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AS/NZS 1580.108.1: 1994

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Paints and related materials-Methods of test
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Method 108.1: Determination of dry film

thickness on metallic substrates-
Non-destructive methods

PREFACE

This joint Standard was prepared by the Joint Australia/New Zealand Standards
Committee CH/3, on Paints and Related Materials, under the direction of the
Multitechnics Standards Policy Board, to replace the 1980 edition, Determination of dry
film thickness on iron and steel substrates (permanent magnet instruments). This edition
extends the range of instruments that may be used and no longer limits the procedure to
iron and steel substrates.
The term 'normative' has been used in this Standard to define the application of the
appendix. A 'normative' appendix is an integral part of a Standard.

METHOD

1 SCOPE This Standard sets out a general procedure for determining the thickness of
non-magnetic coatings on steel or other metallic substrates using non-destructive testing
techniques within the laboratory. It is intended for use with coatings which produce films
that are firm and not subject to indentation by the instruments used. The coating thickness
measurements may be obtained with magnetic torsional pull-off gauges, magnetic
induction or eddy current type instruments. The method is not applicable to coatings of
less than 20 pm thickness.
NOTES:
1 Site testing procedures are described in AS 3894.3.
2 Direct magnetic pull-off gauges are not covered by this Standard.

2 REFERENCED DOCUMENTS The following documents are referred to in this

Standard:
AS
1580 Paints and related materials-Methods of test
1580.101.4 Method 101.4: Conditions of test; temperature controlled
2310 Glossary of paint and painting terms
3894 Site testing of protective coatings
3894.3 Method 3: Determination of dry film thickness

OJ
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NEW ZEALAND
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AS/NZS 1580.108.1:1994 2

3 DEFINITIONS For the purpose of this Standard, the definitions of AS 2310 and those
below apply.
3.1 Calibration shims-a film of non-magnetic material, the thickness of which has
been determined by a micrometer, which is placed on the unpainted substrate to calibrate
the thickness gauges.
3.2 Dry film thickness-the thickn~ss of the coating measured above the peaks of the
profile (anchor pattern or surface profile) of the substrate.

4 PRINCIPLES The film thickness is determined using one of the following types of
instrument: .~

(a) Magnetic torsion pull-off instruments These instruments use the magnetic pull-off
principle to measure the force required to overcome the attraction between a magnet
and the magnetic substrate. The magnitude of the force is dependent on the gap
between the magnet and the substrate which, in the case of painted specimens, is the
coating thickness. Such instruments are only suitable for ferro-magnetic substrates.
(b) Magnetic induction and eddy current instruments An electromagnetic field is
generated in the probe system of both magnetic induction instruments and eddy
current instruments.
Magnetic induction instruments' generate a low-frequency alternating current
(typically 50 Hz to 60 Hz) in a probe which produces measurable magnetic
induction when it is placed on a ferro-magnetic substrate. Sucb instruments measure
non-magnetic metallic coatings and organic coatings on magnetic substrates.
Eddy current instruments generate higher frequencies in the probe (typically about
6000 Hz), which produce eddy currents in the test specimen when the probe is
placed on the test surface. Such instruments measure non-conductive coatings on
non-magnetic substrates and also metallic coatings on metallic substrates which
differ appreciably in conductivity.

5 TEST CONDITIONS The test shall be carried out under the conditions specified in
AS 1580.101.4.

6 PRECAUTIONS TO BE OBSERVED The accuracy of measurement of a coating

thickness can be affected by a number of factors. The precautions listed below should be
observed:
(a) Calibration The instrument should be calibrated immediately prior to use,
recalibrated at least every hour and rechecked at the end of each work period.
(b) Surface profile and roughness Measurements are influenced by the surface
topography of the substrate and of the coating. Rough surfaces and the anchor
pattern of a surface profile can cause both systematic and random errors.
(c) Edge effects Where a reading is to be taken less than 25 mm from an edge or near
re-entrant angles, it should be checked by interposing a calibration shim between the
paint film and the probe of the instrument to verify that the additional thickness
interposed is correctly registered.
(d) Soft coatings Soft coatings may be deformed by the probe. When softness of the
coating is caused by the degree of cure, it may be necessary to defer testing.
(e) Magnetic properties of pigments The magnetic effect of certain pigments and
extenders, such as micaceous iron oxide and red oxide, can affect the accuracy of
measurements obtained from some instruments.

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 3 AS/NZS 1580.108.1:1994

7 APPARATUS
7.1 Calibration standards-shims of suitable material, the thickness of which has been
currently determined by means of a micrometer. Alternatively standard test blocks bearing
calibrated non-magnetic coatings that are traceable to a suitable national standard,
covering the appropriate range of film thickness to be measured, may be used.
7.2 Magnetic pull-off instruq1ents-measuring the attractive force between the
substrate and the probe magnet~ which is separated by the coating thickness to be
measured. The most common form of this instrument incorporates a counterbalance lever
attached to the magnet and connected to a spiral torsion spring (Le. banana gauge). .,
7.3 Magnetic induction or eddy current instruments-using magnetic induction (low
frequency) or eddy current (high frequency) principles to determine the coating thickness
on metallic substrates.

