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Epoxy Per Square Foot — What One Gallon Buys at Every Thickness

How much epoxy per square foot: the exact sq-ft-per-gallon numbers at 1/16" through 2", in imperial and metric, with the linear thickness trade-off and worked per-project amounts.

Last updated: 2026-11-07

Quick answer

One gallon of 100%-solids epoxy covers 1.604 ÷ thickness inches of ground. In the units you actually shop with: 25.7 sq ft/gal at 1/16", 12.8 at 1/8", 6.4 at 1/4". Per square foot that is 0.039 gal at 1/16", 0.078 at 1/8", 0.156 at 1/4" — double the thickness, double the epoxy, every time, no exceptions. The trade-off is linear because a gallon is always 231 cubic inches.

Manufacturer datasheet · 2026-11-07

The per-square-foot table

Thickness	sq ft/gal	gal per sq ft	m²/L	100 sq ft needs
1/16"	25.66	0.039	2.38	3.90 gal
1/8"	12.83	0.078	1.19	7.80 gal
3/16"	8.55	0.117	0.79	11.70 gal
1/4"	6.42	0.156	0.60	15.58 gal
1/2"	3.21	0.312	0.30	31.17 gal
1"	1.60	0.624	0.15	62.34 gal
2"	0.80	1.248	0.08	124.7 gal

(Theory at 100% solids; add your brand's published rate and the 1.10 waste factor for planning. Metric column converts via 1 m² = 10.764 sq ft, 1 gal = 3.785 L.)

Inferred

Why per-square-foot is the wrong question for casting

The table's bottom rows explain the deep-pour economy: at 2" of depth, a gallon covers 0.8 square feet. That is why river tables are always quoted by volume — a 72" × 8" × 1.5" channel is 864 cubic inches regardless of brand, and 864 ÷ 231 = 3.74 gallons. Coverage rates describe films; volume math describes casts. The coverage calculator switches between the two modes explicitly.

Applying it to real projects

Countertop, 1/8" flood: 0.078 gal/sq ft → a 16 sq ft island top is 1.25 gal raw, 1.38 with waste → 2-gal kit.
Seal coat, brushed: brands quote roughly half the flood rate per gallon (TotalBoat seal: 24 sq ft/gal), so ~0.042 gal/sq ft — a $10 coat that prevents bubbles.
Garage floor, 1/16" rolled: 0.039 gal/sq ft → 200 sq ft is 7.8 gal raw, 8.6 with waste → two 4-gal kits. Floors are where per-square-foot math matters most because the area is large and the film is thin.
Cutting board, both faces: two 1.5-sq-ft faces at 1/16" = 3 sq ft × 0.039 × 1.10 ≈ 0.13 gal — under any 1-gal kit, so the real answer is "one quart kit covers several boards".

Converting for metric shopping

The imperial column is what US datasheets quote; the rest of the world buys by m²/L. The conversion chain is exact: 1 sq ft/gal = 0.0929 m²/L (divide by 10.764 square feet per square metre, multiply by 3.785 litres per gallon). Two sanity anchors to keep in a store aisle: the 1/8" theoretical rate (12.8 sq ft/gal) is 1.19 m²/L, and West System's marine saturation coats compute to 27–31 m²/L — a 20× spread that shows why the film thickness on a European label matters more than the coverage headline. Any kit quoting m²/L without a stated film thickness is quoting nothing; ask for the datasheet row or walk away.

Where your brand publishes a different rate, substitute it — the coverage chart lists every published figure with its source, and the cost calculator prices the whole job per brand. For the coat-scheduling side of the same math (seal + flood, two-coat builds), how much epoxy do I need works the examples project by project, and the epoxy brands hub keeps the verification status of every rate visible.

FAQ

How many square feet does one gallon of epoxy cover?

At the 100%-solids baseline: 25.7 sq ft at 1/16", 12.8 sq ft at 1/8", 6.4 sq ft at 1/4". Real published rates land nearby — TotalBoat TableTop quotes exactly 12.8 sq ft/gal at 1/8" (product page + TDS), Primaloc quotes 16 for its flood coat. Use your brand's number when it has one; the baseline when it doesn't.

How much epoxy per square foot at 1/8 inch?

Roughly 0.085 gallons per square foot at the theoretical rate (1 ÷ 12.83), which is about one gallon per 12 sq ft — or with Primaloc's published 16 sq ft/gal, one gallon per 16 sq ft. Add the 10% waste allowance for planning and round up to a whole kit.

Is coverage per gallon different for deep pour epoxy?

Deep pour is volume, not area: a 2-inch pour covers only 0.80 sq ft per gallon of depth math (231 ÷ (2 × 144)). Primaloc's deep pour publishes 6.67 sq ft/gal at 1/4" and TotalBoat Fathom converts to 0.75 at 3" — thickness, not brand magic, is what changes the number.

What is that in metric?

12.8 sq ft/gal at 1/8" converts to 1.19 m²/L (divide sq ft/gal by 10.764, multiply by 3.785). At 1/16" it is 2.38 m²/L; at 1/4" it is 0.59 m²/L. Kit labels in Europe quote m²/L at a stated film thickness — the film thickness is the part that must match, not the marketing headline.