Coatings Industry

Dry Film Thickness (DFT)

Measurement Standards
SSPC Paint Application
Specification No. 2 (PA-2)
IMO PSPC
ISO 19840, 2808, 2178
ASTM D 7091

Key Terms from ASTM D 7091

Calibrationthe high-level, controlled and documented process of
obtaining measurements on traceable calibration standards over the full
operating range of the gage, then making the necessary gage adjustments
(as required) to correct any out-of-tolerance conditions.
Verification of Accuracyobtaining measurements on a reference
standard prior to gage use for the purpose of determining the ability of the
coating thickness gage to produce reliable values, compared to the
combined gage manufacturers stated accuracy and the stated accuracy of
the reference standard.
Adjustmentthe physical act of aligning a gages thickness readings to
match those of a known thickness sample (removal of bias), in order to
improve the accuracy of the gage on a specific surface or within a specific
portion of its measurement range.
Compensation Valuegenerating a verifiable value, which is deducted
from a measured value read from the gage, to correct for any surface
conditions (that is, base metal effect).

Key Terms from SSPC-PA2

Calibration: The controlled and documented process of measuring
traceable calibration standards and verifying that the results are
within the stated accuracy of the gage. Calibrations are typically
performed by the gage manufacturer or by a qualified laboratory in
a controlled environment using a documented process. The
standards used in the calibration are such that the combined
uncertainties of the resultant measurement are less than the stated
accuracy of the gage.
Verification: An accuracy check performed by the user using known
reference standards.
Adjustment: The act of aligning the gages thickness readings to
match those of a known sample in order to improve the accuracy of
the gage on a specific surface or in a specific portion of its
measurement range. Most Type 2 gages can be adjusted on a
coated part or on a shim, where the thickness of the coating or of
the shim is known.

Key Terms from ISO 19840

Individual reading - figure displayed by the film thickness instrument
Correction value - allowance for the influence of the abrasive blastcleaned or otherwise roughened surface on the reading of the film
thickness instrument
Individual dry film thickness - individual reading minus a correction value
Mean dry film thickness - arithmetic mean of all the individual dry film
thicknesses in the inspection area
Nominal dry film thickness (NDFT) - dry film thickness specified for each
coat or for the whole paint system
Adjustment - process of aligning the readings of a dry film thickness gauge
to known thickness values
Calibration is the process of setting and recording the thickness values
displayed on a dry film thickness gauge to known values of thickness
across the range of the gauge

SSPC PA-2 Verification & Adjustment

Coating Thickness Standard (Test Block): A smooth
ferromagnetic substrate with a nonmagnetic coating of
known thickness that is traceable to national standards.
Shim (Foil): A thin strip of non-magnetic plastic, metal, or
other material of known uniform thickness used to verify
the accuracy of coating dry film thickness gages.
Dry Film Thickness Reference Standard: A sample of
known thickness used to verify the accuracy of the gage,
such as coated thickness standards or shims. In some
instances with the owner's permission, a sample part (a
particular piece of coated steel) is used as a thickness
standard for a particular job.

SSPC PA-2 Verification of Accuracy

3.2.1 Measure the thickness of a series of reference standards covering the expected range of
coating thickness (seeNote 7.15). To guard against measuring with an inaccurate gage, the gage
shall be checked at least at the beginning and the end of each work shift with one or more of the
reference standards. If the gage is dropped or suspected of giving erroneous readings during the
work shift, its accuracy shall be rechecked.
3.2.2 Record the serial number of the gage, the reference standard used, the stated thickness of
the reference standard as well as the measured thickness value obtained, and the method used to
verify gage accuracy. If the same gage, reference standard, and method of verification are used
throughout a job, they need to be recorded only once. The stated value of the standard and the
measured value must be recorded each time calibration is verified.
3.2.3 If readings do not agree with the reference standard, all measurements made since the last
accuracy check are suspect. In the event of physical damage, wear, or high usage, or after an
established calibration interval, the gage shall be rechecked for accuracy of measurement. If the
gage is not measuring accurately, it shall not be used until it is repaired and/or recalibrated (usually
by the manufacturer).
3.2.4 Shims of plastic or of non-magnetic metals which are acceptable for verifying the accuracy of
Type 2 (electronic) gages are not used for verifying the accuracy of the Type 1 gages (see Note
7.2.1).

