To calculate the theoretical applied square foot coverage at the suggested dry film thickness of a given gallon of paint, the following variables must be known:
  1. % Volume Solids
  2. Suggested Dry Film Thickness
  3. Material Loss Estimate

The amount of material lost on any project will depend on the amount of spillage/waste, type of application (brush, roll, spray) and configuration of substrate being painted. Once these variables are known, use the following formula to make the calculation:

Practical Sq. Ft. Coverage
At Suggested DFT
= 1604 x % Volume Solids
Suggested Dry Film Thickness
X (1 – Material Loss Estimate)

Example:

  1. 43% Average Volume Solids
  2. Suggested Dry Film Thickness = 2 mils
  3. 10% Loss Estimate
Sq. Ft. Coverage
At Suggested DFT
= 1604 x .43
2 mils
X (1 – 0.10)
= 344.86 X 0.90
= 310 sq. ft. at 2 mils DFT assuming 10%
of the material is lost during application.

The amount of waste can vary widely with method of application and skill of applicator. The generally accepted waste factors are:

Conventional Spray
Airless Spray
Electrostatic
Roller
Brush
25% to 30%
20% to 25%
10% to 15%
5% to 10%
3% to 5%

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