Project notes
Understand this estimate
Theoretical coverage converts liquid volume and volume solids into a maximum area at a specified dry-film thickness, before application losses.
How to use the calculator
Enter available liquid volume
Use the undiluted coating quantity to evaluate.
Inputs Liquid coating volume
Use the product’s volume-solids value
Copy the current product data sheet percentage.
Inputs Volume solids
Enter the specified dry-film target
Use the product or project specification in mils.
Inputs Target dry film thickness
Formula and variables
Theoretical coverage (ft²) = US gallons × 231 in³/gal × volume-solids fraction × 1,000 mil/in ÷ target DFT (mil) ÷ 144 in²/ft².
- VLiquid volume
- Available coating volume.US gal
- VSVolume solids fraction
- Percentage divided by 100.decimal
- DFTTarget dry-film thickness
- Required dry coating thickness.mil
What the result means
Result interpretation
The result is theoretical maximum coverage only. Overspray, transfer efficiency, surface profile, porosity, residue and edge loss are excluded.
Limits and assumptions
This is theoretical coverage only. It excludes transfer efficiency, overspray, surface profile, porosity, edge loss and material left in equipment. It is not an expected job coverage guarantee.
Worked example
One gallon at 60% solids and 1 mil DFT
Assumptions
- The gallon is US liquid volume.
- Volume solids are 60%, and target DFT is 1 mil.
Calculation
- 1 × 231 × 0.60 × 1,000 ÷ 1 ÷ 144 = 962.5 ft².
| Theoretical coverage | 962.5 ft² |
|---|
Common questions
- Will a project actually cover this many square feet?
- Not necessarily. The calculation excludes transfer loss, roughness, porosity, overspray and material left in equipment.
- Where should volume solids come from?
- Use the current technical data sheet for the exact coating.