Dry Fall vs. Brush & Roll

Head to Head Cost Comparison

Spray-Safe Dry Fall System

Industrial Dry Fall - Dry Fall Epoxy Primer, Dry Fall Urethane Topcoat, Dry Fall Epoxy DTM, Dry Fall Alkyd Primer, Dry Fall Acrylic Dry Fall Zinc Rich Epoxy Primer Acrylic Exterior Dry Fall paint

Brand X Brush & Roll System

30,000 Square Foot Tank Exterior - Example

Spray-Safe Application Rate: 350Ft2 Per Coat Per Hour

Man Hours Needed: 257

Material Costs: $32,400.00

Labor Costs: $17,768.98

Total Project Cost: $50,168.98

Completed in 3.6 Work Days

Brush & Roll Application Rate: 125Ft2 Per Coat Per Hour

Man Hours Needed: 720

Material Costs: $14,100.00

Labor Cost: $45,784.80

Total Project Cost: $69,884.80

Completed in 10 Work Days

The data above is pretty compelling. Consider saving 28% on every maintenance project that used to require brush and roller application. That is a fantastic benefit on its own, but Highland dry fall  doesn’t stop there. It also enables jobs to be completed in less than half of the time. This time savings allows facility owners to reduce down time, and make the most of their budgets. Additionally, it allows contractors to bid more competitively, and complete more jobs. All in all, Highland dry fall paint is the obvious choice when compared to competitor brush and roller applied systems. Call us today! 1-828-265-2513 Or visit our Spray-Safe dry fall page for more info.

Material Costs

Highland Dry Fall Epoxy/Urethane System

8 Mils Total DTF in 3 Coats

$1.08 Per Ft2

Brand X B&R Epoxy/Urethane System

8 Mils Total DTF in 3 Coats

$0.47 Per Ft2

  • Details

    Coverage Calculations
    45% Volume Solids
    2.5 Mils DFT
    20% Loss

    1604 x .45 = 721.8 ÷ 2.5 = 288.72 x .8 ≈ 230Ft2

    Coverage Per Gallon: 230Ft2
    Selling Price Per Gallon: $61.95

    $61.95 ÷ 230Ft2 ≈ $0.27 per Ft2

    Brand X Brush & Roll Epoxy Primer

    80% Volume Solids
    2.5 Mils DFT
    10% Loss

    1604 x .80 = 1,283.2 ÷ 2.5 = 513.3 x .9 ≈ 460Ft2

    Coverage Per Gallon: 460Ft2
    Selling Price Per Gallon: $49.50

    $49.50 ÷ 460Ft2 ≈ $0.11 per Ft2

    41% Volume Solids
    3 Mils DFT
    20% Loss

    1604 x .41 = 657.64 ÷ 3 = 219.21 x .8 ≈ 175Ft2

    Coverage Per Gallon: 175Ft2
    Selling Price Per Gallon: $94.11

    $94.11 ÷ 175Ft2 ≈ $0.54 per Ft2

    Brand X Brush & Roll Urethane Topcoat

    62% Volume Solids
    3 Mils DFT
    10% Loss

    1604 x .62 = 994.48 ÷ 3 = 331.49 x .9 ≈ 300Ft2

    Coverage Per Gallon: 300Ft2
    Selling Price Per Gallon: $76.44

    $76.44 ÷ 300Ft2 ≈ $0.25 per Ft2

    1st Coat

    2.5 Mils DFT

    $0.27 per Ft2

    Brand X Brush & Roll Epoxy Primer

    2.5 Mils DFT

    $0.11 per Ft2

    2nd Coat

    2.5 Mils DFT

    $0.27 per Ft2

    Brand X Brush & Roll Epoxy Primer

    2.5 Mils DFT

    $0.11 per Ft2

    3rd Coat

    Brand X Brush & Roll Urethane Topcoat

    3 Mils DFT

    $0.25 per Ft2

Labor & Equipment Costs

Equipment: $29.14 Per Hour

Labor: $40.00 Per Man Hour

Total: $69.14 Per Hour

Equipment: $23.59 Per Hour

Labor: $40.00 Per Man Hour

Total: $63.59 Per Hour

  • Details

    Paint Crew & Working Hours

    8 man crew, 9-hour workday, 6 days per week

    (6 men spraying on 3 man-lifts, 2 support men on the ground)

    8 man crew, 9-hour workday, 6 days per week

    (6 men rolling on 3 man-lifts, 2 support men on the ground)

    Man-Lift Cost Breakdown

    $1500 per Week x 3 Man-Lifts = $4,500

    $4,500 per week for 3 man lifts, used by 8 men for 9 hours per day for 6 days per week = $10.42/man hour

    $1500 per Week x 3 Man-Lifts = $4,500

    $4,500 per week for 3 man lifts, used by 8 men for 9 hours per day for 6 days per week = $10.42/man hour

    Trucks Cost Breakdown

    $900 per Week x 2 Trucks = $1,800

    $1,800 per week for 2 trucks, used by 8 men for 9 hours per day for 6 days per week = $4.17/man hour

    $900 per Week x 2 Trucks = $1,800

    $1,800 per week for 2 trucks, used by 8 men for 9 hours per day for 6 days per week = $4.17/man hour

    Compressor Cost Breakdown

    $1,600 per Week

    $1,600 per week for 1 compressor, used by 8 men for 9 hours per day for 6 days per week = $5.55/man hour

    Not Needed

    N/A

    Consumables Cost Breakdown

    $3,888 per Week

    $3,888 per week for consumables, used by 8 men for 9 hours per day for 6 days per week = $9.00/man hour

    $3,888 per Week

    $3,888 per week for consumables, used by 8 men for 9 hours per day for 6 days per week = $9.00/man hour

These numbers are based on the average costs in 2018. Prices may vary based on location, color, and project type.

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