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 SSPC-PA 2
May 1, 2004

SSPC: The Society for Protective Coatings

PAINT APPLICATION SPECIFICATION NO. 2

Measurement of Dry Coating Thickness with Magnetic Gages

1. Scope adjusted on a coated part or on a shim, where the thickness

of the coating or of the shim is known.
1.1 GENERAL: This standard describes the procedures to
measure the thickness of a dry film of a nonmagnetic coating 2.1.6 Coating Thickness Standard (Test Block): A smooth
applied on a magnetic substrate using commercially available ferromagnetic substrate with a nonmagnetic coating of known
magnetic gages. These procedures are intended to supplement thickness that is traceable to national standards.
manufacturers’ operating instructions for the manual operation
of the gages and are not intended to replace them. 2.1.7 Shim (Foil): A thin strip of non-magnetic plastic,
metal, or other material of known uniform thickness used to
1.2 The procedures for adjustment and measurement are verify the accuracy of coating dry film thickness gages.
described for two types of gages: pull-off gages (Type 1) and
electronic gages (Type 2). 2.1.8 Dry Film Thickness Reference Standard: A sample
of known thickness used to verify the accuracy of the gage,
1.3 The standard defines a procedure to determine if the such as coated thickness standards or shims. In some instances
film thickness over an extended area conforms to the minimum with the owner's permission, a sample part (a particular piece
and the maximum levels specified. This procedure may be of coated steel) is used as a thickness standard for a particular
modified when measuring dry film thickness on overcoated job.
surfaces (see Note 7.1).
2.1.9 Accuracy: Consistency between a measured value
2. Description and Use and the true value of the thickness standard.

2.1 DEFINITIONS 2.1.10 Structure: A unit composed of one or more con-

nected steel members comprising a bridge, tank, ship, etc. It
2.1.1 Gage Reading: A single reading at one point. is possible for a single steel shape (beam, angle, tee, pipe,
channel, etc.) to be considered a structure, if it is painted in a
2.1.2 Spot Measurement: The average of at least three shop.
gage readings made within a 4 cm (1.5 inch) diameter circle.
2.2 DESCRIPTION OF GAGES
2.1.3 Calibration: The controlled and documented process
of measuring traceable calibration standards and verifying 2.2.1 Gage Types: The gage type is determined by the
that the results are within the stated accuracy of the gage. specific magnetic properties employed in measuring the thick-
Calibrations are typically performed by the gage manufacturer ness and is not determined by the mode of data readout, i.e.
or by a qualified laboratory in a controlled environment using digital or analog. This standard does not cover gages that
a documented process. The standards used in the calibra- measure the effect of eddy currents produced in the substrate
tion are such that the combined uncertainties of the resultant (see Note 7.2).
measurement are less than the stated accuracy of the gage.
2.2.2 Type 1 – Pull-Off Gages: In pull-off gages, a per-
2.1.4 Verification: An accuracy check performed by the manent magnet is brought into direct contact with the coated
user using known reference standards. surface. The force necessary to pull the magnet from the surface
is measured and interpreted as the coating thickness value on
2.1.5 Adjustment: The act of aligning the gage’s thickness a scale or display on the gage. Less force is required to remove
readings to match those of a known sample in order to improve the magnet from a thick coating. The scale is nonlinear.
the accuracy of the gage on a specific surface or in a specific
portion of its measurement range. Most Type 2 gages can be

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2.2.3 Type 2 – Electronic Gages: An electronic gage uses within the 4 cm (1.5 inch) diameter circle defining the spot.
electronic circuitry to convert a reference signal into coating Discard any unusually high or low gage reading that is not
thickness. repeated consistently. Take the average of the acceptable
gage readings as the spot measurement.
2.3 USE OF PAINT APPLICATION STANDARD NO. 2:
This document contains the following: 3.1.3 CALIBRATION: Gages must be calibrated by the
• Calibration, verification, adjustment, and measure- manufacturer or a qualified lab. A Certificate of Calibration or
ment procedures (Section 3); other documentation showing traceability to a national standard
• Required number of measurements for conformance is required. There is no standard time interval for re-calibration,
to a thickness specification (Section 4); nor is one absolutely required. Calibration intervals are usually
• Notes on gage principles and various factors affecting established based upon experience and the work environment.
thickness measurement (Notes 7.2 to 7.18); A one-year calibration interval is a typical starting point sug-
• A numerical example of thickness measurement over gested by gage manufacturers.
an extended area (Appendix 1);
• A numerical example of the calibration adjustment of 3.2 VERIFICATION OF ACCURACY
Type 2 gages using plastic shims (Appendix 2);
• An example protocol for measuring DFT on beams 3.2.1 Measure the thickness of a series of reference stan-
or girders (Appendix 3); dards covering the expected range of coating thickness (see
• An example protocol for measuring DFT for a laydown Note 7.15). To guard against measuring with an inaccurate
painted in a shop (Appendix 4); gage, the gage shall be checked at least at the beginning and
• An example protocol for measuring DFT on test panels the end of each work shift with one or more of the reference
(Appendix 5); standards. If the gage is dropped or suspected of giving er-
• An example protocol for measuring DFT of thin coat- roneous readings during the work shift, its accuracy shall be
ings on blast cleaned test panels (Appendix 6). rechecked.

