Measuring Paint Film Thickness on Grit-Blasted Steel: ISO 2808 and Its Effects

By M. Camina Formerly of the Paint Research Association Teddington, UK

Background rotective coating Coatings for steel performance generally are depends partly on applied to blastits thickness. cleaned surfaces Therefore, the abiliwith a definite proty to uniformly file. When the promeasure coating file of a blastthickness is critical cleaned surface is to quality control. magnified, as In practice, howevshown in Figure 1, er, there has been the problem of no uniform method measuring film of measuring film thickness on the thickness on blastroughened surface cleaned steel. This becomes more has been a subject obvious. Wet paint of discussion in the with ideal rheologiindustry for a numUsing a coating thickness gauge on the rough surface of a structural steel project cal properties ber of years. Now, (Photo courtesy of Elcometer Instruments Ltd) would hug the prothe latest version of file so that the coating thickness over the surface ISO 2808, Paints and VarnishesDetermination of would be reasonably constant. In reality, however, Film Thickness, includes a standard method for meathe paint tends to run off the peaks and fill the suring dry film thickness on blast-cleaned steel. This troughs as a result of the effects of viscosity and surarticle explores some of the factors driving this develface tension. opment.
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Table 1: Summary of Film Thickness Measurements Magnetic dry film thickness gauges are commonly used to measure coating thickness on blast-cleaned steel surfaces. One method of calibrating these instruments is to use thin foils or shims of known thickness. This allows the gauge to be set at two known thicknessestypically 0 and a level above the highest expected reading. However, the practice1 of calibrating a magnetic dry film thickness gauge over a rough surface using a shim requires a large number of readings to calculate the mean film thickness and results in a large standard deviation. Also, since the shim sits on the peaks of the profile, as shown in Figure 2, it may deform under the pressure of the probe, which will affect the reading. McKenzie2 has shown that an apparent increase in shim thickness is not constant but varies with the thickness of the shim used. The thicker the shim, the greater the apparent increase in shim thickness. Nugent3 wrote there has been too much discussion about the accuracy of measurement when what is needed is a uniform method of measurement. To illustrate this concern, consider the case of a specifier who says the dry film thickness should be x microns without stating the method of measurement and an applicator who achieves y microns. One of them calibrates the thickness gauge on a rough surface; the other uses a smooth panel. If y < x, an argument ensues. This is the crux of the issue. A single method of measuring dry film thickness that everyone
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Type of surface and method of measurement Smooth steel Magnetic Cp Cross section G12 grit-blasted steel Magnetic Cp Magnetic Cg Cross section Mean peak to surface Mean valley to surface G17 grit-blasted steel Magnetic Cp Magnetic Cg Cross section Mean peak to surface Mean valley to surface G24 grit-blasted steel Magnetic Cp Magnetic Cg Cross section Mean peak to surface Mean valley to surface

Profile Height (microns)

Two Coats (microns)

Four Coats (microns)

65 70 74 57 46 64

136 149

141 129 153 138 169

83 51 42 69 133 108 149 122 170

92 58 47 61 137 98 132 118 152

Source: R. Bishop, M. Camina, and M.M. McKenzie, JOCCA (6) p. 149-156, 1984.

understands and uses would avoid unnecessary disputes as a result of discrepancies between differences in calibration. Should instruments be calibrated on a smooth steel surface of the same magnetic properties as the substrate or on the rough profile of the blastcleaned substrate? The latest version of ISO 2808 calls for calibration on a smooth steel surface.

The Case for Calibration on Smooth Steel Surfaces

Among the changes in the latest version of ISO 2808 (ISO/FDIS 2808:1997) are new standard methods for measuring coating dry film thickness over a variety of surfaces, including Method 10,
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which is specific to blast-cleaned steel. Method 10 calls for calibrating the gauge on smooth steel before measuring the dry film thickness on the coated, blast-cleaned surface. The latest version of the standard presently is in the final discussion stage, which means that only changes in wording, not technical changes, can be made before final publication. It is uncertain when publication will occur. Bishop4 et al. showed that calibration over blast-cleaned steel surfaces produced lower values of film thickness than either calibrating over smooth steel or measuring the actual peak-to-surface

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Table 2: Measurements of Film Thickness over Smooth and Rough Steel Surfaces Using Silicone Rubber Surface Cp Smooth steel panel G17 grit-blasted steel G17 grit-blasted steel G17 grit-blasted steel G24 grit-blasted steel 93 145 235 280 195 Film Thickness in Microns Cg 110 190 250 165 Cross section 102 166 265 300 206 Weight 94 161 243 280 198

height of the film in a cross section of the coating. This work also showed that calibration on a smooth surface produced measurements of film thickness on a rough surface in reasonable agreement with the mean film thickness as measured on the actual paint film on cross section. Table 1, which illustrates Bishops findings, shows film thickness measurements on three degrees of grit-blasted steel panels made with a magnetic dry film thickness gauge following calibration on a smooth surface (Magnetic Cp) and calibration on a grit-blasted surface (Magnetic Cg). In addition, the cross section, mean peak-to-surface, and mean valley-to-surface thickness measurements for each of the gritblasted panels are presented for comparison. As a control, the film thickness measurements on a polished steel panel also are shown.

