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Dry Film Thickness Measurements How Many Are Enough PDF
Dry Film Thickness Measurements How Many Are Enough PDF
Measurements:
D
How Many Are Enough?
A Close Look at Four Major By Rob Francis, Aurecon Australia Pty Ltd
ry film thickness (DFT) need to know how many measure-
International Standards is probably the single ments to make as part of their
most important inspection or QA work. But the owner
SSPC-PA 2 Method
above three standards. used in PSPC, although not specifically
One immediate problem that will defined. PSPC does require the type of
arise when inspectors attempt to gauge and calibration to be in The best known scheme for
compare different standards is the accordance with SSPC-PA 2, but does determining the number of DFT
measurements is the one described in
SSPC-PA 2. In brief, reference areas of
Rob Francis is a metallurgist and a corrosion and about 10 sq m need to be identified.
coatings specialist with engineering consulting company The number of reference areas
Aurecon (formerly Connell Wagner) in its Materials depends on the overall total area.
Technology Group in Melbourne. He has over 30 years Within each reference area, five
experience in metals and materials, especially regarding separate spot measurements are
protective coatings. Dr. Francis has a Ph.D. in corrosion taken, arbitrarily spaced over each
science from the Corrosion and Protection Centre at reference area.
UMIST, Manchester, UK. He is an Australasian Corrosion For structures not exceeding 30 sq m,
Association Corrosion Technologist and Coating each 10-square-meter area must be
Inspector, a NACE Certified Coating Inspector and accredited trainer. He is measured.
chairman of Australian Standards committee which produces AS/NZS 2312, For structures not exceeding 100 sq
Guide to protection of structural steel against atmospheric corrosion by use of m, three 10-square-meter areas are
protective coatings. He edited a book on inorganic zinc silicate coatings, which arbitrarily selected and measured.
was published in 1999. For structures greater than 100 sq m,
He can be contacted at FrancisR@ap.aurecongroup.com. three 10-square-meter areas within the
Table 1: Number of Spot DFT Readings Required by Different Standards for Flat Areas
*1 sq m ~ 10 sq ft
first 100 sq m are measured, followed measurements are required on each of Given the complexity of these
by one 10-square-meter area for each eight surfaces for beams less than 0.91 supplementary methods, and the fact
additional 100 sq m. meters (36 in.) in height, but an extra that it is not a mandatory part of the
In the main part of the standard, two are required on the web for higher standard, the inspector would probably
SSPC-PA 2 does not distinguish beams. benefit by following the better-known 5
between flat areas and other The procedure requires readings per 10 square meters
geometries such as beams that require measurements to be taken on the toes method, unless the 2004 advisory
DFT measurement. If the specification where possible. The standard states appendix is specifically named.
Australian Standard
requirement is simply to carry out the contracting parties may choose not to
AS 3894.3 Method
number of tests as specified by SSPC- measure at this location if the flange
PA 2, then the inspector would be thickness is less than 25 mm (1 in.).
expected to estimate the total area and The standard also notes that The method given in AS 3894.3 for
use the inspection plan described measurement on the toes may not be large areas is nearly identical to the
above. However, an informative practical on rolled beams, presumably SSPC-PA 2 requirement, although spot
appendix (a major addition to the 2004 because of the small size or rolled measurements are required to be
revision of this standard) presents curve. evenly spaced throughout rather than
testing protocols for measuring DFT on The standard gives the option of arbitrarily spaced, as required by the
beams and girders and other shapes carrying out a full DFT determination SSPC standard. The subtle difference
and sizes.2 A complete description of of a beam, which is a very thorough between these two requirements could
the protocols is outside the scope of inspection, or a sample DFT be important in a legal sense, but
this paper but the more complex determination with fewer measure- unlikely to be given in-depth
shapes require many more than five ments required. For a full consideration by the inspector. In
measurements per 10 sq m. Actual determination, the beam is divided into AS 3894.3, for flat areas less than 10
estimating of the required protocol is five equal sections or surfaces, and the sq m, a minimum of three spot
rather complex. Some of the decisions required number of measurements measurements per square meter are
that have to be established by the (between 8 and 14 depending on required.
inspector to determine the number of height and if the toe is measured) are AS 3894.3 has specific schemes for
measurements are listed below. made on each surface. For sample measuring DFT on beams and
The number of spot measurements at determination, only 2 or 3 regions are pipelines, generally a certain number of
each position on the beam depends on measured per beam, depending on measurements per meter length. Unlike
the height of the beam. Spot length. SSPC-PA 2, this is a normative part of
Click our Reader e-Card at paintsquare.com/ric Stop by our booth at the PACE Show.
Measuring DFT
Table 2: Summary of Test Requirements for 500 Square Meters of Area According to Method*
the Australian standard and so is tests are carried out to ensure does allow for an increased number of
mandatory. For beams and columns, 1 conformance with the specification. If measurements to be made on areas
measurement is required on each flat such areas are not identified, then the having difficult configurations, such as
face less than 300 mm (12 in.) in width, whole structure is considered as the stiffeners, brackets, and supports. The
for each linear meter (39 in.). For inspection area. In the latter case, standard also provides guidance for the
beams of less than 300 mm in height, requirements for flat areas are as number of measurements that can be
this would mean 8 measurements per follows. repeated if an individual measurement
meter, and 10 measurements per 5 spot measurements in the first is not within specification.
