I AS 3894.

3-2002

Australian Standard"

Site testing of protective coatings

Method 3: Determination of dry film thickness

PREFACE

This Standard was prepared by the Australian members of the Joint Standards
Australia/Standards New Zealand Committee CH-003, Paints and Related Materials, to
supersede AS/NZS 3894.3:1993. After consultation with stakeholders in both countries,
Standards Australia and Standards New Zealand decided to develop this Standard as an
Australian Standard rather than an Australian/New Zealand Standard.
The terms `normative' and `informative' have been used in this Standard to define the
application of the appendix to which they apply. A `normative' appendix is an integral part
of a Standard, whereas an `informative' appendix is only for information and guidance.
 CONTENTS

Page
FOREWORD 3

SECTION 1 SCOPE AND GENERAL

1 .1 SCOPE 4
1.2 REFERENCED DOCUMENTS 4
1.3 DEFINITIONS 4
1.4 TEST METHODS 5
1.5 PRECAUTIONS 5
1.6 INSPECTION PERIOD 6
1.7 INSPECTION PLANS 6
1.8 INSPECTION OBJECTIVES 10

SECTION 2 MAGNETIC INSTRUMENT METHOD METHOD A

2.1 SCOPE 11
2.2 PRINCIPLE 11
2.3 APPARATUS 11
2.4 PREPARATION OF TEST SURFACE 11
2.5 PRECAUTIONS 12
2.6 PROCEDURE 12
2.7 REPORT 13

SECTION 3 MAGNETIC INDUCTION AND EDDY CURRENT METHODS METHOD B

3.1 SCOPE 13
3.2 APPLICATION 13
3.3 PRINCIPLE 14
3.4 APPARATUS 14
3.5 PREPARATION OF TEST SURFACE 14
3.6 PRECAUTIONS 14
3.7 PROCEDURE 15
3.8 REPORT 16

APPENDICES
A MICROGRAPHIC EXAMINATION OF CROSS-SECTIONS 17
B MICROSCOPIC MEASUREMENT OF PAINT FLAKES 20
C WET FILM THICKNESS BY COMB GAUGE 22
D CALIBRATION OF MEASURING INSTRUMENTS 27
E, A SAMPLE REPORT FORM FOR DRY FILM THICKNESS TESTING 30


FOREWORD
When determining a method of measuring the dry film thickness of a protective coating in
the field, the following factors need to be taken into account:
(a) The need for an uncoated reference substrate that has a surface preparation identical
to that of the work piece.
(b) Provision of standard test blocks bearing a calibrated non-magnetic coating that is
traceable to a national Standard, i.e.. NBS or DIN.
(c) The utilization of non-magnetic or non-metallic shims.
(d) Calibration of instruments and adjustment of instruments.
(e) Examination of coating on various faces as a sampling process.
(f) Expression of results.
The protective coating system examined here is not a separately manufactured article but
one that is part of a manufactured product. There are several ways in which the concept of
thickness, or its quantitative expression, differs from those criteria that usually characterize
the thickness of sheets, foils, films, plates and tubes.
The durability of the protective coating system can be governed by the thickness of film,
above the asperities of the substrate that is lying outside the peaks of the surface profile.
Measurement of this film thickness at a large number of arbitrarily chosen spots on the test
piece will commonly yield a number of readings, some of which are 50% greater than
others. At the same time, on any face of the test piece, a mean value for a large number of
readings will differ from the mean value of the reading observed on another face. It is the
objective of this Standard to achieve uniformity of practice in dealing with such a
distribution of film thickness values.
The coating surface in view may be sensibly smooth even though it has a waviness on the
large scale. As well as being hidden and inaccessible to the instrument, the underside of the
protective film replicates the irregularity of the surface profile, on both the small and the
l arge scale.
Many of the methods available for examining the dry film thickness of a paint coating on a
test panel are not for the use of site testing of protective coatings because of the inability to
weigh the work piece, measure volume of coatings, or to mar the coating by destructive
testing. It is for this reason that only non-destructive instruments, operating on magnetic or
electromagnetic principles, have any practical use. The range of thicknesses of protective
coatings is usually beneath the level of discrimination of acoustic instruments.
ISO 2808, and Steel Structures Painting Council Specification SSPC-PA-2 provide
additional information on the determination of film thickness.


