12/23/2018 Resources | DeFelsko

PRODUCTS  ABOUT US RESOURCES SALES SERVICE & SUPPORT 

Search… 

Galvanizing Thickness Measurement Other Resources

Measuring Total Coating
This article details the use of DeFelsko Coating Thickness Thickness on Plastics,
Gages within the zinc galvanizing industry. It describes different Concrete, Wood & more Using
types of hand held gages, the measurement process, several Max Thick Mode on the
precautions to be taken, and a Q&A section for the most PosiTector 200
commonly asked questions concerning this application.
Measuring Paint Thickness on
Plastic Bumpers/Fascias with
BACKGROUND Advanced Driver Assistance
Steel corrodes when an electrolyte (such as water) connects Systems (ADAS)
anodes and cathodes on a steel surface. The formation of the
Power Tool Cleaned Surfaces:
corrosion cell causes a aky iron oxide known as rust.
New Insights into Surface
To avoid rust, something must prevent the formation of the corrosion cell. Two common methods for preventing Pro le Measurement
corrosion on steel are:
Integrating your Instrument
1. Cathodic protection (by using a sacri cial anode). with Third-party Devices and
2. Creating a barrier to block electrolytes from contacting the steel. Applications

Galvanizing is the process by which a sacri cial anode layer of Concrete Moisture
zinc is applied to the surface of a fabricated steel part to Measurement
provide corrosion protection. The nal step in this process is
the inspection of: Remote Monitoring of
Environmental Conditions
Coating thickness
Visual appearance Duplex Coating System
Adhesion Thickness Measurement

 Uniformity

The thickness of the galvanized coating is directly related to:

https://www.defelsko.com/resources/galvanizing-thickness-measurement 1/10
12/23/2018 Resources | DeFelsko

Service life Adhesion of Sealers on

Amount of corrosion protection Thermal Spray Coatings
Quality
Coating Adhesion Testing in
A thicker coating of galvanize results in a longer service life for the coated part. Consequently, inspection of Accordance with ASTM D4541
coating thickness is the single most important step in determining the quality of a galvanized coating. - Sticky Business

Finish Coatings System

MEASURING GALVANIZE THICKNESS Adhesion and Test Methods
The size, shape and number of pieces to be tested will dictate the
appropriate test method. Speci ed test methods are categorized as Ultrasonic Thickness
either destructive or non-destructive. Measurement of UV-Cured
Coatings on Rigid Substrates
There are four ways to measure the thickness of galvanizing:
Measuring Environmental
1. magnetic principle thickness gages Conditions
2. stripping and weighing
3. weighing the part before and after galvanizing Test Methods for Coating
4. optical microscopy (ASTM B 487) Adhesion

Calibration Terms - Coating

Thickness Gages

The most practical test is the non-destructive method utilizing the magnetic principle
for determining coating thickness. This test is

Non-destructive
Simple, fast, and inexpensive
Complies with recognized international standards including ASTM D7091, CSA G 164-
M and ISO 2808

Because it is non-destructive, magnetic thickness measurement is the most common method of evaluating

galvanizing coating thickness.


https://www.defelsko.com/resources/galvanizing-thickness-measurement 2/10
12/23/2018 Resources | DeFelsko

MAGNETIC PRINCIPLE THICKNESS GAGES

Coating thickness gages that operate on a magnetic principle are designed to measure non-magnetic coatings
applied to ferrous metals. The three most common types of magnetic principle thickness gages fall into one of
two categories:

Comparing Magnetic Gage Types

Mechanical Gages

Measure the strength required to pull a magnet away from steel. The thicker the zinc, the weaker the attractive
magnetic force.
No calibration adjustment required
Simple and rugged

Electronic Gages

Measure the change in ux density using electronic circuitry.

