This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what

changes have been made to the previous version. Because

it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.

Designation:D7091–05 Designation: D7091 – 12

Standard Practice for

Nondestructive Measurement of Dry Film Thickness of
Nonmagnetic Coatings Applied to Ferrous Metals and
Nonmagnetic, Nonconductive Coatings Applied to Non-
Ferrous Metals1
This standard is issued under the fixed designation D7091; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.

1. Scope
1.1This practice describes the nondestructive measurement of the dry film thickness of nonmagnetic coatings applied to the
surface of ferrous metals using magnetic gages and the nondestructive measurement of the dry film thickness of electrically
nonconductive, nonmagnetic coatings applied to the surface of nonferrous metals using eddy current gages. This practice is
intended to supplement the manufacturers’ instructions for the manual operation of the gages and is not intended to replace them.
It includes definitions of key terms, reference documents, the significance and use of the practice, the advantages and limitations
of coating thickness gages, and a description of test specimens. It describes the methods and recommended frequency for verifying
the accuracy of gages and for adjusting (optimizing) the equipment, describes a frequency for measuring the thickness of the
coating(s) and lists the reporting recommendations. *
1.1 This practice describes the use of magnetic and eddy current gages for dry film thickness measurement. This practice is
intended to supplement the manufacturers’ instructions for the manual operation of the gages and is not intended to replace them.
It includes definitions of key terms, reference documents, the significance and use of the practice, the advantages and limitations
of coating thickness gages, and a description of test specimens. It describes the methods and recommended frequency for verifying
the accuracy of gages and for adjusting (optimizing) the equipment and lists the reporting recommendations.
1.2 These procedures are not applicable to coatings that will be readily deformed under the load of the measuring gages/probes,
as the gage probe must be placed directly on the coating surface to obtain a reading. Provisions for measuring on soft or tacky
coatings are described in 5.65.7.
1.3Use of film thickness measuring gages on metal-filled coatings may produce erroneous results, depending on the type and
amount of metal in the coating film. The user should consult the manufacturers instructions regarding the use of coating thickness
gages on these types of coatings.
1.4Coating thickness can be measured using a variety of gages. These gages are categorized as “magnetic pull-off” and
“electronic.” They use a sensing probe or magnet to measure the gap (distance) between the base metal and the probe. This
measured distance is displayed as coating thickness by the gages. Accordingly, these gages cannot distinguish the thickness of
individual layers after they have all been applied. The thickness of each layer must be measured after it is applied. Even then, the
thickness of the measured layer is the cumulative thickness of that layer and all layers beneath it, down to the base metal.
1.5Gages which measure coating thickness using an ultrasonic principle may also be able to measure the thickness of coatings
applied to metal surfaces. This practice does not address the use of ultrasonic coating thickness gages. Test Method D6132 should
be referenced for this application.
1.6Coating thickness can vary widely across a surface. As a result, obtaining single-point measurements may not accurately
represent the actual coating system thickness. This practice provides guidance for the frequency of coating thickness
measurements, based on large areas of coated surface, on test panels and on small parts/components. The governing specification
is responsible for providing the user with the minimum and the maximum coating thickness for each layer, and for the total coating
system.
1.7
1.3 Coating thickness can be measured using a variety of gages. These gages are categorized as “magnetic pull-off” and
“electronic.” They use a sensing probe or magnet to measure the gap (distance) between the base metal and the probe. This
measured distance is displayed as coating thickness by the gages.

1
This practice is under the jurisdiction of ASTM Committee D01 on Paint and Related Coatings, Materials, and Applications and is the direct responsibility of
Subcommittee D01.23 on Physical Properties of Applied Paint Films.
Current edition approved Aug. 1, 2005. Published September 2005. DOI: 10.1520/D7091-05.
Current edition approved April 1, 2012. Published April 2012. Originally approved in 2005. Last previous edition approved in 2005 as D7091 - 05. DOI:
10.1520/D7091-12.

*A Summary of Changes section appears at the end of this standard.