METHOD
1 SCOPE
This Standard provides practical test methods for the on-site determination of the range of
thicknesses and the mean dry film thickness of a protective coating system, or its
component coats, upon a metallic structure or fabrication.
The coated fabrications to which the methods may be applied include tanks or reservoirs,
bridge girders, equipment used in processing chemicals or petroleum, pipelines, and
fabricated articles such as vehicles, white goods and other items of industrial production,
where there is lack of uniformity of substrate thickness, metallographic character, surface
condition and the film of the protective coating.
NOTES:
I Appendix A provides a laboratory test method for the microscopic determination of the
thickness of the film adhering to a substrate. This method would only be used where no other
method is acceptable.
2 Appendix B provides a method for determining the thickness of a flake of the coating using
an optical microscope.
3 ISO 2808 provides information on additional methods of determining film thickness.
2 REFERENCED DOCUMENTS
The following documents are referred to in this Standard:
AS
1 199 Sampling procedures and tables for inspection by attributes
1399 Guide to AS 1199 Sampling procedures and tables for inspection by
attributes
2483 Testing of coatings
AS/NZS
1580 Paints and related materials Methods of test
1580.108.2 Method 108.2: Dry film thickness Paint inspection gauge
2310 Glossary of paint and painting terms
2312 Guide to the protection of iron and steel against exterior atmospheric
corrosion
ISO
2808 Paints and varnishes Determination of film thickness
3 DEFINITIONS
For the purpose of this Standard, the definitions of AS/NZS 2310 and those below apply:
3.1 Dry film thickness
The thickness of the coating measured, at any location on the test surface, above the peaks
of the profile (anchor pattern or surface profile) of the substrate.
3.2 Primary standards
Reference standards that are maintained and housed under controlled conditions at the
principal office of the test organization.
3.3 Reference substrate
A surface used to set the instrument zero, and for comparing results obtained from the test
piece.
3.4 Secondary standards
Standards that are referenced to the primary standards and are used in the field.
4 TEST METHODS
The coating film thickness may be measured using magnetic pull-off gauges (see clause 9),
or by eddy current or magnetic induction type instruments (see clause 10) of the type
generally described in Table 1:
NOTES:
1 Owing to the inherent inaccuracies of some magnetic pull-off gauges, they are recommended
only for process control operations, where accurate and reproducible measurements are not
required.
2 Appendix C provides a method for determining the wet film thickness during application of a
coating, which will assist applicators in achieving the required dry film thickness.
5 PRECAUTIONS
The accuracy of measurement of a coating thickness may be affected by a number of
factors. The following precautions should be observed:
(a) Calibration The instrument should be calibrated in accordance with Appendix D
prior to use, re-calibrated after each hour and rechecked at the end of the work period.
(b) Substrate thickness For each instrument, there is a critical thickness of metal
substrate below which the accuracy of the instrument cannot be assured. Since this
thickness depends on both the measuring frequency of the probe system and the
electrical conductivity or the magnetic permeability of the substrate, its value should
be determined experimentally, unless it is specified by the manufacturer of the test
instrument.
(c) Edge effects Measurements should not be taken close to an edge, hole or inside
corner of a test specimen unless the instrument is calibrated for such measurements.
(d) Curvature Measurements are affected by the curvature of the specimen. The
influence of curvature varies considerably, depending on the make and type of
instrument, but always becomes more pronounced as the radius of curvature
decreases. Measurements made on curved test specimens will therefore not be valid
unless the instrument is specifically calibrated for such measurements.
(e) 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.
(f) Foreign particles The probes of the coating thickness gauge need to make contact
with the test surface. The instruments are therefore sensitive to any foreign material
that prevents intimate contact between the probe and surface of the coating. The
probe tip should be checked periodically for cleanliness and foreign particles
removed using plasticine or similar material.
(g) Soft coatings Soft coatings may be deformed by the probe. Valid measurements on
such test specimens may only be possible with the use of special probes or fixtures.
NOTE: When softness of the film is caused by the degree of cure, it may be necessary to
defer testing.
(h) Surface contamination Sticky, greasy, tacky material, or other types of
contaminants, may cause a build-up on the probe, so care should be taken that such
material does not affect measurements.
NOTE: If contamination is severe, it may become necessary to defer the testing.


(i) Probe pressures Excessive pressure on the probe may damage a coating. Care
should be taken to ensure that magnetic instrument probes are held vertically and that
the coating is not damaged by the probe when determining measurements.
(j) Electromagnetic fields Instruments may not operate correctly in the presence of
strong electromagnetic fields. Inaccurate results may be obtained where strong fields
are present, e.g. near aluminium smelter pot lines or in the vicinity of electric welding
activities.
(k) Magnetic properties of pigments The magnetic effect of certain pigments and
extenders, such as micaceous iron oxide (MIO) and red iron oxide, can affect the
accuracy of measurements obtained from some instruments.
NOTE: Such errors are usually within the normal accuracy of the instrument and may not be
significant.
(1) Temperature effects Extremes of temperature may influence both the readings
obtained from the instrument and the deformation properties of the coating being
measured.
6 INSPECTION PERIOD
All thickness testing on the coating shall be performed at an appropriate time
(a) after the coating manufacturer's specified handling time has elapsed, or when the
coating has hardened sufficiently so that it is not deformed by the application of the
probe;
(b) before the maximum permissible recoating period has elapsed; and
(c) not more than seven days after the manufacturer's specified handling time has
elapsed.
7 INSPECTION PLANS
7.1 General
When devising an inspection plan for the number of measurements required to determine
the thickness of a coated finish, it is necessary to consider such aspects as
(a) the extent and duration of the project;
(b) when the inspection work is to be carried out;
(c) the configuration of the coated work, including the presence of braces, supports and
other appurtenances; and
(d) the pattern of inspection points that has proved acceptable for previous projects that
have used the same coatings, the same methods of application, and operatives of
equivalent skill.
Clauses 7.3 to 7.5 provide a guide to inspection plans that have been found appropriate for
different programs of work. As each of Clauses 7.3 to 7.5 offers a different inspection plan,
a procedure appropriate to the specific program of work needs to be selected.
7.2 Point reading
When determining a reading at a point on the coating, a single reading is sufficient.
However, for suspect or disputed readings the mean of three separate gauge readings, taken
within the area of a 12 mm diameter, should be recorded.
7.3 Large surface areas
For large areas of flat or uniformly curved coated surfaces, five separate point readings (see
Clause 1.7.2), evenly spaced throughout, should be made in each 10 m 2 area examined. The
10 m 2 i nspection areas should be selected as follows: -
(a) Structures not exceeding 30 m 2 Each 10 m2
area should be measured.
2
(b) Structures not exceeding 100 m Three 10 m 2 areas should be chosen at random and
measured.
(c) Structures exceeding 100 m - The first 100 m 2 area should be measured in accordance
with Option (b), and for each additional 100 m 2 area, a 10 m 2 area should be chosen at
random and measured.
(d) Where the thickness for any 10 m 2 area chosen in accordance with Option (b) or (c)
does not meet the required specification, then each 10 m 2 area of surface should be
measured.
NOTE: This inspection plan is recommended by the National Association of Corrosion Engineers
(NACE) and Steel Structures Painting Council Specification SSPC-PA-2.
 TABLE 1
TYPICAL PROPERTIES OF FILM THICKNESS INSTRUMENTS
I nstrument Typical
No. Test range i nstrument Application Scale Calibration Remarks
Type accuracy
1 Pencil gauge 0-600 pm ±15% Magnetic Fixed Nil I nherently
substrates variable in its
Magnetic
accuracy
pull-off
Suitable for
mid-range
readings only
on horizontal
surfaces