SSPC PA-2 Key Measurement Elements

NUMBER OF MEASUREMENTS:
Make five (5) separate spot measurements (average of the gage readings, see
Section 3.1.2) spaced arbitrarily over each 10 m2 (100 ft2) area to be measured.
If the contracting parties agree, more than five (5) spot measurements may be taken
in a given area.

SPOT MEASUREMENT: Repeated gage readings, even at points close

together, often differ due to small surface irregularities of the coating
and the substrate.
Therefore, a minimum of three (3) gage readings shall be made for each spot
measurement of either the substrate or the coating.
For each new gage reading, move the probe to a new location within the 4 cm (1.5
inch) diameter circle defining the spot.
Discard any unusually high or low gage reading that is not repeated consistently.
Take the average of the acceptable gage readings as the spot measurement.

PA-2 Minimum Dry Film Thickness

The average of the spot measurements for each field joint lining
area shall not be less than the specified minimum thickness
No single spot measurement in any field joint lining shall be less
than 80% of the specified minimum thickness Consider this
statement in the context of how we have been calculating the BMR
and Gauge adjustment. Does it require that we factor the BMR and
Gauge Adjustments in to each Spot Measurement not just the final
average?
If the average of the spot measurements for the field joint lining
meets or exceeds the specified minimum thickness, but one or
more spot measurements is less than 80% of the specified minimum
thickness, additional measurements will more precisely define the
non-conforming area and facilitate repair

SSPC PA-2 Maximum Dry Film Thickness

The average of the spot measurements for each field joint
lining area shall not be more than the specified maximum
thickness.
No single spot measurement in any field joint lining area shall
be more than 120% of the specified maximum thickness.
If the average of the spot measurements for a given field joint
lining area meets or falls below the specified maximum
thickness, but one or more spot measurements is more than
120% of the specified maximum thickness, additional
measurements will more precisely define the non-conforming
area and facilitate repair

PA-2 Variation in Thickness Commentary

In any measurement there is a certain level of uncertainty. Two
inspectors using the same gage will not necessarily record the exact
same number for a given spot measurement using the same 4 cm
(1.5 inch) diameter circle.
To allow for this natural fluctuation, an individual spot
measurement is permitted to be below the specified minimum
thickness as long as other spots in the 10 m2 (100 ft2) area are high
enough to make the average thickness meet or exceed the specified
minimum thickness.
Similar reasoning applies to maximum thickness.
The 80% of specified minimum and 120% of specified maximum
allow for the accuracy of the gage and reference standards and for
variations in the substrate.

IMO PSPC DFT Requirements

NDFT is the nominal dry film thickness. A 90/10
practice means that 90% of all thickness
measurements shall be greater than, or equal to, NDFT
and none of the remaining 10% measurements shall be
below 0.9 x NDFT.
Maximum total dry film thickness according to
manufacturers detailed specifications.
Care shall be taken to avoid increasing the thickness in
an exaggerated way. Wet film thickness shall be
regularly checked during application.
Type of gauge and calibration in accordance with SSPCPA2:2004. Paint Application Specification No.2.

IMO PSPC DFT Requirements

The following verification check points of DFT are to be taken:
one gauge reading per 5 m2 of flat surface areas;
one gauge reading at 2 to 3 m intervals and as close as possible to tank
boundaries, but not further than 15 mm from edges of tank boundaries;
longitudinal and transverse stiffener members:
One set of gauge readings as shown below, taken at 2 to 3 m run and not less than
two sets between primary support members;

Note: Arrows of diagram

indicate critical areas and
should be understood to
mean indication for both sides.

