SSPC-PA2 June 1, 1996 SSPC: The Society for Protective Coatings PAINT APPLICATION STANDARD NO. 2 Measurement of Dry Coating Thickness With Magnetic Gages . Scope 1.4 GENERAL: This standard dasoribes the proce- dures to measure the thickness of a dry film of a nonmag- netic coaling applied on a magnetic substrate using com- mercially available magnetic gages. These procedures are intonced to supplement manufacturers’ instructions for the ‘manual operation of the gages and are not intended to replace them. 1.2 The procedures for calibration and measurement are described fortwo types of gages: pul-off gages (Type 1) ‘and constant pressure probe gages (Type 2). 1.8 ‘The standard defines a procedure to determine i the film thickness over an extended area conforms to the ‘minimum and the maximum levels specified 2. Description and Use 2.4 DEFINITIONS: 241 Gage Reading: A single reading at one point. 2.1.2. Spot Measurement three gage readings made circle. The average of at least in a 1.5inch (4 em) diameter 2.2 DESCRIPTION OF GAGES: 2.2.1 Gage Types: The gage ypeis determined by the specific magnetic properties employed in measuring the thicknags and is not determined by the mode of data read- ul, ie, digital or analog. This standard does not cover ‘gages thal measure the effect of eddy currents produced in the substrate. 2.2.2 Type 1—Pull-Off Gages: In pul-off gages, a permanent magnet is brought into direct contact with the coated surtace and a calibrated scale measures the force necessary to pull he magnet from the surface. Less force is required to remove the magnet from a thick coating. The scale is nonlinear. Type 1A - A magnet is attached to one end of & pivoting balance arm. This assembly is connected toaccalibrated helical spring. By rotating a ial, the spring increases the force on the magnet and pulls itfrom the surface. The Type 1A gages ere com monly called “banana” gages. Type 1B -Amagnetis mounted directly orindirectly toacoll spring. The spring acts perpendicularly to the surface to pull off the magnet. The Type 1B, (gages are commonly called “pencil” gages. 2.2. Type 2~Constant Pressure Probe Gages: A constant pressure probe gage uses a probe which exerts a constant a coll spring. The spring acts perpendicularly to the surface to pul off the magnet, The Type 1B gages are commonly called “pencil” gages. 2.2.3 Type 2—Constant Pressure Probe Gages: A Constant pressure probe gage uses a probe which exerts a ‘constant pressure on the coated surface during the entire measuring operation. Electronic crculry is used to convert a reference signal into coating thickness. (See 8.1.) 2.3 USE OF STANDARD: This document contains the following: Calibration, veritication and measurement proce- dures (Section 4). Required number of measurements for confarm- lance to a thickness specification (Section 5). Notes on gage principles and various factors atfect- ing thickness measurement (Section 8) ‘A numerical example of thickness measurement over an extended area (Appendix 1). ‘A numerical example of verification ofthe calibration of Type 2 gages using plastic shims (Appendix 2). 3. Reference Standards 3.4 The documents and standards referenced in this standard are listed in Section 3.4 and form a part of this standard. 3.2 The latest issue, revision or amendment of the rolerenced documents in effect on the date of invitation to bid shal govern unless otherwise specttiog 3.3 If there is a conflict belween the requirements of ‘any of the cited documents and this standard, the requice- ‘ments of this standard shall prevail 3.4 NATIONAL INSTITUTE OF STANDARDS AND ‘TECHNOLOGY (NIST) STANDARD REFERENCE MATE- RIALS. (See Section 8.15.) 024, Calibration, Verification and Measurement Procedures GENERAL 4.1.1 Accoss to Baro Substrate: All gages are af- fected to some degree by substrate conditions such as roughness, shape, thickness and composition. To correct {or this elect, access to the uncoated substrate is recom- mended. Another option is to use separate uncoated refer. ‘ence panels with similar roughness, shape, thickness and composition. (See Sections 8.3 to 8.9.) These would be sed as the bare substratein he procedures of Sections 4.2 and 4.3. Reference panels shall be of sufficient size to prociude edge effects. (See Section 8.7.) Measurements on the bare substrate can be teken before areas during painting. If the coating has already ‘been applied to the entire surface, small areas of coating may be removed and later patched. Do not allow the ‘removal process to alter the condition of the substrate. Paint strippers should be used in order to retain the profie. 