This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles

for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

Designation: D6132 − 13 (Reapproved 2022)

Standard Test Method for

Nondestructive Measurement of Dry Film Thickness of
Applied Organic Coatings Using an Ultrasonic Coating
Thickness Gage1
This standard is issued under the fixed designation D6132; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.

1. Scope 2. Referenced Documents

1.1 This test method describes the use of ultrasonic film 2.1 ASTM Standards:2
thickness gages to measure accurately and nondestructively the D823 Practices for Producing Films of Uniform Thickness
dry film thickness of organic coatings applied over a substrate of Paint, Coatings and Related Products on Test Panels
of dissimilar material. Measurements may be made on field D1005 Test Method for Measurement of Dry-Film Thick-
structures, on commercially manufactured products, or on ness of Organic Coatings Using Micrometers
laboratory test specimens. These types of gages can accurately D4138 Practices for Measurement of Dry Film Thickness of
measure the dry film thickness of organic coatings on a variety Protective Coating Systems by Destructive, Cross-
of substrates such as concrete, wood, wallboard, plastic, fiber Sectioning Means
composites and metal. E177 Practice for Use of the Terms Precision and Bias in
ASTM Test Methods
1.2 This test method is not applicable to coatings that will E691 Practice for Conducting an Interlaboratory Study to
be readily deformable under load of the measuring instrument Determine the Precision of a Test Method
as the instrument probe is placed directly on the coating surface 2.2 SSPC—The Society for Protective Coatings Standards:3
to take a reading. PA 2 Procedure for Determining Conformance to Dry Coat-
1.3 The effective range of instruments using the principle of ing Thickness Requirements
ultrasonics is limited by gage design. A thickness range of 8 µm PA 9 Measurement of Dry Organic Coating Thickness on
Cementitious Substrates Using Ultrasonic Gages
to 7.60 mm (0.3 to 300 mils) has been demonstrated.
2.3 ASME—The American Society of Mechanical Engi-
1.4 The values stated in SI units are to be regarded as neers:4
standard. No other units of measurement are included in this B46.1 Surface Texture (Surface Roughness, Waviness, and
standard. Lay)
1.5 This standard does not purport to address all of the 3. Terminology
safety concerns, if any, associated with its use. It is the
responsibility of the user of this standard to establish appro- 3.1 Definitions of Terms Specific to This Standard:
priate safety, health, and environmental practices and deter- 3.1.1 accuracy, n—the measure of the magnitude of error
mine the applicability of regulatory limitations prior to use. between the result of a measurement and the true thickness of
the item being measured.
1.6 This international standard was developed in accor-
3.1.1.1 Discussion—An accuracy statement predicts the
dance with internationally recognized principles on standard-
ability of a coating thickness gage to measure the true thickness
ization established in the Decision on Principles for the
of a coating to be measured. Accuracy statements provide the
Development of International Standards, Guides and Recom-
performance capability across the full functional measurement
mendations issued by the World Trade Organization Technical
Barriers to Trade (TBT) Committee.
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at [email protected]. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
1
This test method is under the jurisdiction of ASTM Committee D01 on Paint the ASTM website.
3
and Related Coatings, Materials, and Applications and is the direct responsibility of Available from Society for Protective Coatings (SSPC), 800 Trumbull Dr.,
Subcommittee D01.23 on Physical Properties of Applied Paint Films. Pittsburgh, PA 15205, http://www.sspc.org.
4
Current edition approved June 1, 2022. Published July 2022. Originally approved Available from American Society of Mechanical Engineers (ASME), ASME
in 1997. Last previously edition approved in 2017 as D6132 – 13 (2017). DOI: International Headquarters, Two Park Ave., New York, NY 10016-5990, http://
10.1520/D6132-13R22. www.asme.org.