2 Banana gauge 0-10 000 pm ±10% Magnetic Fixed Single Suitable for
using substrates point use in any
Magnetic
separate orientation
torsion pull-
models l ocations
off models
Hand-held,
portable, of
moderate cost
and suitable
for process
control

3 Multi-reel 0-2000 pm ±5 pm* Magnetic or Fixed Single Solid state

readout or non-ferrous point electronic
±5% substrates, i nstrument
Magnetic
according to suitable for
i nduction
model all
Electro- applications
mechanical and
operation orientations
Small,
compact,
battery-
operated,
hand-held

4 Magnetic 0-2500 pm ±5 pm* Magnetic or Adjustable Two points Solid state

i nduction or non-ferrous electronic
±5% substrates, i nstrument
Electronic
according to suitable for
operation
model all
Analogue applications
read out and
orientations

Small,
compact,
battery-
operated,
hand-held

Magnetic 0-20 000 pm ±2 pm* Magnetic Adjustable Two points Suitable for
i nduction or substrates all
±1% only applications
Electronic-
up to and rough
digital liquid
1 2 500 pm surfaces
crystal
display ±5% greater Microprocess
( LCD) than or control
1 2 500µm
 TABLE 1 (continued)
I nstrument Typical
No. Test range instrument Application Scale Calibration Remarks
Type accuracy
(continued)

6 Magnetic 0-10 000 pm ±2 pm* Magnetic or Adjustable Two points Microprocess

i nduction and or non-ferrous or control for
eddy current ±1% up to substrates all
12 500 pm applications
Micro-
±5% greater
processor Statistical/
than
computer memory
1 2 500 pm
controlled capacity/
LCD batch analysis
Hard copy
facility

7 Paint 0-1.3 mm ±10% All substrates Certificate Hand-

inspection for cutter operated
gauge (PIG) optical
microscope. A
Cutter and
destructive
optical
test (refer to
microscope
AS
1 580.108.2)

8 Optical ±2 µm Measurement - Referee

microscope of film flake method
with Not suitable
magnification for site use
up to 500x

* Whichever is the greater.

NOTE: Ultrasonic gauges are available to measure coating thickness on concrete, masonry, timber, glass
and ceramics.

TABLE 2
SAMPLE INSPECTION PLAN FOR COATING
2
Number of 10 m2 areas Number of 10 m Maximum number
in a batch areas to be of defective 10 m`
randomly selected areas for batch to be
for test accepted

(Batch size) (Sample size) (Acceptance number)

2 to 8 2 0
9 to 15 3 0
1 6 to 25 5 0

26 to 50 8 0
51 to 90 13 0
91 to 1 50 20 l

1 51to 280 32 1
281 to 500 50 2
501 to 1200 80 3

1 201 to 3 200 1 25 5
3 201 to 10 000 200 7
1 0 001 and over 315 10
7.4 Small surface areas
For small items and coating areas, point thickness measurements may be taken as follows:
(a) Flat areas less than 10 m 2 A minimum of 3 point readings per square metre.
(b) Pipe work At each metre of pipe run, point readings shall be taken evenly around the
circumference as follows:

Number of
Nominal pipe
circumferential
size, mm
readings
<_150 2
>150 5300 4
>300 5600 6