International Maritime
meter (an extra 2 on the web) for square meter
International Standard
required as for SSPC-PA 2 and AS this clause would be important.
Obligation Level
which is the term normally employed to
denote a mandatory requirement in
Each standard also has significant such a document. The document does
differences in its level of obligation for say that additional spot checks are to
the inspector to follow the given
measurement procedure. Actual
be taken to verify coating thickness for
any area considered by the coating HIGH QUALITY,
interpretation of requirements could
require legal opinion, but the
differences appear to be as follows:
inspector. This language implies that
the number of measurements specified
is a minimum, and the inspector can
NOT HIGH COST
The number of measurements given take more if considered necessary
in SSPC-PA 2 shall be carried out, without approval from other parties.
measurements than described without would need to be divided into 5 areas of shape of the face to minimize pressure points. The
strong and rigid outer shell prevents the masks from
any approval from the contractor or 100 sq m each. Within the first 100 sq m,
collapsing in humid and moist environments. The
specifier. three test areas of approximately 10 sq m dual head straps keep the mask comfortably in
For the ISO standard, the number of would be identified, and 5 measurements place. What makes the ONE-Fit N95 particulate res-
measurements required is the minimum pirators even more appealing is that they are almost
made in each. For each additional 100
half the cost of other equal quality NIOSH-approved
number, which implies that inspectors square meter area, one 10-square-meter N95 particulate respirators.
may carry out more (but not fewer) area would identified, and five measure- For more information on ONE-Fit respirators or any
without approval from other parties. In ments would be made in each. Figure 1 of the other head-to-toe personal protective equip-
fact, the standard specifically requires (p. 28) shows a typical inspection plan for ment available from Sperian Protection, call
866.786.2353 or visit www.sperianprotection.com.
that the number shall be increased for such work. Assuming that each 10-
inspection areas having difficult square-meter region is thoroughly tested,
30%of the first 100 sq m of area is case, we will also look at the actual become of little consequence. Each 100
tested, but only 10% of each subsequent number of individual measurements sq m would have a 10-square-meter
region. In all, about 14% of the area is because this will have a significant effect area tested with 5 spot measurements.
tested using these methods. on timing and costs. This gives a total of 15,000
If the work were to be carried out to If measurements were carried out in measurements. For SSPC-PA 2, each
ISO 19840, we again would divide it up accordance with SSPC-PA 2 and AS spot measurement is an average of
into 5 regions of 100 sq m. But in this 3894.3, the area would be divided into three gauge measurements, so the total
case, we would carry out a minimum of approximately 3,000 areas of 100 sq m number of gauge measurements is
30 measurements in the first 100- each. In this case, the extra few 45,000. For the other standards, only a
square-meter area, and 10 measure- measurements for the first 100 sq m single gauge measurement is required
ments in each additional 100-square-
meter-area. As well as having more
measurements than the above
standards, the ISO 19840 measure-
ments can be spread over the entire
area, rather than concentrated in 10-
square-meter areas (Fig. 2). The
measurements could concentrate on
edges, weld regions or other areas
where low thickness is likely. Fig. 1: A suggested inspection plan according to SSPC-PA 2 or AS 3894.3
The PSPC document is not designed for 500 square meters of flat surface area. Figures 15 courtesy of the author.
much greater with the large surface there must not be any areas of triple flange facepiece design allows for added seal-
area, with PSPC requiring 20 times as insufficient thickness. A significant ing protection on a greater range of face shapes and
many measurements as SSPC-PA 2 or variation in DFT is possible over a sizes. The smart placement of its exhalation valve
AS 3894.3 and ten times as many as square meter, and one measurement and cartridge ports allows for an enhanced
field of vision. With all these features and an un-
ISO 19840. may not identify this. matched price, the PREMIER Plus is a value that
Requirements
picture of the spread of DFT results For more information on the PREMIER Plus or any of
may be desirable, the costs and delays the other head-to-toe personal protective equipment
It could be argued that the SSPC and must be considered if thousands of available from Sperian Protection, call 866.786.2353
Australian Standard methods do not measurements are required. As or visit www.sperianprotection.com.
References
using the latest computerized thickness
gauges is covering the entire painted
area, when, in fact, the critical regions 1. T. Lohmann, Implementing the IMO
are not being measured and cannot be PSPC for Ballast Water Tanks,
inspected, at least by film thickness JPCL, February 2009, pp. 12-20.
Conclusions
of facepiece options including half masks, full face-
p. 14. pieces and a Tyvek hood. All of our half masks and
The testing protocols of the various 6. J F. Fletcher, Electronic Inspection full facepieces convert to APR applications. In addi-
DFT testing standards used around the Data Management for Salt Water tion, we offer several facepiece options that convert
to PAPR applications. Our unmatched variety and
world are significantly different from Ballast Tanks, Marine Coatings product flexibility ensure that we are always meeting
one another and have a range of Conference 2008, Hamburg, your changing needs.
requirements regarding both sampling Germany, September 2425, 2008. For more information on the Survivair SAR-CF Supplied