3. Calibration, Verification, Adjustment, and 3.2.2 Record the serial number of the gage, the reference
Measurement Procedures standard used, the stated thickness of the reference standard
as well as the measured thickness value obtained, and the
3.1 GENERAL method used to verify gage accuracy. If the same gage, refer-
ence standard, and method of verification are used throughout
3.1.1 ACCESS TO BARE SUBSTRATE: All gages are a job, they need to be recorded only once. The stated value of
affected to some degree by substrate conditions such as the standard and the measured value must be recorded each
roughness, shape, thickness, and composition (see Notes time calibration is verified.
7.3 to 7.8). To correct for this effect, access to the uncoated
substrate is recommended. Another option is to use separate 3.2.3 If readings do not agree with the reference standard,
uncoated reference panels with similar roughness, shape, all measurements made since the last accuracy check are
thickness, and composition (see Notes 7.3 to 7.8). These would suspect. In the event of physical damage, wear, or high usage,
be used as the bare substrate in the procedures of Sections or after an established calibration interval, the gage shall be
3.2, 3.3 and 3.4. Reference panels shall be of sufficient size rechecked for accuracy of measurement. If the gage is not
to preclude edge effects (see Note 7.9). Other conditions that measuring accurately, it shall not be used until it is repaired
could affect measurements are described in Notes 7.10 to and/or recalibrated (usually by the manufacturer).
7.14. Measurements on the bare substrate are taken before
the coating is applied or by masking off small representative 3.2.4 Shims of plastic or of non-magnetic metals which
areas during painting. If the coating has already been applied are acceptable for verifying the accuracy of Type 2 (electronic)
to the entire surface, it is customary to remove small areas of gages are not used for verifying the accuracy of the Type 1
coating for measurement and later patch them. Do not allow gages (see Note 7.2.1).
the removal process to alter the condition of the substrate. If
chemical paint strippers are used, the existing profile will be 3.3 ADJUSTMENT AND MEASUREMENT - TYPE 1,
retained (see Section A2.3). PULL-OFF GAGES

3.1.2 SPOT MEASUREMENT: Repeated gage readings, 3.3.1 Type 1 gages have nonlinear scales and any adjusting
even at points close together, often differ due to small surface feature is linear in nature. Any adjustment of these gages will
irregularities of the coating and the substrate. Therefore, a limit the DFT range for which the gage will provide accurate
minimum of three (3) gage readings shall be made for each readings, and is not recommended.
spot measurement of either the substrate or the coating. For
each new gage reading, move the probe to a new location 3.3.2 Measure the bare substrate at a number of spots
to obtain a representative average value. This average value
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is the base metal reading (BMR). CAUTION: the gage is not 4.2 SPECIFYING THICKNESS: It is recommended that
to be adjusted to read zero on the bare substrate. both a maximum and a minimum DFT thickness be specified
for the coating. If a maximum thickness value is not explicitly
3.3.3 Measure the dry coating at the number of spots specified, the specified thickness shall be the minimum and
specified in Section 4. Section 4.3.2 would not apply.

3.3.4 Subtract the base metal reading from the gage 4.3 CONFORMANCE TO SPECIFIED THICKNESS
reading to obtain the thickness of the coating.
4.3.1 Minimum Thickness: The average of the spot
3.4 ADJUSTMENT AND MEASUREMENT - TYPE 2, measurements for each 10 m2 (100 ft2) area shall not be less
ELECTRONIC GAGES than the specified minimum thickness. Although no single spot
measurement in any 10 m2 (100 ft2) area shall be less than
3.4.1 Different manufacturers of Type 2 (electronic) gages 80% of the specified minimum thickness, it is possible for any
follow different methods of adjustment for measuring dry film single gage reading to under-run by a greater amount. If the
thickness over a blast-cleaned surface. Adjust the gage ac- average of the spot measurements for a given 10 m2 (100
cording to the manufacturer’s instructions (see Appendix 2). ft2) area meets or exceeds the specified minimum thickness,
but one or more spot measurements is less than 80% of the
3.4.2 Measure the dry coating at the number of spots specified minimum thickness, additional measurements will
specified in Section 4. more precisely define the non-conforming area and facilitate
repair (see Appendix 1 and Notes 7.16 and 7.17).
4. Required Number of Measurements for
Conformance to a Thickness Specification 4.3.2 Maximum Thickness: The average of the spot
measurements for each 10 m2 (100 ft2) area shall not be more
4.1 NUMBER OF MEASUREMENTS: Make five (5) sepa- than the specified maximum thickness. Although no single spot
rate spot measurements (average of the gage readings, see measurement in any 10 m2 (100 ft2) area shall be more than
Section 3.1.2) spaced arbitrarily over each 10 m2 (100 ft2) area 120% of the specified maximum thickness, it is possible for
to be measured. If the contracting parties agree, more than any single gage reading to over-run by a greater amount. If the
five (5) spot measurements may be taken in a given area (see average of the spot measurements for a given 10 m2 (100 ft2)
Section 4.1.5). The five spot measurements shall be made for area meets or falls below the specified maximum thickness,
each 10 m2 (100 ft2) of area as follows: but one or more spot measurements is more than 120% of the
specified maximum thickness, additional measurements will
4.1.1 For structures not exceeding 30 m2 (300 ft2) in area, more precisely define the non-conforming area and facilitate
each 10 m2 (100 ft2) area shall be measured. repair (see Appendix 1 and Notes 7.16 and 7.17).