IMO PSPC DFT Requirements

3 gauge readings for each set of primary support members and 2
gauge readings for each set of other members as indicated by the
arrows in the diagram;
For primary support members (girders and transverses) one set of
gauge readings for 2 to 3 m run as shown in figure 3 above but not
less than three sets;
Around openings one gauge reading from each side of the opening;
Five gauge readings per square metre (m2) but not less than three
gauge readings taken at complex areas (i.e., large brackets of
primary support members); and
Additional spot checks are to be taken to verify coating thickness
for any area considered necessary by the coating inspector.

ISO 19840
Paints and varnishes Corrosion
protection of steel structures
by protective paint systems
Measurement of, and acceptance
criteria for, the thickness of dry films on
rough surfaces

ISO 19840
For the purposes of this standard, any specified thickness is taken
to be nominaland the dry film thickness is the typical thickness
above the peaks of the surface profile.
The procedure described in this International Standard is based on
the use of instruments of the permanent magnet and inductive
magnet type. Instruments are adjusted to zero and a known
thickness on a smooth surface.
Measurements taken on a coating on a roughened steel substrate
will therefore be higher than the actual value above the peaks of
the profile. The thickness of the dry film above the peaks of the
profile is defined as the instrument reading minus an appropriate
correction value.
The dry film thickness is obtained by using the appropriate
correction value applied to readings based on adjustment on a
smooth, flat, steel surface.

ISO 19840
Where individual readings, based on adjustment on a smooth, flat
steel surface without the use of correction values, are specified or
agreed, it is important to recognize that this method does not
conform with this International Standard.
This standard is applicable if the nominal dry film thickness is 40 m
or greater.

ISO 19840 Terms & Definitions

Dry film thickness (DFT) - thickness of a coating remaining over the peaks of a
rough surface when the coating has hardened
Individual reading - figure displayed by the film thickness instrument
Correction value - allowance for the influence of the abrasive blast-cleaned or
otherwise roughened surface on the reading of the film thickness instrument
Individual dry film thickness - individual reading minus a correction value
Mean dry film thickness - arithmetic mean of all the individual dry film thicknesses
in the inspection area
Nominal dry film thickness (NDFT) - dry film thickness specified for each coat or
for the whole paint system
Inspection area - designated area for which a sampling plan is established and
which can be the whole structure or sections of the whole structure
Sampling plan - plan which defines the number of measurements to be taken on
an inspection area
Adjustment - process of aligning the readings of a dry film thickness gauge to
known thickness values

ISO 19840
All instruments for measuring dry film
thicknesses will give variable values within very
small areas on roughened surfaces due to the
influence of the surface roughness and the
variations inherent in the method(s) used to
apply the paint.
The type of measuring equipment and material
shall be specified or agreed between the
interested parties before the measurements
commence.

ISO 19840
Foils/Shims - Foils/shims with verified thickness with assigned
values traceable to recognized standards and with thicknesses
above the dry film thickness to be measured.
NOTE 1 The use of other foils/shims is permitted provided they are
verified by a traceable method.
NOTE 2 Care should be taken to ensure that foils/shims are in good
condition before they are used. Foils/shims will wear more quickly
when used on roughened surfaces.

Uncoated test plates - An uncoated smooth, flat, visually clean steel

test plate free of mill scale and at least 3 mm thick and with
minimum dimensions of 25 mm 25 mm.
Pre-coated test plates - Certified, smooth, flat, visually clean precoated steel test plates with assigned values traceable to
recognized standards and with coating thicknesses near to the
expected dry film thickness to be measured. The dimensions shall
be at least equal to those specified above

ISO 19840 Sampling Plan

Sampling plan - The sampling plan defines the
number of measurements to be taken in an
inspection area. If the structure has not been
divided into individual inspection areas, the
whole structure is considered as the
inspection area for measuring the dry film
thickness.

ISO 19840 Sampling Plan

The minimum number of randomly taken measurements to
be taken for verifying the dry film thickness on inspection
areas is given in Table 1. The number of measurements
given is generally considered as being representative for
inspection areas for the purposes of this standard. This
number shall be increased for inspection areas having a
difficult configuration with regard to paint application or
measurement or limitations in accessibility (difficult areas).
Each difficult area, e.g. stiffeners, brackets, supports,
attached piping, shall have additional random
measurements taken appropriate to its area in accordance
with Table 1, over and above the random measurements in
the inspection area.

