Estimate epoxy resin volume, product quantity, and waste allowance for garage, industrial, and decorative floors. Adjust thickness, coverage rate, and multi-coat settings to get a professional-grade material list.
Area
20.0 m²
Volume
4.0 L
Longest dimension of floor
Shortest dimension of floor
Multiply area per room
Primer + build + topcoat
Dry film thickness per coat
From product datasheet (at 200 µm)
Resin/hardener mix density
Total Area
40.0
m²
Epoxy Volume
8.0
litres
Product Mass
11.2
kg
With Waste
12.3
kg
Estimate only. Actual consumption depends on substrate porosity, profile, temperature, mixing ratio, and application method. Always confirm with the manufacturer's datasheet and order 5–10% extra for touch-ups.
Understanding the variables that determine resin consumption is the difference between a profitable job and a costly reorder.
Epoxy systems are specified by dry film thickness (DFT) in micrometres (µm) or mils. A typical garage floor build coat is 200–500 µm DFT; self-levelling systems reach 1,500–3,000 µm. Wet film thickness (WFT) is higher and depends on the volume solids of the product. As thickness doubles, volume consumption doubles — this is the single biggest driver of material cost.
The datasheet coverage rate (e.g. 8 m²/kg) is only valid at a stated DFT — usually 200 µm. If you apply thicker, scale consumption linearly. Volume solids (the percentage of the liquid that remains after solvent evaporation) tells you the true spreading rate. 100% solids epoxy doesn't shrink; solvent-based products lose 30–50% of their volume.
A full epoxy floor system typically has 2–3 coats: a primer (penetrating, 100–150 µm), a build coat (self-levelling or roll-on, 300–500 µm), and a topcoat (UV-stable, 100–200 µm). This calculator multiplies area × coats × thickness to give total volume. Always add a waste factor for roller loss, mixing residue, and substrate absorption.
Epoxy is sold by weight (kg) or volume (L). Density (typically 1.1–1.5 kg/L) converts between them. This matters when the coverage rate is given in m²/kg but you buy in litres — or vice versa. A 10 L kit at 1.4 kg/L weighs 14 kg and covers 112 m² at 200 µm. Always check the mixing ratio (e.g. 3:1 by volume) before ordering.
A real-world estimate for a 6 m × 5 m garage with a 2-coat system.
Order recommendation: with a 10% waste factor, order 10.4 kg (≈ 7.4 L). A standard 10 kg kit plus a 1 kg top-up, or a 15 kg kit if you plan to add a third coat.
Divide 1 by the coverage rate. If the datasheet says 8 m²/kg at 200 µm, then 1 kg covers 8 m². For a different thickness, scale inversely: at 400 µm, coverage halves to 4 m²/kg. Multiply the floor area by the number of coats, then divide by the adjusted coverage rate to get total kilograms.
Use 5% for smooth, non-porous concrete with a squeegee application. Use 10–15% for porous or broom-finished concrete, roller application, or complex rooms with columns. Add an extra 5% if you're mixing small batches and anticipate pot-life waste. Never go below 5% — running short mid-coat causes lap marks.
Yes — dramatically. Volume consumption is directly proportional to thickness. Doubling from 200 µm to 400 µm doubles the material required. A self-levelling floor at 3,000 µm uses 15× the resin of a 200 µm sealer coat. Always confirm the specified DFT before ordering.
Multiply litres by density (kg/L) to get kilograms. Most 100% solids epoxy resins have a density of 1.1–1.5 kg/L. For example, 10 L × 1.4 kg/L = 14 kg. If your datasheet gives coverage in m²/kg but you buy in litres, convert first. The mixing ratio (e.g. 3:1 by volume) doesn't change the combined density calculation.
Yes. The primer is a separate product with its own coverage rate and thickness. It penetrates the substrate and is often applied at 100–150 µm. Calculate it separately or add it as a coat with its own thickness and coverage. Don't assume the primer and build coat have the same consumption.