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 D7091 – 12
1.4 Coating thickness can vary widely across a surface. As a result, obtaining single-point measurements may not accurately
represent the actual coating system thickness. SSPC-PA2 prescribes a frequency of coating thickness measurement based on the
size of the area coated. A frequency of measurement for coated steel beams (girders) and coated test panels is also provided in the
appendices to SSPC-PA2. The governing specification is responsible for providing the user with the minimum and the maximum
coating thickness for each layer, and for the total coating system.
1.5 The values stated in SI units are to be regarded as the standard. The values given in parentheses are for information only.
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility
of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory
limitations prior to use.
2. Referenced Documents
2.1 ASTM Standards:2
D609 Practice for Preparation of Cold-Rolled Steel Panels for Testing Paint, Varnish, Conversion Coatings, and Related Coating
Products
D823 Practices for Producing Films of Uniform Thickness of Paint, Varnish, and Related Products on Test Panels
D1730 Practices for Preparation of Aluminum and Aluminum-Alloy Surfaces for Painting
D6132Test Method for Nondestructive Measurement of Dry Film Thickness of Applied Organic Coatings Using an Ultrasonic
Gage Practices for Preparation of Aluminum and Aluminum-Alloy Surfaces for Painting
2.2 SSPC Standards: SSPC Standard:
SSPC-PA 2Paint Application Standard No. 2 Measurement of Dry Coating Thickness with Magnetic Gauges Procedure for
Determining Conformance to Dry Coating Thickness Requirements3
2.3 ISO Standard:
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 surfaces4
3. Terminology
3.1 Definitions of Terms Specific to This Standard:
3.1.1 accuracy, n—the measure of the magnitude of error between the result of a measurement and the true thickness of the item
being measured.
3.1.1.1 Discussion—An accuracy statement predicts the ability of a coating thickness gage to measure the true thickness of a
coating to be measured. Accuracy statements provide the performance capability across the full functional measurement range of
the gage. Accuracy statements frequently include a fixed portion that remains constant across the measurement range, plus a
variable portion that is related to the measurement result for a particular thickness.
3.1.2 adjustment, n—the physical act of aligning a gage’s 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.
3.1.2.1 Discussion—An adjustment will affect the outcome of subsequent readings. Also known as “optimization.”
3.1.3 area measurement, n—the average of several spot measurements obtained over the coated surface.
3.1.3.1Discussion—For large surfaces, an area measurement is commonly the average of at least five spot measurements
obtained in approximately 9 m2 (100 ft2) of surface area. For small test panels, it is commonly the average of three spot
measurements on each test face (one from the top third, one from the middle third and one from the bottom third).
3.1.4base metal reading (BMR), n—a measurement obtained on the uncoated substrate using a coating thickness gage.
3.1.4.1
3.1.3.1 Discussion—The BMR is the measured effect of substrate roughness on a coating thickness gage that is caused by the
manufacturing process (for example, castings) or surface profile (roughness)-producing operations (for example, power tool
cleaning, abrasive blast cleaning, etc.). Non-compensation for the base metal effect can result in an overstatement of the true
thickness of the coating. The base metal reading is measured, recorded and deducted from the thickness of each coat, in order to
correctly state the thickness of the coating over the surface roughness.
3.1.5—The BMR is the determined effect of substrate roughness on a coating thickness gage that is caused by the manufacturing
process (for example, castings) or surface profile (roughness)-producing operations (for example, power tool cleaning, abrasive
blast cleaning, etc.). Non-compensation for the base metal effect can result in an overstatement of the true thickness of the coating.
3.1.4 calibration, n—the 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.

2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM Standards
volume information, refer to the standard’s Document Summary page on the ASTM website.
3
Available from Society for Protective Coatings (SSPC), 40 24th St., 6th Floor, Pittsburgh, PA 15222-4656. (see www.sspc.org)
4
Available from National Institute of Standards and Technology (NIST), 100 Bureau Dr., Stop 3460, Gaithersburg, MD 20899-3460.
4
Available from American National Standards Institute (ANSI), 25 W. 43rd St., 4th Floor, New York, NY 10036, http://www.ansi.org.

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 D7091 – 12
3.1.5.1
3.1.4.1 Discussion—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. The outcome of the
calibration process is to restore/realign the gage to meet/exceed the manufacturer’s stated accuracy.
3.1.6
3.1.5 certification, n—documentation of the state of condition of the gage, which can (but not required by definition) be
accompanied by corrective action (such as adjustment or calibration, or both, or the replacement of components) necessary to
correct any out-of-tolerance conditions.
3.1.7coating thickness standard (test block)
3.1.6 coating thickness standard, n—a smooth, metal substrate with a coating of known thickness that is traceable to a national
standard.
3.1.8—coated or plated metal plates, or uncoated shims of flat sheet, with assigned values traceable to a National Metrology
Institution.
3.1.6.1 Discussion—In the case of the eddy current principle, the coating and shim material must be non-metallic, whereas in
the case of the magnetic induction and the Hall-effect methods the material must be nonmagnetic.
3.1.7 compensation value, n—generating 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).
3.1.9
3.1.8 dry film thickness, n—the thickness of a coating (or coating layers) as measured from the surface of the substrate.
3.1.9.1
3.1.8.1 Discussion—If the surface is roughened, the dry film thickness is considered the thickness of the coating or coating
layers above the peaks of a surface profile.
3.1.10
3.1.9 ferrous, n—a magnetic material such as carbon steel.
3.1.10.1—containing iron.
3.1.9.1 Discussion—Also known as ferro-magnetic.
3.1.11gage—Describes a magnetic material such as carbon steel. That material may also be known as ferromagnetic.
3.1.10 gage (gauge), n—an instrument for measuring quantity, or an instrument for testing.
3.1.11.1
3.1.10.1 Discussion—In this practice, the term “gage” refers to an instrument for quantifying coating thickness.
3.1.12
3.1.11 manufacturer’s specifications, n—a statement or set of statements that describes the performance characteristics of the
gage under a given set of conditions.
3.1.12.1
3.1.11.1 Discussion—Manufacturer’s specifications typically includesinclude the range of measurement, accuracy statement,
operating temperature range, power source, dimensions and weight, and conformance to industry standards.
3.1.133.1.12 measurement, n—the value obtained when placing the probe of a thickness gage in contact with a surface.
3.1.14
3.1.13 micrometer (micron), n—one one-thousandsth of a millimeter (0.001 mm); 25.4 microns = 1 mil.
3.1.153.1.14 mil, n—an imperial unit of measure; one one-thousandsth of an inch (0.001 in.); 1 mil = 25.4 microns.
3.1.163.1.15 non-conductive, n—a material that is unable to conduct electricity.
3.1.17
3.1.16 non-ferrous metal, n—a non-magnetic metal such as aluminum.
3.1.18reference standard—a nonmagnetic metal or metal alloy (for example, copper, aluminum or brass).
3.1.17 reference sample, n—a specimen of known thickness used to verify the accuracy of a coating thickness measuring gage.
3.1.18.1—a coated or uncoated metal specimen of the same material and geometry as the specific measuring application used
to adjust and/or verify the accuracy of a coating thickness measuring gage for a specific project.
3.1.17.1 Discussion—A reference standard may or may not be traceable to a National or International registry. References
should include notations stating the accuracy of the standard. Reference Standards may be coated or plated metal plates, or may
be shims (with samples of substrate material). Subject to agreement between the buyer and the seller, a piece of coated substrate
may also be used as a project-specific reference standard. Traceability may not be required for reference standards used on a
day-to-day basis. However, the reference standard should contain the stated value and the degree of accuracy.
3.1.19—A coated reference sample may or may not have thickness values traceable to a National Metrology Institution.
However, the reference sample should be marked with the stated value and the degree of accuracy. The coating thickness of the
sample should be close to the user’s coating thickness measurement requirement.
3.1.18 shims, n—strips of flat, non-metallic sheet (typically polyester, flat sheet, with the thickness stated or referenced in some
form) form, that can be used to adjust (optimize) a coating thickness gage in the intended range of use,use over the surface of the
representative substrate material.