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States

'RZQORDGHG3ULQWHG$FFHVVHGE\XVHU/RUHQD5RPHUR0HQGH]_'DWH:HG-XO
 D6132 − 13 (2022)
range of the gage. Accuracy statements frequently include a intended application, used to adjust and/or verify the accuracy
fixed portion that remains constant across the measurement of an ultrasonic coating thickness measuring gage for a specific
range, plus a variable portion that is related to the measurement project.
result for a particular thickness. 3.1.13.1 Discussion—A coated reference sample may or
3.1.2 adjustment, n—the physical act of aligning a gage’s may not have thickness values traceable to a National Metrol-
thickness readings to match those of a known thickness sample ogy Institution. However, the reference sample should be
(removal of bias), in order to improve the accuracy of the gage marked with the stated value and the degree of accuracy. The
on a specific coating. coating thickness of the sample should be equal to or slightly
3.1.2.1 Discussion—An adjustment will affect the outcome greater than the user’s coating thickness measurement require-
of subsequent readings. ment and the coating material must have the same acoustic
velocity and attenuation as the coating to be measured.
3.1.3 calibration, n—the high-level, controlled and docu-
mented process of obtaining measurements on traceable cali- 3.1.14 substrate, n—the base material, the type of surface,
bration standards over the full operating range of the gage, then or the component that is being coated.
making the necessary gage modification (as required) to correct 3.1.15 verification of accuracy, n—obtaining measurements
any out-of-tolerance conditions. on coating thickness standards, comprising of at least one
3.1.3.1 Discussion—Calibration of coating thickness gages thickness value close to the expected coating thickness, prior to
is typically performed by the equipment manufacturer, their gage use for the purpose of determining the ability of the
authorized agent, or by an accredited calibration laboratory in coating thickness gage to produce thickness results within the
a controlled environment using a documented process. The gage manufacturer’s stated accuracy.
outcome of the calibration process is to restore/realign the gage
to meet/exceed the manufacturer’s stated accuracy. 4. Summary of Test Method
3.1.4 certification, n—documentation of the state of condi- 4.1 Instruments complying with this test method measure
tion of the gage, which can (but not required by definition) be thickness by emitting an ultrasonic pulse into the coating that
accompanied by corrective action (such as adjustment or is reflected back from the substrate to the probe. The travel
calibration, or both, or the replacement of components) neces- time is converted into a thickness reading. The instrument’s
sary to correct any out-of-tolerance conditions. probe must be placed directly on the coating surface to take a
3.1.5 coating thickness standard, n—coated metal plates, or reading.
uncoated shims of flat sheet, with assigned values traceable to 4.2 After verifying accuracy on a known coated part of the
a National Metrology Institution. object or material of the same kind, the instrument probe is
3.1.6 couplant, n—a substance such as water, oil, grease, or coupled with the coated specimen, after proper cure and
paste used to avoid the retarding of sound transmission by air conditioning according to the coating manufacturer’s instruc-
between the transducer and the test piece during ultrasonic tions.
examination. 4.3 It should be recognized that the accuracy of the mea-
3.1.7 dry film thickness, n—the thickness of a coating (or surements can be influenced when:
coating layers) as measured from the surface of the substrate. 4.3.1 The coated object to be measured is not planar with
3.1.8 gage (gauge), n—an instrument for measuring respect to the transducer face at the point of measurement,
quantity, or an instrument for testing. 4.3.2 Coating density is not uniform, and
3.1.8.1 Discussion—In this test method, the term “gage” 4.3.3 The substrate peak-to-valley surface profile of the
refers to an instrument for quantifying coating thickness. coated specimen exceeds the coating thickness.
3.1.9 manufacturer’s specifications, n—a statement or set of NOTE 1—The height of surface profile can be determined in accordance
with ASME B46.1.
statements that describes the performance characteristics of the
gage under a given set of conditions.
5. Significance and Use
3.1.9.1 Discussion—Manufacturer’s specifications typically
include the range of measurement, accuracy statement, oper- 5.1 Many coating properties are markedly affected by the
ating temperature range, power source, dimensions and weight, film thickness of the dry film such as adhesion, flexibility,
and conformance to industry standards. wear, durability, chemical resistance, and hardness. To be able
to compare results obtained by different operators, it is essen-
3.1.10 measurement (reading), n—the value obtained when
tial to measure film thickness carefully.
placing the probe of a thickness gage in contact with a surface.
3.1.11 micrometer (micron), n—one one-thousandth of a 5.2 Most protective and high performance coatings are
milimetre (0.001 mm); 25.4 microns = 1 mil. applied to meet a requirement or a specification for the dry-film
thickness of each coat, or for the complete system, or both.
3.1.12 mil, n—a U.S. term referring to the imperial unit of Coatings must be applied within certain minimum and maxi-
measure of one one-thousandth of an inch (0.001 in.) referred mum thickness tolerances in order that they can fulfill their
to elsewhere in the world as “one thou;” 1 mil = 25.4 microns. intended function. In addition to potential performance
3.1.13 reference sample, n—a specimen, coated with a deficiencies, it is uneconomical to apply more material than
material that is as close as possible in composition to the necessary when coating large areas such as floors and walls.