4.4.2 Spot Measurement: Repeated gage readings, ‘even at points close together, may differ due losmail surface irregularities of the coating and the substrate. Therefore, a ‘minimum of three (8) gage readings shall be made for each spot measurement of either the substrate or the coating. For ‘each new gage reading, move the probe to a new tocation wilhin the 1.5 inch (4 cm) diameter circle defining the spot. Discard any unusually high ar low gage reading that cannot be repeated consistenlly. Take the average of the accept- able gage readings as the spol measurement 4.2 CALIBRATION, VERIFICATION AND MEASURE- MENT: TYPE 1—PULL-OFF GAGES 4.2.4 For Type 1 gages, use test blocks bearing cali- brated nonmagnetic coatings that are raceabieto a suitable national standard. (See Section 8.15.) The standards must 'be large enough to exceed the critical mass of steel needed to satisly the magnetic field ofthe Type 1 (pull-off) magnets. ‘Shims of plastic or of non magnetic metals which are acceptable for calibration of Type 2 (constant pressure probe) gages should no! be used for calibration of the Type 4 gages. (See Section 8.1.1.) Ifthe manufacturer's instruc- tions are in conflict with this standard by allowing the use of plastic or other nonmagnetic shims for the calibration of 2 ‘Type 1 gage, the contracting parties must both be notified of this fact and agres on a method of calibration. proprietary thickness standards are tobe used, agree- ment between contracting parties should be reachedprior to starting the jb. 4.2.2 Using the Type 1 (pulloff) gage, measure the thickness of a series of calibration standards covering the SSPC-PA 2 June 1, 1996 ‘expected range of coating thickness. To guard against ‘measusing with aninaccurate gago, recheck the gage al the boginring end the end of each work shift with one or more of the standards. uring the work shift, if the gage is dropped or suspected of giving erroneous readings, its calibration should be rechecked. If deemed appropriate by the contracting partes, initial agreement can be reached on the details and frequency of verification or calibration, Record the calibration data and the method used to verify the calibration, the gage is found to be out of calibration attho ‘end ofthe work shit, all measurements made since the last calibration are suspect. 4.2.3 When the gage no longer agraes with the stan. dard, check the probe for cleanliness. If dirty, clean as described in Section 8.5.1. Ifthe gage stil does not agree with the standard, the gage is in need of repair or replace- ment. Some gages can be adjusied to read accurately in & given tange. Adjust the gage to read correctly on a given standsrd. Then check the gage on nonlinear scales and any Aagjusthg feature islinearin natura, Theretore, only a given segment of he scale can be accurate after adjustment, 4.2.4 Measure the bare eubstrate at a number of spots to oblain a representative average value. This average value isthe base metal reading (BM). Note the gage isnot to be calibrated on the bare substrate. 4.25 Measure the cry coating at the number of spots pacified in Section 5. 4.2.6 Subtract the base metal reading from the gage reading to obtain the thickness of the coating. 4.3 CALIBRATION, VERIFICATION AND MEASURE- MENT: TYPE 2—CONSTANT PRESSURE PROBE GAGES 1 Different manufacturers of Type 2 (constant pres- «ure probe) gages follow different methods of calibration or adjustment. Calibrate the gage according to manufacturer's instructions. 4.3.2 With a properly calibrated gage, measure the ory coating as specified. (See Section 4.1.2) 4.3.3 Verily the calibration ofthe gage at the beginning and the end of each work shift with one or more of the standards. (See Appendix 2). During the work shit, i the ‘2898 is dropped or suspected of giving erroneous readings, ite oalaeation should be rechecked. If deemed appropriate by the contracting parties, initial agreement can be reached (on the details and frequency of verification or calibration, Recor’ the calibration data and the method used to verify the calibration. Ifthe gage is found to be out of calipration ‘at the end of the works shift, ell measurements made since the last calibration are suspect 503SSPO-PA2 June 1, 1896 5. Required Number of Measurements for Conformance to a Thickness Specification 5.1 NUMBER OF MEASUREMENTS: Make five (5) separate spot measurements (average of the gage read- ings, see Section 4.1.2) spaced randomly over oach 10 m® (100 ft) area to be measured. If the contracting parties ‘29788, more than five (5) spot measurements may be taken ina given area, (See Section 8.3.) The five spot measure- ments shall be made for gach 10 m® (100 ft) of area as follows 5.1.1 For structures not exceeding 30 m? (800 7) in area, each 10 m? (100 ft?) area shall be measured. 