Take the Guesswork out of Your Projects
Use this calculator to estimate how much product your project calls for.*
*A reminder that these are estimates. Environments vary, so it's important to discuss these with your sales rep to confirm you're ordering the right amount.
1 How big is the floor?
Just the area you are coating.
Not sure? Multiply length by width in feet.
2 What is the floor used for?
This sets how thick the coating needs to be.
3 Product
We have picked the usual choice. Change it if you already know what you want.
4 How many coats?
Most plant floors get two.
You will need about
— gallons
Show how this was worked out
| Product | — |
|---|---|
| Film thickness | — |
| Volume solids | — |
| Coverage, perfect surface | — |
| Coverage after 10% loss | — |
| One coat | — |
| Total, all coats | — |
| Plus 5% contingency | — |
coverage = 1,604 × volume solids % ÷ mils dry film
1 US gallon spread 1 mil thick covers 1,604 sq ft.
This one needs a system, not a product
Heavy forklift traffic, impact damage and floors that need rebuilding as well as coating are quoted as a system. The material depends on the condition of the slab, and we would rather look at it than guess.
1 What are you repairing?
2 How big is it?
Measure the crack after you have chipped it out to solid concrete.
3 Anything special about the area?
This picks the right patch for the conditions.
You will need
— kits
Show how this was worked out
| Product | — |
|---|---|
| Space to fill | — |
| Plus 10% for mixing and waste | — |
| One kit holds | — |
| Kits needed | — |
| Or, as master kits | — |
A kit is a volume. A kit that covers 21 sq ft at ¼" holds
21 × 144 × 0.25 = 756 cubic inches.
Figures are a planning guide and assume the surface is sound and prepared. Irregular spalls, open concrete and spray application all consume more. For a job you are quoting, call 800.456.6255.
Why the number on the label is not the number you need
Every datasheet quotes coverage on a perfect surface with nothing wasted. Real plant floors absorb material, rough surfaces swallow it, and some always stays in the pail. We build in 10% for that, then suggest 5% on top so you are not short.
Coming up short in the middle of a shutdown costs far more than a spare pail. If in doubt, order the extra.
For coatings, thickness is the whole story
Coverage and thickness move in opposite directions, always. Lay a coating on twice as thick and a gallon goes half as far. That is why our 233 LV covers 320 square feet per gallon and Z-Poxy HP covers 80 — both are the same 100% solids chemistry, but one goes on at 5 mils and the other at 20, because they are doing different jobs.
So pick the thickness from what the floor has to survive, then work out the material. Never the other way round.
For repairs, depth is the whole story
Patch kits are sold by square feet at a quarter inch, which is useless for a crack. A crack has depth, and depth is what eats material.
The way through is to stop thinking in square feet. A kit is a volume. A kit covering 21 square feet at a quarter inch holds 756 cubic inches. Once you know that, any repair is simple arithmetic, which is what the calculator above is doing.
Depth is always more than it looks. A repair that seems half an inch deep is often an inch and a half once you have chipped back to solid concrete. Chip it out first, then measure, then order. Guessing from the surface is the most common reason a crew runs short.
Coating coverage
| Product | Thickness | Coverage | What it is for |
|---|---|---|---|
| 144NF Water-Based Hybrid Urethane | 3–4 mils | 200–350 sq ft/gal | Recoating a sound floor. Low odour, fast back in service |
| 233 LV Low Viscosity Epoxy | 5 mils | 320 sq ft/gal | Dust control, foot traffic, sealing bare concrete, priming |
| 233 MV Medium Viscosity Epoxy | 10 mils | 160 sq ft/gal | General build coat |
| Z-Poxy 100% Solids Epoxy | 10 mils | 160 sq ft/gal | General plant floors, pallet jack traffic |
| Z-Poxy HP Novolac Epoxy | 20 mils | 80 sq ft/gal | Chemicals, wash-down, aggressive cleaning |
Patch kit sizes
| Product | Covers at ¼" | Volume | What it is for |
|---|---|---|---|
| Ranger Patch RD-12 | 8 sq ft | 288 cu in | Damp concrete. Small single repairs |
| Z-Patch | 16 sq ft | 576 cu in | Heavy impact, expansion joints |
| Ranger Patch RE-18 | 16 sq ft | 576 cu in | 100% epoxy repair, ready-mixed kit |
| Ranger Patch RU-10 | 21 sq ft | 756 cu in | Cementitious urethane. High moisture |
| Perma-Fil High-Strength | 21 sq ft | 756 cu in | General floor repair |
| Perma-Fil Quick Set | 21 sq ft | 756 cu in | Back in service fast |
| Perma-Fil Damp Patch | 21 sq ft | 756 cu in | Damp and wet concrete |
| Perma-Fil Cold | 21 sq ft | 756 cu in | Freezers and cold areas |
| Perma-Fil Chemical Resistant | 21 sq ft | 756 cu in | Chemical exposure |
| Perma-Fil master kit | 210 sq ft | 7,560 cu in | Ten single kits in one package |
Before you order
- Chip repairs back to solid concrete and square the edges. Patch over loose material fails at the bond line no matter how strong it is, and a feathered edge is the first thing a forklift finds.
- Do not place patch deeper than two inches in one pour. Build it up in two-inch lifts. A deep mass of epoxy makes heat as it cures and has nowhere to put it.
- Patch first, then coat. Coating is not a levelling compound, and using it as one is the priciest way to fill a hole.
- Test for moisture if the slab is damp. Some of our products are made for damp and wet concrete. Most coatings, ours included, are not, and a coating over a slab pushing moisture will blister.
- Order the whole job from one batch. Colour varies a little between batches and the difference is permanent under plant lighting.
Common questions
Why does my real coverage never match the datasheet?
The datasheet assumes a perfect surface and no waste. On a real plant floor, expect to lose about 10% to the concrete soaking it up, the roughness of the surface and what stays in the pail. The calculator already subtracts that.
I have a 20 ft crack, an inch wide and three inches deep. How many kits?
That is 720 cubic inches of space to fill. One Perma-Fil kit holds 756, so you are right on the line — two kits with the waste allowance in. It is also three inches deep, so place it in two lifts rather than one pour.
Why does one gallon cover 320 sq ft and another only 80?
Thickness. 233 LV goes on at 5 mils and Z-Poxy HP at 20, and they are both 100% solids, so at the same thickness they would cover exactly the same. Four times thicker, a quarter of the coverage. The heavier build is what gives the novolac its chemical resistance.
How thick should my floor coating be?
Pick it from the job, not the budget. Roughly: 3 to 5 mils to recoat a sound floor or control dust, 10 mils for a general plant floor, 20 mils for chemicals and wash-down. Heavy forklift traffic and floors that need rebuilding want a thicker system, and those are worth a call rather than a calculator.
How deep can I fill in one go?
Two inches. Deeper than that, build it up in two-inch lifts. Some crews pour to four and we would rather they did not. The minimum is an eighth of an inch — for anything thinner, use less of the kit aggregate for a skim consistency, which means you will need more kits, not fewer.
How much spare should I order?
The calculator adds 5% on top of the 10% loss allowance. Make it 10% if the floor is rough, there is a lot of edge and detail work, or you cannot shut down a second time.