Epoxy floor calculator: gallons by coat & kits
Coverage comes from chemistry, not guesswork: 1,604 sq ft per gallon at 1 mil for 100% solids, scaled by volume solids and the dry film thickness you specify. Add each coat, application loss and kit size, and get gallons, kits and cost.
- Coverage from volume solids & DFT
- Primer, body and topcoats
- Application loss
- Kits and cost
1 · Area & system Per the coating data sheet
2 · Loss & packaging
1604 is the number of square feet one US gallon (231 in³) covers at 1 mil (0.001 in) thick: 231 ÷ 0.001 ÷ 144 = 1604. Theoretical coverage = 1604 × volume solids ÷ DFT, the standard coatings formula used on product data sheets. Application loss is an editable assumption.
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The 1,604 rule
One US gallon is 231 cubic inches. Spread over 1,604 square feet, it makes a film 1 mil (0.001 in) thick. That is where the 1,604 figure comes from: a 100% solids coating covers 1,604 sq ft per gallon at 1 mil dry. For a coating with lower volume solids, multiply by the solids fraction; for a thicker film, divide by the dry film thickness. The result is theoretical coverage. Real coverage is lower because of surface profile, porosity, mixing losses and application method.
- Volume solids. From the product data sheet, as a percentage by volume (not by weight).
- Dry film thickness (DFT). From the specification or the manufacturer's system sheet, per coat.
- Application loss. Squeegee and roller losses, leftover in pails, surface profile. An editable percentage.
- Broadcast systems. Aggregate or flake broadcast and the resin to lock it in should be added as their own lines.
Coat by coat
| Volume solids | DFT (mils) | Theoretical coverage (sq ft/gal) |
|---|---|---|
| 100% | 10 | 160 |
| 100% | 20 | 80 |
| 80% | 8 | 160 |
| 60% | 3 | 321 |
| 50% | 2 | 401 |
Theoretical values from 1,604 × solids ÷ DFT. Follow the coating manufacturer's system data and the specification.
Prep is often the biggest line
Material is predictable once coverage is right. Surface preparation (grinding or shot blasting to the required profile), crack and joint repair, moisture mitigation, cove base and cure time between coats drive the schedule and the price. Carry prep per square foot, repairs per linear foot, cove per linear foot and coating labor per coat, and keep equipment and consumables (diamonds, shot, vacuum) visible.
RenderDraw's AI takeoff proposes floor areas by finish or coating system, plus cove and joint lengths where they are drawn, with the sheet attached for every quantity.
Epoxy cost per sq ft, m² and litre
The calculator reports material plus labor per square foot and per square metre (1 m² = 10.764 sq ft). Enter your kit price and labor hours, and both update together, so you can quote either unit without a second spreadsheet.
Suppliers outside the US often price coatings per litre. One US gallon is 3.785 litres, so a coverage of 160 sq ft per gallon at 10 mils and 100% solids is about 42 sq ft (3.9 m²) per litre. Convert the data sheet coverage the same way rather than mixing units mid-estimate.
Price per area for an installed system depends heavily on prep (grinding, shot blasting, crack and joint repair), the number of coats and film builds, broadcast flake or quartz, and access. Price those as separate lines so a change to one coat does not hide in a lump sum.
Finish areas and transitions, room by room.
RenderDraw's AI takeoff proposes finish polygons, transitions and base from floor plans and the finish schedule, links each quantity to its sheet, and holds uncertain items for estimator review.
- Finish polygons by room. Each area carries the finish code from the schedule.
- Transitions and base as linear quantities. Captured alongside the areas.
- Addenda through the same review. Send the changed sheets back through takeoff and estimator review.
- Waste and pricing stay yours. Apply your waste factors, labor and margin to reviewed rows.
Send one flooring set
Include the finish schedule. Files stay private while RenderDraw assesses the request. No obligation.
RenderDraw does not publish accuracy percentages or time-saved claims. Test it on your own plan set.
Questions estimators ask.
How much epoxy do I need per square foot?
Divide 1,604 × volume solids by the dry film thickness in mils to get coverage in sq ft per gallon. A 100% solids coat at 10 mils covers about 160 sq ft per gallon before losses.
What does the 1,604 number mean?
One gallon (231 in³) spread at 0.001 in thick covers 1,604 sq ft. It is the basis for theoretical coverage of any coating.
How much loss should I add for epoxy?
It depends on the surface and method. Rough, porous concrete and primer coats lose more. The field is editable.
How many kits do I need?
Total gallons for all coats with loss, divided by the kit size, rounded up. The calculator does this for the kit size you enter.
Can RenderDraw measure coating areas?
RenderDraw's AI takeoff proposes areas by finish and system from drawings with sources and flags. Get a free sample takeoff.
How much does epoxy floor coating cost per square metre?
Enter your kit price and labor in the calculator; it shows material plus labor in $/sq ft and $/m². Installed prices vary with prep, film build and system, so use your own supplier and labor numbers.
How do I convert epoxy coverage per litre?
Divide coverage per US gallon by 3.785 to get coverage per litre, and convert square feet to square metres by dividing by 10.764.
Coating areas by system, from the drawings.
Send a set. RenderDraw proposes floor areas by finish or coating system with their sheets, and flags rooms with unclear finish codes.
- Upload the plans, specs and schedules, plus an addendum if you have one.
- RenderDraw reviews the set and the scope you want tested.
- We follow up with extracted quantities, flagged items and next steps.