8 PROCEDURE The procedure shall be as follows:

(a) Select an instrument appropriate for the coating and substrate concerned and with a
mid range appropriate to the thickness to be measured. Table 1 indicates the type of
instrument that may be used for specific situations.
(b) Inspect the probe tip and the surface to be measured to ensure that they are clean.
NOTE: Magnetic pull-off instruments are prone to contamination by steel grit.
(c) Calibrate the instrument in accordance with the manufacturer's instructions using
either calibration shims or suitable standard blocks. (See Appendix A.)
(d) Ensure that the coating is hard enough to resist deformation by the probe of the
. instrument.
(e) Take measurements, at a minimum of six locations selected at random, to obtain
l
representative results ~ver the painted area.
NOTE: Tbe distribution of measurements and levels of acceptance for a specified thickness
should be agreed with the contracting parties. This will depend upon the area of coated
surface to be inspected or the precision in coating thickness required by the specifier.
(f) Recalibrate the instruments at appropriate periods, at least each hour and at the end
of each work period.
(g) Record the results to the smallest scale division of the instrument.
NOTE: These readings may be rounded off, depending on the accuracy of the instrument
and the thickness of the film (see Table 1).

9 REPORT The test report shall include the following information:

(a) Name of testing authority.
(b) Date of test and report number.
(c) Identification and description of item tested and its coating, including substrate
material and coating type.
(d) Description of test equipment used and calibration details.
(e) All film thickness measurements and the mean, in micrometers.
(f) Reference to this Australian/New Zealand Standard, Le. AS/NZS 1580.108.1.

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AS/NZS 1580.108.1:1994 4

TABLE 1
GUIDE TO SELECTION OF TYPE OF INSTRUMENT

Instrument Typical test Typical

instrument Application Remarks
type range
accuracy
I
Magnetic 0-10000 p,m :!:10% Magnetic Suitable for use
torsion pull- using substrates in any
off models separate only orientation
models locations
;..
Banana Hand-held,
gauge portable, of
moderate cost
and suitable for
.
process control

Magnetic 0-1 250 p,m :!:5% Magnetic Suitable for

induction substrates many applications
only Suitable for
rough surfaces
Microprocessor
control

Electronic- May have

digital or statistical!
analogue liquid memory capacity!
crystal batch analysis
display Hard copy
(LCD) facility

Magnetic 0-1 250 p,m - ::!:2% Magnetic Microprocessor

induction or non- control for all
and eddy ferrous applications
current substrates for
eddy current
instruments

Micro- Magnetic May have

processor substrates only statistical!
computer- for many memory capacity!
controlled magnetic batch analysis
(LCD) induction Hard copy
instruments facility

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 5 AS/NZS 1580.108.1:1994

APPENDIX A
CALIBRATION OF MEASURING INSTRUMENTS
(Normative)
,
Ai GENERAL Instruments should be calibrated and used in accordance with the
manufacturer's instructions, using suitable thickness standards. Calibration should be,
carried out under conditions and over a range of film thicknesses typical of those that will
apply during the tests. .

To ensure accuracy of measurements, calibrations should be carried out at frequent

intervals during use, at least each hour and at the completion of each work period.
The type of calibration standard will depend on the type of iI}strument and the nature of
the coating under test.

A2 CALIBRATION SHIMS Calibration shims may be made of plastics materials or

of a non-magnetic metal such as brass which give a similar equipment response to the
coating to be tested.
The use of shims is advantageous for "the calibration of instruments used for measuring
curved surfaces. They are also more readily available than coated standards.
To avoid errors in measurement, it is necessary to ensure intimate contact between a shim
and the substrate.
Calibration shims are subject to indentation and require replacement when worn or
damaged. Resilient shims should not be used.

A3 COATED STANDARDS - Coated standards consist of appropriate coatings bonded

to a substrate material with properties similar to the test piece. The coating shall have an
equipment response similar to the coating to be tested and have a known uniform
thickness.

A4 REFERENCE SUBSTRATES Substrate references are used for setting the zero
and comparing results obtained from the test piece. Reference substrates may be made
from the material under test or may be an uncoated smooth metal plate. The reference
substrate should be of similar geometry for small or curved sections. For use with
magnetic induction instruments, they may also be made from material having similar
permeability to the material under test. For eddy current instruments, material having
similar electrical response properties may be used.
The reference substrate should be smooth, without roughness or profile.
When the substrate thickness is below the minimum critical thickness, the thickness may
be built up by adding packing pieces of the same metal. However, packing pieces should
only be used as a last resort.
Packing pieces are not suitable when the substrate is coated on both sides or when there is
a gap between the substrate and the back-up metal.

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