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 NonFerrous 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*
1.1 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 5.7.
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.
1.4 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

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 April 1, 2012. Published April 2012. Originally
approved in 2005. Last previous edition approved in 2005 as D7091 - 05. DOI:
10.1520/D7091-12.

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
2.2 SSPC Standard:
SSPC-PA 2 Procedure for Determining Conformance to Dry
Coating Thickness Requirements3
2.3 ISO Standard:
ISO 19840 Paints and varnishescorrosion 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:
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 standards 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 American National Standards Institute (ANSI), 25 W. 43rd St.,
4th Floor, New York, NY 10036, http://www.ansi.org.

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

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D7091 12
3.1.1 accuracy, nthe 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 DiscussionAn 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, nthe physical act of aligning a gages
thickness readings to match those of a known thickness sample
(removal of bias), in order to improve the accuracy of the gage
on a specific surface or within a specific portion of its
measurement range.
3.1.2.1 DiscussionAn adjustment will affect the outcome
of subsequent readings. Also known as optimization.
3.1.3 base metal reading (BMR), na measurement obtained on the uncoated substrate using a coating thickness
gage.
3.1.3.1 DiscussionThe 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.). Noncompensation for the base metal effect can result in an
overstatement of the true thickness of the coating.
3.1.4 calibration, nthe 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.
3.1.4.1 DiscussionCalibration 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 manufacturers stated accuracy.
3.1.5 certification, ndocumentation 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.
3.1.6 coating thickness standard, ncoated or plated metal
plates, or uncoated shims of flat sheet, with assigned values
traceable to a National Metrology Institution.
3.1.6.1 DiscussionIn 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 Halleffect methods the material must be nonmagnetic.
3.1.7 compensation value, ngenerating 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).
3.1.8 dry film thickness, nthe thickness of a coating (or
coating layers) as measured from the surface of the substrate.

3.1.8.1 DiscussionIf 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.
3.1.9 ferrous, ncontaining iron.
3.1.9.1 DiscussionDescribes a magnetic material such as
carbon steel. That material may also be known as ferromagnetic.
3.1.10 gage (gauge), nan instrument for measuring quantity, or an instrument for testing.
3.1.10.1 DiscussionIn this practice, the term gage refers
to an instrument for quantifying coating thickness.
3.1.11 manufacturers specifications, na statement or set
of statements that describes the performance characteristics of
the gage under a given set of conditions.
3.1.11.1 DiscussionManufacturers specifications typically include the range of measurement, accuracy statement,
operating temperature range, power source, dimensions and
weight, and conformance to industry standards.
3.1.12 measurement, nthe value obtained when placing
the probe of a thickness gage in contact with a surface.
3.1.13 micrometer (micron), none one-thousandth of a
millimeter (0.001 mm); 25.4 microns = 1 mil.
3.1.14 mil, nan imperial unit of measure; one onethousandth of an inch (0.001 in.); 1 mil = 25.4 microns.
3.1.15 nonconductive, na material that is unable to conduct electricity.
3.1.16 non-ferrous metal, na nonmagnetic metal or metal
alloy (for example, copper, aluminum or brass).
3.1.17 reference sample, na 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 DiscussionA 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 users
coating thickness measurement requirement.
3.1.18 shims, nstrips of flat sheet, with the thickness
stated or referenced in some form, that can be used to adjust a
coating thickness gage in the intended range of use over the
surface of the representative substrate material.
3.1.18.1 DiscussionOther 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.
3.1.19 substrate, nthe base material, the type of surface,
or the component that is being coated.
NOTE 1This practice addresses only metal substrates.

3.1.20 surface profile, nsurface texture generated during

the manufacturing process (for example, casting), or the
peak-to-valley depth generated by some power tools and by
abrasive blast cleaning operations.

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D7091 12
3.1.21 Type 1 gage, na magnetic pull-off instrument that
measures the dry film thickness of nonmagnetic coatings over
a ferrous metal base.
3.1.21.1 DiscussionFor 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.
3.1.22 Type 2 gage, nan electronic instrument that uses
electronic circuitry and (but not limited to) the magnetic
induction, Hall-effect or eddy current principles, or a combination of a magnetic and eddy current principles, to convert a
reference signal into a coating thickness reading.
3.1.22.1 DiscussionThe probe of a Type 2 gage remains
on the surface during the measurement process. Also known as
constant pressure probe or electronic gages.
3.1.23 verification of accuracy, nobtaining 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 manufacturers stated accuracy.
4. Significance and Use
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 manufacturers recommendations published on product data sheets can
become the governing document(s). Equipment manufacturers
produce nondestructive 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.
5. Principles, Advantages, and Limitations of Gages
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 manufacturers 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 manufacturers 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 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 nonferrous 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