'RZQORDGHG3ULQWHG$FFHVVHGE\XVHU/RUHQD5RPHUR0HQGH]_'DWH:HG-XO
 D6132 − 13 (2022)
5.3 Low readings may occur occasionally on coatings with coating thickness standards and, if necessary, any deficiencies
rough surfaces. The instrument may allow a user adjustment to found shall be corrected. The probe should also be examined
prevent this. for cleanliness and excessive wear before verifying the accu-
5.4 This test method may not be applicable to measure racy and before obtaining coating thickness measurements.
organic coating thickness on all substrates. The instrument’s 8.2.1 If gage readings obtained during verification are
ability to detect a distinct interface between the coating and the outside the combined accuracy of the coating thickness stan-
substrate may be impeded if the coating and the substrate are dard and the manufacturer’s stated gage accuracy, the gage
of similar composition, density or attenuation or if the coating should be returned to the manufacturer or their authorized
is non-homogeneous. Verify operation on a known thickness of agent for calibration.
the coating/substrate combination if these circumstances are 8.3 Adjustment—Measurement accuracy directly corre-
thought to exist. sponds to the sound velocity of the coating being measured.
5.5 Multilayered coatings have many interfaces and the Because ultrasonic instruments measure the transit time of an
instrument will measure to the interface separating the two ultrasonic pulse, they may require an adjustment by the user for
most acoustically different materials. Some instruments have each coating material. To determine if an adjustment is
the ability to detect and measure the individual layer thick- necessary, the user should measure a known thickness of the
nesses in a multi-layer system. coating (reference standard) as determined by:
8.3.1 Using a destructive, cross-sectioning method such as
5.6 The use of this test method is not necessarily limited by described in Practice D4138, or
the type of substrate material. 8.3.2 Nondestructively (that is, not destroying film integ-
6. Apparatus rity) removing and measuring the coating with a micrometer in
accordance with Test Method D1005, or
6.1 Gage Body—an electronic instrument that utilizes trans- 8.3.3 Cross sectioning the product and measuring the coat-
ducer probes. ing thickness by imaging the coating cross-section under a
6.2 Transducer Probe—a measurement probe (sensor) using microscope or by using computerized image analysis. In the
an ultrasonic principle and numerical techniques, attached to case of variable coating thickness or coatings applied to rough
the gage body. The appropriate transducer probe is selected substrate surfaces the average coating thickness should be
based on the anticipated organic coating dry film thickness. calculated by computer image analysis.
The gage manufacturer may be contacted for a recommenda- 8.4 Best adjustment results are achieved on coatings with a
tion. thickness equal to or greater than the coating thickness range to
be measured and on coating material having the same acoustic
7. Test Specimen
velocity and attenuation as the coating to be measured. Follow
7.1 When this test method is used in the field, the specimen the manufacturer’s instructions.
is the coated structure or article on which the dry film thickness
is to be evaluated. NOTE 3—It has been reported that the physical properties of some
coatings such as acrylic-melamine can vary over the time of the cure.
7.2 For laboratory use, apply the materials to be tested to
panels of the same composition, structure or article on which 9. Procedure
the dry film thickness is to be evaluated. Cure the organic 9.1 Use the instrument only after calibration has been
coating in accordance with the coating manufacturer’s instruc- verified in accordance with Section 8.
tion.
9.2 Ensure that the coating is properly cured prior to use of
NOTE 2—Coatings should be applied in accordance with Practices the instrument.
D823, or as agreed upon between the purchaser and the seller.
9.3 A couplant is often required to transmit the ultrasonic
8. Calibration, Verification and Adjustment of Apparatus pulse from the gage’s probe into the coating. Water is ideal for
8.1 Calibration of coating thickness gages is performed by coatings with a smooth surface. For coatings with a rough
the equipment manufacturer, their authorized agent, or by an surface, a propylene glycol gel couplant is best, providing it is
accredited calibration laboratory in a controlled environment not a contaminant for the coating to be measured. Other
using a documented process. A certificate of calibration show- couplants such as liquid, wall paper paste, oil, etc., may be
ing traceability to a National Metrology Institute can be issued. used. Under certain conditions for example if the coating is
There is no standard time interval for re-calibration, nor is one soft, the probe may function without a couplant. For specific
absolutely required, but a calibration interval can be estab- information regarding the use of couplants, refer to the gage
lished based on experience and the work environment. A manufacturer’s instructions.
one-year calibration interval is a typical frequency suggested 9.4 Place the instrument’s probe flat on the surface and
by many gage manufacturers. apply constant pressure. Hold the probe steady during the
8.2 Verification of Accuracy—Before use, each instrument’s measurement.
calibration accuracy shall be verified by the user in accordance 9.5 Take a sufficient number of readings to measure the
with the instructions of the manufacturer, employing suitable coating thickness with required statistical accuracy.

