Bill Corbett

KTA-Tator, Inc.
Coating Adhesion Testing Methods
and Equipment
Webinar Content:
Why Measure Adhesion Properties?
What is Being Measured?
Selecting an Adhesion Testing Method
Measuring Adhesion by the Tape Test
Measuring Adhesion by the Knife Test
Measuring Pull-off Adhesion
Fixed Alignment Mechanical
Self-Aligning Hydraulic (3 devices)
Self Aligning Pneumatic
Special Requirements for Testing Concrete Coating Adhesion
Common Pitfalls When Testing Coating Adhesion
Reporting


Learning Outcomes
Completion of this webinar will enable the participant
to:

Explain the purpose of testing the adhesion properties of coatings

Describe the two types of adhesion testing mechanisms

List four standard test methods used to test the adhesion of coating
systems

Describe the difference between shear adhesion and tensile

adhesion

Measure the adhesion of coating systems using the tape method

Measure the adhesion of coating systems using the knife method

Learning Outcomes, continued

Describe the difference between fixed alignment and self aligning

adhesion testers

Explain the differences between testing the pull-off strength of

coatings applied to steel and concrete surfaces

Measure the tensile (pull-off) strength of coating systems using

mechanical, hydraulic and pneumatically-operated testing devices

List common pitfalls associated with adhesion testing of coatings

Evaluate potential locations of break, including adhesion,

cohesion and glue

Describe the reporting requirements for adhesion testing

Why Measure Adhesion Properties?
Determine specification
compliance
Common in-process
inspection of TSC
Determine maintenance
strategy for existing
coating systems
Adhesion data is not
typically a predictor of
coating performance
What is Being Measured?
Measuring Coating Strength at Different Planes
Adhesion Strength
Bond strength between the substrate and the coating and/or
the coating layers to one another
Cohesion Strength
Inner-strength of a coating layer
Adhesion strength is highly variable
No industry-wide adhesion acceptance value
Minimum adhesion values may be on a PDS or in a
specification
Selecting a Test Method
ASTM Standard Method
D 3359-09 Adhesion By Tape Test
D 6677-07 Knife Adhesion
D 4541-09 Pull-off Strength of Coatings Using Portable Adhesion Testers
D 7234-05 Pull-off Strength of Coatings on Concrete Using Portable
Pull-off Adhesion Testers
Selecting a Test Method
Tape and Knife Adhesion require minimal equipment
and can be conducted quickly
Evaluate shear or peel strength (peel-back)
Pull-off adhesion requires specialized equipment and
the testing takes comparatively longer to perform
Evaluates pull-off strength (resistance to perpendicular
pull)
Cannot compare data, since testing mechanisms are
different
Adhesion testing is destructive to the coating film
Measuring Adhesion By Tape Test
Equipment
Steel ruler or guide
Utility knife
Brush
Adhesive tape
Magnifier
ASTM Test Method
Cross-cut Tester
(alternative to knife
and guide)


Measuring Adhesion By Tape Test
Step 1: Select test area(s) and conduct triplicate tests
per area
Step 2: Determine the thickness of the coating system
Step 3: Select the test method based on the coating
thickness
Method A (X-cut): Coating thickness > 5 mils
Method B (Cross-cut): Coating thickness < 5 mils
Up to 2 mils: Use 1mm spacing between incisions (11 cuts)
From 2-5 mils: Use 2mm spacing between incisions (6 cuts)
Measuring Adhesion By Tape Test
Method A (X-cut)
Make a single 1.5 cut
through the coating
system. Avoid multiple
passes.
Make a second cut to
form an X
30-45 angle at
intersection of the X
Measuring Adhesion By Tape Test
Method A (X-cut)
Remove cutting debris
Remove 2 laps of tape
(discard)
Apply 3 piece of tape to
X-cut
Cover all of X-cut
Assure good tape contact
Remove tape within 90
+/- 30 seconds
Remove tape 180 back
across X-cut (do not pull
upwards)
Measuring Adhesion By Tape Test
Method A (X-cut)
Rating Description
5A No peeling or removal
4A Trace peeling or removal along the incisions
3A Jagged removal along the incisions up to 1/16 on either side
2A Jagged removal along the incisions up to 1/8 on either side
1A Removal of most of the coating from the area of the X under
the tape
0A Removal of coating beyond the area of the X
Measuring Adhesion By Tape Test
Method B (Cross-cut)
Make series of 6 or 11
parallel incisions
through the coating
system. Avoid multiple
passes.
Make a second series of
incisions perpendicular
to first series
Measuring Adhesion By Tape Test
Method B (Cross-cut)
Remove cutting debris
Remove 2 laps of tape
(discard)
Apply 3 piece of tape to
grid
Cover all of grid
Assure good tape contact
Remove tape within 90
+/- 30 seconds
Remove tape 180 back
across cross-cut (do not
pull upwards)
Measuring Adhesion By Tape Test
Method B (Cross-cut)
Rating % Description
5B 0% Edges of cuts completely smooth
4B <5% Small flakes of coating detached
at intersections
3B 6-15% Small flakes of coating detached
along edges & at intersections
2B 16-35% Coating flaked along edges and
parts of squares
1B 36-65% Coating flaked along edges in
large ribbons and whole squares
detached
0B >65% Flaking & detaching worse than
1B
Measuring Adhesion By Knife Test
Equipment
Steel ruler or guide
Utility knife
ASTM Test Method