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 D7091 – 12
3.1.19.13.1.18.1 Discussion—Other uses include: placement over soft coatings to obtain thickness measurements without the
gage probe depressing the coating film, and verification of gage operation. Also known as “foils.”
3.1.20spot measurement, n—the average of at least three measurements made within a 12 mm (1⁄2 in.) diameter circle.
3.1.21
3.1.19 substrate, n—the base material, the type of surface, or the component that is being coated.
NOTE 1—This practice addresses only metal substrates.
3.1.22
3.1.20 surface profile, n—surface roughnesstexture generated during the manufacturing process (for example, casting), or the
average peak-to-valley depth generated by some power tools and by abrasive blast cleaning operations.
3.1.233.1.21 Type 1 gage, n—a magnetic pull-off instrument that measures the dry film thickness of non-magnetic coatings over
a ferrous metal base.
3.1.23.13.1.21.1 Discussion—For Type 1 gages, a probe containing a permanent magnet is brought into direct contact with the
coated surface. The force necessary to pull the magnet from the surface is measured and interpreted as the coating thickness value
on a scale or display on the gage. Less force is required to remove the magnet from a thick coating. The scale is nonlinear. Also
known as “pull-off gage.”
3.1.243.1.22 Type 2 gage, n—an electronic instrument that uses electronic circuitry and (but not limited to) the magnetic
induction, Hall-effect or the eddy current principles, or both, a combination of a magnetic and eddy current principles, to convert
a reference signal into a coating thickness reading.
3.1.24.13.1.22.1 Discussion—The probe of a Type 2 gage remains on the surface during the measurement process. Also known
as “constant pressure probe” or “electronic” gages.
3.1.25
3.1.23 verification of accuracy, n—obtaining 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 manufacturer’s
stated accuracy and the stated accuracy of the reference standard. —obtaining measurements on coating thickness standards,
comprising of at least one thickness value close to the expected coating thickness, prior to gage use for the purpose of determining
the ability of the coating thickness gage to produce thickness results within the gage manufacturer’s stated accuracy.

4. Significance and Use

4.1Most 4.1 This practice describes three operational steps necessary to ensure accurate coating thickness measurement —
calibration, verification and adjustment of coating thickness measuring gages, as well as proper methods for obtaining coating
thickness measurements on both ferrous and non-ferrous metal substrates.
4.2 Many specifications for commercial and industrial coatings projects stipulate a minimum and a maximum dry film thickness
for each layer in a coating system. Additionally, most manufacturers of high performance coatings will warranty coating systems
based upon, in part, achieving the proper thickness of each layer and the total coating system. Even if a project specification is
not provided, the coating manufacturer’s recommendations published on product data sheets can become the governing
document(s). Equipment manufacturers produce non-destructive coating thickness testing gages that are used to measure the
cumulative or individual thickness of the coating layers, after they are dry. The manufacturers provide information for the
adjustment and use of these gages, normally in the form of operating instructions. The user of this equipment must be
knowledgeable in the proper operation of these devices, including methods for verifying the accuracy of the equipment prior to,
during and after use as well as measurement procedures. 4.2This practice was prepared to describe the proper methods for verifying
the accuracy of coating thickness measuring gages, as well as the proper methods for obtaining coating thickness measurements
on both ferrous and non-ferrous metal substrates.