ISO 19840 Sampling Plan

ISO 19840
Adjustment of the instrument
Before use, it shall be ascertained that the
instrument is in good working condition and
correctly adjusted.
Verification shall then be carried out on uncoated
test plates (5.3.2) at zero and with verified
foils/shims (5.3.1) above and below the specified
dry film thickness. Pre-coated test plates (5.3.3)
may be used instead of verified foils/shims.

ISO 19840
Adjustment is carried out by the user in most
cases.
Calibration is the process of setting and
recording the thickness values displayed on a
dry film thickness gauge to known values of
thickness across the range of the gauge.
Calibration is carried out by the gauge
manufacturer using traceable thickness
standards in most cases.

ISO 19840

Measurements on the dry film shall only be taken after adjustment and checking
of the instrument has been carried out in accordance with 6.2. The measuring
instrument shall then be used in accordance with the instrument manufacturer's
instructions.
Following completion of a series of measurements, and preferably during the
measurements, the adjustment of the instrument shall be re-verified. If this is not
in accordance with 6.2, the results of the measurements shall be rejected.
When during a series of measurements an individual dry film thickness value does
not meet a criterion [see 9 b) and d)], a repeated measurement not more than 10
mm from the point of the first measurement shall be carried out. The first value
shall then be rejected and replaced by the result of the repeated measurement.
This new measurement will then be the individual dry film thickness. If this
individual dry film thickness does not meet the criterion (see Clause 9), it shall not
be replaced. For maximum numbers of repeated measurements within an
inspection area see Table 1. The number of replaced measurements shall be
indicated in the test report.

ISO 19840 Correction Value

If the surface profile is known and conforms to
ISO 8503-1, correction values given in Table 2
shall be used.

ISO 19840 Correction Value

The specification/contract might require the determination of a specific correction

value, that is a correction value determined on the abrasive blast-cleaned or
otherwise roughened substrate with the particular dry film thickness instrument
being used. In this case, the correction value shall be determined in accordance
with Annex D.
If the surface profile is not known and an uncoated sample is not available, a
correction value of 25 shall be used.
If a sample showing the surface profile is available and the profile is not in
accordance with ISO 8503-1, the correction value shall be determined in
accordance with Annex D.
If a correction value is used, it shall be subtracted from the individual reading to
give the individual dry film thickness in micrometres.
NOTE 1 The correction value is applied once on every reading no matter if the
coating consists of a single layer or multiple layers.
NOTE 2 For deviating surface profiles or in case of particular agreements between
the interested parties, a method for determining the correction value to be used is
given in Annex D.

ISO 19840 Acceptance/Rejection Criteria

For the acceptance of an inspection area the following
criteria shall be fulfilled:
a) The arithmetic mean of all the individual dry film thicknesses
shall be equal to or greater than the nominal dry film thickness
(NDFT);
b) All individual dry film thicknesses shall be equal to or above
80 % of the NDFT;
c) Individual dry film thicknesses between 80 % of the NDFT and
the NDFT are acceptable provided that the number of these
measurements is less than 20 % of the total number of
individual measurements taken;
d) All individual dry film thicknesses shall be less than or equal
to the specified maximum dry film thickness. If it is not specified
see ISO 12944-5.

ISO 19840 Annexes

Annex A (informative) Method based on adjusting the instrument to
known thicknesses on a rough surface
This annex describes a method of measuring the dry film thickness of a
coating on an abrasive blast-cleaned or otherwise mechanically roughened
substrate based on adjusting the instrument to known thicknesses on a rough
surface representative of the surface to be measured.

Annex B (informative) Multiple readings

B.1 Multiple readings on a test area A circular surface of diameter 30 mm of
the inspection area is used as the test area, and multiple readings are taken
within this test area. If the number of readings is not specified in the contract
or specification, five individual readings (3.2) are taken. The
acceptance/rejection criterion is then based on the arithmetic mean of these
multiple readings; no significance is attached to any individual reading when
this annex is used.
B.2 Number and distribution of test areas The number of test areas and their
distribution should be as given in Table 1 for inspection areas.

