How do you calculate how much flake you need?
Multiply the floor area in square feet by the broadcast rate in pounds per square foot to get pounds of flake. Divide by 44 and round up to get whole 44 lb boxes.
- Pounds of flake = floor area (sq ft) x broadcast rate (lb per sq ft)
- Boxes = pounds of flake / 44, rounded up to the next whole box
Example: a 24 x 24 ft two car garage is 576 sq ft. For a full broadcast of 1/4 in flake at the planning rate, 576 x 0.20 = 115 lb. Then 115 / 44 = 2.6, so order 3 boxes.
Shortcut for 1/4 in flake: at the planning rate, one 44 lb box covers 220 sq ft. Divide the floor by 220 and round up.
Every blend is the same $85 per 44 lb box, before freight, so pick the color on the blends page once you have the box count.
Epoxy flake coverage chart by broadcast type
A full broadcast of 1/4 in flake typically uses 0.14 to 0.20 lb per sq ft. Order at the planning rate of 0.20 lb per sq ft. Partial broadcasts use a small fraction of that.
Every blend is stocked in 1/4 in flake, so these are the rates for every blend we sell.
| Broadcast | Range, lb per sq ft | Range, sq ft per lb | Typical rate, lb per sq ft | Planning rate, lb per sq ft |
|---|---|---|---|---|
| Full, 1/4 in chips | 0.14 to 0.20 | 5 to 7 | 0.167 | 0.20 |
| Heavy partial | 0.02 to 0.04 | 25 to 50 | 0.03 | 0.04 |
| Light accent | 0.005 to 0.02 | 50 to 200 | 0.0125 | 0.02 |
| Double broadcast, 1/4 in, both coats | 0.28 to 0.40 | 2.5 to 3.5 | 0.334 | 0.40 |
- Where the ranges come from. The full broadcast range comes from one manufacturer's published data sheet, the Torginol polymer flake technical data sheet, not from tests of our blends. Most system guides we reviewed land inside or near that range. Rust-Oleum lists 0.18 to 0.20, Sherwin-Williams 0.20 per broadcast for its epoxy systems and Simiron 0.167, while Laticrete (about 0.14) and Floorguard (0.13) sit at or just under the low end.
- Typical rate is the middle of the published data. Planning rate is the top of the range, the number to order by.
How many square feet does a 44 lb box of flake cover?
One 44 lb box typically covers about 220 to 310 sq ft at a full broadcast of 1/4 in flake. As a partial broadcast, one box covers 1,100 sq ft or more.
| Broadcast | One 44 lb box, sq ft | At the typical rate, sq ft | At the planning rate, sq ft |
|---|---|---|---|
| Full, 1/4 in chips | 220 to 310 | about 263 | 220 |
| Heavy partial | 1,100 to 2,200 | about 1,470 | 1,100 |
| Light accent | 2,200 to 8,800 | 3,520 | 2,200 |
| Double broadcast, 1/4 in | 110 to 155 | about 132 | 110 |
How many boxes of flake for a 1, 2 or 3 car garage?
For a full broadcast of 1/4 in flake at the planning rate, order 2 boxes for a one car garage, 2 to 3 boxes for a two car garage and 4 boxes for a three car garage.
| Garage | Floor | Full 1/4 in, at typical rate | Full 1/4 in, at planning rate |
|---|---|---|---|
| 1 car | 12 x 20 ft, 240 sq ft | 40 lb, 1 box | 48 lb, 2 boxes |
| 1 car | 12 x 24 ft, 288 sq ft | 48 lb, 2 boxes | 58 lb, 2 boxes |
| 2 car | 20 x 20 ft, 400 sq ft | 67 lb, 2 boxes | 80 lb, 2 boxes |
| 2 car | 22 x 22 ft, 484 sq ft | 81 lb, 2 boxes | 97 lb, 3 boxes |
| 2 car | 24 x 24 ft, 576 sq ft | 96 lb, 3 boxes | 115 lb, 3 boxes |
| 3 car | 32 x 22 ft, 704 sq ft | 118 lb, 3 boxes | 141 lb, 4 boxes |
| 3 car | 36 x 24 ft, 864 sq ft | 144 lb, 4 boxes | 173 lb, 4 boxes |
At $85 a box, the planning rate column comes to $170 for a one car garage, $170 to $255 for a two car garage and $340 for a three car garage, before freight.
Garages are not standard. Angi puts the average one car garage at 240 sq ft and the average two car at 360 sq ft, while Alan's Factory Outlet treats 20 x 20 ft as the two car minimum. Measure the floor, add any stem walls or steps you will coat, and enter the real number above.