'RZQORDGHG3ULQWHG$FFHVVHGE\XVHU/RUHQD5RPHUR0HQGH]_'DWH:HG-XO
 D6132 − 13 (2022)
TABLE 1 Instrument AA — Coating Thickness (µm) conducted in 2007. Each of eight laboratories tested seven
Repeatability Reproducibility
Repeatability Reproducibility different coated panels using two types of instrumentation.
Panel AverageB Standard Standard
Deviation Deviation
Limit Limit Every “test result” represents an individual determination. All
X̄ Sr SR r R laboratories reported two replicate test results for every panel
1 77.05 2.31 2.69 6.47 7.52 with each instrument. Practice E691 was followed for the
2 52.86 2.52 4.16 7.05 11.66 design and analysis of the data; the details are given in
3 59.48 1.25 2.65 3.51 7.43
4 51.73 2.09 2.64 5.85 7.39 Research Report No. RR:D01-1144.
5 66.01 1.64 1.70 4.59 4.76 11.1.1 Repeatability Limit (r)—Two test results obtained
6 81.50 1.89 4.08 5.30 11.43
7 139.5 2.03 7.47 5.70 20.91
within one laboratory shall be judged not equivalent if they
A
differ by more than the “r” value for that material; “r” is the
No adjustments as described in 8.3 were made to the instrument prior to this
interlaboratory study. interval representing the critical difference between two test
B
The average of the laboratories’ calculated averages. results for the same material, obtained by the same operator
using the same equipment on the same day in the same
laboratory.
TABLE 2 Instrument BA — Coating Thickness (µm)
11.1.1.1 Repeatability limits are listed in Table 1 and Table
Repeatability Reproducibility
Panel AverageB Standard Standard
Repeatability Reproducibility 2.
Limit Limit
Deviation Deviation 11.1.2 Reproducibility Limit (R)—Two test results shall be
X̄ Sr SR r R judged not equivalent if they differ by more than the “R” value
1 71.92 2.54 3.21 7.11 8.98
2 41.55 1.81 6.93 5.08 19.41
for that material; “R” is the interval representing the critical
3 55.63 1.94 3.90 5.44 10.92 difference between two test results for the same material,
4 47.53 0.89 1.35 2.50 3.79 obtained by different operators using different equipment in
5 64.73 1.00 1.80 2.80 5.04
6 75.20 0.87 3.21 2.44 9.00
different laboratories.
7 114.9 1.50 5.44 4.19 15.24 11.1.2.1 Reproducibility limits are listed in Table 1 and
A
No adjustments as described in 8.3 were made to the instrument prior to this Table 2.
interlaboratory study. 11.1.3 The above terms (repeatability limit and reproduc-
B
The average of the laboratories’ calculated averages.
ibility limit) are used as specified in Practice E177.
11.1.4 Any judgment in accordance with statements 11.1.1
NOTE 4—SSPC-PA 2 specifies the location and number of readings and 11.1.2 would have an approximate 95 % probability of
needed to characterize a coated metal surface and SSPC-PA 9 specifies the being correct.
location and number of readings needed to characterize a coated cemen-
titious surface. Select the method most appropriate for the material being 11.2 Bias—At the time of the study, there was no accepted
tested. reference material suitable for determining the bias for this test
10. Report method, therefore no statement on bias is being made.
10.1 Record the following information at the time of the 11.3 The precision statement was determined through sta-
measurements and include in the report: tistical examination of 224 results, from eight laboratories, on
10.1.1 Type of coating and substrate, seven coated panels. These seven coated panels were described
10.1.2 Instrument used including manufacturer, model as the following:
number, serial number, and date of calibration, Panel 1: UV cured coating on hickory
10.1.3 Type of coating thickness standard or reference Panel 2: water borne acrylic primer on plywood
standard, or both, together with the method used for accuracy Panel 3: factory primer on untextured molded hardboard
verification or any adjustment, or both. Panel 4: UV cured coating on unfilled maple
10.1.4 Mean, and standard deviation of the thickness read- Panel 5: a roll and curtain coated acrylic filler/base/top
ings found, coats on hardboard
10.1.5 Operator identification, and Panel 6: sprayed lacquer on oak
10.1.6 Date of inspection. Panel 7: powder coating on medium-density fiberboard
10.2 Depending upon the application, it may be useful to 11.4 Each instrument’s default calibration setting was used.
record the individual measurements as well. For rough sub- For best accuracy, each instrument should be checked against
strates or coatings, it is recommended to measure the coating in a known thickness of the particular coating being measured and
accordance with SSPC-PA 2 or SSPC-PA 9. adjusted if necessary. To judge the equivalency of two test
results, it is recommended to choose the coating/panel combi-
11. Precision and Bias5
nation closest in characteristics to the test panel and coating.
11.1 Precision—The precision of this test method is based
on an interlaboratory study of Test Method D6132 – 04, 12. Keywords
5
12.1 coatings; coating thickness; dry film thickness; nonde-
Supporting data have been filed at ASTM International Headquarters and may
be obtained by requesting Research Report RR:D01-1144. Contact ASTM Customer structive thickness; paint thickness; thickness testing; ultra-
Service at [email protected]. sonic thickness gage