4.1.2 For structures not exceeding 100 m2 (1,000 ft2) in 5. Accuracy

area, three 10 m2 (100 ft2) areas shall be arbitrarily selected
by the inspector and measured. 5.1 To qualify under this standard, a gage must have an
accuracy at least within ± 5% (see Note 7.18). For thicknesses
4.1.3 For structures exceeding 100 m2 (1,000 ft2) in area, less than 25 µm (1 mil), the gage must have an accuracy at
the first 100 m2 (1,000 ft2) shall be measured as stated in Sec- least within ± 2.5 µm (0.1 mil).
tion 4.1.2 and for each additional 100 m2 (1,000 ft2) of area or
increment thereof, one 10 m2 (100 ft2) area shall be arbitrarily 6. Disclaimer
selected by the inspector and measured.
6.1 While every precaution is taken to ensure that all
4.1.4 If the dry film thickness for any 10 m2 (100 ft2) area information furnished in SSPC standards and specifications is
(see Sections 4.1.2 and 4.1.3) is not in compliance with the as accurate, complete, and useful as possible, SSPC cannot
requirements of Sections 4.3.1 and 4.3.2, then additional assume responsibility nor incur any obligation resulting from
measurements must be made to isolate the non-conforming the use of any materials, coatings or methods specified therein,
area, and each 10 m2 (100 ft2) area painted during that work or of the specification or standard itself.
shift shall be measured.
6.2 This standard does not attempt to address problems
4.1.5 Other size areas or number of spot measurements concerning safety associated with its use. The user of this
may be specified by the owner in the job specifications as ap- standard, as well as the user of all products or practices
propriate for the size and shape of the structure to be coated described herein, is responsible for instituting appropriate
(see Appendices 3, 4, 5, and 6). health and safety practices and for ensuring compliance with
all governmental regulations.

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7. Notes 7.2.2 Type 2 (electronic) gages operate on two different

magnetic principles. Some Type 2 gages use a permanent
Notes are not requirements of this standard. magnet. When the magnet is brought near steel, the mag-
netic flux density at the tip of the magnet is increased. By
7.1 OVERCOATING: Maintenance painting often involves measuring this change in flux density, which varies inversely
application of a new coating over an existing coating system. to the distance between the magnet and the steel substrate,
It is very difficult to accurately measure the DFT of this newly the coating thickness can be determined. Hall elements and
applied coating using non-destructive methods. First, access magnet resistance elements positioned at the tip of the mag-
to the profile is not available, compromising the accuracy of the net are the most common ways that this change in magnetic
BMR or the adjustment of a Type 2 gage. Second, unevenness flux density is measured. Other Type 2 gages operate on the
in the DFT of the existing coating necessitates careful mapping principle of electromagnetic induction. A coil containing a soft
of the “before and after” DFT readings. This unevenness also iron rod is energized with an AC current thereby producing
adds to the statistical variation in trying to establish a base a changing magnetic field at the tip of the probe. As with a
DFT reading to be subtracted from the final DFT. permanent magnet, the magnetic flux density within the rod
A paint inspection gage (sometimes called a Tooke or PIG increases when the probe is brought near the steel substrate.
gage) will give accurate DFT measurements, but it cuts through This change is easy to detect by using additional coils. The
the coating, so each measurement site must be repaired. output of these coils is related to coating thickness.
Ultrasound gages may be used, but their accuracy is much
less than a Type 1 or a Type 2 gage. A practical approach to 7.3 REPEATABILITY: Magnetic gages are necessarily
monitoring DFT when overcoating is to compute DFT from wet sensitive to very small irregularities of the coating surface or
film thickness readings and the volume solids of the coating of the steel surface directly below the probe center. Repeated
being applied. gage readings on a rough surface, even at points very close
If the DFT of the existing coating is not too uneven, the together, frequently differ considerably, particularly for thin
average DFT of the existing coating can be measured to films over a rough surface with a high profile.
establish a base DFT. This base DFT is then subtracted from
the total DFT to get the thickness of the overcoat(s). 7.4 ZERO SETTING: Type 1 magnetic gages should not
be adjusted or set at the scale zero (0) with the gage applied
7.2 PRINCIPLES OF THE MAGNETIC GAGE: Each of to either a rough or a smooth uncoated steel surface. Some
these gages can sense and indicate only the distance between Type 2 gages can be adjusted to read zero (0) on an uncoated
the magnetic surface of the steel and the small rounded tip blast cleaned surface. In all cases follow the manufacturer’s
of the magnet or probe that rests on the top surface of the recommendations.
coating. For this measured distance (from the top surface of
the coating to the magnetic zero) to equal the coating thick- 7.5 ROUGHNESS OF THE STEEL SURFACE: If the steel
ness above the peaks, the gage readings must be corrected surface is smooth and even, its surface plane is the effective
for the profile of the steel surface and to a lesser extent the magnetic surface. If the steel is roughened, as by blast clean-
composition and shape of the steel. Such correction is made ing, the “apparent” or effective magnetic surface that the gage
as described in Section 3.3 for Type 1 gages and Section 3.4 senses is an imaginary plane located between the peaks and
for Type 2 gages. valleys of the surface profile. Gages read thickness above the
imaginary magnetic plane. If a Type 1 gage is used, the coating
7.2.1 Type 1 (pull-off) gages measure the force needed to thickness above the peaks is obtained by subtracting the base
pull a small permanent magnet from the surface of the coated metal reading (see Section 3.3). With a correctly calibrated
steel. The magnetic force holding the magnet to the surface and adjusted Type 2 gage, the reading obtained indicates the
varies inversely as a non-linear function of the distance between coating thickness above the peaks (see Section 3.4).
magnet and steel, i.e., the thickness of the dry coating (plus
any other films present). 7.6 DIRTY, TACKY, OR SOFT FILMS: The surface of
Normally, Type 1 gages are not adjusted or reset for each the coating and the probe of the gage must be free from dust,
new series of measurements. Shims of sheet plastic or of non- grease, and other foreign matter in order to obtain close contact
magnetic metals, which are permissible for adjusting Type 2 of the probe with the coating. The accuracy of the measurement
(electronic) gages should not be used for adjusting Type 1 will be affected if the coating is tacky or excessively soft. Tacky
gages. Such shims are usually fairly rigid and curved and do coating films may cause unwanted adhesion of the magnet of
not lie perfectly flat, even on a smooth steel test surface. Near a Type 1 gage. Unusually soft films may be dented by the pres-
the pull-off point of the measurement with any Type 1 gage, sure of the probe of a Type 1 or a Type 2 gage. Soft or tacky
the shim frequently springs back from the steel surface, raising films can sometimes be measured satisfactorily with Type 2
the magnet too soon and causing an erroneous reading. gages by putting a shim on the film, measuring total thickness
of coating plus shim, and subtracting shim thickness.