ISO 19840 Annexes

Annex C (informative) Areas requiring special consideration
Coating thickness gauges based on magnetic principles are affected by the
magnetic properties, the shape and the surface finish of the substrate under
test.

Annex D (normative*) Determination of a specific correction value

When a specific correction value is to be determined, proceed as follows:
Adjust the instrument in accordance with the manufacturer's instructions and
6.2. Check the adjustment for intermediate values following the
manufacturer's specification.
Use the adjusted instrument on the blast-cleaned or otherwise roughened
surface to check a measured foil/shim of approximately 125 m thickness (see
note). Using the foil/shim, take 10 measurements at different points on the
blast-cleaned or otherwise roughened surface and determine the arithmetic
mean value. From the mean value, subtract the known value of the foil
thickness. The value obtained is the correction value.
NOTE The thickness of the foil/shim should not be less than 125 m or greater
than 150 m.
*Generically, it means relating to an ideal standard or model. In practice, it has strong connotations of relating
to a typical standard or model

ISO 19840 Annexes

Annex E (informative) Example of a test
report form
A

ASTM D 7091-05
5.5 Most electronic coating thickness-measuring gages can
be verified for accuracy using either traceable reference
stan- dards or measured non-metallic shims. Gage
operation should be verified on prepared, uncoated
substrate having the same composition, shape and surface
roughness to which the coating will be applied to, for the
intended range of use. If necessary, the gage should be
adjusted as described in 7.6 or 7.7. Gages that cannot be
adjusted by the user should be returned to the
manufacturer for calibration if the readings obtained on the
reference standards or shims are outside of the combined
accuracy of the standard/shim and the manufacturers
stated gage accuracy.

ASTM D 7091-05 Considerations

5.6 Type 2 gages should not be used on soft or tacky
coatings, as the pressure on the probe can indent the
coating yielding false low measurements, or coating
materials may contaminate the probe yielding false
high measurements. A shim (of known thickness) can
be placed on top of the soft/tacky coating film and a
measurement of the coating thickness obtained by
subtracting the shim thickness from the total
measurement of the shim and the coating. Note that
some Type 2 gages can be programmed to
automatically deduct the shim thickness (known as
zero offset).

ASTM D 7091-05 Considerations

Type 2 gages may be sensitive (to some degree) to
substrate effects including, but not limited to edges,
corners and holes in the substrate, as well as substrate
thickness, curvature or conductivity, or both. In
general, the user should remain a minimum of 25 mm
(1 in.) from edges when measuring coating thickness,
unless the probe specification indicates otherwise.
The manufacturers specifications will contain a
temperature operating range. Use of the gage or the
probe outside of this range may generate false coating
thickness measurements and may damage the
instrument.

ASTM D 7091-05 Considerations

7.1 Calibration of coating thickness gages is performed by
the equipment manufacturer, an authorized agent, or by an
authorized, trained calibration laboratory in a controlled
environment using a documented process.
7.2 Type 1 (magnetic pull-off) and Type 2 (electronic)
coating thickness gages should be verified for accuracy (and
adjusted if required and when possible) prior to, during and
after each period of use. Type 1 and Type 2 gages can be
verified for accuracy using coated/plated reference
standards or shims (see Note 5 and Appendix X1). The gage
should be verified for accuracy in the intended range of
use. Also, the probe should be examined for cleanliness
before verifying the accuracy and before obtaining coating
thickness measure- ments.

ASTM D 7091-05 Considerations

7.3 Verification of Accuracy of Type 1 Gages Using Coated/ Plated
Reference StandardsType 1 coating thickness gages can be verified for
accuracy using traceable reference standards (for example, NIST4 Coating
Thickness Reference Standards) or proprietary reference standards
produced by coating thickness gage manufacturers. If the gage reading is
outside of the combined accuracy of the coating thickness standard (test
block) and the manufacturers stated gage accuracy, the instrument should
be returned to the manufacturer or authorized agency for calibration. Type
1 coating thickness gages should never be adjusted by the user.
7.3.1 For example, if the gage accuracy is +/-5 % and the standards accuracy is
+/-5 %, then the combined accuracy of the gage and the standard will be +/-7
% as given by the sum of the squares formula.
7.3.2 For the gage to be in agreement with the standard, the average
thickness measured by the gage must be within +/-7 % of the standards
thickness.

