How to Calculate the Consumption of Polyurea Coating?

Accurate calculation of polyurea material consumption is essential for budgeting, material preparation, and cost control. Polyurea is typically applied by spray, and its density and coating thickness form the basis for theoretical consumption. However, in actual construction, spray atomization, substrate conditions, and environmental factors will all influence real consumption. This article provides a practical reference for calculating polyurea consumption based on common engineering parameters.

1. Theoretical Consumption of Polyurea

The density of polyurea is generally around 1.05 g/cm³. According to industry standards, if the spray thickness is 1.5 mm, the theoretical consumption is approximately 1.6 kg per square meter. If the spray thickness is 2 mm, the theoretical consumption is around 2.05 kg per square meter. These values are commonly used as the baseline in engineering estimations.

2. Considering Construction Loss

During application, polyurea is sprayed using a high-pressure heated system. The material atomizes as it exits the spray gun, and natural losses occur as it contacts the substrate; some material will also remain in the barrels and hoses. Therefore, the actual amount of polyurea used is typically higher than the theoretical calculation.

Loss rates vary with surface type and project scale:

• Vertical surfaces and overhead spraying result in higher loss than flat surfaces.

• Small or complex-shaped parts have greater loss than large-area spraying.

Typically:

• Large-area projects (roofs, parking decks, tanks) experience 10%–20% loss.

• Small components or complex structures may reach 40%–80% loss.

3. Additional Factors Affecting Material Loss

 It is important to note that polyurea loss is not a fixed value. It can be affected by many on-site conditions, such as the applicator’s spraying habits, gun movement speed, and whether the spray gun’s mixing chamber and nozzle are properly configured. Therefore, actual projects should assess these factors comprehensively. You may also contact our technical team for assistance—we can help estimate material usage based on experience with similar projects.