Port, Crane & Terminal Equipment worked example

Corrosion Protection Cost at 75% high-exposure zone share: a worked example

What does the result look like when high-exposure zone share reaches 75%? The full calculation is worked below with real intermediate numbers. A reliability engineer scopes a metallizing and cathodic protection package for the legs of a portal crane sitting in a tidal splash zone.

The inputs for this scenario

  • Protected Steel Area: 5,200 ft2 (unchanged)
  • Protection Cost per Square Foot: 3.4 $/ft2 (unchanged)
  • High-Exposure Zone Share: 75 % (raised for this scenario; the documented default is 65)
  • Cathodic Protection & Inspection: 9,500 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Corrosion cost = protected area x cost per ft2 x high-exposure share% + cathodic/inspection) to the inputs above produces each figure below.
  • At this operating point the engine returns 22,760 $ for total corrosion protection cost, the number this scenario is built around.
  • At this operating point the engine returns 4.38 $ / piece for corrosion protection cost per unit.
  • At this operating point the engine returns 13,260 $ for variable corrosion protection cost.
  • At this operating point the engine returns 9,500 $ for fixed corrosion protection cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where high-exposure zone share sits at 65% and the headline result is 20,992 $, this scenario comes in 8.42% above the baseline at 22,760 $.
  • A figure at this level is achievable when high-exposure zone share is genuinely sustained, not just peaked for a shift. The high-exposure share is treated as a single multiplier, so it does not separately price the heavier duplex systems that true C5-M splash zones often require versus milder atmospheric areas.

Results at a glance

  • Total corrosion protection cost: 22,760 $ (headline result)
  • Corrosion protection cost per unit: 4.38 $ / piece
  • Variable corrosion protection cost: 13,260 $
  • Fixed corrosion protection cost adder: 9,500 $

Run it with your numbers

  • Every input above is editable in the live Corrosion Protection Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.