5. Principles, Advantages, and Limitations of Gages

5.1Type 1 Magnetic Pull-Off gages are mechanical instruments that measure the force required to pull a permanent magnet from
a coated ferrous metal substrate. The magnetic force of attraction to the steel substrate beneath the coating is opposed by a spring
or coil. Tension is applied to the spring/coil until the magnetic attraction to the steel is overcome. The gage must be placed directly
on the coated surface to obtain a measurement. The force holding the permanent magnet to the ferrous base is inversely
proportional to the thickness of the coating layer(s) between the magnet and the ferrous substrate. For example, a thin coating
applied to a ferrous substrate will require greater spring tension to pull the magnet off than will a thicker coating, since the magnet
is closer to the ferrous substrate with the thinner coating. This inverse relationship is reflected on the nonlinear gage scale. Most
Type 1 magnetic pull-off gages do not require a power source (for example, batteries). The manufacturer’s stated accuracy is
typically 5 to 10% of the reading.
5.2Type 1 magnetic pull-off gages are susceptible to vibrations, which may cause the magnet to release from the coated substrate
prematurely, yielding a false high value. The manually operated gages may be susceptible to human error caused by inadvertently
turning the dial wheel past the point at which the magnet pulls from the surface, yielding a false low measurement. Type 1 gages
should not be used on soft or tacky coatings, as the magnet may adhere to the coating causing false low measurements, or coating
materials may dry on the magnet causing false high measurements. The exposed magnet may attract metal filings, which can

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 D7091 – 12
contaminate the magnet and cause false high measurements. Type 1 gages cannot be used to measure the thickness of coatings
applied to non-ferrous metal substrates. The manufacturer’s specifications will contain a temperature operating range. Use of the
gage outside of this range may generate false coating thickness measurements and may damage the instrument.
5.3Type 2 gages are instruments that employ a measuring probe and the magnetic induction, Hall-effect or eddy-current
measurement principle in conjunction with electronic microprocessors to produce a coating thickness measurement. The gage
probe must be placed directly (in a perpendicular position) on the coated surface to obtain a measurement. For gages measuring
on ferrous substrates, the magnetic induction or Hall-effect principles determine the effect on the magnetic field generated by the
probe due to the presence of the substrate. For gages measuring on non-ferrous metals, the gage probe is energized by alternating
current that induces eddy currents in the metal substrate. Note that gages/probes for measuring coating thickness on non-ferrous
metals should not be used to measure coating thickness on ferrous surfaces, even though a reading may be displayed.
5.4Type 2 gages are available with integral, separate or remote (unconnected) probes, and they can be used to measure coating
thickness on ferrous or non-ferrous metal substrates, or both, depending on the probes supported by the particular gage platform.
The thickness of the coating is displayed digitally. In general, access to tight areas is easier with Type 2 gages, especially those
equipped with separate or remote probes. Type 2 gages are available with memory, measurement batching, statistical analysis
packages and data download/print-out. The manufacturer’s stated accuracy is typically 1 to 3% of the reading.
5.5Most electronic coating thickness-measuring gages can be verified for accuracy using either traceable reference standards 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 manufacturer’s stated gage accuracy.
5.6Type 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”). 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 manufacturer’s 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.
5.1 Type 1 magnetic pull-off gages employ an attraction principle and a static (non-time varying) magnetic field. These
mechanical instruments measure the force required to pull a permanent magnet from a coated ferrous metal substrate. The magnetic
force of attraction to the steel substrate beneath the coating is opposed by a spring or coil. Tension is applied to the spring/coil until
the magnetic attraction to the steel is overcome. The gage must be placed directly on the coated surface to obtain a measurement.
The force holding the permanent magnet to the ferrous base is inversely proportional to the thickness of the coating layer(s)
between the magnet and the ferrous substrate. For example, a thin coating applied to a ferrous substrate will require greater spring
tension to pull the magnet off than will a thicker coating, since the magnet is closer to the ferrous substrate with the thinner coating.
This inverse relationship is reflected on the nonlinear gage scale. Most Type 1 magnetic pull-off gages do not require a power
source (for example, batteries). The manufacturer’s stated accuracy is typically 5 to 10 % of the reading.
5.2 Type 1 magnetic pull-off gages are susceptible to vibrations, which may cause the magnet to release from the coated
substrate prematurely, yielding a false high value. The manually operated gages may be susceptible to human error caused by
inadvertently turning the dial wheel past the point at which the magnet pulls from the surface, yielding a false low measurement.
Type 1 gages should not be used on soft or tacky coatings, as the magnet may adhere to the coating causing false low
measurements, or coating materials may dry on the magnet causing false high measurements. The exposed magnet may attract
metal filings, which can contaminate the magnet and cause false high measurements. Type 1 gages cannot be used to measure the
thickness of coatings applied to non-ferrous metal substrates. The manufacturer’s specifications will contain a temperature
operating range. Use of the gage outside of this range may generate false coating thickness measurements and may damage the
instrument.
5.3 Type 2 gages are instruments that employ a measuring probe and the magnetic induction, Hall-effect or eddy current
measurement principle in conjunction with electronic microprocessors to produce a coating thickness measurement. The gage
probe must be placed directly (in a perpendicular position) on the coated surface to obtain a measurement.
5.3.1 For gages measuring on ferrous substrates, the magnetic induction or Hall-effect principles are used to measure a change
in magnetic field strength within their probes to produce a coating thickness measurement. These gages determine the effect on
the magnetic field generated by the probe due to the proximity of the substrate.
5.3.2 For gages measuring on non-ferrous metals, the gage probe coil is energized by alternating current that induces eddy
currents in the metal substrate. The eddy currents in turn create a secondary magnetic field within the substrate. The characteristics
of this secondary field are dependent upon the distance between the probe and the basis metal. This distance (gap) is measured

