Question:

How do you calculate a sprayable gallon?

Answer:

Many of our products consist of several individual components which once combined and sprayed on the the surface, provide a total volume of product. In our product descriptions, we call this a sprayable gallon. This total volume is also used to calculate the total required product to cover a certain square footage at any given thickness since our products are 100% solids and do not lose volume as they cure.

Like many polyureas, urethanes or hybrids, chemical reaction and fusion occurs to produce the cured coating.  Our Plural Component Linings consist of liquids (parts A & B- Resin/Binder) and solids (PART C- poly micro-powder in fine and coarse grain). Texture control is achieved by varying the ratio between liquid and solid components along with they type of part C utilized. Additional texture control and expansion rate is further provided by spray techniques such as over-spray. Collectively, the curing process and the spray process itself provides an average expansion over the liquid volume of approximately 1.23

Example of total sprayable gallons using materials in a standard 6’ bed liner kit:

Bed liner is mixed from 1:1 to 3:1 as solids: liquid.  For standard adhesion and thickness, use 1.5:1 as liquids to powders.
.75 gallons of liquids mixed with 1.5 part solids will = 1.875 gallons * 1.23 (expansion) = 2.32 gallons fully cured
Other calculations for total volume of finished bed liner kit

Base coat + top coat to achieve thicker bed with greater adhesion –  In this example, a base coat comprised of 1:1 as solids to liquid for higher adhesion rate.  In conjunction, a second layer applied at 2:1 is used to achieve a thick top layer where adhesion is not as much of a concern between same materials (bed liner attached to bare metal versus 2nd layer of bed liner bonded to first layer of bed liner)

How expansion is calculated for 2 layer bed liner:

Liquids for layer 1 is .75 gallons/2 = .375 gallons
Solids for layer 1 is .375 gallons of polymers
Total for layer 1 = .75 * expansion rate of .18 = .885 gallons
Liquids for layer 2 is .375 gallons
Solids for layer 2 is .75 gallons
Total for layer 2 = 1.125 * 1.25 (expansion) = 1.4 gallons
Total Sprayable gallons = 2.29 gallons