5.1.2 For structures nol exceeding 100 m® (1,000 ft) in ‘area, three 10 m* (100 ft) areas shall be randomly selected ‘and measured, 8.1.3 For structures exceeding 100 m* (1,000 ft") in ‘area, the first 100 m* (7,000) shall be measured as stated In Section 6.1.2 and for each additional 100m? (1,000 1) of {area or increment thereof, one 10 m? (100 t?) area shall be randomly selected and measured. 5.4.4 Ifthe dey film thickness for any 10m (1001) area (s0e Sections 5.1.2 and 8.1.9) is notin compliance withthe requirements of Sections §.2.1 and 8.2.2, then additional measurements must be made to isolate the nonconforming 5.2 SPECIFYING THICKNESS: Both a maximum and {a minimum thickness should be spectied forthe coating. If a maximum thickness value is not explicitly specified, the specified thickness shall be the minimum. 5.2.4 Minimum Thickness: The average of the spot, measurements for each 10m* (10011) area shall not beless than the specified minimum thickness. No single spot measurement in any 10 m# (100 ft) area shail be less than '80% of the specified minimum thickness. Any gage reading may under-run by a greater amount. If the average of the ‘spot measurements fora given 10 m® (100 tt) area meets or exceeds the specified minimum thickness, but one of more ‘spat measurements is less than 80% of the specified mini= mum thickness, additional measurements may be made to define the nonconforming area. (See Appendix 1.) 5.2.2 Maximum Thickness: The average of the spot ‘measurements for each 10 m* (100 i) area shall not be ‘more than the specified maximum thickness. No single spot ‘measurement in any 10 m? (100 ft?) area shall be mare than 120% of the specified maximum thickness. Any gage reading may overrun by agreater amount. Ifthe average of the spot measurements for a given 10 m? (100 ff) area ‘meets or falls bolow the specified maximum thickness , but 504 lone or more spot measurements is more than 120% of the specified maximum thickness, additional measurements maybe made to define the nonconforming area. Manutac- turers’ Iterature may be consulted to determine if higher rmaxmum thickness readings are allowable under specific circumstances, 5.8 Other size areas or number of spot measurements ‘may be specified in the procurement documents as appro- piiata for tho size and shape of the structure to be mea- sured. 6. Accuracy 5.1 To qualify under this standard, a gage must have {an accuracy atleast within 410% For thicknesses less than 284m (1 mil), he gage musthave an accuraoy atleast within $2.5 4m (0.1 mil. 7. Disclaimer 7.1 While every precaution is taken to insure that all Information furnished in SSPC standards.and specifications is as accurate, complete and useful as possible, SPC ‘canrot assume responsibilty nor incur any obligation result- ing from the use of any materials, coatings or methods ‘specified therein, or of the specification or standard iteet. 8. Notes Notes are not a requirement of this standard. 3.1. PRINCIPLES OF THE MAGNETIC GAGE: Each of these gages can sense and indicate only the distance between the magnetic surface of the stool and the small rounded tip of the magnet or probe that rests on the top surlace ofthe coating. This measured distance, from the top surtsee of the coating, must be corrected forthe thickness cof any extrangous films or otherinterfering conditions on the surlece of the steel. Such correction is described in Section 4.2 for Type * gages and manufacturer's instructions for Type 2 gages. 