Measuring Adhesion By Knife Test
Select test area
Make a single 1.5 cut
through the coating
system. Avoid multiple
passes.
Make a second cut to
form an X
30-45 angle at
intersection of the X
Attempt to lift coating
with tip of knife blade
Measuring Adhesion By Knife Test
Rating Description
10
Coating is extremely difficult to remove. Fragments no larger than 1/32
x 1/32 removed with great difficulty
8
Coating is difficult to remove. Coating chips from 1/16 x 1/16 to 1/8 x
1/8 removed with difficulty
6
Coating is somewhat difficult to remove. Coating chips from 1/8 x 1/8
to 1/4 x 1/4 removed with slight difficulty
4
Coating is somewhat difficult to remove. Coating chips in excess of 1/4
x 1/4 removed using light pressure with knife blade
2
Coating is easy to remove. Once started with the knife blade, the
coating can be grasped with fingers and easily peeled to a length of at
least 1/4
0
Coating is easy to remove. Once started with the knife blade, the
coating can be grasped with fingers and easily peeled to a length greater
than 1/4
Pitfalls to Avoid
ASTM D3359 is for coatings on metallic surfaces
Dull knife blades can produce erroneous results
Maintain proper spacing between incisions when
employing the cross-cut tape adhesion method
When employing the X-cut methods (tape or knife
adhesion procedures), maintain proper angle at
intersection of X. The legs of the X should be ~ 1
apart (width of adhesive tape)
Report tape used. Store tape properly
Tape may not be effective in cold temperatures
What Tape Should be Used?
Note 5 in the current standard lists
Permacel 99 as suitable
Permacel 99 discontinued in 2009
No immediate replacement
Intertape Polymer Group LA26 will
be investigated (backing, adhesive,
thickness & adhesion to steel
similar)
Section 5.3 indicates 1 (25 mm)
width and adhesion strength as
agreed is acceptable
Exercise caution when comparing
data using different tapes/batches
of tape
Reporting
Substrate type and coating system; method of cure
Environmental conditions (temperature and RH)
No. of tests performed
Manufacturer and type of tape employed (when used)
Mean and range of ratings
Location of Break (between coats, within a coat,
between substrate surface and primer, etc.)
Measuring Pull-off Adhesion
ASTM D4541, Pull-off Strength of Coatings Using
Portable Adhesion Testers
Annex A1: Fixed Alignment Type II (mechanical)
Annex A2: Self Aligning Type III (hydraulic)
Annex A3: Self Aligning Type IV (pneumatic)
Annex A4: Self Aligning Type V( hydraulic)
Annex A5: Self Aligning Type VI (hydraulic)

Note: Different testers may yield different pull-off values
Preparing the Test Surfaces
Remove dirt, chalking,
oil or other interfering
materials
Lightly roughen smooth
or glossy surfaces using
fine grit paper or
abrasive pad
Remove any residual
dust using a compatible
solvent
Loading Fixture Design
Fixed Alignment
Type II
Self-Aligning
Type III
Self-Aligning
Type VI
Self-Aligning
Type V
Self-Aligning
Type IV
Preparing the Loading Fixtures
Loading fixtures for Type
II and Type IV testers are
available pre-abraded

