Paint for Corrugated Surfaces

The Paint for Corrugated Surfaces calculator computes the amount of paint needed for a corrugated surface.

INSTRUCTIONS:  Choose units and enter the following:

• (L) Length
• (W) Width
• (cF) Corrugation Factor
• (nC) Number of Coats
• (CVG) Coverage per Gallons (see manufacturer recommendation)

Paint for Corrugated Surfaces (GP): The calculator returns the following: 

• (GP) Gallons of Paint
• (SA) Apparent Surface Area
• (cSA) Corrugated Surface Area.  This takes into account the corrugation.

The above can be automatically converted into compatible units via the pull-down menu.

The Math / Science

The calculator assumes that the face of the surface is rectangular with corrugation in one direction, along the width:

SA = L * W * CF

where:

• (SA) Apparent Surface Area
• (L) Length of Area
• (W) Width of Area
• (CF) Corrugation Factor

With the Surface Area (SA), calculation of the gallons of paint is division by the area coverage.

Area Coverage

Most indoor paints cover 400 ft² per gallon, and most exterior paint cover 300 ft² per gallon.  You can use whatever value for CVG you wish and override the default (300 ft²) for exterior paint, but it is recommended that one use the manufacturer's recommended coverage area.

Corrugation Factor

Surface area is a simple length times width calculation, but what if one of the dimensions is not smooth?  This is found in corrugated material.  To account for this, this calculator has a corrugation factor that is applied to the length and width dimensions to account for corrugation. 

Straight (Squared) Corrugation Profile

Curved Corrugation Profile:

Corrugation refers to the process of shaping a material into a series of parallel ridges and grooves. This is commonly seen in corrugated materials, such as cardboard or metal sheets. The purpose of corrugation is often to add strength and rigidity to the material while maintaining flexibility. In the case of corrugated cardboard, for example, the corrugated structure provides strength and helps the material withstand pressure and impacts. Corrugated metal sheets are used in roofing and packaging for similar reasons.

To calculate the Corrugation Factor, do the following:

1. Measure the linear Width (W in the diagram above), for any length of the corrugation.
2. Use a string, and lay it on top of the same length, letting is fall into all the recesses as much as possible.
3. Mark the end of the string to match the end of the Width.
4. Pull the string straight and measure how much longer it is than the Width.

The formula for the Corrugation Factor is:

CF = SL / W

where:

• CF = Corrugation Factor
• SL = String Length
• W = Width of Corrugated Segment

Corrugation

Corrugation refers to the process of shaping a material into a series of parallel ridges and grooves. This is commonly seen in corrugated materials, such as cardboard or metal sheets. The purpose of corrugation is often to add strength and rigidity to the material while maintaining flexibility. In the case of corrugated cardboard, for example, the corrugated structure provides strength and helps the material withstand pressure and impacts. Corrugated metal sheets are used in roofing and packaging for similar reasons.

Corrugation adds complexity to the basic surface area calculation.  Without corrugation the surface area of a rectangle can be calculated as length time width.  To account for corrugation, and in essence flatten the surface area calculation, one can use a Corrugation Factor (CF) that can by applied to a dimension (e.g., width) in order to make an accurate surface area of a corrugated surface calculation.

Corrugation can have a smooth (curved) or straight segment pattern with squared ends in its profile.

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