Flake Flooring System Calculator

Size a full flake floor — base coat, flake, and top coat — from your floor area and coverage rates, with gallons, pounds, kits, and boxes to order.

Calculate Your Full Flake Floor System

Enter your floor size and the coverage rate for each layer. The calculator sizes the whole flake system in one go — base coat (epoxy), flake, and top coat (poly) — and returns the gallons and pounds required, rounded up to the kits and boxes you need to order.

Units
The area you're coating. The rates below are pre-filled with typical values — adjust to match your products.

Coverage Rates

How far each layer spreads.

From your epoxy's data sheet (TDS). Higher number = the product spreads further.

Pack Sizes

The kit and box sizes you order in.

Enter a floor size to calculate the flake floor system.

Coverage rates are estimates. Actual usage varies with substrate porosity, application method, broadcast density, and the specific products used. Always confirm coverage and pack sizes against each product's Technical Data Sheet (TDS) before ordering.

How the Flake Flooring System Calculator Works

  1. Enter the floor size in square feet
  2. Set the base coat (epoxy) coverage in sqft per gallon — 130 is a typical default
  3. Set the flake coverage in sqft per lb — 7 is a typical full broadcast default
  4. Set the top coat (poly) coverage in sqft per gallon — 100 is a typical default
  5. Read the gallons and pounds required for each layer, plus the kits and boxes to order
  6. Copy the results for your order or job sheet

Examples

Scenario500 ft² garage — default ratesInputBase 130 · Flake 7 · Top 100 sqft/gal-lbResultBase 3.85 gal (2 kits) · Flake 71.43 lb (2 boxes) · Top 5.00 gal (3 kits)
Scenario1,000 ft² showroom — default ratesInputBase 130 · Flake 7 · Top 100 sqft/gal-lbResultBase 7.69 gal (3 kits) · Flake 142.86 lb (4 boxes) · Top 10.00 gal (5 kits)
Scenario250 ft² utility room — light flakeInputBase 130 · Flake 14 · Top 100 sqft/gal-lbResultBase 1.92 gal (1 kit) · Flake 17.86 lb (1 box) · Top 2.50 gal (2 kits)

Frequently Asked Questions

What coverage rates should I use?

The defaults — 130 sqft per gallon for the base epoxy, 7 sqft per lb for a full flake broadcast, and 100 sqft per gallon for the polyaspartic top coat — are typical industry figures. Your actual rates depend on the specific products, film thickness, and how heavily you broadcast the flake. Always confirm against each product's Technical Data Sheet (TDS) before ordering.

What kit and box sizes does the calculator assume?

It rounds the base coat up to 3-gallon kits, the flake up to 40 lb boxes, and the top coat up to 2-gallon kits — the common pack sizes for a flake floor system. If your supplier uses different pack sizes, use the gallons and pounds figures and divide by your own pack size.

Why does the calculator round up to whole kits and boxes?

Epoxy and polyaspartic are sold in pre-measured kits with a fixed mix ratio, and flake is sold in fixed boxes. You cannot split a kit and keep the correct ratio, so the calculator always rounds up to make sure you have enough material to finish the job.

Does this cover primer or a moisture barrier?

No — this sizes the three core layers of a flake floor: base coat, flake, and top coat. If your system needs a separate primer or a moisture vapor barrier, calculate those separately and add them to your order.

Important Notes

  • Coverage rates are estimates — porous or rough concrete typically needs more base and top coat than smooth, prepared surfaces
  • A full flake broadcast uses far more flake than a partial broadcast — adjust the sqft per lb rate to match your chosen profile
  • Base coat is rounded up to 3-gallon kits, flake to 40 lb boxes, and top coat to 2-gallon kits
  • Always verify coverage rates and pack sizes against each product's Technical Data Sheet before placing your order
  • Order a small overage on flake to allow for blend touch-ups and uneven broadcast
Flake Broadcast CalculatorSize just the flake layer by product and broadcast profile, with boxes to order and estimated surplus.Flake Color Blend CalculatorSplit your total flake quantity across multiple colors by percentage to get exact amounts to order.