Armorseal Rexthane 1 price typically ranges from about $120 to $220 per gallon, with five-gallon quantities often costing $550 to $950 before tax. A coated project can cost much more once surface preparation, primer, application labor, and access are included; coverage, substrate condition, and local contractor rates are major variables.
| Item | Low | Average | High | Notes |
|---|---|---|---|---|
| Rexthane 1, one gallon | $120 | $165 | $220 | Estimated dealer price; color and availability affect quotes |
| Rexthane 1, five gallons | $550 | $725 | $950 | Bulk pricing may lower the per-gallon rate |
| Coating materials per sq ft | $0.50 | $1.00 | $1.75 | Product and typical primer allowance |
| Installed coating per sq ft | $2.00 | $4.00 | $7.00 | Includes ordinary prep and application; repairs cost extra |
What a gallon of Rexthane 1 typically costs
For budgeting, allow $120-$220 for a single gallon and roughly $550-$950 for a five-gallon purchase. These are planning estimates, not a fixed manufacturer price: industrial coatings are commonly sold through authorized distributors, and color, package availability, order size, and local dealer terms can change the quote.
Rexthane 1 is a single-component moisture-cure urethane coating. The amount required depends on the specified film thickness, surface profile, application method, and losses. A rough planning allowance is 250-400 sq ft per gallon per coat on a reasonably smooth surface; rough or porous substrates can use more.
For an ordinary smooth surface, budget about $0.30-$0.90 per sq ft for one coat of product alone. A complete coating system may require primer or additional coats, so product coverage should be confirmed against the current product data sheet and the project specification.
How primer, surface prep, and labor shape the quote
Installed pricing reflects more than the topcoat. Contractors may charge separately for cleaning, abrasion or blasting, repairs, primer, masking, application, and cleanup. The table shows common planning ranges; complex access or strict industrial specifications can push costs above them.
| Quote component | Typical price | What changes the charge |
|---|---|---|
| Rexthane 1 coating | $0.30-$0.90 per sq ft per coat | Coverage, color, film thickness, and waste |
| Primer or compatible base coat | $0.25-$1.00 per sq ft | Substrate and specified coating system |
| Cleaning and surface preparation | $0.50-$3.00 per sq ft | Oil, rust, old coating, and required profile |
| Application labor | $1.00-$3.50 per sq ft | Area, masking, access, and application method |
| Repairs and containment | $150-$1,500 per project | Cracks, corrosion, protection, and disposal needs |
Preparation can equal or exceed the coating cost when the existing surface is damaged or contaminated. Labor estimates may also include mobilization or a minimum service charge for small jobs.
Which surface and coverage details raise material cost
Square footage and surface texture are key drivers. A 1,000-sq-ft smooth surface needing one coat could use roughly 3-4 gallons at the planning coverage above, before waste; a rough surface or a two-coat specification may require substantially more. Confirm the specified wet- and dry-film thickness rather than pricing by area alone.
Substrate and condition matter, too. Bare steel, previously coated metal, concrete, and other surfaces may need different primers or preparation. If blasting, rust removal, or coating removal is required, the labor and equipment charge can increase sharply. Color changes, small batch orders, and unusual site conditions may also affect availability and pricing.
Get the specified substrate, coat count, and coverage rate in writing before comparing gallon prices. A low product quote may not include the primer or surface work required for the intended system.
Can a small Rexthane 1 job cost more per square foot
Yes. A contractor may have a minimum charge for setup, travel, masking, and cleanup, even when the coated area is small. A 100-sq-ft repair could therefore cost $300-$900 overall, while a larger, accessible project may fall closer to $2-$5 per sq ft when ordinary preparation is sufficient.
For commercial work, labor can be estimated at roughly $50-$100 per worker-hour, with crew size and job conditions affecting duration. Night work, shutdown coordination, ventilation controls, or elevated surfaces can add time and cost.
Small repairs should be compared by total quote, not only by the quoted per-gallon or per-square-foot rate. Ask whether travel, masking, disposal, and return visits are included.
How regional labor rates shift the installed price
Material pricing may be relatively similar across markets, but labor and access costs vary. As a broad planning comparison, major coastal metro areas can run 15%-30% above a national midrange estimate; smaller markets may be 5%-20% below it when contractors and equipment are readily available.
Remote industrial sites can still cost more than urban projects because of travel, mobilization, and limited contractor availability. These percentages are directional rather than guaranteed local quotes. A distributor price and a separate installer bid can help show whether the difference comes from materials or labor.
Use local bids for the installed rate and a distributor quote for the coating itself. This separates product cost from regional labor and project logistics.
Three sample budgets for different coating scopes
A 250-sq-ft accessible metal surface with light cleaning and one coat might need about one gallon, with product and incidental supplies around $200-$400. With contractor preparation and application, a practical total could be $700-$1,500, depending on minimum charges.
A 1,000-sq-ft surface requiring primer and two finish coats could use several gallons of topcoat plus primer. Materials might run $1,000-$2,500, while preparation and labor could bring the project to roughly $3,000-$7,000.
A 2,500-sq-ft industrial area with corrosion removal, containment, and difficult access might total $12,000-$25,000 or more. The price reflects surface restoration and site controls as much as coating quantity.
These examples assume contractor-applied work and are not substitutes for a site inspection. Confirm measured area, coat count, prep method, and exclusions on each written estimate.
Ways to lower a Rexthane 1 project quote
Accurate measurements help avoid excess material, but the quote should allow for surface texture and application loss. Ask whether a five-gallon package reduces the per-gallon price and whether leftover product can be stored or used elsewhere. Do not buy more than the project can use within the product’s stated handling and storage limits.
Compare bids with the same preparation standard, primer, coat count, and thickness. Combining nearby work can reduce mobilization costs; completing basic site clearing before the crew arrives may also help. Avoid omitting necessary cleaning or primer just to reduce the initial quote, since poor preparation can lead to early coating failure.
The most reliable savings come from controlling scope and comparing equivalent coating systems. Request line-item pricing for materials, preparation, application, repairs, and disposal.