(c) Beams/angles One reading on each flat face less than 300 mm in width, for each
linear metre.
7.5 Statistical sampling
Depending on the nature of the work, it may be appropriate to devise a specific inspection
plan based on statistical sampling. Such a procedure will only be effective if the following
requirements are met:
(a) The sample is drawn randomly from work of known history. The sample should
enable verification of coatings produced at essentially the same time using essentially
the same process and system of control.
(b) For each situation, a suitable inspection plan needs to be defined. An inspection plan
devised for one contractor of given capability, when applying a particular coating,
may not be relevant to another contractor applying the same coating.
For statistical sampling to be of value, the contractor needs to have a demonstrated
level of expertise. Sampling and the establishment of an inspection plan should be
carried out in accordance with AS 1199, guidance to which is given in AS 1399.
NOTE: Table 2 provides an example of an inspection plan based on an AQL of 1.5%.
8 INSPECTION OBJECTIVES
8.1 General
The procedures of Clause 9 or Clause 10 shall be followed, according to the type of
instrument employed, to record an appropriate number of determinations with a properly
calibrated instrument.
The objective is to ascertain whether the structure or steel fabrication has the desired
thickness of protective coating; however, this is commonly a contractual matter between at
least two parties. For any point at which a measurement reveals a reading that is outside the
specification limits, it is not only necessary to inspect closely the immediate area to
establish the extent of the out-of-specification film, but also to identify and mark it for
further consideration or action.
The criteria for further action will depend upon the service to which the substrate is likely
to be exposed, and are given in Clauses 1.8.2 to 1.8.4. In some instances, it may be essential
that the specified maximum coating thickness be not exceeded, to ensure adequate
performance of the coating.
8.2 Severe environment
For surfaces that are to be immersed, buried or subjected to a very severe chemical or
marine environment, a minimum film thickness should be specified and achieved.
Although, for cost-effective reasons, a specification may in such cases accept an absolute
minimum area of somewhat lower thickness, irrespective of the inspection plan adopted,
any point thickness determination found to be outside the specified thickness range should
be identified to enable restorative action to be taken.
8.3 Atmospheric exposure
For structures exposed to the atmosphere, especially when protected by coating systems
nominated in AS/NZS 2312, the following requirements should be met:
(a) The average of five point readings for each 10 m2 area of coating surface should not
be outside the specified coating thickness range.
(b) No single point reading in any 10 m 2 area should be less than 80% of the specified
minimum coating thickness. However, where three readings are averaged to produce a
point reading, an individual reading may be less than 80% of the minimum coating
thickness.
8.4 Large numbers of small components
Where a statistical inspection plan is adopted, such as shown in Table 2, the number of
defective areas should not exceed that permitted by the plan.
9 MAGNETIC INSTRUMENT METHOD-METHOD A
9.1 Scope
These Clauses set out a method for measuring the thickness of non-magnetic dried coatings
( Method A) on structural steel or other ferromagnetic substrates. It is intended for use with
paints that produce films that are firm and are not indented by the instruments used.
9.2 Principle
Instruments using the magnetic pull-off principle measure the force required to overcome
the attraction between a magnet and the magnetic substrate. The magnitude of the force is
dependent on the distance between the magnet and the substrate, which, in the case of
painted specimens, is the coating thickness.
9.3 Apparatus
9.3.1 Calibration standards
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.
9.3.2 Magnetic pull-off instrument
Measuring the attractive force between the substrate and the magnet, which is separated by
the coating thickness to be measured.
The instrument may be one of a type incorporating either of the following:
(a) A spring that is extended by the action of lifting the instrument (by hand) with the
magnet in place on the coating. The graduated extension at the point where the
magnet leaves the coating provides a measure of film thickness.
(b) A counterbalance lever attached to the magnet and connected to a spiral torsion
spring. The spring is wound up by smooth rotary action applied by the thumb, to
increase the force of retraction on the magnet lever. At the point of pull-off, the
calibrated dial provides a reading of film thickness.
NOTE: Instruments used in Option (a) are not recommended for routine inspection work.
9.4 Preparation of test surface
The test surface shall be clean, free of foreign matter and, if necessary, degreased using a
suitable degreasing agent that does not attack the coating.


9.5 Precautions
9.5.1 General

In addition to factors referred to in Clause 1.5, magnetic pull-off instruments should be

subject to the considerations given in Clauses 9.5.2 to 9.5.5.
9.5.2 Reproducibility

To ensure reproducibility of results, hand operation of the instrument should be carried out
slowly with a smooth action.
9.5.3 Vibration

Care should be taken that vibration of the test surface does not influence the reading
obtained.
9.5.4 Measuring

For instruments in Clause 9.3.2(b), the measuring uncertainty inherent in the method is
typically ±10% of the coating thickness. The inaccuracy is greater at each end of the scale.
9.5.5 Probe position

Care should be taken to ensure that the probes are held vertical to the test coating.
9.6 Procedure
The coating thickness shall be measured as follows:
(a) Select an instrument with a mid-range appropriate to the thickness to be measured.
(b) Ensure that the coating is firm and resists deformation prior to use of the instrument.
(c) Inspect the probe tip and the surface to be measured to ensure that they are clean.
(d) Calibrate the instrument in accordance with Appendix D.
(e) Take readings in areas that are free of vibration and electrical or magnetic fields.
(f) For a film thickness less than three times the profile height, measure the uncoated
substrate (A) at a number of points to obtain a representative average value, then
follow Steps (g) and (h).
(g) Measure the dry coating film (B) at the specified number of points to obtain a
representative average value.
(h) Subtract reading (A) from (B) to obtain the thickness of the coating film.
NOTES:
1 When a fixed scale gauge is used, it is necessary to correct the A and B measurements
using the corrections determined in Steps (b) and (d) of Paragraph D5.2 Appendix A.
2 Where the thickness of the measured coating exceeds three times the surface profile
height of the uncoated substrate, it is not necessary to determine a reading on uncoated
substrate for subtraction from the reading obtained over the coating.
3 For practical purposes, when the profile height is not accessible, as a guide a value of one
third of the expected profile height may be used as a correction for profile effects as a
deduction from measurement B.
(i) If thickness readings are found outside the range of accuracy determined in Step (d),
repeat the calibration procedure in that range. Check the calibration frequently during
use to ensure that the instrument continues to read correctly.
(j) Recalibrate the instrument at appropriate periods (see Clause 1.5.1).
(k) Take a sufficient number of readings in accordance with Clause 1.7.
(1) Take measurements no closer than 25 mm to an edge, and no closer than 75 mm to
another mass of metal.


NOTE: If measurements are required within these specified limits, recheck the calibration in
the specific area to determine the effect that the edge or mass of metal has on the instrument
reading.

(m) Record the results.

9.7 Report

The report shall include the following information:

(a) Name of testing organization/inspector.

(b) Date of the test and report number.

(c) Identification and description of the item tested and its coating, including shape,
substrate material, coating type and specified film thickness.

(d) A description of the location where the test was conducted, the project identification
and the test conditions.

(e) Description of the test equipment used and calibration details.

(f) Film thickness measurements, in micrometres.

(g) Reference to this Australian/New Zealand Standard, i.e. . AS/NZS 3894.3, Method A.

( h) Any deviations from this test method.

NOTE: Appendix E provides a sample test report form.

10 MAGNETIC INDUCTION AND EDDY CURRENT METHODS-METHOD B

10.1 Scope

This Clause sets out methods for non-destructive measurement of the thickness of cured
coatings, as follows:

(a) Magnetic induction (low frequency) method For non-magnetic metallic coating and
organic coatings on magnetic substrates.