8.1.1 Type 1 (pull-olf) gages use a calibrated spring ‘mechanism to measure the force needed to pull a smal perrranent magnet from the surface ofthe coated steel, The magnolic force holding the magnet to the surface varies inversely as a nonlinear function of the distance betwoen magnet and steel, i.e. he thiokness ofthe éry coating (plus any other films present). ‘The Type 1A "banana gagesuse a helical spring to pull small permanent magnet from the surface. Internal bal ancing mechenisms in most banana gages compensate for horizontal, vertical and overhead positions so thal there is no need to recalibrate when changing orientation, fn a Typo 18 “pencil” gage, a calibrated coil spring measures the force necessary to pullthe permanent magnetfrom the surface. Because of gravitational effects, these gages must be recalibrated when the orientation of the surface changes; e.g., a gage calibrated on a horizontal surface will not be accurate when measuring a vertical surface. Some gages have three separate indicators which ‘compensate for horizontal, vertical and overhead positions. ‘Type 18 gages are generally nol as precise as Type 1A ‘gages. Normally, Type 1 gages are not adjusted or reeet for ‘each new series of measurements ‘Shims of sheet plastic or of nonmagneticmetals, which are permissible for calibrating Type 2, (constant pressure probe) gages, should not be used for calibration of Type 1 ‘gages. Such shims are usually fairy rigid and eurved and.do not lie perfectly flat, even on a smooth steel test surface, Near the pull-of point ofthe calioration measurements with any Type 4 gage, the shim frequently springs back Irom the steel surlace, raising the magnet too soon and causing erroneous calibration readings, 8.1.2 Type 2 (constant pressure probe) gages operate ‘on two different magnetic principles. Some Type 2 gages Use apermanent magnet. When the magnetis brought near steel, the magnetic flux density within the magnet ie in- ‘creased. By measuring this change in flux density, which varies inversely tothe distance between the magnet and the steel substrate, the coating thickness can be determined Halloloments and magnet resistance elements are the most ‘common ways to measure magnetic lux densily. However, the response of these elements is temperature dependent, ‘s0 temperature compensation is required Other Type 2 gages operate on the principle of electro magnetic AC current thereby producing @ changing meg- netic field at the probe. As with @ permanent magnet, the ‘magnetic flux density within the rod increases when the probe is brought near the stael substrate, This change is easy to dotect by using a second coil. The output of the ‘second col is related to coating thickniese and this reation- ship can ba determined experimentally, 8.2 REPEATABILITY: Magnelic gages are necessar- ily sensitive to very small irregularities of the coating aurtace oF of the steel surface directly below the probe center Repeated gage readings on a rough surtace, even at points very close together, frequently cltter considerably, particu- larly for thin fms over a rough eurface with a high proil, 8.3 ZERO SETTING: Type 1 magnetic gages should not be adjusted or set al the scale zero (0) with the gage applied to either a rough or a smooth uncoated steet sur- face. 8.4 ROUGHNESS OF THE STEEL SURFACE: If the steel surface is smooth and even, its surface plane is the effective magnetic surface. I tho stool is roughened, as by blast cleaning, the “apparent” or effective magnetic surface 505 SSPC-PA 2 June 1, 1986 that he gage senses is an imaginary plane located between the peaks and valleys ofthe surface profile. With acocectly calitrated and adjusted Type 2 gage, the reading abtained indicates the coating thickness above this imaginary plane. (See Section 4.3.) Ia Type t gage is used, the coating thickress is obtained by subtracting the base metal reading. (See Section 4.2.) 8.5 DIRTY, TACKY OR SOFT FILMS: The surface of the coating and ihe probe of the gage must be ree from dust, ‘grease and other foreign matter in order to obtain close contact of the prove with the coating and algo to avoid adhesion of the magnet. The accuracy of he measurement will te affected if the coating is tacky or excessively soft ‘Tacky coating films also cause unwanted adhesion of the ‘magnet. Unusually soft lms may be dented by the prassure of the probe, Soft or tacky fms ean sometimes be mea: sured satisfactorily by pulling a shim on the film, measuring total thickness of coating plus shim and subtracting shim thickness, 8.5.1 Ordinary dit and grease can be removed trom a probe by wiping with a soit cloth. Magnetic particles adher- Ing to the probe can be removed using an adhesive backed tape. Any adhosive residue left on the probe must then be removed, 86 ALLOY STEELSUBSTRATES: Diferencesamong most mild low-carbon steels will not signiticantly effect magnetic gage readings. For higher alloy steels, the gage rasponse should be checked, In any ever, the gage should be rezalibrated on the same steel over which the coating has oon appliod, 8.7 PROXIMITY TO EDGES: Magnetic gages are sen- sitive to geometrical discontinuities of the steel, such as holes, comers or edges. Tho sensitivity to edge offacts and discontinuities varies from gage to gage. Measurements closer than 2,6 em (1 in) from the discontinuity may not be valid unless, the gage is calibrated specifically for that location. £.8 PROXIMITY TO OTHER MASS OF STEEL: The colder two-pole Type 2 gages with permanent magnets are sensitive to the presence of another mass of steel closa to the body of the gage. This effect may extend as much as three inches (7.6 em) from an inside angle. 