層，尤其是在當(dāng)前低利率和降低公司稅收的環(huán)境下。

這可能意味著對(duì)應(yīng)用的涂層進(jìn)行更嚴(yán)格的檢查，使用QA認(rèn)證的涂敷器，或堅(jiān)持要求供應(yīng)商提供涂層性能保證，以更好地管理風(fēng)險(xiǎn)，避免不可避免的、成本高于預(yù)期的未來維護(hù)成本。