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 D7091 – 12
by the probe and shown on the gage display as the thickness (microns or mils) of the intervening coating. Note that gages/probes
for measuring coating thickness on non-ferrous metals should not be used to measure coating thickness on ferrous surfaces, even
though a reading may be displayed.
5.4 Type 2 gages are available with integral or separate (wired or wireless) probes, and they can be used to measure coating
thickness on ferrous or non-ferrous metal substrates, or both, depending on the probes supported by the particular gage platform.
The thickness of the coating is displayed digitally. In general, access to tight areas is easier with Type 2 gages, especially those
equipped with separate or remote probes. Type 2 gages are available with memory, measurement batching, statistical analysis
packages and data download/print-out. The manufacturer’s stated accuracy is typically 1 to 3 % of the reading.
5.5 Instruments using either a magnetic or eddy current principle measure total film thickness only. In multi-layer coating
systems the thickness of each layer must be measured after it is applied. Even then, the thickness of the measured layer is the
cumulative thickness of that layer and all layers beneath it, down to the base metal.
5.5.1 Some instruments employ both principles and may be capable of measuring the individual thickness of two layers such
as paint over zinc (duplex coating) on steel.
5.6 Most electronic coating thickness measuring gages can be verified for accuracy using coating thickness standards. Gages
that cannot be adjusted by the user should be returned to the manufacturer for calibration if the readings obtained on the coating
thickness standards are outside of the combined accuracy of the standard and the manufacturer’s stated gage accuracy.
5.6.1 Gage operation should be verified on a prepared, uncoated substrate having the same composition, shape and surface
profile to which the coating will be applied to, for the intended range of use. If necessary, the gage should be adjusted as described
in 7.3.
5.7 Type 2 gages should not be used directly on soft or tacky coatings, unless expressly designed for this application, 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”).
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. The manufacturer’s 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.
5.8 Coating thickness measurement accuracy can also be affected by, but is not limited to, the following factors:
5.8.1 Curvature—The influence of curvature varies considerably with the make and type of instrument but often becomes more
pronounced as the radius of curvature decreases.
5.8.2 Foreign Particles—Instruments of all types must make physical contact with the test surface and are, therefore, sensitive
to foreign material that prevents intimate contact between probe and coating surface. Both the test surface and instrument probe
should be kept free of foreign material.
5.8.3 Stray Magnetic Fields—Strong stray magnetic fields, such as are produced by various types of electrical equipment, can
seriously interfere with the operation of instruments based on magnetic principles.
5.8.4 Metal-filled Coatings—Instruments may produce erroneous results depending on the type and amount of metal in the
coating film
5.8.5 Electrical Properties of the Basis Metal—Eddy current measurements may be affected by the electrical conductivity of
the basis metal, which itself is often affected by heat treatments.
5.8.6 Pressure—The pressure with which the probe is applied to the test specimen affects the instrument readings and should
therefore be kept constant.
NOTE 2—Consult the instrument manufacturer for details on the specific effects of these factors, and how they are addressed by the instrument.
6. Test Specimen
6.1 The test specimen can be the coated structure or component/part on which the thickness is to be evaluated, or can be test
panels of similar roughness,surface profile, shape, thickness, composition and magnetic properties on which it is desired to measure
the coating thickness.
NOTE 23—Applicable test panel description and surface preparation methods are given in Practices D609 and D1730.
NOTE 34—Coatings should be applied in accordance with Practices D823 or as agreed upon between the contracting parties.
NOTE4—Test 5—Test panels may be fabricated from thin gage materials and special consideration for calibrationgage adjustment may be required.
7. Frequency and Methods for Verifying the Accuracy and for Adjusting a Coating Thickness Gage
7.1Calibration 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. A Certificate of Calibration showing
traceability to a national standard can be issued. There is no standard time interval for re-calibration, nor is one absolutely required,
but a calibration interval can be established based on experience and the work environment. A one-year calibration interval is a
typical frequency suggested by many gage manufacturers. The type of reference standard used to verify gage accuracy should be
predicated upon the type that provides the best and most appropriate method of verification, considering the type of gage, the
sample surface geometry, and prevailing contract requirements.