Confirmation of these results is shown in Table 2, which includes measurements made by PRA on a silicone rubber coating applied to both polished and grit-blasted surfaces. Due to the softness of the rubber, the measurements were made over a metal shim of known thickness, which was subtracted from the measured figure. Since the cured silicone rubber film could easily be peeled from both types of surface, measurements of cross-section thickness and weight (by calculating volume) were made for comparison. Very good agreement was obtained from the calibration over a smooth surface with the calculated thickness of the peeled film by weight, which is considered the more accurate criterion.

to be done on smooth steel of the same magnetic nature as the substrate. The reasons for this stem from work by Smith et al.5 who demonstrated the need to use steels with the same alloy factor for calibration. They defined the extent to which steel alloyed with various elements could affect the thickness measurement. An increase in concentrations of manganese, chromium, and carbon would cause an increase in the alloy factor, while nickel, being ferromagnetic, would cause a decrease. One gauge was found to read 17 microns higher on steel with a high alloy factor than a low alloy steel. Most steels used for structural purposes have low alloy factors, so it is important to use a low alloy smooth substrate when calibrating the thickness gauge.

Measuring Low Film Thickness

Measuring low film thickness by Method 10 may present a problem because, as noted, paint tends to run off the peaks and fill the troughs of the profile. The thickness gauge cannot distinguish between a paint film and the air space between the probe and the surface (Fig. 2), which can result in lower overall thickness measurements since the thickness in the troughs is not taken into account. This is particularly true for thicknesses below 60 microns, as shown in Table 3. Film thicknesses on G12 grit-blasted steel, a smooth steel plate, and a Leneta square (a small stick-on tab used to measure film thickness during spraying) were measured after calibrating the gauge on a
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Magnetic Effect of Steel Substrates

Method 10 calls for calibration
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Table 3: Effect of Low Film Thickness Coats Film Thickness in Microns G12 one two three four 17 31 62 89 Smooth 24 45 64 91 Leneta
PROBE

28 53
SHIM

59
STEEL

AIR

90
Fig. 2: Scale drawing of instrument probe and 25-micron shim over a grit-blasted surface (G24)

smooth surface. Up to 60 microns, a large difference is evident between the readings on the rough (G12) surface and the others, whereas above 60 microns, more uniform readings were obtained. However, the ISO committee deemed 60 microns to be too high. It set the minimum thickness measurable by this method at 25 microns, but said it is preferred the method be used for thicknesses greater than 50 microns for meaningful results.

no additional thickness should be added, since they have a smoother profile.

applied paint is within specification or not.

Conclusion Practical Applications of Method 10

Designers of structures need to know what level of coating protection is required to achieve the necessary corrosion resistance. Specifiers need to know how to translate that requirement into a practical specification. Paint applicators must know how much paint they need to use to achieve the required paint film thickness, and inspectors need to demonstrate that applicators have achieved the specifiers requirements. Method 10 can meet the needs of each segment of the industry in a uniform way so everyone uses the same system and gets the same measurement results. The advantage for designers and specifiers is that Method 10 can help ensure that a paint film covers the peaks of the profile and, therefore, gives the performance required. For applicators, measuring an applied film thickness according to Method 10 can help them meet the required specification. And for inspectors, using a uniform method of calibration and measurement can help prevent disagreements about whether the
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ISO 2808 Method 10 describes a simple test method for calibrating a thickness gauge on smooth steel before measuring the dry film thickness on the coated blastcleaned surface. If adopted, everyone will know how film thickness has been measured, resulting in a uniformity not currently found in the industry.

References
1. L. Igetoft, Eurocoat 9, p. 544549, 1992. 2. M.M. McKenzie, JOCCA 70 (12), p. 3543-3549, 1987. 3. J. Nugent, Industrial Corrosion 1, p. 13-14, 1989. 4. R. Bishop, M. Camina, and M.M. McKenzie, JOCCA (6) p. 149-156, 1984. 5. S.S. Smith, Metal Finishing (4), p. 17-26, 1994. This article is based on a presentation given at PCE 97, 17-20 March 1997 at The Hague, The Netherlands, and published in the conference proceedings, Painting Industrial and Marine Structures with Coatings.

Compensating for Peaks

Another problem, particularly for designers and specifiers, is that measuring film thickness by calibrating on a smooth surface will not determine the thickness on peaks of the profile, which is important for corrosion protection. To compensate for this problem, it was agreed in the ISO meetings that about half the profile height (approximately 30 microns) should be added to the specified dry film thickness measured using Method 10. However, for surfaces corresponding to grade fine of ISO 8503-1 (Preparation of Steel Substrates Before Application of Paints and Related Products Surface Roughness Characteristics of Blast-Cleaned Steel Substrates),
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