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D7091 12
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
manufacturers 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 manufacturers 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
manufacturers specifications will contain a temperature operating range. Use of the gage or the probe outside of this range
may generate false coating thickness measurements and may
damage the instrument.
5.8 Coating thickness measurement accuracy can also be
affected by, but is not limited to, the following factors:
5.8.1 CurvatureThe 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 ParticlesInstruments 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 FieldsStrong 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 CoatingsInstruments may produce erroneous results depending on the type and amount of metal in the
coating film
5.8.5 Electrical Properties of the Basis MetalEddy current measurements may be affected by the electrical conductivity of the basis metal, which itself is often affected by heat
treatments.
5.8.6 PressureThe pressure with which the probe is applied to the test specimen affects the instrument readings and
should therefore be kept constant.
NOTE 2Consult 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 surface profile, shape, thickness,
composition and magnetic properties on which it is desired to
measure the coating thickness.
NOTE 3Applicable test panel description and surface preparation
methods are given in Practices D609 and D1730.
NOTE 4Coatings should be applied in accordance with Practices D823
or as agreed upon between the contracting parties.
NOTE 5Test panels may be fabricated from thin gage materials and
special consideration for gage adjustment may be required.

7. Frequency and Methods for Verifying the Accuracy

and for Adjusting a Coating Thickness Gage
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 AccuracyBefore use, each instruments
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 manufacturers 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:

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=5 2 15 2 5 7.071 or approximately 7 %.

(1)

D7091 12
7.2.2.1 For the gage to be in agreement with the standard,
the average thickness measured by the gage must be within
67 % of the standards thickness. If the average thickness
measured on a 254 m (10 mil) standard is between 236 m
(9.3 mils) and 272 m (10.7 mils), the gage is properly
adjusted. The minimum value of 236 m is calculated as 254
m minus 7 % of 254 m (9.3 mils is 10 mils minus 7 % of 10
mils); the maximum of 272 m is 254 m plus 7 % of 254 m
(10.7 mils is 10 mils plus 7 % of 10 mils). Otherwise the
accuracy of the gage is suspect.
7.2.3 If the user elects to use shims to verify the accuracy of
Type 1 gages (see Note 6 and Appendix X1), 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 manufacturers stated gage accuracy, the gage
should be returned to the manufacturer or authorized agency
for calibration. See 7.2.2 for an example of calculating the
combined gage and calibration shim accuracy. Otherwise the
accuracy of the gage is suspect. The user should never adjust
Type 1 coating thickness gages.
7.2.4 Since the gage is verified for accuracy using smoothsurfaced 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, casting) or from abrasive blast
cleaning. This is known as a Base Metal Reading or BMR. The
BMR is the effect of substrate (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 in
order to report the thickness of the coating layer(s) over the
surface profile.

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 manufacturers 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 manufacturers stated gage accuracy,
then the user should carefully follow the gage manufacturers
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
ProcedureA two-point adjustment fixes the instruments
calibration curve at two known thicknesses. Coated reference
samples or shims placed over the uncoated substrate or over an
uncoated 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 manufacturers instructions for performing a two-point adjustment, as
the actual step-by-step procedures vary widely.

NOTE 6SSPC-PA 2 prohibits the use of shims to verify the accuracy

of Type 1 gages. See Appendix X1 for more information.

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.

7.3 AdjustmentMany 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 manufacturers 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
ProcedureA one-point adjustment involves fixing the instruments 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

NOTE 7When 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

8.1 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 manufacturers
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.

8.4 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:
9.1.1 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),
9.1.5 The value of each measurement,
9.1.6 Operator identification, and
9.1.7 Date.

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D7091 12
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,

be measured can be more appropriate than using plated or

coated standards. Some gage manufacturers produce certified
shims.
NOTE X1.1Data 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 7.2.4.

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:

X1.3.4 Shim thickness inconsistency (due to the pressure of

the probe tip) that may be a permanent dimple in the shim.

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 nonconductive coatings (for example, paint).

X1.4 Even with these factors, in many applications, verification of gage accuracy using shims directly on the sample to

X1.6.2 Gages that use the Hall-effect principle are not

effected by the conductive nature of the coating.

X1.3.3 Distortion due to environmental conditions, such as

temperature, and

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.

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D7091 12
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