Free tool
Enter the floor, the flake size and the broadcast, and see how many pounds and boxes to order, plus base and top coat. Every rate comes from a manufacturer's own data sheet, listed below. Checked October 6, 2026.
To rejection: the resin is completely covered
Order
3 boxes
of 40 lb, enough for the heavy end of the range
1/4" full broadcast at 5 to 7 sq ft per lb, plus 10%. Base coat at 134 to 200 sq ft per gallon (about 8 to 12 mils), top coat over flake at 100 to 160. Your product's data sheet decides.
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Pounds are the floor area divided by the manufacturer's coverage rate. Fewer square feet per pound means more pounds, so the heavy end of the range uses the low rate. The box count to order uses the heavy end, plus the extra you pick, rounded up to whole boxes.
Manufacturers agree on the big picture and differ on the details. For a full broadcast of 1/4" flake most data sheets sit at 5 to 7 sq ft per pound, but some publish lighter rates, and a thicker broadcast coat takes more flake. Treat the range as a planning number and your product's data sheet as the final word.
Base and top coat use typical published rates for flake systems. Smaller flake needs more top coat.
Full broadcast: 1/2" 7–9, 1/4" and 1/8" 5–7, 1/16" and hybrid 3–5 sq ft per lb. Heavy 25–50 and light 50–200 sq ft per lb. 40 lb cartons.
Full broadcast: 1/4" 5–7, 1/8" 4–6, 1/16" 3–5 sq ft per lb. Allow up to 20% more chip when broadcasting into epoxy. 40 lb boxes.
Broadcast at an average of 5 to 7 sq ft per pound.
1/4" chip at 6 sq ft per lb. 1100SL base coat 134–200 sq ft per gallon at 8–12 mils; Polyaspartic HS top coat 100–160. Do not reuse swept chip without extra precautions.
Double broadcast: 0.2 lb of flake per sq ft for each broadcast.
Base coat 200 sq ft per gallon at 8 mils, 160 at 10, 133 at 12. Smaller flakes need more top coat to be fully encapsulated.
Top coat over broadcast flake 150 sq ft per gallon, against 200–230 over a smooth floor.
A safety factor of 10–15% minimum so you don't run out during the application.
Order 10–15% extra for waste; professional installers typically order 10–20% extra.
For a full broadcast of 1/4" flake, manufacturers publish about 5 to 7 sq ft per pound. A 450 sq ft garage takes about 64 to 90 lb, or 71 to 99 lb with 10% extra: two to three 40 lb boxes. Smaller flake takes more.
None of the manufacturers say. Their full-broadcast rates go with broadcasting to excess, until no wet resin shows, so read them as the amount thrown before the loose flake is scraped and swept. Simiron and Sherwin-Williams say not to reuse swept flake unless you have taken extra precautions; Laticrete says loose excess can be re-boxed, but scraped chip cannot be reused.
About twice as much flake, plus a second broadcast coat. Sherwin-Williams and Simiron both rate each broadcast on its own.
Full means broadcasting until the resin is completely covered, also called broadcasting to rejection. Suppliers don't name the partial levels the same way, so this calculator uses Torginol's: heavy at 25 to 50 sq ft per pound, light at 50 to 200.
Published buffers run from 10 to 15% (ArmorPoxy, Concrete Floor Supply) up to 20%, and Laticrete allows up to 20% more chip when broadcasting into epoxy. The calculator adds 10% by default; running short in the middle of a broadcast is worse than a spare box.
Every manufacturer that lists sizes agrees: 1/16" and hybrid blends cover about 3 to 5 sq ft per pound, against 5 to 7 for 1/4". Smaller flakes also need more top coat to be fully encapsulated.