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7.6.1 Ordinary dirt and grease can be removed from a probe When these gages are set up for verification of calibration or
by wiping with a soft cloth. Magnetic particles adhering to the measurement of coating films, there should be no apparent
probe can be removed using an adhesive backed tape. Any vibration.
adhesive residue left on the probe must then be removed.
7.15 COATING THICKNESS STANDARDS: Coating
7.7 ALLOY STEEL SUBSTRATES: Differences among thickness standards consisting of coated steel plates with as-
most mild low-carbon steels and high strength low alloy (HSLA) signed thickness values traceable to national standards are
steels will not significantly affect magnetic gage readings. For available from several sources, including most manufacturers
higher alloy steels, the gage response should be checked. of coating thickness gages. Shims of known thicknesses are
Regardless of the alloy type, the gage should be adjusted to also available from most of these same sources.
the same steel over which the coating has been applied.
7.16 VARIATION IN THICKNESS – 80% of MINIMUM/
7.8 CURVATURE OF STEEL SURFACE: Magnetic gage 120% of MAXIMUM: In any measurement there is a certain
readings may be affected by surface curvature. If the curvature level of uncertainty. Two inspectors using the same gage will
is appreciable, valid measurements may still be obtained by not necessarily record the exact same number for a given
adjusting the gage on a similarly curved surface. spot measurement using the same 4 cm (1.5 inch) diameter
circle. To allow for this natural fluctuation, an individual spot
7.9 PROXIMITY TO EDGES: Magnetic gages are sensi- measurement is permitted to be below the specified minimum
tive to geometrical discontinuities of the steel, such as holes, thickness as long as other spots in the 10 m2 (100 ft2) area are
corners or edges. The sensitivity to edge effects and discon- high enough to make the average thickness meet or exceed
tinuities varies from gage to gage. Measurements closer than the specified minimum thickness. Similar reasoning applies to
2.5 cm (1 inch) from the discontinuity may not be valid unless maximum thickness. The 80% of specified minimum and 120%
the gage is adjusted specifically for that location. of specified maximum allow for the accuracy of the gage and
reference standards and for variations in the substrate.
7.10 PROXIMITY TO OTHER MASS OF STEEL: The
older two-pole gages with permanent magnets are sensitive 7.17 CORRECTING LOW OR HIGH THICKNESS: The
to the presence of another mass of steel close to the body of contracting parties should agree upon the method of correct-
the gage. This effect may extend as much as 8 cm (3 inches) ing film thicknesses that are above the maximum or below
from an inside angle. the minimum specification. This method may be specified
in the procurement documents, may follow manufacturer’s
7.11 TILT OF PROBE: All of the magnets or probes must instructions, or may be a compromise reached after the non-
be held perpendicular to the coated surface to produce valid conforming area is discovered.
measurements.
7.18 TYPE 1 PEN GAGES: Instances may arise where a
7.12 OTHER MAGNETIC FIELDS: Strong magnetic fields, pen-type pull-off gage is the only practical method for measur-
such as those from welding equipment or nearby power lines, ing DFT. Although these gages do not normally meet the 5%
may interfere with operation of the gages. Residual magnetism accuracy requirement, they may be used if the contracting
in the steel substrate may also affect gage readings. With fixed parties agree.
probe two-pole gages in such cases, it is recommended that
the readings before and after reversing the pole positions be APPENDIX 1 - Numerical Example of Average
averaged. Other gages may require demagnetization of the Thickness Measurement
steel.
Appendix 1 does not form a mandatory part of this stan-
7.13 EXTREMES OF TEMPERATURE: Most of the dard.
magnetic gages operate satisfactorily at 4°C and 49°C (40°F The following numerical example is presented as an il-
and 120°F). Some gages function well at much higher tem- lustration of Section 4. Metric values are calculated equivalents
peratures. However, if such temperature extremes are met from U.S. Customary measurements. (Reference Journal of
in the field, the gage might well be checked with at least one Protective Coatings and Linings, Vol. 4, No 5, May 1987.)
reference standard after both the standard and the gage are Suppose this structure is 30 m2 (300 ft2) in area. Mentally
brought to the same ambient temperature. Most electronic divide the surface into three equal parts, each being about
gages compensate for temperature differences among the 10 m2 (100 ft2).
gage, the probe, and the surface. Part A - 10 m2 (100 ft2)
Part B - 10 m2 (100 ft2)
7.14 VIBRATION: The accuracy of the Type 1 (pull-off) Part C - 10 m2 (100 ft2)
gages is affected by traffic, machinery, concussions, etc.