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 D7091 – 12
7.2Type 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 measurements.
7.3Verification of Accuracy of Type 1 Gages Using Coated/Plated Reference Standards—Type 1 coating thickness gages can be
verified for accuracy using traceable reference standards (for example, NIST 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 manufacturer’s 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.
7.3.1For example, if the gage accuracy is 65% and the standards accuracy is 65%, then the combined accuracy of the gage
and the standard will be 67% as given by the sum of the squares formula:
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. A Certificate of Calibration
showing traceability to a National Metrology Institute can be issued. There is no standard time interval for re-calibration, nor is
one absolutely required, but a calibration interval can be established based on experience and the work environment. A one-year
calibration interval is a typical frequency suggested by many gage manufacturers.
7.2 Verification of Accuracy—Before use, each instrument’s calibration accuracy shall be verified by the user in accordance with
the instructions of the manufacturer, employing suitable coating thickness standards and, if necessary, any deficiencies found shall
be corrected. 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 measurements.
7.2.1 If the gage reading obtained during verification are outside the combined accuracy of the coating thickness standard and
the manufacturer’s stated gage accuracy, the gage should be returned to the manufacturer or authorized agency for calibration.
7.2.2 For example, if the gage accuracy is 65 % and the standards accuracy is 65 %, then the combined accuracy of the gage
and the standard will be 67 % as given by the sum of the squares formula:
=52 1 52 5 7.071 or approximately 7 % D7091-05_1 (1)

=52 1 52 5 7.071 or approximately 7 %. D7091-12_1 (1)

7.3.2For7.2.2.1 For the gage to be in agreement with the standard, the average thickness measured by the gage must be within
67 % of the standard’s thickness. If the average thickness measured on a 254 µm (10 mil) reference standard is between 236 µm
(9.3 mils) and 272 µm (10.7 mils), the gage is properly adjusted. The minimum value of 236 µm is calculated as 254 µm minus
7 % of 254 µm (9.3 mils is 10 mils minus 7 % of 10 mils); the maximum of 272 µm is 254 µm plus 7 % of 254 µm (10.7 mils
is 10 mils plus 7 % of 10 mils). Otherwise the reliabilityaccuracy of the gage is suspect.
7.4Verification of Accuracy of Type 1 Gages Using Shims—Type 1 coating thickness gages may be verified for accuracy using
shims 7.2.3 If the user elects to use shims to verify the accuracy of Type 1 gages (see Note 56 and Appendix X1). If ), the user
elects to use shims to verify the accuracy of Type 1 gages, the shim(s) representing the intended range of use should be placed
onto a smooth steel surface (zero plate), and a measurement taken. If the gage reading is outside of the combined accuracy of the
shim and the manufacturer’s stated gage accuracy, the instrumentgage should be returned to the manufacturer or authorized agency
for calibration. See 7.37.2.2 for an example of calculating the combined gage and calibration shim accuracy. Otherwise the
reliabilityaccuracy of the gage is suspect. Type 1 coating thickness gages The user should never be adjusted by the user. adjust Type
1 coating thickness gages.
7.57.2.4 Since the gage is verified for accuracy using smooth-surfaced reference standards (or using a smooth zero plate), a
compensation value may be required if the substrate to be coated is different from the standard (such as, but not limited to,
curvature or composition) or roughened from the manufacturing process (for example, castings)casting) or from abrasive blast
cleaning. This is known as a Base Metal Reading or BMR. The BMR is the effect of substrate roughness (for example, surface
profile) on a coating thickness gage. The user obtains a minimum of ten (10) readings on the prepared, uncoated substrate. The
arithmetic mean of these values becomes the Base Metal Reading. The BMR is deducted from the coating thickness values,values
in order to report the thickness of the coating layer(s) over the surface profile.
NOTE5—SSPC-PA2 6—SSPC-PA 2 prohibits the use of shims to verify the accuracy of Type 1 gages. See Appendix X1 for more information.
7.6Verification of Accuracy of Type 2 Gages Using Coated/Plated Reference Standards—Type 2 coating thickness gages can be
verified for accuracy using traceable reference standards (for example, NIST Coating Thickness Reference Standards) or
proprietary reference standards produced by coating thickness gage manufacturers. Most Type 2 gages can be adjusted using either
a one-point or a two-point procedure. Gages that cannot be adjusted by the user should be returned to the manufacturer or
authorized agency for calibration if the readings obtained on the reference standards are outside of the combined accuracy of the
standard and the manufacturer’s stated gage accuracy. See 7.3 for example of calculating the combined gage and calibration
standard accuracy. Otherwise the reliability of the gage is suspect.