6&9 CURVATURE OF STEEL SURFACE: Magnetic gagereadings may be affected by surface curvature. Ifthe curvature is appreciable, valid measurements may sill be oblained by calibrating or adjusting the gage on a similarly curved surface. £10 TILT OF PROBE: All of the magnets or probes mustbe held perpendicular o the coated surface to produce valid measurements.SSPC-PA2 June 1, 1996 8.11 OTHER MAGNETIC FIELDS: Strong magnetic, fields, such as those from welding equipment or nearby powerlines, mayinteriere with operation ofthe gages. Also, residual magnetism in the steel substrate may alfect gage readings. With ficed probe two-pole gages in such cases, it i recommended that the readings before and after revers ing the pole positions be averaged. Other gages may require demagnelization of the steel 8.12 EXTREMES OF TEMPERATURE: Most of the magnetic gages operate satisfactorily al 4°C and 49 °C (40 °F and 120 °F). Some gages function well at much higher temperatures. However, if such temperature extremes are ‘met inthe field, the gage might well be checked with atleast ‘one reference standard after both the standard and the gage are brought to the same ambient temperature. Most elec tronic gages compensate for temperature differences among the gage, probe and surface. 8.13 VIBRATION: The accuracy of the Type 1 (pul-otf) gages is alfected by trafic, machinery, concussions, etc. When these gages are set up for calibration or measure- ‘mento coating films, there should be no apparent vibration, 8.14 VARIATION IN THICKNESS - 80% OF MINIMUM/ 120% OF MAXIMUM: In any measurement hereisacertain level of uncertainty. Two inspectors using the same gage will not necessarily record the exact same number for a given spot measurement using the same 4 om (1.5 in) diameter circle. To allow for this natural fluctuation, an individual spot measurement is permitted to be below the specified minimum thickness astong as other spotsin the 10, rm? (100 ft) area are high enough to make the average thickness meet or exceed the specified minimum thickness, ‘Similar reasoning applies to maximum thickness, The 80% of specitied minimum and 120% of specifiad maximum allow for the tolerance of the gage and calibration standards and {or variations in the substrate, 8.18 Polished metal calibration standards are manutac- tured by the National Institute of Standards and Technology (NIST). The chrome plated panes are fat smooth stee!2.86 2.86 0m (1.125x1.128in) in size. Examples of some NIST standards are: Cortified Coating Thickness Calibration Standards Nonmagnetic Coating on Steel SRM 1358 Set of 8 80, 225, 1000 jm (8, 9, 40 mil} SRM 1359. Set of 4 48, 140,505, 800m (2, 5.5, 20, 31 mil 40, 80,140, 205 jm (1.6,9, 5.5, mil) Single standards from 3 yim (0.4 mil) to-62 jum (2.4 mil) SRM 13628 Set of 4 SRM 1331 to 13394 8.16 CORRECTING LOW OR HIGH THICKNESS: The contracting parties should agree upon the mothod of corecting film thicknesses that are above the maximum or below the minimum specification. This method may be spzcified in the procurement documents, may follow manufacturer's instructions or may be a compromise reached atter the nonconforming area is discovered APPENDIX 1—Numerical Example of Aver- age Thickness Measurement ‘The following numerical example is presented as an ilustration of Section 8. (Reference JPCL, Vol 4, No 5, May 1987). Suppose this structure is 30 m® (300 f1) in area, Mentally divide the surlace into three equal parts, 2azh being about 10 m* (100 ft), Part A= 10 m® (100 #19) Part 8 - 10m? (100 tF) Part © - 10 m* (100 1) First, measure the coating thickness on Part A. This involves atleast 16 readings of the thickness gage. (See Figure A1.) Assume the specification calls for 64 ym (2.5, mils) minimum thickness. The average thickness or area A's then the average of the five spot measurements, made on atea A, namely 66 jum (2.6 mils), Spott 