Measuring Dry Film Coating Thickness According to SSPC-PA 2(按照SSPC-PA2标准的要求检测干膜厚度)
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PCS, KTA-Tator, Inc.
Bill Corbett is the Vice President and Professional Services Group Manager for KTATator, Inc., where he has been employed for 33 years. He chairs SSPC committees C.3.2 on Dry Film Thickness and C.6 (Education). He is an SSPC-approved instructor for four SSPC courses, and he holds SSPC certifications as a Protective Coatings Specialist, Protective Coatings Inspector (Level 3), and Bridge Coatings Inspector (Level 2). He is also a NACE Level 3-certified Coatings Inspector. He was the co-recipient of the SSPC 1992 Outstanding Publication Award, co-recipient of the 2001 JPCL Editors’ Award, recipient of SSPC’s 2006 Coatings Education Award, and recipient of SSPC’s 2011 John D. Keane Award of Merit.
Bill Corbett是KTATator公司的副总裁和专业服务集团经理,他在那儿已经工作33年了。他担任SSPC委员会C.3.2干膜厚度和C.6(教育)的主席。他是SSPC四门课程的讲师,并持有SSPC防护涂层专家、防护涂层检验员(3级)和桥梁涂层检验员(2级)证书,他还是NACE3级认证的涂层检验员。他是SSPC1992年杰出出版物奖,2001年JPCL编辑奖,2006年SSPC涂层教育奖和2011年SSPC John D. Keane荣誉奖的获得者。
Coating thickness shall be measured in accordance with SSPC: The Society for Protective Coatings Paint Application Standard No. 2 (SSPC-PA 2) is a simple enough statement, yet this common specification requirement is often misinterpreted or regarded as a document that simply states how to measure the dry film thickness (DFT) of coatings, something we already profess to know how to do. Yet the requirements of SSPC-PA 2 regarding gage calibration, verification of gage accuracy and adjustment procedures, the number of measurements to obtain, and the tolerance of the measurements are complex and should be fully understood by the specification writer before invoking PA 2 in a contract.
涂层厚度应按照SSPC的要求进行测量:防护涂层协会油漆施工标准No.2(SSPC-PA2)是非常简单的条文,但是这么普通的规范要求经常被曲解或被认为是简单的描述成如何测量涂层干膜厚度的文件,有时候我们声称知道如何去做。但是SSPC-PA2关于表的校正、表精度的确认和校正程序、测量点的数量、复杂结构测量误差的要求,在合同引用PA2之前,规范的起草者应完全理解这些内容。

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On more than one occasion, I have heard the question, “When did SSPC-PA 2 and dry film thickness measurement become so complicated?” In fact, when you take a close look, measuring DFT isn’t that complex. We have allowed it to become more technologically complex while making the data easier to analyze. We can gather hundreds of gage readings in a relatively short time; batch the measurements; print the data or upload it to a computer for graphing; report the highest, the lowest, the mean, and standard deviation of the collected data; incorporate digital images of the structure or coated area; and even program the gage to produce an audible signal if a spot measurement is outside of the tolerance range. I am no doubt leaving out other bells and whistles, but my point is that while we are able to do a lot with the readings obtained, measuring DFT involves four or five basic steps.不止一次,我听说过这个问题,“什么时候SSPC-PA2和干膜厚度测量变得如此复杂?”事实上,当你仔细看,测量DFT并不复杂。我们已经使用更复杂的技术来使数据分析更加容易。我们可以在相对较短的时间内收集数以百计的读数;分批处理这些读数;打印这些读数或上传到电脑上绘制图形;记录收集这些读数的最高点、最低点、平均值和标准偏差;结合结构或涂装区域的数字图像;甚至在仪表中设置了超出单个测量点误差范围的报警信号。毫无疑问的,我不去考虑这些花俏的功能,但我的观点是:虽然我们可以对所获得的读数做很多分析,但是测量DFT只涉及到四或五个步骤。
Step 1: Instrument Calibration
步骤1:仪表标定
Step 2: Verification of Gage Accuracy on Certified Coated Standards or Certified Shims
步骤2:在经校验的涂覆标准或垫片上校验表的准确性
Step 3: Base Metal Reading Acquisition or Gage Adjustment (using certified or measured shims)
步骤3:母材读数获取或表的调整(使用经校验的或测量垫片)
Step 4: Measurement of Coating Thickness
步骤4:涂层厚度测量
Step 5: Correction for Base Metal Reading (if acquired).