Loading fixtures for
other testers may need to
be abraded to enhance
bond to surface
(recommended)
Clean fixtures before use
Selecting an Adhesive
High solids epoxy
adhesives
Cyanoacrylate adhesive
Ensure compatibility
with coating
UV curable adhesive
available with Type IV
tester (requires special
loading fixtures with
transparent base)
Attaching the Loading Fixtures
Apply adhesive to the
loading fixture, surface, or
both
Addition of No. 5 glass
beads (1%) assists with
fixture alignment
Attach the loading fixture
to the coated surfaces
Push downward; do not
twist
Remove excess adhesive
Attaching the Loading Fixtures
(Type III Tester)
Insert Teflon plug
Apply adhesive to the
loading fixture, surface, or
both
Attach the loading fixture
to the coated surfaces
Push downward; do not
twist
Remove Teflon plug
Remove excess adhesive
Attaching the Loading Fixtures
Secure loading fixture
until adhesive cures
Use magnetic or
mechanical fixture
holder or tape
If using tape, ensure it
doesnt relax during
adhesive cure
Scoring Around Loading Fixture
Light scoring can be
performed to remove
excess adhesive
Scoring of the coating is
not recommended
If scoring is performed,
must be done carefully
Scoring (if done) must
be reported with test
results
Measuring Pull-off Adhesion Using
the Type II Tester
Model No. Range
106/1 0-500 psi
106/2 (shown) 0-1000 psi
106/3 0-2000 psi (uses wrench)
106/4 0-3200 psi (uses wrench)
106/4A Use w/ 2 diameter pull stubs
(uses wrench)
106/5 0-30 psi
Measuring Pull-off Adhesion Using
the Type II (fixed alignment) Tester
1. Lower the jaw by
turning the hand wheel
(nut) counterclockwise
2. Slide the jaw opening
over the head of the
loading fixture
3. Verify levelness
4. Set the drag pin to zero
(push downward)
1
4 3
2
Measuring Pull-off Adhesion Using
the Type II (fixed alignment) Tester
5. Rotate hand wheel
(nut) clockwise to
increase load (<150
psi/second)
6. Break (or maximum
force) should occur in
100 seconds or less
7. Record the value
corresponding to the
bottom of the drag pin,
E.g. 6 is 600 psi

Measuring Pull-off Adhesion using
the Type III (hydraulic) Tester
Insert pin through center
hole of stainless steel
loading fixture (may need
to loosen black threaded
hand lever)
Pull upwards on the quick
connect and allow the
locking ring to engage the
outside flange of the
loading fixture.
Pull upwards to verify
locking ring is engaged
Measuring Pull-off Adhesion using
the Type III (hydraulic) Tester
Return red sweep needle
to zero (or zero set the
digital display)
Rotate the black threaded
handle clockwise until
break occurs or maximum
pressure is achieved
Read pressure from analog
or digital display
Loading fixtures (stainless
steel) can be cleaned with
heat clamp
Measuring Pull-off Adhesion using
the Type IV (pneumatic) Tester
Device uses air pressure
inside a piston to provide a
constant, perpendicular
pull on a threaded loading
fixture
Piston pressure is
converted to psi (or Kpa)
using conversion charts
based on piston size
Measuring Pull-off Adhesion using
the Type IV (pneumatic) Tester
Piston Range
F-1 0-500 psi
F-2 0-1,000 psi
F-4 0-2,000 psi
F-8 0-4,000 psi
F-16 0-8,000 psi
F-8/12 0-4,000/0-10,000 psi
Round base with pigtail hose
Silicone rubber gasket (lifted upward)
Round threaded top plate
Measuring Pull-off Adhesion using
the Type IV (pneumatic) Tester
Connect piston hose to
the main air hose (brass
coupling)
Push air hose connection
into the base unit
Insert CO2 cartridge into
sleeve
Thread the CO2 sleeve
onto the base unit
Measuring Pull-off Adhesion using
the Type IV (pneumatic) Tester
Place piston over the
loading fixture
Thread top plate onto
the fixture until contact
is made with the piston,
then reverse the top
plate -1/2 turn to allow
silicone gasket to raise
Close the Rate Valve
(dont over-tighten)
Rate Valve
Measuring Pull-off Adhesion using
the Type IV (pneumatic) Tester
Turn the Power switch to
the on position
Push the peak reset button
Push in and hold the Run
button, while slowly
opening the Rate Valve
until pressure increases at
~2 psi/second
Do not exceed 6 psi/
second
On/off
Peak
Reset
Run
Rate
valve
Measuring Pull-off Adhesion using
the Type IV (pneumatic) Tester
Read the Piston Pressure
from the digital display
Convert the Piston Pressure
to psi (or Kpa) using the
conversion chart
corresponding to the piston
used and diameter of the
loading fixture
Example: 46 psi piston
pressure = 937.3 psi adhesion
strength (F4 piston and 0.5
diameter loading fixture)
Measuring Pull-off Adhesion using
the Type V (hydraulic) Tester
Type V uses hydraulic
pressure to apply
perpendicular force to
the loading fixture
Pull-off strength is read
directly from digital
display
Manual version is
shown
Measuring Pull-off Adhesion using
the Type V (hydraulic) Tester
Open the pressure relief
valve and push actuator
handle into assembly
Power-up tester (green)
Verify LCD reads zero
Select pull-stub size (*)
Select units (**)
* **
Measuring Pull-off Adhesion using
the Type V (hydraulic) Tester
Position actuator over
loading fixture. Attach
quick connect coupling to
head of fixture
Close the pressure relief
valve
Pump lever until digital
display indicates pressure
is applied
Measuring Pull-off Adhesion using
the Type V (hydraulic) Tester
Continue pumping
uniformly (<150 psi/ second)
Monitor pull rate using LCD
display (psi/s)
Display holds maximum
pressure of pull-off
Record value, or press
memory pad (*) to store
value
Depress green button to zero
display
*
Measuring Pull-off Adhesion using
the Type V (hydraulic) Tester
Automatic version
applies hydraulic
pressure to actuator
without pumping of a
lever
Measuring Pull-off Adhesion using
the Type VI (hydraulic) Tester
Type VI tester uses
hydraulic pressure to
apply perpendicular
force to the loading
fixture
Pull-off strength is read
directly from the gage
dial (up to ~ 2,470 psi)
Measuring Pull-off Adhesion using
the Type VI (hydraulic) Tester
Type VI tester consists of a
turning crank/pressure
gage & testing head
Verify crank and
tightening wheel are in
start position
Press 4 pistons against
even surface to return oil to
the pump
Measuring Pull-off Adhesion using
the Type VI (hydraulic) Tester
Lift outer ring of the quick
release coupling; mount
the testing head to the
loading fixture
Release the quick connect
and listen for click,
indicating it is locked into
the groove
Return the red sweep
needle to zero
Measuring Pull-off Adhesion using
the Type VI (hydraulic) Tester
Turn the tightening wheel
at base of pump until
piston legs contact surface
and gage dial initiates
movement
Turn hand crank smoothly
& evenly until a break
occurs or the maximum
pressure is reached
Read pressure from gage
dial (psi x 100 on red dial)
Special Requirements for Pull-off
Adhesion of Coatings on Concrete
Standard Test Method ASTM D7234-05
SSPC SP13/NACE No. 6, Appendix A1.6 describes
procedures for testing concrete coating adhesion
Testing procedures are similar; minor differences in
equipment and test procedures
This section is not comprehensive
SSPC CCI (Concrete Coating Inspector) Training
Program contains more detail
Four considerations described
Special Requirements for Pull-off
Adhesion of Coatings on Concrete
1. Scoring the coating
Thick film coatings (>20 mils) have lateral bond
strength
May produce misleading pull-off values (false, high)
Scoring through coating (down to the concrete surface)
is typically performed
Scoring is done prior to attachment of loading fixture
(except if loading fixture is square)
Scoring coatings <20 mils may also be required
When attaching loading fixture, verify adhesive does not
flow into groove