641m 2.5 mils Spot2 76 3.0 Spots 632.1 Spot4 76 3.0 Spots 58 23 Avg. 65)1m 2.6 mils ‘The average, 66 um, exceeds the specitied minimum of 34 um and thus satisties the specification. However it must be decided ifthe lowest spot measurement, 53 1m, is within 80% ofthe specified minimum thickness. Eighty percent of 64 unis 5t pm (0.80 x 64 =51). Although 53 tum is below the specified minimum, itis stil within 80 Percent of it, 60 the specification is satisfied. [The avarage, 2.6 mils, exceeds the specified minimum of 2.5, mis and thus satisfies the specification. However it must be decided ifthe lowest spot measurement, 2.1 mils, is within 80% of the specified minimum thickness, Eighty percent of 2.5 milsis 2.0 mils (0.80x2.5 =2.0). Although 2.1 mils is below the specified minimum, itis sill within 80 percent of i, so the specification is satisfied} ‘There are individual gage readings of 38 jim at spot 5 end 46 ym at spot 3, both of which are clearly less than 51 Im, This is allowed because only the average of the this readings (.6., the spot measurement) must be greater than or equal fo 51 um. [There are individual gage readings of 1.5 mils at spot § and 1.8 mils at spot 3, both of which are clearly less than 2.0 mils. This is allowed because only the average of the tree readings (.e., the spot measurement) must be greator than or oqual to 2.0, mis] 506SSPC-PA 2 June 1, 1996 FIGURE A1 Part "A" of Structure (Area Approx. 10 m? {100 ft'}) GAGE READINGS Spot 2 ett Part “Be 5 nt Since the structure used in this example is about 30m* —_racommendation. Now its calibration over blast cleaned (@00 1, the procedure used to measure the film thickness steel must be verified. A test coupon which had been blast of part A must be applied to both part B and part C. The leaned during the time the structure was blasted and has measured thickness of part B must exceed the 64 jim (2.5 _a profile representative of that under the coating is avail- mils) specified minimum as must the thickness of part C. able. Atler selecting a 50 um (2.0 mil) and a 260 jum (10.0 ‘To monitor the thickness of this entire 30 m* (300 f#) mil) plastic shim, proceed to take thickness readings of the structure, at least 45 individual gage readings must be shims lying on the bare blasted surface, takon, from which 15 spot measurements aro caloulated. -—-Secause of the randomized nature of a blast cleaned ‘The five spot measurements trom each 10 rv (100 ft) part surtace, repeated readings may exhibit significant varia- of the slructure are Used to calculate the thickness of that tion. Thus, make at least 10 measurements on each shim part and record their averages. There is no need to keep track of each individual reading. Many gages will compute the Appendix 2—Example of Verification of the average for you. Calibration of Type 2 Gages Using Plastic “The thickness ofa plastic shim is typically accurate to Shims within 45%, Alor calibration according to manufacturer's instructions, tho gage is probably accurate to within 25% ‘This example describes a method to check a Type 2 2l80. Therefore, for the gage to be in agreement withthe {9209 is property callbrated shim, the average thickness measured by the gage should Suppose the coating thickness is specified at 100 um _D¢ within 410% of the shim’s thickness. I the average (4.0 mis), The Type 2 constant pressure probe gage being hiknoss moasurod on the St im (2.0 mi) shim is 56 um Used has been calibrated according to the manutacturer’s (2:2 mils) the gage is in egreement with the shim because " 56 is within £10% of 51 (2.2 is within 10% of 2.0), 507SSPC-PA2 June 1, 1986 Similary, ifthe average thickness of the 254 um (10.0, mil) shim is measured to be 279 ym (11.0 mils), the gage calibration is veriies because 279 is within 10% of 254 (11.0 is within 210% of 10.0). In summary, ifthe average measurement of the S1 ym {2 mil) shimis between 46 and 86 1m (1.8 and 2.2rls), and ifthe average measurement of the 254 uum (10.0 mil) shim is between 229 and 279 um (8.0 and 11.0 mils), the calibra: tion is veritieg Check that another shim of intermediate thickness, for example 127 jum (5.0 mils), is also within #10%, If the calibration ie verified on both the high and the low shims, it |salmost always verified on the intermediate value shim. NOTE: With some gages it may be more practical to ‘just the gage at the intermediate thicknoss (e.g. 127 mm him) first and then verity hat the gage also reads the high ‘and the low shims correct. 508