Economic Benefit
Duplex systems provide tremendous economic advantages because of the extended time to first maintenance and delayed maintenance cycle. Initially, the cost of a duplex system is high because you must pay for both corrosion protection systems. However, because of the synergistic effect the initial premium cost pays off over the life of the project and in the end is less expensive than coating bare steel.
For duplexed projects where the paint/powder system is used strictly to prolong life and the color finish is not critical, the initial cost can also be your final cost. But for most duplex projects, the top coat will be maintained and on these projects, the delayed maintenance cycle can significantly decrease the cost over the life-cycle.
Cost Case Study
As stated before, the cost of utilizing a duplex system is more expensive initially because you are paying for both the HDG and the paint system. However, specifying a duplex system of paint over hot-dip galvanized steel means less money will be spent on maintenance over the life of the structure, as can be seen by the table indicating when maintenance is necessary. The delayed maintenance cycle of the duplex system resulted in four less maintenance cycles during the 60-year life, allowing the owner more time to earn interest on the money.
Due to the synergistic effect of delayed and even eliminated maintenance over a project’s planned, useful life cost savings of a duplex system are often significantly greater than the initial ‘premium’ cost of the galvanizing and paint combination. Because of the additional maintenance cycles, the life-cycle cost of the paint system only is nearly double that of the structure that utilized a duplex system. Therefore, utilizing a duplex system for corrosion protection pays for itself – delivering maximum value and aesthetic appeal to project owners throughout the design life. In summation, decreased maintenance costs over the life of the project result in lower life-cycle costs for a structure utilizing a duplex system.
Initial Cost
As stated before, the cost of utilizing a duplex system is more expensive initially because you are paying for both the HDG and the paint system. However, specifying a duplex system of paint over hot-dip galvanized steel means less money will be spent on maintenance over the life of the structure, as can be seen by the table indicating when maintenance is necessary. The delayed maintenance cycle of the duplex system resulted in four less maintenance cycles during the 60-year life, allowing the owner more time to earn interest on the money.
| Coating System | $/ft2 | Total |
|---|---|---|
| Epoxy/Polyurethane (Black Steel) | $3.14 | $152,050 |
| Duplex System (HDG + epoxy/poly) | $5.28 | $263,950 |
| Maintenance (Years) | Black Steel | HDG Steel |
|---|---|---|
| Touch-Up Repaint | 11 & 31 & 51 | 22 & 51 |
| Maintenance Repaint | 14 & 34 & 54 | 29 & 58 |
| Full Repaint | 20 & 40 | -- |
Life Cycle Cost
Due to the synergistic effect of delayed and even eliminated maintenance over a project's planned, useful life cost savings of a duplex system are often significantly greater than the initial 'premium' cost of the galvanizing and paint combination. Because of the additional maintenance cycles, the life-cycle cost of the paint system only is nearly double that of the structure that utilized a duplex system. Therefore, utilizing a duplex system for corrosion protection pays for itself - delivering maximum value and aesthetic appeal to project owners throughout the design life. In summation, decreased maintenance costs over the life of the project result in lower life-cycle costs for a structure utilizing a duplex system.
| Coating System | $/ft2 | Total |
|---|---|---|
| Epoxy/Polyurethane (Black Steel) | $42.34 | $2,177,000 |
| Duplex System (HDG = epoxy/poly) | $22.84 | $1,124,000 |
| Duplex System life-Cycle Cost Savings = 46% | ||
Cost Case Study
Tommy Garrott Aquatics Center: Gallatin, TN 2017
What used to be an empty field in Gallatin, Tennessee is now the most exciting place to cool off on hot days in Summer County. The Tommy Garrott Aquatics Center offers visitors Gallatin's first zero-depth pool, complete with a splash pad, spray toys, two towering twisting water slides and a speed slide all at a low-cost admission. With plans to add a lazy river and therapy pool, the days of driving hours to an expensive waterpark, just to wait in long lines in cramped spaces, are over.
Hot-dip galvanizing has been used successfully in the waterpark industry for years and has now become an industry standard.
The waterpark fabricator, Vortex Aquatics Structures, is no stranger to the corrosive waterpark environment. With over 6,500 installations in 45 countries, Vortex's mission is to lead the aquatic play industry by continuing to develop the most fun, innovative and safe products to families and children of all ages and abilities. This industry experience led them to the selection of a duplex system for every steel component in The Tommy Garrott Aquatics Facility to ensure residents and visitors can enjoy it safely for many years to come.
Hot-dip galvanizing has been used successfully in the waterpark industry for years and has now become an industry standard. Powder coating over the galvanized steel adds an additional layer of protection while providing the fun, exciting visual appearance people expect out of a waterpark. With an annual expected attendance of 30,000-40,000 people from up to a 75-mile radius, minimal maintenance and optimal performance was a necessity.
The Tommy Garrot Aquatics Facilty, named after former late Gallatin mayor and city councilor Joseph "Tommy" Garrott, has been recognized regionally and statewide for its impact to the community. The Tennessee Recreation and Parks Association selected the facility for a prestigious Four Star Award and the Greater Nashville Regional Council honored it with the Parks and Recreation Award.
Christie Simpson from the City of Gallatin Department of Parks and Recreation shared, "The City of Gallatin was in need of a new outdoor pool and we wanted a facility that was going to be afforable for the people of our community - for people to be able to come and enjoy themselves. A place where everyone can play, have fun and be outdoors with their family and friends. Getting off the couch and on their feet, moving towards a healthier lifestyle and enjoying the sunshine. It is rare for a city of our size to offer a facility of this magnitude for citizens to enjoy."
Thanks to the dual protection of hot-dip galvanizing and powder coating in a duplex system, the citizens of Gallatin will be able to splash the days away at the Tommy Garrott Aquatics Facility for decades to come.