'RZQORDGHG3ULQWHG$FFHVVHGE\XVHU/RUHQD5RPHUR0HQGH]_'DWH:HG-XO
 D6132 − 13 (2022)
ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentioned
in this standard. Users of this standard are expressly advised that determination of the validity of any such patent rights, and the risk
of infringement of such rights, are entirely their own responsibility.

This standard is subject to revision at any time by the responsible technical committee and must be reviewed every five years and
if not revised, either reapproved or withdrawn. Your comments are invited either for revision of this standard or for additional standards
and should be addressed to ASTM International Headquarters. Your comments will receive careful consideration at a meeting of the
responsible technical committee, which you may attend. If you feel that your comments have not received a fair hearing you should
make your views known to the ASTM Committee on Standards, at the address shown below.

This standard is copyrighted by ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959,
United States. Individual reprints (single or multiple copies) of this standard may be obtained by contacting ASTM at the above
address or at 610-832-9585 (phone), 610-832-9555 (fax), or [email protected] (e-mail); or through the ASTM website
(www.astm.org). Permission rights to photocopy the standard may also be secured from the Copyright Clearance Center, 222
Rosewood Drive, Danvers, MA 01923, Tel: (978) 646-2600; http://www.copyright.com/

'RZQORDGHG3ULQWHG$FFHVVHGE\XVHU/RUHQD5RPHUR0HQGH]_'DWH:HG-XO