(b) Eddy ' current (high frequency) method For non-conductive coatings on non-magnetic
metallic substrates.

(c) Eddy ' current (high frequency) method For metallic and non-metallic coatings on
metallic substrates which differ appreciably in conductivity.

10.2 Application

The methods may be applied to coatings and substrates referred to in Clause 3.1, where the
coating thickness is not less than 2 µm, and the, surface contour permits calibration of the
appropriate instruments (see also Appendix D).

The magnetic induction (low frequency) method is suitable for the measurement of
non-magnetic metallic coatings, such as silver, tin and zinc, and organic coatings such as
paints and plastics on magnetic substrates.

The eddy current (high frequency) method is frequently applied to the measurement of
organic coatings on non-magnetic metallic substrates and to the measurement of anodized
coatings.

With suitable instruments using appropriate frequencies, it is possible to measure the

thickness of various metallic coatings on either magnetic or non-magnetic substrates; e.g.
tin-lead on copper, silver on nickel-silver, copper on steel, zinc on steel, cadmium on steel,
tin on steel, copper on a non-metallic base, and silver on a non-metallic base.

These methods, under the best conditions of use, are accurate to 2 µm, or ±5%, whichever is
the greater.
NOTE: The methods are not suitable for the measurement of chemical conversion coatings.
10.3 Principle
An electromagnetic field is generated in the probe system of both the magnetic induction
instrument and the eddy current instrument.
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 test specimen with a magnetic metal substrate. A controlled oscillator produces
a low-level alternating voltage, which energizes one coil in a multi-coil probe. This in turn
induces a voltage in the coil in close proximity to the first. As the magnitude of this voltage
depends on the distance between the probe and the ferromagnetic substrate, this voltage
represents the coating thickness.
Eddy current instruments generate higher frequencies in the probe (typically about
6000 kHz), which produces eddy currents in the test specimen when the probe is placed on
the test surface. A single coil probe is driven by a low-level alternating voltage produced by
a crystal controlled oscillator. This voltage induces small currents (eddy currents) which
flow in conductive materials in opposition to the original field and effectively reduce the
voltage across the coil. The change in voltage is dependent upon the distance of the probe
from a conductive substrate; this distance is the coating thickness.
10.4 Apparatus
An instrument that complies with the appropriate principle that is outlined in Clause 3.3 and
which can be calibrated for the known thicknesses of coating (see Appendix D) is required.
10.5 Preparation of test surface
The test surface shall be clean, free of foreign matter and, if necessary, shall be degreased
using a suitable degreasing agent that does not attack the coating.
10.6 Precautions
In addition to the factors in Clause 1.5, eddy current and magnetic induction type
instruments should be subject to the following considerations:
(a) Conductivity of the substrate Measurements using eddy current instruments can be
affected by the electrical conductivity of the substrate. This is a function of the
composition and heat treatment of the material. The influence of electrical
conductivity on the measurement varies considerably with the make and type of
instrument.
If the substrate alloy or its heat treatment changes, the zero reading should be
rechecked and the instrument recalibrated if necessary.
For eddy current instruments, the assumption is made that the full properties are
known. In the event that a change in substrate conductivity is suspected, a small area
of coating shall be removed to allow calibration of the instrument on the bare metal.
A rapid change in a series of readings may indicate that there is a change in substrate
composition.
(b) Measuring accuracy The measuring uncertainty inherent in this method is typically
±2 pm or ±5% of the coating thickness, whichever is the greater.
(c) Probe temperature The characteristics of the probe may vary as the temperature
changes. Wherever possible, measurement should only be taken under the conditions
that apply during calibration of the instrument probe combination. Where extreme
surface temperatures are encountered, the probe manufacturer's advice should be
sought.


10.7 Procedure
The coating thickness shall be measured as follows, using the method appropriate to the
coating (see Clause 3.2):
(a) Check that the substrate thickness is greater than the critical minimum thickness
specified by the instrument manufacturer.
(b) Ensure that the coating is firm and resists deformation prior to use of the instrument.
(c) Inspect the probe tip and the surface to be measured to ensure that they are clean.
(d) Check the calibration of the instrument on a smooth substrate similar to that being
tested (see Appendix D).
(e) Press the probe on the point to be measured, at right angles to the test surface.
(f) For a film thickness less than three times the profile height, measure the uncoated
substrate (A) at a number of points to obtain a representative average value, then
follow Steps (g) and (h).
(g) Measure the dry coating film (B) at the specified number of points to obtain a
representative average value.
(h) Subtract reading (A) from (B) to obtain the thickness of the coating film.
NOTES:
1 When a fixed scale gauge is used, it is necessary to correct the A and B measurements
using the corrections determined in Steps (b) and (d) of Paragraph D5.2, Appendix D.
2 Where the thickness of the measured coating exceeds three times the surface profile
height of the uncoated substrate, it is not necessary to determine a reading on the
uncoated substrate for subtraction from the reading obtained over the coating.
3 For practical purposes, when the profile height is not accessible, as a guide a value of one
third of the expected profile height may be used as a correction for profile effects as a
deduction from measurement B.
(i) Recalibrate the instrument at appropriate periods (see Clause 1.5.1).
(j) Take a sufficient number of readings in accordance with Clause 1.7.
(k) Record the results.
NOTE: Appendix E shows a typical form that may be used to record results.


