How Much Flake Do You Need for a Full Broadcast Floor?
Broadcast to refusal explained, why flake size changes the coverage rate, and how to avoid running short mid-floor.
A full decorative flake floor is broadcast “to refusal” — flake thrown until the wet epoxy can’t visually absorb any more and no base coat shows through. The Flake Broadcast Calculator defaults to a typical full-broadcast rate of 8 ft² per lb, but flake size and technique both shift that number, so always check it against your product’s TDS.
How to read the inputs
Floor Area
- The total area you’re broadcasting, in ft² or m² — feed this straight from the Square Meters / Square Feet Calculator
Coverage rate
- Pre-filled for a full 1/4″ broadcast to refusal — edit it if your product’s TDS gives a different rate, or you’re doing a lighter accent broadcast
Box size
- The weight per box you’re ordering, so the result rounds to whole boxes instead of an odd fractional weight
Boxes Required
- Always rounded up — the result also shows the full purchased weight and your surplus, so you know what’s left over
Worked example
A typical single garage measures 540 ft². At the default full-broadcast rate of 8 ft² per lb, that needs 540 ÷ 8 = 67.5 lb of flake. Ordering in 40 lb boxes, that rounds up to 2 boxes (80 lb purchased), leaving a 12.5 lb surplus — well under a quarter box, so there’s no need to size down.
Try it with your own floor
Enter your floor area — the default coverage rate assumes a full broadcast to refusal, so edit it if your job or product differs.
Full result gives the weight required, boxes to order, and surplus.
Open the live calculator →Common mistakes
- Using the full-broadcast default rate for a lighter accent broadcast — it will significantly over-order flake for a partial application
- Not checking flake size on the product TDS — larger flake covers more area per pound than fine flake at the same visual density
- Ordering the exact required weight instead of rounding up to full boxes — running short mid-broadcast on a wet floor is a serious problem
- Not accounting for extra material on porous, textured, or outdoor surfaces exposed to wind
Frequently Asked Questions
What does “broadcast to refusal” mean?
Throwing flake until the wet epoxy visually can’t absorb any more and no base coat shows through. That’s the standard for a full decorative flake floor, and what the default coverage rate on this calculator assumes.
Why does my flake size affect the coverage rate?
Larger flake covers more area per pound than fine flake at the same visual density, so the ft²/lb (or m²/kg) figure changes with flake size. Always confirm against your specific product’s TDS rather than relying on the default.
What if I only want a light accent broadcast, not a full one?
Edit the coverage rate to a much higher ft²/lb (m²/kg) number. The default assumes a full broadcast to refusal, and using it for a lighter accent broadcast will significantly over-order flake.
How much extra should I keep on hand?
Flake is inexpensive relative to the labor and downtime of re-ordering mid-job, so it’s fine to round up a full extra box. Running short mid-broadcast on a wet floor is a much bigger problem than a partial box of leftover flake.