Epoxy Flooring Calculator
Estimate primer, body coat, topcoat, resin kit count, broadcast aggregate, cove resin, waste allowance, and pot-life batch zones for epoxy floor systems.
✦Epoxy Floor Presets
📏Project Inputs
▦Material And Spec Grid
📋Epoxy Coat Coverage Reference
| Coat Layer | Typical Coverage | Wet Film Range | Purpose In System | Calculator Note |
|---|---|---|---|---|
| Primer | 180 to 250 sq ft/gal | 4 to 8 mil | Seal concrete and reduce outgassing | Reduced for porosity and profile |
| Body coat | 80 to 180 sq ft/gal | 9 to 20 mil | Build color coat and receive media | Uses body coat count |
| Self-leveling body | 55 to 90 sq ft/gal | 18 to 30 mil | Higher build decorative or smooth floor | Best for metallic systems |
| Topcoat or grout coat | 120 to 220 sq ft/gal | 4 to 10 mil | Lock media and set texture | Uses topcoat count |
| Mortar binder | 35 to 65 sq ft/gal | 30 to 45 mil | Bind sand overlay or patch bed | High aggregate demand |
▣Broadcast Media Planning Table
| Broadcast Type | Planning Rate | Texture Result | Topcoat Demand | Common Use |
|---|---|---|---|---|
| Light aluminum oxide | 0.03 to 0.06 lb/sq ft | Fine grip | Low | Clear or solid color topcoat |
| Partial vinyl flake | 0.04 to 0.08 lb/sq ft | Decorative speckle | Low to medium | Utility rooms and retail floors |
| Full vinyl flake | 0.10 to 0.16 lb/sq ft | Full-chip rejection | Medium | Garage and commercial decorative floors |
| Single quartz | 0.60 to 0.90 lb/sq ft | Dense slip-resistant texture | High | Locker rooms and wet service floors |
| Double quartz | 1.20 to 1.80 lb/sq ft | Heavy broadcast texture | Very high | Food service and industrial areas |
| Mortar aggregate | 4.00 to 6.00 lb/sq ft | Troweled build layer | Sealed or grouted | Repairs and heavy build overlays |
⚙Surface Profile And Slab Factors
| Condition | Calculator Factor | Material Effect | Use When |
|---|---|---|---|
| CSP 1-2 smooth | 1.00 | Base coverage | Lightly abraded smooth concrete |
| CSP 2-3 light grind | 1.06 | Small coverage increase | Typical epoxy preparation |
| CSP 4-5 medium profile | 1.14 | More resin fills texture | Shotblast before broadcast |
| CSP 6-7 rough profile | 1.25 | Heavy primer and body demand | Scarified or roughened slab |
| Porous or patched slab | 1.12 to 1.24 | Primer absorption risk | Old concrete, pinholes, patch edges |
🗂Preset Scenario Table
| Scenario | Typical Area | System | Broadcast | Coat Stack |
|---|---|---|---|---|
| Two-car garage | 440 sq ft | Full flake epoxy | 0.14 lb/sq ft | Primer, body, topcoat |
| Basement utility room | 360 sq ft | Clear sealer | None | Primer and topcoat |
| Wet locker room | 720 sq ft | Quartz broadcast | 0.85 lb/sq ft | Primer, body, two topcoats |
| Retail decorative floor | 1,000 sq ft | Partial flake | 0.06 lb/sq ft | Primer, color body, topcoat |
| Mortar repair overlay | 180 sq ft | Epoxy mortar | 5 lb/sq ft | Primer, mortar body, grout coat |
🧪System Comparison Grid
ℹEpoxy Calculation Tips
Calculating the amount of epoxy resins that will be required to coat a floor involve considering several variables. If you dont purchase enough epoxy resin for you job, the chemical will permanently damage the floor. For instance, if you should run out of epoxy resin while you are applying it to the floor, the epoxy resin may create a seam in the floor, or the floor may begin to cure before you can add more epoxy resin to the area.
Because epoxy resin will harden over time, you cannot simply add more to the floor after it has begun to cure. For these reasons, you must calculate the amounts of epoxy resin that will be required for the job by considering several different variables. One of the variables to consider is the porosity of the concrete.
How Much Epoxy Resin You Need for a Floor
Because concrete is a porous material, the concrete slab will absorb the epoxy resin as if it was an sponge. If the concrete slab has a rough surface profile cause by shotblasting the concrete, the slab will require more epoxy resin to fill the valleys and the peaks of that profile than a slab that is smooth and polished. Thus, a rough concreate slab will require more epoxy resin than a smooth slab.
There are also different layer of epoxy resin that must be considered in the calculation of the amount of epoxy resin that will be required for the job. For instance, one of the first layer of epoxy resin that is applied to the concrete slab is a primer that seal the concrete to prevent bubbles from forming in the floor. The second layer is the body coat that provides the color of the floor and adheres to any broadcast media.
If broadcast media is to be use, then more epoxy resin will be required for the topcoat than for a floor that feature a different color of epoxy resin. The broadcast media will create a textured and jagged area on the floor that requires more epoxy resin to fill the gaps between the flake of broadcast media. Thus, a floor that features broadcast media will require more epoxy resin than a floor of a solid color.
If an integral cove base is to be installed on the floor, another variable to consider is the amount of epoxy resin that will be required for that cove base. An integral cove base is an area where the epoxy resin will form a waterproof barrier by curving up the side of the wall. Because epoxy resin will be required for forming that waterproof barrier, the cove base will require epoxy resin to be purchased for the job.
Thus, the linear footage of the length of the cove base should of be factored into the calculations for epoxy resin to ensure that there is enough resin to coat the area and walls. The amount of time that epoxy resin can be mixed with hardener, referred to as the “pot life” of the epoxy resin, is another variable to consider. Pot life is the amount of time that epoxy resin can be mixed with hardener.
If the epoxy resin is mixed with hardener, the epoxy resin will begin to cure after it is mixed. The higher the temperature, the shorter the life of the epoxy resin. If the life of the epoxy resin is short, then you cannot mix all of the epoxy resin at once.
Thus, epoxy resin that is mixed too much at once may begin to harden and create streak on the floor. One other variable to consider is the waste that will occur during mixing. Because epoxy resin will adhere to the sides of the mixing buckets, the mixing paddles, and the rollers, there will be waste of the epoxy resin.
Not every drop of epoxy resin that is poured into the mixing containers will be usable for pouring onto the floor. Thus, ten to fifteen percent of resin should be purchased in addition to the amount that is calculated for the floor to ensure that there is enough epoxy resin for the job. It is better to purchase extra epoxy resin that can be discarded than to run out of resin before the floors is finished.
By calculating the variables of porosity, broadcast media, cove bases, pot life, and waste, you can ensure that you purchase the appropriate amount of epoxy resin to complete the job of applying epoxy resin to your floor.