10.8 Report
The report shall include the following information:
(a) Name of testing organization/inspector.
(b) Date of the test and report number.
(c) Identification and description of the item tested and its coating, including shape,
substrate material, coating type and specified film thickness.
(d) A description of the location where the test was conducted, the project identification
and the test conditions.
(e) Description of the test equipment used and calibration details.
(f) Film thickness measurements, in micrometres.
(g) Reference to this Australian/New Zealand Standard, i.e. . AS/NZS 3894.3, Method B.
(h) Any deviations from this test method.
NOTE: Appendix E provides a sample test report form.
 APPENDIX A

MICROGRAPHIC EXAMINATION OF CROSS-SECTIONS

(Informative)

Al SCOPE
This Appendix sets out the method for measuring the local thickness of protective coatings
by micrographic examination of cross-sections.
The method is suitable for measuring the thickness of protective coatings on various
substrates. It provides a general method for measuring, to within 2 µm or better, the
thickness of a protective coating on a section cut from a test panel or coated article.
It is recommended as a referee method where a dispute cannot be resolved concerning the
thickness of a protective coating. It is particularly useful for measuring variations in
thickness, which occur due to unevenness of the substrate, for example on grit-blasted steel.

A2 PRINCIPLE
Test specimens are cut from coated products, prepared for testing and then examined
micrographically.

A3 APPARATUS
A microscope fitted with distance measuring equipment such that the uncertainty is not
greater than ±2 µm.

A4 PREPARATION OF TEST SPECIMENS

A4.1 General
Test specimens should be free of foreign matter and, if necessary, should be degreased in a
solvent that does not attack the coating.
For soft coatings, with thickness less than 50 µm, the degreased surface of the coating
should be painted with a contrasting plastics coating. The paint should not be reactive with
the coating to be measured.
A4.2 Mounting of test specimen (see Note 1)
The test specimen may be mounted in a plastics material that is neither reactive to nor
affects the coating, e.g. a suitable clear-coating cold-setting resin or material such as Plaster
of Paris. Care should be taken to ensure that voids do not form between the test specimen
and the mounting material, and that the coated surface is at right angles to the surface being
ground and polished (see Note 2).
NOTES:
I When testing coated sheet and strip metals, test specimens may be appropriately clamped
prior to mounting and polishing.
2 A deviation of only 10 ° from the vertical introduces an error of approximately 2% in the
coating thickness determination.
A4.3 Grinding and polishing
The surface of the test specimen, prepared as described in Paragraph A4.1, is generally in a
condition suitable for the grinding operation. Should burrs be present on either the test
piece or its mountings, they may be removed by means of a smooth file.


The test specimen is to be ground and polished in accordance with good micrographic
practice. The following procedure has been found to be satisfactory:
(a) Abrade the test specimen with successively finer silicon carbide wet and dry abrasive
papers placed on a flat glass plate and copiously lubricated with water during the
grinding process.
NOTE: A satisfactory finish is generally obtained by first using P180 grade paper and then
successively using P360, P600 and P1200 grades.
(b) In each case, immediately before passing to the next finer grade of paper, the test
specimen should be abraded with a back and forth movement in a straight line to
ensure that, before washing, scratches due to that particular paper are in one
direction.
(c) On transferring the test specimen to the next finer paper, rotate the test piece through
90% and then repeat the back and forth movement across previous scratches until
they disappear. This provides a convenient way of determining when to transfer the
test specimen to the next finer grade of paper.
(d) When operations have been finished on the finest grade paper, rinse and polish the
test specimen by using either a water suspension of a suitable polishing medium, such
as finely divided magnesium oxide, aluminium oxide, or diamond dust (0 to I µm)
suspended in a suitable wax or paste. The polishing operation should be carried out
using a soft cloth without the use of undue pressure.
NOTES:
I ` Selvyt' cloth or chamois, or materials of similar softness, are suitable polishing cloths.
2 The following precautions will facilitate the preparation of satisfactory test specimens:
(a) Polished surfaces should not be fingered.
( b) Polishing pads should be covered when not in use to avoid contamination by
airborne dust.
(c) At the completion of the polishing process, the surface should be washed with a
suitable solvent, rinsed in alcohol and dried in an air stream.

A5 PROCEDURE
The coating thickness is measured as follows:
(a) Project the image of the test specimen section onto the screen of a metallographic
microscope at a known and properly calibrated magnification.
(b) Measure accurately the thickness of the deposit on the projected image using a
graduated linear scale.
The actual thickness of the coating may be determined by dividing this measurement
by the magnification, or by measuring the thickness using a metallurgical microscope
fitted with a micrometer eyepiece that has been calibrated against an accurately
graduated reference scale.
In either case the magnification used should be sufficient to allow the thickness of the
coating to be determined to the required accuracy.
(c) A minimum of 10 readings should be made. The thickness of the coating should be
read from the highest peak of the metal substrate in the field of view.
(d) Record the result in micrometres.

A6 REPORT
The report should include the following information:
(a) Test specimen identification.


(b) Relevant product specification.

(c) Each thickness measurement of the coating, in micrometres.
(d) Report number and date.
(e) Reference to this test method, i.e. . AS/NZS 3894.3, Appendix A.
(f) Any deviations from this test method.


APPENDIX B

MICROSCOPIC MEASUREMENT OF PAINT FLAKES

(Informative)

BI SCOPE
This Appendix sets out a method of speedily determining the film thickness of small
specimens of paint flakes removed from the substrate, using a micrographic examination of
the cross-sections. The method also allows the determination of the number and thickness
of visibly different overlapping coatings.

B2 PRINCIPLE
A cross-section of a paint flake is mounted in wax or plasticine on a glass slide and is
examined and its thickness is measured under a microscope.

B3 APPARATUS
133.1 Optical microscope
Binocular type of variable magnification up to 100x, fitted with appropriate measuring
graticules.
B3.2 Camera
Where required, capable of being used in conjunction with the microscope (B3.1).