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First, measure the coating thickness on Part A. This involves thus satisfies the specification. Next, determine if the lowest
at least 15 readings of the thickness gage (see Figure A1). spot measurement, 53 µm, is within 80% of the specified
Assume the specification calls for 64 µm (2.5 mils) minimum minimum thickness. Eighty percent of 64 µm is 51 µm (0.80 x
thickness. The coating thickness for area A is then the aver- 64 = 51). Although 53 µm is below the specified minimum, it
age of the five spot measurements made on area A, namely is still within 80% of it so the specification is satisfied. There
66 µm (2.6 mils). are individual gage readings of 38 µm (1.5 mils) at spot 5 and
Spot 1 64 µm 2.5 mils 46 µm (1.8 mils) at spot 3, both of which are clearly less than
Spot 2 76 3.0 51 µm. This is allowed because only the average of the three
Spot 3 53 2.1 readings (i.e., the spot measurement) must be greater than
Spot 4 76 3.0 or equal to 51 µm.
Spot 5 58 2.3 Since the structure used in this example is about 30 m2
Average 66 µm 2.6 mils (300 ft2), the procedure used to measure the film thickness of
part A must be applied to both part B and part C. The measured
Considering the U.S. Customary Measurements: The thickness of part B must exceed the 64 µm (2.5 mils) specified
average, 2.6 mils, exceeds the specified minimum of 2.5 mils minimum, as must the thickness of part C.
and thus satisfies the specification. Next, determine if the low- To monitor the thickness of this entire 30 m2 (300 ft2)
est spot measurement, 2.1 mils, is within 80% of the specified structure, at least 45 individual gage readings must be taken,
minimum thickness. Eighty percent of 2.5 mils is 2.0 mils (0.80 from which 15 spot measurements are calculated. The five spot
x 2.5 = 2.0). Although 2.1 mils is below the specified minimum, measurements from each 10 m2 (100 ft2) part of the structure
it is still within 80 percent of it, so the specification is satisfied. are used to calculate the thickness of that part.
There are individual gage readings of 1.5 mils at spot 5 and
1.8 mils at spot 3, both of which are clearly less than 2.0 mils. APPENDIX 2 - Examples of the Adjustment of
This is allowed because only the average of the three readings
Type 2 Gages Using Shims
(i.e. the spot measurement) must be greater than or equal to
2.0 mils.
Appendix 2 does not form a mandatory part of this
standard.
Considering Equivalent Metric Measurements: The aver-
This example describes a method of adjustment to
age, 66 µm, exceeds the specified minimum of 64 µm and
improve the effectiveness of a Type 2 (electronic) gage on a
FIGURE A1
PART "A" OF STRUCTURE
(APPROXIMATELY 10 M2 [100 FT2])

Part "B"