步骤5:母材读数修正(如果需要的话)
After a brief review of the history of SSPC-PA 2, this article will describe each of the five steps, based on the 2012 edition of SSPC-PA 2. Special attention will be given in the article to how PA 2 addresses the required number of coating thickness measurements; the acceptability of gage readings, spot measurements, and area measurements; nonconforming thickness; measuring DFT on coated edges; and measuring DFT on pipe exteriors.
在简短的回顾SSPC-PA2历史之后,本文将按照2012版SSPC-PA2标准来叙述这五个步骤。本文将针对PA2描述的涂层厚度测量点数;表的读数合格率、测量点和测量区域;不合格厚度;在涂层边缘测量DFT;和在管道外表面测量DFT给予特别关注。
(未完待续)
Some History
SSPC-PA 2 was originally published as a temporary standard 40 years ago in 1973 (73T) as “Measurement of Dry Coating Thickness with Magnetic Gages.” The standard referenced gages like the one shown in Fig. 1, which are now all but obsolete. The standard has been updated on multiple occasions. Until 2012, the most recent technical changes were published in May 2004, with a minor editorial revision in 2009 to one of the appendices (regarding measurements on test panels). The SSPC Committee on Dry Film Thickness Measurement began revising and updating the 2004 version in 2007. The revisions took five years to complete. The latest edition of the standard (“Procedure for Determining Conformance to Dry Coating Thickness Requirements”) is dated May 2012 and was made available to the industry in July 2012.
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| Fig. 1: One type of magnetic gage referenced in original SSPC-PA 2 for measuring dft Figures courtesy of the author except where otherwise indicated |
| 2004 | 2012 |
| “Measurement of Dry Coating Thickness with Magnetic Gages” | “Procedure for Determining Conformance to Dry Coating Thickness Requirements” |
| Addressed measurement of coatings on steel only | Addresses measurement of coatings on ferrous and non-ferrous metal surfaces |
| No referenced standards section | ASTM D7091 and SSPC Guide 11 included by reference |
| Definitions section included Calibration; Verification; Adjustment; Coating Thickness Standard; Shim (foil); Dry Film Thickness Reference Standard; Accuracy; Structure. | Definitions section includes Gage Reading, Spot Measurement and Area Measurement only. All definitions related to gage calibration, accuracy and adjustment are incorporated by reference in ASTM D7091. Spot measurement definition was expanded. |
| No. of “Area Measurements” based on the size of the structure | No. of “Area Measurements” based on the size of the area of coated surface |
| Isolation of nonconforming areas required measurement of each 100 square foot area painted during the work shift. | The magnitude of nonconforming thickness assessed by obtaining spot measurements in eight equally spaced directions radiating outward from the nonconforming area |
| Recommended specifying minimum & maximum thickness range; if no range was specified, thickness value was considered minimum (with no maximum) | If a single value is specified and the coating manufacturer does not recommend a range, the minimum and maximum thickness range is established at ±20% of the stated value |
| Contained a minimum gage accuracy requirement to qualify for use | No minimum gage accuracy requirement to qualify for use |
| Conformance to Specified Thickness: Gage Readings: Unrestricted Spot Measurements: ± 20% of specified range Area Measurements: Per Specification | Conformance to Specified Thickness: Five different Coating Thickness Restriction Levels established. If no Restriction Level is specified, default is based on 2004 conformance requirement. |
| Notes section contained principles of gage operation and various substrate/surface conditions that may affect measurements; overcoating; and correcting for low/high thickness. | Notes section includes Overcoating and Correcting for Low/High Thickness only ASTM D7091 describes principles of gage operation and various substrate/surface conditions that may affect measurements. |
| Contained 6 appendices | Contains 8 appendices. Six appendices from 2004 version included. Added two: |
Gage Types
SSPC-PA 2 addresses two types of DFT gages, both of which are supplied by a variety of manufacturers. Magnetic pull-off gages are categorized as Type 1 (Fig. 2).