B4 PREPARATION OF THE TEST SPECIMEN

The specimen is prepared as follows:
(a) Snap the flake to be examined or, in the case of a very flexible specimen, tear the
flake to present as straight an edge as possible. Do not cut or polish the specimen as
this will blur the detail and burr the edges.
(b) Mount the specimen in wax or plasticine, on a glass slide.
(c) Ensure that the specimen is held vertically and edge-onto the lens.
NOTE: A deviation of only 10° from the vertical introduces an error of approximately 2% in
the coating thickness determination.
(d) Adjust the flake to expose as large a portion of the edge as possible, positioned at
right angles to the lens mounting.

B5 PROCEDURE
The test procedure is as follows:
(a) Illuminate and focus on the cross-sectional edge, using the lowest magnification first,
e.g., 50x.
NOTE: For measurement of film thickness, 50x and 100x are the most frequently used
magnifications.
(b) Align the linear graticule across the flake and record the measurement.
(c) Determine the thickness of the specimen by viewing through the microscope. The
readings on the graticule are interpreted as follows:
(i) 50x 1 mm on the graticule represents 2000 µm.


(ii) 100x 1 mm on the graticule represents 1000 µm.

(d) Determine the thickness of the specimen by producing a micrograph. The specimen
thickness may be measured from the print using the following conversion:
(i) 50x 1 mm represents 20 µm.
(ii) 100x 1 mm represents 10 µm.
(e) Record the measured thickness of the specimen.

B6 REPORT
The report should include the following information:
(a) Test specimen identification.
(b) Relevant product specification.
(c) Each thickness measurement of the coating, in micrometres.
(d) Report number and date.
(e) Reference to this test method, i.e. . AS/NZS 3894.3, Appendix B.
(f) Any deviations from this test method.


APPENDIX C

WET FILM THICKNESS BY COMB GAUGE

(Informative)

C1 SCOPE
This Appendix describes a method of determining a field measurement of the wet film
thickness of a coating using a comb gauge.
The comb gauge gives only a rough indication of wet film thickness and consequently is
used mainly for field checks during painting operations and to show that major deviations
in film thickness are not occurring. Use of a suitable correction factor with the wet film
thickness obtained by the comb gauge will provide an estimate of the dry film thickness of
the finished coating.

C2 PRINCIPLE
The comb gauge is inserted in the wet film, normal to the coated surface, and is then
examined to determine the shortest tooth touching the coating.

C3 APPARATUS-COMB GAUGE
Of metal or plastics material, the outer teeth of which form a baseline (see Figure C1). The
inner teeth are progressively shorter, thus presenting a range of gaps between the tips of the
teeth and the baseline which correspond to a scale marking on the gauge.

C4 PROCEDURE
The procedure is as follows:
(a) Immediately after the application of the paint, place the comb gauge firmly onto the
substrate in such a way that the teeth are normal to the plane of the surface.
(b) Remove the gauge and examine the teeth to determine which is the shortest one to
have touched the wet paint film.
(c) Record
,
the film thickness as lying between the last `touching' tooth and first
non-touching' tooth, as shown on the tooth calibrations marked on the gauge.
(d) Take at least two further readings in different places to obtain representative results
over the painted area.
(e) Clean the gauge teeth after each film thickness determination.
(f) If required, estimate the dry film thickness using a conversion method given in
Paragraph C5.

C5 ESTIMATION OF DRY FILM THICKNESS

The dry film thickness may be estimated from a wet film measurement using the following
equation:
DFT= WFTxv
. . . C5(1)
100+t
 TABLE CI
REDUCED PERCENTAGE VOLUME SOLIDS IN PAINT AFTER THINNING

Percentage Percentage of thinner added

volume solids
3Y 5 6'/d 7' 10 1 2' 1 8' 37 %z
before thinning
1 00 98 97 96-95 94 93 91 89 84 80 73

95 93 93 91-90 90 89 88 87 85 81 77 70
90 88 87 86 84 84 82 80 76 72 66

85 83 82 81 80 79 78 76 72 68 62
80 78 78 77-76 75 74 73 71 68 64 58
75 73 73 72 71 70 69-68 67 63 60 55

70 68 68 67 66 65 64 62 -) 9 56 51
65 64 63 62 61 60 60-59 58 55 52 47

60 59 58 57 57 55-56 55 53 51 48 44

55 54 53 53-52 52 51 50 49 46 44 40

50 49 48 48 47 46 46 45 42 40 36

45 44 44 43 42 42 41 38 36 33
40 39 39 38 38 37 37 36 36 34 32 29

35 34 34 34 33 33 32 31 30 28 28

30 29 29 29 28 28 27 27 25 24 22

25 24 24 24 24 23 23 22 21 20 18

TABLE C2
WET FILM THICKNESS, IN MICROMETRES, TO ACHIEVE SPECIFIED DRY
FILM THICKNESS FOR PAINT OF VARIOUS VOLUME SOLIDS

Required Percentage volume solids in applied film

dry film
thickness 35 40 45 50 55 60 65 70 75 80 85 90 95
µm

25 71 63 56 50 46 42 39 36 33 31 29 ' 26
1
50 1 3 1 25 11 1 00 91 83 77 71 67 59 56 53

75 214 1 88 1 67 1 50 1 36 125 115 1 07 1 00 94 88 83 79

1
1 00 286 250 227 200 1 82 1 67 1 54 143 1 33 1' 5 1 18 11 1 1 05

1 25 357 313 278 250 227 208 1 92 1 79 1 67 1 56 1 7 1 39 1 32

1 50 29 375 333 300 '')73 250 231 214 200 1 88 1 76 1 67 1 58

1 75 500 438 389 350 318 292 269 250 233 219 206 1 94 1 84

200 571 500 444 400 364 333 308 286 267 ?50 235 ')2 211

250 71 625 556 500 455 417 385 357 333 313 294 278 263

300 857 750 667 600 146 500 462 429 400 375 353 333 316
NOTE: The comb gauge illustrated is for the range 25-3200 Am; combs are
available in a range of scales, shapes and sizes.