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7.6.1Adjustment Using a One-Point Procedure—If the user elects to perform a one-point adjustment procedure, a reference
standard representing the target range of gage use should be selected and a measurement taken. If the value displayed by the gage
is with the combined accuracy of the coating thickness standard (test block) and the manufacturer’s stated gage accuracy (see 7.3),
then no adjustment is necessary and the gage is considered “optimized” for that targeted thickness. If the gage reading is outside
of the combined accuracy of coating thickness standard (test block) and the manufacturer’s stated gage accuracy (see 7.3), then
the user should carefully follow the gage manufacturer’s instructions for proper adjustment, as the actual step-by-step procedures
vary widely. It is recommended that the gage be verified for accuracy during the measurement procedure and after the coating
thickness measurements have been acquired.
7.6.2Adjustment Using a Two-Point Procedure—If the user elects to perform a two-point adjustment procedure, two reference
standards (representing a thickness below and above the targeted range of gage use) should be selected. The user should carefully
follow the gage manufacturer’s instructions for performing a two-point adjustment, as the actual step-by-step procedures vary
widely. It is recommended that the gage be verified for accuracy during the measurement procedure and after the coating thickness
measurements have been acquired.
7.6.3Since the gage is verified for accuracy using smooth-surfaced reference standards, a compensation value may be required
if the substrate to be coated is roughened from the manufacturing process (for example, castings) or from abrasive blast cleaning.
This is known as a Base Metal Reading or BMR. The BMR is the effect of substrate roughness on a coating thickness-measuring
gage. The user obtains a minimum of ten (10) readings on the prepared, uncoated substrate. The arithmetic mean of these values
becomes the Base Metal Reading. The BMR is deducted from the coating thickness values, in order to report the thickness of the
coating layer(s) over the surface profile.
7.7Verification 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. Most Type 2 gages can be adjusted using either a one-point or a two-point procedure. Gages that cannot be
adjusted by the user should be returned to the manufacturer or authorized agency for calibration if the readings obtained on the
shim(s) are outside of the combined accuracy of the shim and the manufacturer’s stated gage accuracy. See 7.3 for example of
calculating the combined gage and calibration shim accuracy. Otherwise the reliability of the gage is suspect.
7.7.1Adjustment Using a One-Point Procedure—If the user elects to perform a one-point adjustment procedure, a shim
representing the target range of gage use should be selected and placed onto the prepared, uncoated surface, and a measurement
taken. If the value displayed by the gage is within the combined accuracy of the shim and the manufacturer’s stated gage accuracy
(see 7.3), then no adjustment is necessary and the gage is considered “optimized” for that targeted thickness. If the value is not
within the combined accuracy of the shim and manufacturer’s stated gage accuracy (see 7.3), then the user should carefully follow
the gage manufacturer’s instructions for proper adjustment, as the actual step-by-step procedures vary widely. Note that it may be
necessary to “zero” the gage on the uncoated substrate prior to conducting a one-point adjustment procedure. It is recommended
that the gage be verified for accuracy during the measurement procedure and after the coating thickness measurements have been
acquired.
7.7.2Adjustment Using a Two-Point Procedure—If the user elects to perform a two-point adjustment procedure, two shims
(representing a thickness below and above the targeted range of gage use) should be selected and placed onto the prepared,
uncoated surface. The user should carefully follow the gage manufacturer’s instructions for performing a two-point adjustment,
as the actual step-by-step procedures vary widely. Note that it may be necessary to “zero” the gage on the uncoated substrate prior
to conducting a two-point adjustment procedure. It is recommended that the gage be verified for accuracy during the measurement
procedure and after the coating thickness measurements have been acquired.
8.
7.3 Adjustment—Many instruments can be adjusted by the user in order to improve their accuracy on a specific surface or within
a specific portion of its measurement range. In most instances it should only be necessary to check zero on the uncoated substrate
and begin measuring. However the effects of properties of the substrate (composition, magnetic properties, shape, surface profile,
edge effects) and coating (composition, mass, surface texture), as well as ambient and surface temperatures, may require
adjustments to be made to the instrument. Follow the manufacturer’s instructions.
7.3.1 The user should never adjust Type 1 coating thickness gages.
7.3.2 Most Type 2 gages can be adjusted using either a one-point or a two-point procedure.
7.3.2.1 Adjustment of Type 2 Gages Using a One-Point Procedure—A one-point adjustment involves fixing the instrument’s
calibration curve at one point after taking several readings on a single coating thickness standard or reference sample. Adjusting
to zero on an uncoated sample of the test specimen is the simplest form of a one-point adjustment. If the user elects to perform
a one-point adjustment procedure to a known thickness, a reference sample representing the target range of gage use should be
selected and a measurement taken. If the value displayed by the gage is within the combined accuracy of the reference sample and
the manufacturer’s stated gage accuracy (see 7.2.2), then no adjustment is necessary. If the gage reading is outside of the combined
accuracy of reference sample and the manufacturer’s stated gage accuracy, then the user should carefully follow the gage
manufacturer’s instructions for proper adjustment, as the actual step-by-step procedures vary widely.
7.3.2.2 Adjustment of Type 2 Gages Using a Two-Point Procedure—A two-point adjustment fixes the instrument’s calibration
curve at two known thicknesses. Coated reference samples or shims placed over the uncoated substrate or over an uncoated

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 D7091 – 12
reference sample may be used. The two thicknesses selected must be on either side of the expected coating thickness. The user
should carefully follow the gage manufacturer’s instructions for performing a two-point adjustment, as the actual step-by-step
procedures vary widely.
NOTE 7—When access to the uncoated substrate is not available, ISO 19840 describes the use of a profile correction value.

