Epoxy Coverage Per Gallon
One gallon of epoxy covers 200 square feet at 1/16 inch and 100 square feet at 1/8 inch — but those are ideal numbers on smooth, sealed surfaces. This guide gives you the real-world coverage tables for every thickness and surface type, plus gallons needed for every common project size.
Enter your dimensions to get exact gallons needed for your project.
Calculate Gallons Needed →Coverage Per Gallon by Coat Thickness
One US gallon = 128 fluid ounces. Coverage decreases as pour depth increases. All figures below assume a smooth, previously sealed surface.
| Coat Thickness | Sq ft per gallon | Gallons per 100 sq ft | Gallons per 500 sq ft | Typical Use |
|---|---|---|---|---|
| 1/32 in (0.8mm) | ~400 sq ft | 0.25 gal | 1.25 gal | Seal coat / sizing |
| 1/16 in (1.6mm) | ~200 sq ft | 0.50 gal | 2.50 gal | Floor topcoat, thin surface coat |
| 3/32 in (2.4mm) | ~133 sq ft | 0.75 gal | 3.75 gal | Medium coat |
| 1/8 in (3.2mm) | ~100 sq ft | 1.00 gal | 5.00 gal | Table flood coat, floor basecoat |
| 3/16 in (4.8mm) | ~67 sq ft | 1.50 gal | 7.50 gal | Thick table coat, heavy floor |
| 1/4 in (6.4mm) | ~50 sq ft | 2.00 gal | 10.00 gal | Bar top, deep flood |
| 3/8 in (9.5mm) | ~33 sq ft | 3.00 gal | 15.00 gal | Heavy industrial coat |
| 1/2 in (12.7mm) | ~25 sq ft | 4.00 gal | 20.00 gal | Shallow casting layer |
Real-world coverage on bare or porous concrete: reduce by 15–25%. Always add 10% waste buffer.
Gallons Needed by Project Size
Pre-calculated totals including a 10% waste buffer. Select your project size and coat system.
| Project Size | 1 coat (1/8 in) | 2 coats (1/8 in ea) | Seal + 2 floods |
|---|---|---|---|
| 50 sq ft (small countertop) | 0.6 gal | 1.1 gal | 1.2 gal |
| 100 sq ft (small floor/large counter) | 1.1 gal | 2.2 gal | 2.5 gal |
| 200 sq ft (1-car garage / room) | 2.2 gal | 4.4 gal | 4.7 gal |
| 400 sq ft (2-car garage) | 4.4 gal | 8.8 gal | 9.4 gal |
| 500 sq ft (large room) | 5.5 gal | 11.0 gal | 11.7 gal |
| 800 sq ft (large garage / shop) | 8.8 gal | 17.6 gal | 18.7 gal |
| 1,000 sq ft (commercial) | 11.0 gal | 22.0 gal | 23.4 gal |
Kit Sizes and What They Cover
Epoxy is sold in quart, half-gallon, gallon, 2-gallon, and 5-gallon kits. Here's what each covers at the two most common pour depths.
| Kit Size | Fluid Ounces | Coverage at 1/16 in | Coverage at 1/8 in | Best For |
|---|---|---|---|---|
| Quart (0.25 gal) | 32 fl oz | ~50 sq ft | ~25 sq ft | Small tables, detail work, seal coats |
| Half-gallon (0.5 gal) | 64 fl oz | ~100 sq ft | ~50 sq ft | Coffee tables, countertop sections |
| 1 gallon | 128 fl oz | ~200 sq ft | ~100 sq ft | Dining tables, small floors |
| 2 gallon | 256 fl oz | ~400 sq ft | ~200 sq ft | 1-car garage (1 coat), large tables |
| 5 gallon | 640 fl oz | ~1,000 sq ft | ~500 sq ft | Large floors, commercial projects |
Coverage on Different Surface Types
Why Surface Type Affects Coverage
The published coverage rate (200 sq ft/gallon at 1/16 in) assumes a smooth, non-porous surface. Real surfaces vary:
- Sealed concrete or previous epoxy coat: Full rated coverage (200 sq ft/gal at 1/16 in)
- Sanded wood (tabletop): 5–10% loss — wood grain absorbs a small amount
- Bare concrete (garage floor): 15–20% loss — porous surface consumes more product
- Rough or shot-blasted concrete: 20–30% loss — surface profile holds epoxy in valleys
- Old, unsealed wood (river table slabs): 10–15% loss — use a seal coat first to reduce absorption
Frequently Asked Questions
How many square feet does 1 gallon of epoxy cover?
At 1/16 inch (standard floor topcoat), 1 gallon covers approximately 200 square feet. At 1/8 inch (standard table flood coat or floor basecoat), 1 gallon covers about 100 square feet. At 1/4 inch (thick bar top coat), 1 gallon covers approximately 50 square feet.
How many gallons of epoxy do I need for a 200 sq ft garage?
A 200 sq ft garage with two coats at 1/8 inch each needs about 4 gallons plus a 10% buffer = 4.4 gallons. Round up to 5 gallons. If adding a primer coat at 1/16 inch, add another 0.6 gallons for the primer, totaling 5–6 gallons.
How many square feet does a quart of epoxy cover?
A quart (32 fl oz, 0.25 gallon) covers approximately 50 square feet at 1/16 inch, or 25 square feet at 1/8 inch. Quarts are practical for small tabletop projects, detail work, and seal coats on surfaces under 30 square feet.