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 SSPC-PA 2
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blast cleaned or otherwise roughened surface. Blast cleaning A2.2 TWO POINT CALIBRATION ADJUSTMENT: This
is used throughout this example, but these methods are ap- example uses two shim values, one above and one below the
plicable to other types of surface preparation. A less uniform expected film thickness to be measured. It should be noted that
surface, such as partially rusted hand tool cleaned steel, may not all film thickness gages can be adjusted in this manner.
require more gage readings to achieve a satisfactory level of Assuming that the coating thickness to be measured is
statistical significance. Since gage operation differs among 100 µm (4.0 mil), then shims of 250 µm (10.0 mil) and 50 µm
manufacturers, follow the manufacturer’s instructions for (2.0 mil) are appropriate for setting the upper and lower values
adjustment of a particular gage. on the scale of the gage.
A Type 2 gage needs to be adjusted to account for the As protective coatings are normally applied to blast cleaned
profile of the substrate in order to read the coating thickness metal surfaces, a statistical approach is required to obtain a
directly. typical value for the adjustment. Ten readings on a shim are
A portion of the substrate, after blast cleaning but prior sufficient to establish a reliable average value for that shim on
to coating, can be used to adjust the gage. Alternatively, an the roughened surface. Following the manufacturer’s instruc-
uncoated test panel, blasted at the time the structure was blast tions, the gage is adjusted so that the actual shim thickness
cleaned and having a profile representative of the structure is then used to set the gage.
can be used to adjust the gage provided the test panel is of This procedure should be repeated for both the upper and
material with similar magnetic properties and geometry as the lower shim values.
substrate to be measured. If this is not available then a cor- The average of 10 readings on an intermediate shim,
rection value can be applied to a smooth surface adjustment approximately 100 µm (4.0 mil) thick in the case described
as described below. above, will confirm that the gage has been adjusted correctly.
Three adjustment techniques can be used depending It is acceptable for the average reading to be within ± 4% of
on the capability and features of the gage to be used for the the shim thickness.
inspection. Note that due to the statistical variation produced This method ensures that the gage reads the thickness
by a roughened surface, individual readings taken using these of the coating over the peaks of the profile.
three methods may not perfectly agree.
The first two examples describe adjustment and verification A2.3 SMOOTH SURFACE CALIBRATION ADJUST-
to one or more shims. When shims are used, resultant gage MENT: If access to the bare blast cleaned substrate is not avail-
measurements are less accurate and must be recalculated. able because the coating already covers it, a smooth surface
For example, the accuracy of a properly calibrated gage is can be used to adjust the gage. Adjust the gage on a smooth
probably ± 2%. The thickness of a shim might be accurate to surface according to the manufacturer’s instructions.
within ± 3%. The combined tolerance of the gage and the shim Readings taken on the blast-cleaned substrate will be
will be ± 4% as given by the sum of squares formula: higher than the true value by an amount dependant on the
22 + 32 = 3.6055 ≈ 4 surface profile and the gage probe design. For most applications
a correction value of 25 µm (1.0 mil) is generally applicable.
For the gage to be in agreement with the shim, the aver- Note that this value is not related to the actual surface profile
age thickness measured by the gage must be within ±4% of measurement. This correction value must be subtracted from
the shim’s thickness. If the average thickness measured on a each gage reading to correct for the effect of the profile. The
250 µm (10 mil) shim is between 240 µm (9.6 mils) and 260 resulting corrected reading represents the thickness of the
µm (10.4 mils), the gage is properly adjusted. The minimum coating over the peaks.
240 is 250 minus 4% of 250 (9.6 is 10 minus 4% of 10); the For fine profiles the correction value may be as low as 10
maximum of 260 is 250 plus 4% of 250 (10.4 is 10 plus 4% of µm (0.4 mil) but for coarse profiles it could be as high as 40
10). [4% of 250 is 10; 4% of 10 is 0.4.] µm (1.6 mil). Table A2 gives approximate correction values to
be used when a blast cleaned surface is not available to adjust
A2.1 SINGLE POINT CALIBRATION ADJUSTMENT: This the gage.
example uses a single shim value at or close to the thickness to The use of coated standards to adjust gages means that
be measured. The thickness range over which this adjustment a correction value must be applied to readings as the coated
achieves the required accuracy will vary with gage design. standards make use of smooth substrate surfaces.
Assuming that the coating thickness to be measured is
100 µm (4.0 mil), then a shim of approximately 100 µm (4.0 APPENDIX 3 - Methods for Measuring Dry Film
mil) should be used to adjust the gage. The shim is placed on
Thickness on Steel Beams (Girders)
an area of the substrate that has been blast cleaned to the
required standards, or on a blasted test coupon with a similar
Appendix 3 is not a mandatory part of this standard, but it
surface profile.
provides two sample protocols for measuring DFT on beams
The average of 10 readings on the shim is sufficient to
and girders.
allow for the statistical variation in the blast profile.