ASTM D 7091-05 Considerations

7.4 Verification of Accuracy of Type 1 Gages Using Shims
Type 1 coating thickness gages may be verified for accuracy
using shims (see Note 5 and Appendix X1).
7.6 Verification of Accuracy of Type 2 Gages Using Coated/
Plated Reference StandardsType 2 coating thickness
gages can be verified for accuracy using traceable reference
standards (for example, NIST Coating Thickness Reference
Standards)
7.7 Verification of Accuracy of Type 2 Gages Using Shims
Type 2 coating thickness gages can be verified for accuracy
using shims. The shim(s) representing the intended range of
use should be placed onto the prepared, uncoated surface,
and a measurement taken.

ASTM D 7091-05 Frequency of Measurement

The thickness of a coating or a coating system can vary
from area to area on a structure or part. Accordingly, it
is recommended that a number of measurements be
obtained and the arithmetic mean calculated to
determine the high, low and average coating thickness
in a given area.
8.2 For larger structures, five spot measurements (each
spot measurement being the average of three
individual gage measurements acquired within a 12
mm (12 in.) diameter circle) should be obtained in
every 9 m2(100 ft2) area of coated surface. The
number of areas to measure is dependent on the size
of the structure or part.

ASTM D 7091-05 Frequency of Measurement

8.2.1 For surfaces totaling up to 28 m2(300 ft2), measure
and record the thickness as described in 8.2 in each 9
m2(100 ft2) area.
8.2.2 For surfaces totaling between 28 and 93 m2(300 and
1000 ft2), measure and record the thickness as described in
8.2 in three random 9 m2 (100-ft2) areas. If thickness
measurements outside of the specified range are observed,
then more frequent measurements may be required.
8.2.3 For surfaces totaling greater than 93 m2(1000 ft2),
measure and record the thickness as described in 8.2 in
three random 9 m2(100 ft2) areas for the first 93 m2(1000
ft2) and in one additional 9 m2 (100-ft2) area for each
additional 93 m2 (1000 ft2).

ASTM D 7091-05 Appendix X1

APPENDIX (Nonmandatory Information) X1.
PRECAUTIONS REGARDING VERIFICATION OF GAGE
ACCURACY
X1.1When selecting shims to verify the accuracy of Type 1
coating thickness gages, it is necessary to be aware of additional
characteristics that can affect the measured values. Shim stock
typically has an inherent curve. This curve can act as a leaf
spring and cause a magnetic pull-off gage to be pushed off the
surface prematurely, resulting in an incorrect reading.
X1.2With some materials and thickness, it is possible that the
shim will not lie flat, which will also cause an erroneous reading.
Various techniques exist to minimize this effect, such as
mounting the shim in a holder that maintains tension on the
shim to eliminate the tendency of the shim to curve. Special
tensioned ring shims are also available.

ASTM D 7091-05 Appendix X1

X1.3 Other factors experienced with plastic shims
(applicable to both Type 1 and Type 2 coating thickness
gages), which are not usually present with coated or
plated calibration standards include (but are not
limited to):
X1.3.1 Permanent creases in the shim due to folding,
X1.3.2 Air entrapment between the shim and substrate,
X1.3.3 Distortion due to environmental conditions, such
astemperature, and
X1.3.4 Shim thickness inconsistency (due to the pressure
ofthe probe tip) that may be a permanent dimple in the
shim.

ASTM D 7091-05 Appendix X1

X1.4 Even with these factors, in many
applications, verification of gage accuracy
using shims directly on the sample to be
measured can be more appropriate than using
plated or coated standards. Some gage
manufacturers produce certified shims.