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| Fig. 2: Example of magnetic DFT gage categorized as Type 1 in SSPC-PA 2 |
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| Fig. 3: Example of electronic DFT gage categorized as Type 2 in SSPC-PA 2 |
Gage Calibration, Accuracy Verification, and Adjustment
To help assure the reliability of the coating thickness measurements, ASTM D 7091 describes three operational steps that must be performed before taking the measurements. These steps are (1) gage calibration, (2) verification of gage accuracy and (3) gage adjustment. The steps are incorporated by reference in SSPCPA 2 and are completed before obtaining coating thickness measurements to determine conformance to a specified coating thickness range. The steps to verify the accuracy of the gage are based on the principle that you check the gage by measuring a known thickness before you use the same gage to measure an unknown thickness. Verification of gage accuracy is typically performed using certified coated thickness standards (for Type 1 or Type 2 gages) or certified shims (Type 2 gages). Adjustment of Type 2 gages to compensate for substrate characteristics (described later) is typically performed using certified shims. Measured shims (individually labeled with a stated thickness value) commonly supplied with Type 2 gages can also be used for gage adjustment.Dry film thickness gages are calibrated by the equipment manufacturer, its authorized agent, or an accredited calibration laboratory (under controlled conditions). A test certificate or other documentation showing traceability to a national metrology institution is required. While there is no standard time interval for re-calibration, an interval can be established based on experience, the work environment, and/or the internal equipment calibration procedures of the company using the gage. A one-year calibration interval is a typical starting point suggested by gage manufacturers.
Verifying Gage Accuracy
To guard against measuring with an inaccurate gage, SSPC-PA 2 requires that gage accuracy be verified (at a minimum) at the beginning and end of each work shift according to the procedures described in ASTM D 7091. If a large number of measurements are being obtained, the user may opt to verify gage accuracy during measurement acquisition (for example, hourly). If the gage is dropped or suspected of giving erroneous readings during the work shift, its accuracy should be rechecked.
Verifying the Accuracy of Type 1 Gages
The accuracy of Type 1 (magnetic pull-off) gages is verified by placing the gage probe onto a certified coated thickness standard (Figs. 4 and 5). A one-point or two-point accuracy verification procedure can be performed; typically, the two-point verification provides greater accuracy. If a one-point verification procedure is adopted, the coated standard should be selected based on the intended range of use. For example, if the intended use is between 4 and 6 mils, then a five-mil coated standard is appropriate. Using the same example, if a two-point verification procedure is adopted, then a two-mil and an eight-mil set of coated standards (slightly below and above the intended range of use) is appropriate.
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| Fig. 4: (top) and 5 (bottom) Verifying the accuracy of Type 1 gages using certified coated thickness standards |
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| Fig. 6: Obtaining base metal readings with Type 1 gage |
This requirement makes Type 1 gages very difficult to use. While some gage operators may simply subtract a fixed amount (for example, 0.5 mils) from any reading, such a practice is not in compliance with SSPC-PA 2.
Verifying the Accuracy of Type 2 Gages
The accuracy of Type 2 (electronic) gages can be verified by placing the gage probe onto a certified coated thickness standard (described for Type 1 gages) or certified shims (Figs. 7 and 8). The certified shim should be placed onto a smooth, uncoated metal surface to remove any effect of the surface roughness during this process. A one-point or two-point accuracy verification procedure can be performed (as described earlier for Type 1 gages).
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| Fig. 7: Verifying accuracy of Type 2 gage on a certified coated standard |
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| Fig. 8: Verifying accuracy of Type 2 gage using a certified shim |
Adjusting Type 2 Gages
The final step in the process is to adjust the gage on the surface to which the coating will be applied. Adjustment is accomplished by placing a certified or measured shim (or shims) onto the prepared, uncoated metal surface and adjusting the gage (when feasible) to compensate for substrate characteristics including (but not limited to) substrate metallurgy, geometry, thickness/thinness, and roughness (Fig. 9). The gage reading is adjusted to match the thickness of the shim, which effectively removes any influence from the underlying surface.
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| Fig. 9: Adjusting Type 2 gage using a measured shim on the surface to which the coating will be applied |
Required Number of Coating Thickness Measurements
The section of SSPC-PA 2, “Required Number of Measurements for Conformance to a Thickness Specification,” causes many users confusion, which can result in either under- or over-inspection. Arguably the most critical section in the document, Section 8, describes how many areas to check, the size of the areas, the number of measurements to obtain in each area, and the steps to take if spot or area measurements do not conform to the specification.SSPC-PA 2 contains three definitions that are critical to understanding this next area of discussion.