A partial broadcast is a different story: one box covers any of these garages. The largest, 864 sq ft, needs about 35 lb at the heavy partial planning rate of 0.04 lb per sq ft.
How much flake for a double broadcast?
A double broadcast takes about twice the flake of a single one. For 1/4 in chips, expect 0.28 to 0.40 lb per sq ft in total, or about 110 to 155 sq ft per 44 lb box.
- Rates in system guides are usually given per broadcast. Sherwin-Williams' Resuflor Deco Flake DB instructions, for example, call for 0.20 lb per sq ft in each of two broadcasts.
- Some double broadcast systems use lighter passes. If your system guide gives its own per-broadcast rate, multiply the area by that rate and by two.
- In the calculator, tick Double broadcast. It doubles the full broadcast rate.
- Example: a 450 sq ft two car garage, double broadcast of 1/4 in flake, uses about 150 lb at the typical rate (4 boxes) and 180 lb at the planning rate (5 boxes).
Why order at the planning rate?
Running out halfway through a broadcast costs far more than one extra box. The base coat keeps curing while the crew waits, and flake will not embed in resin that has started to set.
- Resin will not wait. Simiron asks for a resin that stays open long enough to receive the chips, and warns that chips may not embed in a system that cures too fast. Some polyaspartic base coats can be walked on in 1 to 2 hours.
- Bare spots show. Sherwin-Williams warns that any epoxy left visible after the broadcast will yellow, so a full broadcast has to continue until no wet or shiny areas remain.
- Extra on hand is standard advice. Laticrete's chip installation guide recommends having extra media on hand.
- The gap is usually one box. On most garages, the difference between the typical rate and planning rate counts is zero or one box: $85.
We do not add a separate waste factor on top. The planning rate is already the top of the published range, and the count is rounded up to whole boxes. If your own crew's records show heavier use than 0.20 lb per sq ft, order to your number.
Can you reuse leftover flake?
Sometimes. Clean, unscraped flake can be saved, but the manufacturers disagree on it, and scraped debris always goes in the trash. At a full broadcast, flake that does not stick is swept and vacuumed off once the base cures.
- Laticrete says clean, unscraped excess blown off the floor can be re-boxed for future jobs, and scraped debris cannot.
- Sherwin-Williams and Simiron say not to save and reuse swept or vacuumed chip unless extra precautions are taken.
- Only keep leftovers that stayed free of dust and broom bristles, store them sealed and dry, and reuse them only in the same color.
- For future repairs, set aside a few pounds of the mixed flake from the same job rather than counting on a later box to match it.
Storage and handling are covered in the flake guide.
Worked examples
Each row uses the planning rate and rounds up to whole 44 lb boxes. Flake costs are at $85 per box, before freight.
| Job | Flake needed | Boxes | Flake cost |
|---|---|---|---|
| 1 car garage, 12 x 22 ft, full broadcast of 1/4 in | 264 sq ft x 0.20 = 52.8 lb | 52.8 / 44 = 1.2, so 2 | $170 |
| 2 car garage, 22 x 22 ft, full broadcast of 1/4 in | 484 sq ft x 0.20 = 96.8 lb | 96.8 / 44 = 2.2, so 3 | $255 |
| 2 car garage, 20 x 20 ft, double broadcast of 1/4 in | 400 sq ft x 0.40 = 160 lb | 160 / 44 = 3.6, so 4 | $340 |
| 2 car garage, 24 x 24 ft, heavy partial broadcast | 576 sq ft x 0.04 = 23 lb | 23 / 44 = 0.5, so 1 | $85 |
| Shop floor, 1,100 sq ft, full broadcast of 1/4 in | 1,100 sq ft x 0.20 = 220 lb | 220 / 44 = 5.0, so 5 | $425 |
Two of these deserve a second look:
- The 264 sq ft garage needs 2 boxes even at the typical rate. 264 x 0.167 = 44.1 lb, just over one box.
- The 1,100 sq ft shop lands on exactly 5 boxes, with nothing spare at the planning rate. If the crew tends to broadcast heavy, a sixth box is the margin.
Should you mix the boxes for one floor?
Yes. Order every box for a floor at the same time and blend them together before you broadcast, so the color stays even from one end of the floor to the other.
One flake manufacturer notes that its variegated and marble flake can vary slightly from lot to lot, and recommends intermixing lots before use. Pour all the boxes into one large clean container, leave the fines at the bottom of each box, and mix by hand before you fill the broadcast pails. The flake guide covers broadcast technique, the wet edge, scraping and topcoats.