Definition - What does Theoretical Coverage mean?
Theoretical coverage refers to the mathematical expression of how a coating that is applied to a metal to prevent corrosion responds to heat and other environmental changes.
More often, it can also refer to the application rate of the coating to an entirely flat surface.
Corrosionpedia explains Theoretical Coverage
The theoretical coverage rate of a coating is determined with the use of a mathematical equation, which is determined by using the square footage that would be achieved with a 100% solids coating across the entire surface. That number is then multiplied by a decimal equivalent of solids content (e.g., 0.95 for a 95% solids coating). After which, the number is divided by the unit of lengths the coating is needed for.
Generally, in preventative applications two thin coats are preferred to one heavy coat. In certain instances (for example, very high temperature applications), applying too thick of a coating can contribute to material failure.