DIMENSIONS IN MILLIMETRES

FIGURE C1 TYPICAL- COMB GAUGE

FIGURE C2 CHART FOR THE CORRECTION OF VOLUME SOLIDS FOLLOWING THE ADDITION OF THINNERS AND
DETERMINATION OF REQUIRED WET FILM THICKNESS TO ACHIEVE A SPECIFIED DRY FILM THICKNESS
 APPENDIX D

CALIBRATION OF MEASURING INSTRUMENTS

( Normative)

D1 SCOPE
This Appendix provides requirements for and information on the calibration of magnetic
pull-off gauges and magnetic induction and eddy current measuring instruments.

D2 GENERAL
Instruments shall be operated in accordance with the manufacturer's instructions. Using
suitable thickness standards, calibration shall be carried out in the range of thicknesses to
be measured during the tests.
To ensure consistency of measurements, recalibration checks using secondary standards or
suitable reference substrates shall be carried out at frequent intervals during testing.
The type of calibration standards used will depend on the type of instrument and the nature
of the coating under test.

D3 CALIBRATION STANDARDS
D3.1 General
Primary standards for magnetic pull-off gauges and magnetic induction and eddy current
measuring instruments shall be in accordance with Paragraph D3.2. Secondary standards
may be in accordance with Paragraph D3.3.
D3.2 Primary standards
Primary standards shall be test blocks bearing calibrated non-magnetic coatings that are
traceable to a national standard. They may consist of small panels, each uniform in
thickness, covering the appropriate range of film thicknesses to be measured.
NOTE: Eddy current measuring instruments may only be calibrated using a non-metallic coating
on a metal substrate, or a substrate with a coating having the same magnetic properties as the
material under test.
D3.3 Secondary standards
Secondary standards may take the form of plastic films, shims . or precoated reference
panels, made either of plastics materials or a non-magnetic metal, which give a similar
equipment response to the coating to be tested, e.g. shims of non-magnetic metal such as
brass for the magnetic pull-off gauge, and plastics for the other types of instruments.
The use of plastic films is advantageous for the calibration of instruments used for
measuring curved surfaces.
To avoid errors in measurement, ensure intimate contact between a film and the substrate.
Calibration foils are subject to indentation and require replacement when worn or damaged.
Resilient foils should not be used.

D4 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 as the material under test. For eddy current
i nstruments, 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.

D5 PROCEDURE
D5.1 General
The calibration of test equipment entails simulating the coating under test by use of
incremental thicknesses of calibration foils, films or coating standards.
Instruments shall be adjusted during calibration, in accordance with the manufacturer's
instructions (see Paragraphs D5.2 and D5.3). Appropriate calibration standards shall be
used.
Magnetic pull-off gauges shall be calibrated in accordance with Paragraph D5.2. Magnetic
induction instruments and eddy current instruments shall be calibrated in accordance with
Paragraph D5.3.
D5.2 Magnetic pull-off gauges
Instruments that are capable of calibration shall be calibrated using the following
procedure:
(a) Measure the thickness on a primary standard (see Paragraph D3.2), at or slightly
above the expected range of coating thickness.
(b) Depending upon the type of instrument, either adjust the reading or record the
calibration variation at standard thickness. To guard against gauge drift during use,
recheck the gauge with one or more of the standards at least once each hour and on
completion of each work shift.
(c) Record the thickness of the calibration standards.
( d) Crosscheck in the field using a precoated reference panel as a secondary standard, at
or slightly above the expected range of coating thickness.
NOTE: Although not ideal, for practical purposes in the field, shims may be used as a
secondary standard as an alternative to precoated reference panels.
(e) When the gauge adjustment has drifted so far that large corrections are needed,
readjust closer to the standard values and recalibrate. When the gauge can no longer
be adjusted to the calibration standards, have it rebuilt or replaced.
(f) Do not zero the gauge on the profile of the uncoated substrate.
D5.3 Magnetic induction and eddy current instruments
The procedure for calibration is as follows:
(a) Adjust the zero of the instrument on the smooth clean reference substrate (see
Paragraph D4).
(b) Hold the instrument probe firmly against a primary or secondary standard, but avoid
excessive pressure, which could indent the coating.
(c) Set the instrument while holding the probe firmly against the calibration film.


(d) Confirm the instrument setting by measuring the calibration film at several areas of
the smooth clean reference substrate.
(e) Recheck the instrument using Steps (a) through to (d) as needed to obtain an average
setting representative of the calibration range.
(f) Record the thickness of the calibration standard.
(g) Recheck the instrument setting at hourly intervals to guard against gauge drift during
use.


APPENDIX E

A SAMPLE REPORT FORM FOR DRY FILM THICKNESS TESTING*

(Informative)

TEST REPORT AS 3894.3 METHOD A/B

Site testing of protective coatings-Dry film thickness

Project:
Contract No.:
Name of testing laboratory/authority:
Date of conduct of test: Report number:
I dentification/description of test item
Substrate material:
Surface profile:
Description of workpiece:
Coating system:
Method of coating application and date:
Curing conditions (time/temperature):

Method of cure:
Specified dry film thickness-Maximum: Minimum:
Test procedure
Make and model of instrument used:

Calibration standard thickness:

Test results (attach results sheets)
Dry film thickness: (micrometres)
Maximum Minimum

Readings taken Total No:

No. above specification No. below specification

I nspector's name (print) Signature

Name of contractor's representative (print):

Signature of contractor's representative:
Average dry film thickness-conforms to specified thickness
Yes No

Modification of this form may be necessary depending on the size and scope of the project.