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May 1, 2004

A3.1 A problem for the painter in coating steel beams or A3.2 FULL DFT DETERMINATION OF A BEAM: Divide the
girders is providing the same uniform thickness over high and beam or girder into five equal sections along its length. Identify
low vertical surfaces as over horizontal surfaces. On a beam, the 12 surfaces of the beam as shown in Figure A3 for each
there are proportionately more edges that tend to have low dry section. For tall beams where the height of the beam is 91 cm
film thickness (DFT) and inside corners that tend to have high (36 inches) or more, divide the web in half along the length of
DFT compared to the center of the flat surfaces. Each painter the beam. For the full DFT determination, each half of the web
usually develops a pattern of work for a specific task. Hence, is considered a separate surface. Take one spot measurement
the DFT on the underside of the top flange, for example, may (as defined in Section 3.1.2) on surface 1 in each of the five
be consistently on the high side or the low side of the target sections. The location of the surface 1 measurement within
DFT. This type of error is easy to detect and correct. Random a section is arbitrarily chosen by the inspector in each of the
errors pose a more difficult problem. Gross errors where the five sections. The average of these five spot measurements
paint is obviously too thin or too thick must be corrected and is the DFT of surface 1. Repeat for the other 11 surfaces (7
are beyond the scope of this standard. surfaces if the toe is not measured; 14 surfaces for tall beams).
The number of spot measurements in these protocols The data can be reported in a format shown in Table A3.1.
may far exceed the “5 spot measurement per 10 m2 (100 ft2)”
required in the standard. The full DFT determination, described A3.3 No single spot measurement can be less than 80%
in Section A3.2, provides a very thorough inspection of the of the specified minimum DFT. No single spot measurement
beam. The sample DFT determination, described in Section can be more than 120% of the specified maximum DFT. The
A3.4, allows for fewer spot measurements. The user does average value for each surface must conform to the specified
not have to require a full DFT determination for every beam DFT. (There will be only eight average values if the DFT of the
in the structure. For example, the requirement may be for a toe is not measured; there may be as many as 14 average
full DFT determination on one beam out of ten, or a sample values for tall beams.)
DFT determination on one beam out of five, or a combination
of full and sample DFT determinations. A3.4 SAMPLE DFT DETERMINATION OF A BEAM:
A beam has twelve different surfaces as shown in Figure In lieu of a full DFT determination of each beam, the job
A3. Any one of these surfaces may have a DFT outside the specification may require only a sample DFT determination
specified range, and hence, shall be measured. If the thick- for selected beams less than 18 m (60 ft) long. For a sample
ness of the flange is less than 25 mm (1 inch), the contracting DFT determination, the web of tall beams is not split.
parties may choose not to measure the DFT on the toe,2 i.e.,
surfaces 2, 6, 8, and 12 of Figure A3. As an informal initial A3.4.1 Beams less than 6 m (20 ft): For beams less
survey, the inspector may want to check for uniformity of DFT than 6 m (20 ft), take two spot measurements, randomly
across each surface. Is the DFT of the flange near the fillet the distributed, on each of the 12 surfaces (8 surfaces if the toe
same as near the toe? Is the DFT uniform across the web? The is not measured) of the beam as defined in Figure A3. Each
inspector must be sure to use a gage that is not susceptible spot measurement must conform to the specified DFT.
to edge effects. Follow the gage manufacturer’s instructions
when measuring the edges. A3.4.2 Beams between 6 m (20 ft) and 18 m (60 ft):
For beams between 6 m (20 ft) and 18 m (60 ft), take three
spot measurements, randomly distributed, on each of the 12
surfaces (8 surfaces if the toe is not measured) of the beam as
TABLE A2 defined in Figure A3. Each spot measurement must conform
TYPICAL GAGE CORRECTION VALUES USING to the specified DFT.
ISO 8503 PROFILE GRADES
(SOURCE: prEN ISO 19840)1 A3.5 NON-CONFORMANCE: If any spot measurement
falls outside the specified range, additional measurements
ISO 8503 Correction Correction
may be made to define the non-conforming area.
Profile Grade Value (µm) Value (mil)
Fine 10 0.4 A3.6 RESTRICTED ACCESS: If the beam is situated
Medium 25 1.0
such that one or more of the surfaces are not accessible, take
Coarse 40 1.6
measurements on each accessible surface in accordance with
Section A3.2 or Section A3.4, as specified.

1
International Organization for Standardization (ISO), Case Postale 56, Geneva CH-1211, Switzerland. ISO standards may be obtained
through the American National Standards Institute (ANSI), 1819 L Street NW, Suite 600 Washington DC 20036. Standards may also be
downloaded from http://www.ansi.org. The standard from which this data originates is under development and has not formally been ad-
opted as of June 1, 2004.
2
On rolled beams, measurement of surfaces 2, 6, 8, and 12 may not be practical.

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May 1, 2004

FIGURE A.3
THE SURFACES OF A STEEL BEAM

TABLE A3
DATASHEET FOR RECORDING SPOT MEASUREMENTS AND AVERAGE DFT VALUES
FOR THE 12 SURFACES OF A BEAM OR GIRDER

Surface* Section 1 Section 2 Section 3 Section 4 Section 5 Average

1
2
3
4t
4b
5
6
7
8
9
10t
10b
11
12

* t = top half of web (for tall beams)

b = bottom half of web (for tall beams)

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May 1, 2004

A3.7 ATTACHMENTS: Stiffeners and other attachments A4.4 SAMPLE DFT DETERMINATION: In lieu of a full
to a beam shall be arbitrarily measured at a frequency speci- DFT determination of each painted piece as described in Sec-
fied in the job specification. tion A4.2, the job specification may require only a sample DFT
determination for selected pieces.
APPENDIX 4 - Methods for Measuring Dry Film
Thickness for a Laydown of Beams, Structural A4.4.1 Beams less than 6 m (20 ft): Follow the procedure
Steel, and Miscellaneous Parts AfterShop Coating described in Section A3.4.1.