8. Frequency for Measurement of Coating Thickness

8.1The 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.
8.2For larger structures, five spot measurements (each spot measurement being the average of three individual gage
measurements acquired within a 12 mm (1⁄2 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. The following general guidance is provided for
measuring coating thickness on larger surfaces.
8.2.1For 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.
8.2.2For 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. For example, the thickness may need to be measured in each 9 m2 (100-ft2) area (in accordance
with 8.2.1) coated during that work shift, in order to identify the deficient areas for subsequent rework.
8.2.3For 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).
Example: for a structure comprised of 2323 m2(25000 ft2), a total of 27 — 9 m2(100-ft2) areas should be measured. If thickness
measurements outside of the specified range are observed, then more frequent measurements may be required. For example, the
thickness may need to be measured in each 9 m2 (100-ft2) area (in accordance with 8.2.1) coated during that work shift, in order
to identify the deficient areas for subsequent rework.
8.3For test panels having minimum dimensions of 3 by 5 in., three spot measurements (each spot measurement being the average
of three individual gage measurements acquired within a 12 mm (1⁄2 in.) diameter circle) are recommended on each test face (one
from the top third, one from the middle third and one from the bottom third).
8.4For small parts or components, the number of coating thickness measurements is typically based on the criticality of the
application, and should be as agreed upon between the purchaser and seller.
8.5For mass quantities of manufactured products, the frequency of coating thickness measurement is dictated by the volume
produced and should be based on statistical process control (SPC) calcualtions for sample size selection.
8.1 Thickness is determined by placing the probe of the instrument onto the surface of the coated metal material and obtaining
the thickness measurement as per the manufacturer’s instructions.
8.2 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. SSPC-PA2 prescribes a frequency of coating thickness measurement based on the size
of the area coated.
8.3 For small parts or components, the number of coating thickness measurements is typically based on the criticality of the
application, and should be as agreed upon between the purchaser and seller.
8.4 For mass quantities of manufactured products, the frequency of coating thickness measurement is dictated by the volume
produced and should be based on statistical process control (SPC) calculations for sample size selection.
9. Report
9.1 The following items should be reported:
9.1.1Gage type (manufacturer, model and serial no.),
9.1.2Date of calibration,
9.1.3Method of accuracy verification,
9.1.1 Type of instrument used including manufacturer, model number, serial number, and date of calibration,
9.1.2 Type of coating thickness standard and/or reference standard and the method used for accuracy verification and any
calibration adjustment,
9.1.3 Size and description of test specimen,
9.1.4 Base Metal Reading (if appropriate),
9.1.5Spot and area coating thickness measurements,
9.1.6Minimum and maximum thickness for each area,
9.1.7Depending upon the application, the individual gage readings may be recorded, and
9.1.8Gage operator’s name.
9.1.5 The value of each measurement,
9.1.6 Operator identification, and
9.1.7 Date.

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10. Keywords
10.1 coatings; coating thickness; dry film thickness; eddy current thickness gages; magnetic gages; magnetic method;
nondestructive thickness; paint thickness; thickness testing
APPENDIX

(Nonmandatory Information)

X1. PRECAUTIONS REGARDING VERIFICATION OF GAGE ACCURACY

X1.1 When 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.
X1.2 With some materials and thicknesses, 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.
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 as temperature, and
X1.3.4 Shim thickness inconsistency (due to the pressure of the probe tip) that may be a permanent “dimple” in the shim.
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.
NOTE X1.1—Data produced using Type 1 (magnetic pull-off) gages and shims placed onto an abrasive blast cleaned steel surface indicate that the
surface texture beneath the shim has an adverse effect on the gage reading. Since Type 1 gages cannot be field adjusted, the use of shims to verify gage
accuracy on abrasive blast cleaned surfaces is not recommended. If shims are selected to verify gage accuracy, they should be placed on a smooth steel
plate (zero-plate). A Base Metal Reading (BMR) is obtained and subtracted from the coating thickness (to compensate for the effect of roughness), as
described in 7.57.2.4.
X1.5 Independent of what standard is employed, they should be periodically verified to ensure the assigned value is correct.
Even coated metal plates can wear or be damaged to an extent that gage readings are affected.
X1.6 When verifying the accuracy of magnetic gages on coated steel standards it is important to be aware of the effect of the
coating on some types of magnetic gages. For best accuracy when measuring with magnetic induction principle gages, consider
the following:
X1.6.1 Verify gage accuracy on metal plated (conductive coating) standards when measuring conductive coatings (for example,
chrome and zinc); verify gage accuracy on epoxy coated (non-conductive) standards when measuring non-conductive coatings (for
example, paint).
X1.6.2Gages that use the Hall-effect principle are not effected by the conductive nature of the coating.
X1.6.2 Gages that use the Hall-effect principle are not effected by the conductive nature of the coating.
SUMMARY OF CHANGES

Committee D01 has identified the location of selected changes to this standard since the last issue (D7091 - 05)
that may impact the use of this standard. (Approved April 1, 2012.)
(1) Definitions were revised for coating thickness standard, reference sample, and verification of accuracy.
(2) Section 5 was expanded to include additional factors that affect instrument accuracy and to reference multi-layer coating
applications.
(3) Verification and adjustment descriptions for Type 1 and Type 2 gages were combined within Section 7.
(4) Requirements for spot and area measurements were removed from Section 8.
(5) Reportable items in Section 9 were updated.
(6) Editorial changes were made throughout the document.
ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentioned
in this standard. Users of this standard are expressly advised that determination of the validity of any such patent rights, and the risk
of infringement of such rights, are entirely their own responsibility.

This standard is subject to revision at any time by the responsible technical committee and must be reviewed every five years and
if not revised, either reapproved or withdrawn. Your comments are invited either for revision of this standard or for additional standards
and should be addressed to ASTM International Headquarters. Your comments will receive careful consideration at a meeting of the
responsible technical committee, which you may attend. If you feel that your comments have not received a fair hearing you should
make your views known to the ASTM Committee on Standards, at the address shown below.

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