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| Fig. 10: Approximate 100-square-foot area containing gage readings and spot measurements, as depicted in Appendix 1 of SSPC-PA 2. Courtesy of SSPC |
Acceptability of Gage Readings, Spot Measurements, and Area Measurements
While individual gage readings that are unusually high or low (and cannot be repeated consistently) can be discarded, there are limitations on the thickness values representing the spot measurements (the average of three gage readings). A minimum thickness and a maximum thickness are normally specified for each layer of coating. However, if a single thickness value is specified and the coating manufacturer does not provide a recommended range of thickness, then the minimum thickness and maximum thickness for each coating layer are established by SSPC-PA 2 at ±20% of the stated value. For example, if the specification requires 3 mils’ DFT and the coating manufacturer does not provide any additional information regarding a recommended thickness range, then, by default, the specified range is established as 2.4–3.6 mils. Because the coating may not perform at the lower thickness, it is important for the specifier to indicate an acceptable range for each coating layer. To assist the specifier, the 2012 edition of SSPC-PA 2 incorporates a Restriction Level Table (Fig. 11). The Table enables the specifier to select from five different restriction levels related to spot and area measurements.
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| Fig. 11: Coating Thickness Restriction Levels (as shown in Table 1 of SSPC-PA 2, Section 9) Courtesy of SSPC |
For example, assume that the specification requires a four- to six-mil application of primer. The actual minimum and maximum spot and area thickness requirements are shown in Fig. 12 for each of the five restriction levels.
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| Fig. 12: Coating Thickness Restriction Levels Based on a Four-to-Six-Mil Requirement Derived using the 2012 edition of SSPC-PA 2, “Table 1, Coating Thickness Restriction Levels” |
Determining the Magnitude of Nonconforming Thickness
Another change in the 2012 version of the standard is the procedure for identifying nonconforming areas (Fig. 13). In the 2004 edition, if spot or area measurements were out of conformance, each 100-square-foot area coated during the work shift had to be measured, and nonconforming areas had to be demarcated. On a larger structure with multiple applicators, the measurement and documentation process could be extensive, so the approach was changed in the 2012 revision. If a nonconforming area is identified, spot measurements are made at five-foot intervals in eight equally spaced directions radiating outward from the nonconforming area, as shown in Fig. 13.
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| Fig. 13: Depiction of procedure for identifying nonconforming areas, as described in the 2012 edition of SSPC-PA 2. Courtesy of SSPC |
Non-compliant areas are demarcated using removable chalk (or another specified marking material) and documented. All of the area within five feet of any non-compliant spot measurement is considered non-compliant. For a given measurement direction or unit measurement, any compliant area or unit preceding a non-compliant area or unit is designated as suspect, and, as such, is subject to re-inspection after corrective measures are taken.
Appendices to the Standard
There are eight appendices in the 2012 version of SSPC-PA 2. Two of the eight appendices were added in 2012 (the remaining were in the 2004 edition) and are highlighted below. The appendices to SSPC-PA 2 are not mandatory but may be invoked by contract documents.
Appendix 6: Method for Measuring the Dry Film Thickness of Coatings on Edges
For decades, the industry was cautioned about taking coating thickness measurements within one inch of an edge, let alone on an edge. However, several Type 2 (electronic) gage manufacturers offer a variety of probe configurations, some of which are less affected by proximity to edges and are designed to better measure the thickness of coatings on edges (Fig. 14). Obviously, the gage operator should consult the gage manufacturer’s instructions before measuring coating thickness on edges.
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| Fig. 14: One of a variety of Type 2 gage probe configurations designed to better measure DFT of coatings on edges |
Appendix 7: Method for Measuring Dry Film Thickness on Coated Steel Pipe Exterior
Appendix 7 was added to accommodate pipe coaters that need to determine coating thickness conformance on non-flat (or non-plate) areas, including smaller pipe sections on a cart or rack and longer pipe spools.Pipe sections loaded onto a cart or rack can be considered a complete unit (Fig. 15). The total number of spot and area measurements is based on the total square footage of pipe on the cart or rack. The square footage is calculated as shown on p. 35.
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| Fig. 15: (top and bottom): Appendix 7 of the 2012 edition of SSPC-PA 2 describes a method for measuring DFT on non-flat steel, such as pipe sections that can be loaded on racks or carts. Photos courtesy of Turner Industries Group, L.L.C. |
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| Comment from Louis Vincent, (5/9/2013, 8:51 AM) | |||||||
| Bill, This is a superb explanation of a complicated measurement standard, but not nearly as complicated as the IMO PSPC requirement. This one goes on my desktop where I can access it easily. Lou Vincent |
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