A4.4.2 Beams between 6 m (20 ft) and 18 m (60 ft): Follow

Appendix 4 is not a mandatory part of this standard, but
the procedure described in Section A3.4.2.
it provides two sample protocols for measuring DFT for a
laydown.
A4.4.3 Miscellaneous parts: For a miscellaneous part,
take three spot measurements, randomly distributed on the
A4.1 GENERAL: A “laydown” is a group of steel members
part. Each spot measurement must conform to the specified
laid down to be painted in one shift by one painter. For inspec-
DFT.
tion of a laydown, first make a visual survey to detect areas
with obvious defects, such as poor coverage, and correct as
A4.5 NON-CONFORMANCE: If any spot measurement
necessary. As an informal initial survey, the inspector may
falls outside the specified range, additional measurements
want to check for uniformity of DFT across each surface.
may be made to define the non-conforming area.
A4.2 FULL DFT DETERMINATION
A4.6: RESTRICTED ACCESS: If a beam or miscellaneous
part is situated such that one or more of the surfaces are not
A4.2.1 Beam (Girder): Follow the procedure described
accessible, take measurements on each accessible surface in
in Section A3.2.
accordance with Section A4.2 or Section A4.4, as specified.
A4.2.2 Miscellaneous Part: Take one spot measurement
A4.7 NUMBER OF BEAMS OR PARTS TO MEASURE: In
(as defined in Section 4.1.2) on each surface of the part. If
a laydown, the number of beams or parts to receive a full DFT
the part has fewer than five surfaces, take multiple spot mea-
determination and the number to have a sample DFT determination
surements on the larger surfaces to bring the total to five. If
can be specified. For example, do a full DFT determination on a
the total area of the part is over 10 m2 (100 ft2), take 5 spot
piece painted near the beginning of the shift, near the middle of
measurements randomly distributed over the part for each 10 m2
the shift, and near the end of the shift in accordance with Section
(100 ft2) or fraction thereof.
A4.2; and perform a sample DFT determination on every third piece
in accordance with Section A4.4.
A4.3 No single spot measurement can be less than 80%
of the specified minimum DFT. No single spot measurement
A4.8 ATTACHMENTS: Stiffeners and other attachments
can be more than 120% of the specified maximum DFT. The
to a beam shall be arbitrarily measured at a frequency speci-
average value of the spot measurements on each surface must
fied in the job specification.
conform to the specified DFT. If there is only a single spot mea-
surement on a surface, it must conform to the specified DFT.

TABLE A3.1
NUMBER OF SPOT MEASUREMENTS NEEDED ON EACH SURFACE OF A BEAM
FOR A FULL OR A SAMPLE DFT DETERMINATION

NUMBER OF SPOT MEASUREMENTS PER SURFACE

LENGTH OF BEAM FULL DFT DETERMINATION1 SAMPLE DFT DETERMINATION
less than 6 m (20 ft) 5 2
from 6 to 18 m (20 to 60 ft) 5 3
over 18 m (60 ft) 5 NA
1
For tall beams (91 cm [36 inches]) or more, the top half and bottom half of the web are treated as separate
surfaces in a full DFT determination.

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APPENDIX 5 - Method for Measuring Dry Film APPENDIX 6 - Method for Measuring Dry Film
Thickness on Coated Steel Test Panels Thickness of Thin Coatings on Coated Steel Test
Panels that Had Been Abrasive Blast Cleaned
Appendix 5 is not a mandatory part of this standard, but
it provides a sample protocol for measuring DFT on coated Appendix 6 is not a mandatory part of this standard, but
steel test panels. it provides a sample protocol for measuring DFT of thin coat-
ings on coated steel test panels that had been abrasive blast
A5.1 Panel Size: The test panel shall have a minimum cleaned.
area of 116 cm2 (18 in2) and a maximum area of 930 cm2 (144
in2); e.g., minimum 7.5 x 15 cm (3 x 6 inch) and maximum 30 A6.1 A coating is defined as thin if the dry film thickness
x 30 cm (12 x 12 inch). (DFT) is on the order of 25 micrometers (1 mil) or less. Because
the DFT is the same order as the statistical fluctuations of a
A5.2 Procedure: Use a Type 2 electronic gage. Take DFT gage on bare blast cleaned steel, many gage readings
two gage readings from the top third, the middle third, and the must be taken to get a meaningful average.
bottom third of the test panel. Readings shall be taken at least
12 mm (one-half inch) from any edge and 25 mm (one inch) A6.2 Panel Size: The test panel shall have a minimum
from any other gage reading. Discard any unusually high or area of 116 cm2 (18 in2) and a maximum area of 930 cm2 (144
low gage reading that cannot be repeated consistently. The in2); e.g., minimum 7.5 x 15 cm (3 x 6 inch) and maximum 30
DFT of the test panel is the average of the six acceptable gage x 30 cm (12 x 12 inch).
readings.
A6.3 Procedure: Use a properly adjusted Type 2 electronic
A5.3 Minimum Thickness: The average of the acceptable gage. Take ten gage readings randomly distributed in the top
gage readings shall be no less than the specified minimum third of the panel. Compute the mean (average) and standard
thickness. No single gage reading shall be less than 80% of deviation of these ten readings. Similarly, take ten readings
the specified minimum. from the middle third and ten readings from the bottom third of
the test panel and compute their means and standard devia-
A5.4 Maximum Thickness: The average of the acceptable tions. Readings shall be taken at least 12 mm (one-half inch)
gage readings shall be no more than the specified maximum from any edge and 25 mm (one inch) from any other gage
thickness. No single gage reading shall be more than 120% reading. Discard any unusually high or low gage reading, i.e.,
of the specified maximum. a reading that is more than three standard deviations from the
mean. The DFT of the test panel is the average of the three
A5.5 Rejection: If a gage reading is less than 80% of means.
the specified minimum DFT or exceeds 120% of the speci-
fied maximum DFT, additional measurements may be made A6.4 Minimum Thickness: The average of the means
to reevaluate the DFT on the area of the test panel near the shall be no less than the specified minimum thickness. No single
low or high gage reading. If the additional measurements in- mean shall be less than 80% of the specified minimum.
dicate the DFT in the disputed area of the panel to be below
the minimum or above the maximum allowable DFT, the panel A6.5 Maximum Thickness: The average of the means
shall be rejected. shall be no more than the specified maximum thickness.
No single mean shall be more than 120% of the specified
maximum.

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