Epoxy Floor Coating Thickness Calculator
Calculate dry film thickness (DFT), wet film thickness (WFT), and material volume required for epoxy floor coating projects.
Formulas Used
Wet Film Thickness (WFT) per coat:
WFT (mils) = DFT (mils) ÷ (Volume Solids / 100)
Theoretical Coverage:
Coverage (ft²/gal) = 1,604 × (Volume Solids / 100) ÷ WFT (mils)
Derived from: 1 US gallon = 231 in³; 1 mil = 0.001 in; 1 ft² = 144 in²
→ 231 ÷ (0.001 × 144) = 1,604.17 ≈ 1,604
Actual Coverage (with waste):
Actual Coverage = Theoretical Coverage ÷ (1 + Waste% / 100)
Total Gallons Required:
Total Gallons = (Floor Area ÷ Actual Coverage) × Number of Coats
Unit Conversions:
1 mil = 25.4 µm | 1 US gallon = 3.78541 liters
Assumptions & References
- The 1,604 constant is the standard industry coverage factor derived from unit analysis of US gallons, mils, and square feet (SSPC Paint Application Standard No. 2).
- DFT is the thickness of the cured, dry coating film; WFT is the thickness applied wet before solvent evaporation.
- 100% volume solids epoxies (e.g., pure epoxy with no solvent) yield WFT = DFT.
- Waste factor accounts for surface porosity, roller/brush absorption, overspray, and edge losses; 10–15% is typical for smooth concrete floors.
- Typical floor coating DFT ranges: primer 2–4 mils, base coat 6–12 mils, topcoat 2–4 mils (ASTM D4138 for DFT measurement).
- Coverage calculations assume a flat, uniform surface. Rough or porous concrete may require additional material.
- Reference: ASTM D1212 (WFT measurement), ASTM D4138 (DFT measurement), SSPC-PA 2 (coating thickness standards).