Special Requirements for Pull-off
Adhesion of Coatings on Concrete
2. Loading Fixture Size
Unlike steel, concrete is non-uniform and contains
cement and aggregate
Round loading fixture diameter should be 2 (50 mm)
to ensure test is performed over a representative area
Square loading fixtures are used with some testers
3. Loading Rate
The pressure loading rate should be 30 psi/second; the
test should be completed in 5-30 seconds

Special Requirements for Pull-off
Adhesion of Coatings on Concrete
4. Compressive Vs. Tensile Strength
Concrete has high compressive strength (i.e., 4000
psi), but low tensile strength (i.e., 400 psi)
Low pull-off values common
Plane of fracture commonly within the concrete
When fracture occurs in the concrete, report the
minimum coating tensile adhesion properties; actual
coating tensile strength remains unknown



Recording the Type and Location
of Break
Adhesion Break: A break between coating layers or
between the substrate and first coating layer
Cohesion Break: A break within a single coating layer
Glue Break: Coating adhesion and/or cohesion
strength exceeds bonding strength of the adhesive

If multiple locations of break occur, estimate the
percentage of each (e.g., 75% cohesion within primer;
25% adhesion between primer and intermediate coats)
Illustration of Various Locations of
Break
Recording the Type and Location
of Break
Disregard any test where glue break represents more
than 50%
If glue break occurs and the pull-off value is greater
than the acceptance value, re-attachment is not
necessary (report pass with pull-off strength > X psi)
Pitfalls to Avoid
Determine which tester to use. Different testers generate
different pull-off values on the same coating
Verify testing equipment has current calibration
Perform testing in triplicate
The rigidity of the substrate can affect the testing
Clean the surface and the loading fixtures to reduce the
possibility of glue failures. Use care when abrading the surface to
prevent introduction of surface flaws
Verify adhesive is compatible with the coating
Allow the adhesive to cure. Conducting pull tests before adhesive
is cured often results in glue breaks
Verify perpendicular pull
Support pull-off device on vertical surfaces

Reporting
General Nature of Test
Substrate type and coating system (thickness, type, surface
orientation)
Field or laboratory testing
Air temperature and relative humidity
Testing apparatus employed; loading fixture type/dimensions
Adhesive type employed
No. of tests performed
Load applied (pull-off values, in psi, KPa or MPa)
Mean and range of pull-off values
Location of break (between coats, within a coat, between substrate
surface and primer, etc.)
Note scoring, if employed (and any other deviations from procedure)

THE END