| Use case | Geometry | Inputs (units shown) | Count | Waste | Approx. total (L) |
|---|---|---|---|---|---|
| Anchor pocket fill | Cylinder | D=75 mm, H=200 mm | 6 | 10% | ~6.0 |
| Conduit sleeve grout | Annulus | Do=110 mm, Di=60 mm, H=250 mm | 4 | 8% | ~7.8 |
| Small trench repair | Rectangle | L=1.2 m, W=0.12 m, D=0.08 m | 1 | 12% | ~12.9 |
| Equipment base void | Rectangle | L=0.8 m, W=0.35 m, D=0.05 m | 2 | 8% | ~30.2 |
| Irregular cavity | Custom | Custom=10 L | 1 | 5% | ~10.5 |
Examples are illustrative; your site conditions may differ.
- Rectangular: V = L × W × D
- Cylindrical: V = π × (D/2)² × H
- Annular: V = π × ((Do/2)² − (Di/2)²) × H
- Custom: Enter measured volume directly.
The calculator multiplies by cavity count, applies fill percent, then adds waste: Vtotal = Vbase × (1 + waste%). It also splits the total by your A:B mix ratio.
- Select the geometry that best matches your cavity.
- Pick the correct unit, then enter dimensions and count.
- Adjust fill percent for occupied space or partial fills.
- Set waste allowance based on handling and batch size.
- Enter density to estimate total mass for ordering.
- Set the A:B ratio to plan part volumes per batch.
- Add a unit cost to estimate total material spend.
If your product specifies ratio by weight, convert using datasheet densities. When in doubt, keep a larger waste factor for small mixes.
Encapsulant quantity planning for construction tasks
Encapsulants are commonly used to fill anchor pockets, sleeve annuli, cable penetrations, and equipment base voids. Quantity planning matters because small cavities often require multiple batches, and batch size drives handling losses. This calculator standardizes inputs across crews by converting geometry to volume, then applying consistent allowances.
Geometry mapping and measurement discipline
Field measurements should reflect the true fillable space, not the nominal component size. For cylindrical holes, measure the actual drilled diameter and the effective depth after cleaning. For annular spaces, confirm both outer and inner diameters and use the filled embed length. For trenches, record the average width and depth over the repair length.
Allowances: fill percentage and waste factor
Fill percent adjusts for partial occupancy (reinforcement, ducts, or inserts) and prevents over-ordering. Waste allowance compensates for mixing losses, tool wetting, spillage, and material remaining in containers. Practical waste ranges are often 5–15% for controlled pours, and higher for small batches or congested access. Use a conservative value when temperature, pot life, or access conditions are uncertain.
Density, mass conversion, and logistics checks
When procurement is by weight, density converts total volume to estimated mass. Many two-part systems fall near 1,050–1,250 kg/m³, but product datasheets should govern. Mass helps you plan carrying limits, hoisting needs, and container counts on elevated work fronts. Always verify compatibility with substrate moisture and required cure time for the application.
Mix ratio splitting and ordering strategy
Two-part products typically specify an A:B ratio by volume or by weight. The calculator splits total liters into Part A and Part B to support batching and kit selection. Match batch size to pot life and crew placement rate, then add contingency for rework. Store results in CSV/PDF to support material requests and daily pour plans.
| Example | Inputs | Count | Waste | Approx. total (L) |
|---|---|---|---|---|
| Anchor pockets | Cylinder: D=75 mm, H=200 mm | 6 | 10% | ~6.0 |
| Conduit sleeve | Annulus: Do=110 mm, Di=60 mm, H=250 mm | 4 | 8% | ~7.8 |
| Trench repair | Rectangle: 1.2 m × 0.12 m × 0.08 m | 1 | 12% | ~12.9 |
1) Which geometry should I select?
Choose the shape that best matches the cavity. Use rectangle for trenches/slots, cylinder for round holes, annulus for sleeve gaps, and custom when the void is irregular or already measured.
2) What waste percentage should I use?
Start with 5–10% for controlled pours and clean access. Increase it for small batches, short pot life, rough substrates, or when mixing/placement will occur in multiple locations.
3) How do I handle partial fills?
Reduce the fill percent to reflect occupied space or a planned partial depth. This is useful when inserts, reinforcement, or existing material reduces the true fillable volume.
4) My product ratio is by weight, not volume. What now?
Use the total mass output for ordering, then split parts using the manufacturer’s weight ratio. If densities differ between parts, follow the datasheet conversion guidance for accurate batching.
5) Why does estimated cost show a dash?
Cost is shown only when a unit cost is entered. Set a value per liter or per kilogram, and the calculator multiplies it by total liters or total mass accordingly.
6) Can I work in inches or feet?
Yes. Select inches or feet as the length unit, enter dimensions in that unit, and results will still be provided in liters, cubic meters, and US gallons for ordering and reporting.
7) How do the CSV and PDF downloads work?
After you calculate, the latest result is stored for the session and can be exported. Recalculate if you change inputs, then download again to capture the updated quantities.