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Success Story -  A Case Study
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Making a Maintenance Painting Program Work Harder¡­Cost Less!

A client operating a petrochemical plant in the Gulf Coast area was dissatisfied with their current maintenance painting program. They were spending just under $1,000,000 per year in direct contractor costs but were still suffering expensive steel loss and poor plant appearance.

We first performed a Current Practice Assessment to help site management understand what problems they may have, their severity and how to overcome them most effectively. We analyzed everything from how work scopes are selected to the efficiencies of the contractor painting crew. The results were interesting.

bulletAnnual work scopes were a "wish list". One example was painting a single pipeline in an elevated pipe rack that contained several dozen pipes in similar or worse condition. Another example included painting a group of tanks without painting the associated access stairs, platforms, ladders, pumps and piping. The actions to paint the tanks actually damaged these associated items, increasing the rate of corrosion, making the cost to eventually paint these items many times what it should have cost.
bulletThere was evidence of significant application deficiencies that were dramatically reducing the lifecycle of the coating system. These included problems with surface preparation, inadequate film thickness, and occasionally using the wrong coating for the environment. This was in spite of the fact that the client was paying for a full time NACE certified coatings inspector provided by the contractor.
bulletOverall contractor productivity was many times less efficient than it should have been. This was a result of several factors; laborious daily permitting procedures, poorly organized and supervised work crews, inefficient work scopes, etc.

Further analysis showed only about 2% of the plant was getting painted each year with much of that being done with inadequate quality to insure a normal life of 8-10 years for that environment. The result?........Steel loss, poor appearance, and getting farther behind each year with more money spent!

A Strategic Coatings Assessment was developed and implemented. The result?

bullet12-18% of the plant gets painted each year.
bulletWork scopes use strategic factors such as optimum condition level and geographic bundling for improved cost efficiency.
bulletLonger coatings life is assured.
bulletCosts ($/ft2) fell to less than 1/10th of past work.
bulletSteel loss will be nearly eliminated.
bulletPlant appearance is improving.

However the best news was that after about six years of spending about what they are currently spending, the plant will have to spend only about 2/3rds of current expenditures to maintain their gains!

Helping Business Execute