Clear, digital readout
Variety of specialized probe styles
Many offer built-in memory
Adjustments can be made for substrate conditions

Magnetic Gage Features

Mechanical/Pen Style

No calibration adjustment required

Very small, unique magnet allows pinpoint placement
Ideal for use on small, hot, or di cult-to-access

 measurement locations
±10% accuracy

https://www.defelsko.com/resources/galvanizing-thickness-measurement 3/10
12/23/2018 Resources | DeFelsko

Mechanical/Dial Type

No calibration adjustment required

Simple, durable, universally accepted
No batteries/electronics
GO/NO-GO button can be preset for rapid measurement
±5% accuracy

Electronic

Fast and simple operation

Manual calibration adjustments are possible for increase
accuracy

 Easy-to-read digital display

Versatile - variety of integral or cabled probes

https://www.defelsko.com/resources/galvanizing-thickness-measurement 4/10
12/23/2018 Resources | DeFelsko

Connectivity options - direct printing, USB, WiFi, Bluetooth

Statistical capabilities - averaging, min/max
Powerful software for reporting measurement data
Built-in memory
±1% accuracy

Measurement
Precautions:

Follow gage manufacturer's instructions

Verify gage accuracy regularly using reference standards
Ensure that the test surface is free from dirt, grease, oxide, and
corrosion products
Measurement points should be chosen to avoid obvious peaks or
irregularities in the coating
A su cient number of readings should be taken to obtain a true
average coating thickness

When utilizing
a mechanical
gauge, perform the
following steps:

1. To compensate for the in uence of substrate conditions

(including mass, metallurgy, roughness, temperature and
curvature), measure the uncoated substrate/part at a number
of spots to obtain a representative average value. This
average value is called the “base metal reading” or “BMR”.
2. Measure the zinc thickness at the number of spots required
by the relevant procedure or standard.
3. Subtract the base metal reading (BMR) from the gage reading
to obtain the thickness of the galvanizing.

When utilizing an electronic gauge, perform the following steps:

 1. To compensate for the in uence of substrate conditions (including mass, metallurgy, roughness, temperature and
curvature), check zero on the uncoated substrate/part and adjust if necessary.
2. Check by measuring shims placed on the uncoated substrate.
https://www.defelsko.com/resources/galvanizing-thickness-measurement 5/10
12/23/2018 Resources | DeFelsko

3. Measure the galvanized part. The gage reading indicates the thickness of the applied galvanizing.

MEASURING DUPLEX COATING SYSTEMS

Duplex coating systems use a combination of two corrosion protection systems – typically paint or powder
coating over galvanized steel (hot-dip, electro or zinc spray metallizing). The corrosion protection which results
from a duplex coating system is superior to either protection system used independently.

DeFelsko’s PosiTector 6000 FNDS coating thickness gage non-destructively measures the individual thicknesses
of both the paint and the zinc galvanize layers in a duplex coating system with a single reading.

See our Duplex Coating System Thickness Measurement application note to learn more.

CONVERSIONS
Magnetic coating thickness gages report measurement values in units of linear distance, not coating weight.
However, the gage reading can easily be converted to an expression of coating weight.


https://www.defelsko.com/resources/galvanizing-thickness-measurement 6/10
12/23/2018 Resources | DeFelsko

Example Conversions
Example A: Imagine you take a measurement on a steel coil
coated with zinc galvanize using a PosiTector 6000 F gage and
obtain a single-side thickness reading of “0.35 mils.” This can
be easily converted to oz/ft² using the following method:

1. Multiply the gage reading of 0.35 mils by 2 to account for

 both sides of the panel (0.70 mils)

https://www.defelsko.com/resources/galvanizing-thickness-measurement 7/10
12/23/2018 Resources | DeFelsko

2. Multiply 0.70 by a factor of 0.5938 to convert to oz/ft²

(0.4157 oz/ft²)
3. 0.4157 oz/ft² of zinc galvanize indicates G40 weight (0.40
oz/ft² minimum average, total of both sides per ASTM A 653)
Example B: Alternately, you can quickly con rm that a galvanized
steel sheet meets a speci c coating weight. According
to ASTM A 653, a G90 coating designation means the weight of
zinc on both sides of a steel sheet is 0.90 oz/ft².

However, a magnetic thickness gage measures only one side.

Therefore:

0.45 oz/ft² x 1.684 = 0.76 mils per side, or 0.45 oz/ft² x 42.78 = 19 microns per side
Example C: Tocalculate grams/meter² from a result displayed in microns, rst multiply the gage reading (or the
average of a series of readings) by a factor of 2, and then multiply that result by 7.133. The nal calculation will
indicate the coating weight for both sides of the coated part.

Q&A
Q: Why does it seem that I never obtain the same gage reading twice?

A: Although the galvanized surface may appear smooth, microscopic surface roughness exists on both the zinc
and steel. Therefore, the best representation of coating thickness is obtained by averaging a series of readings as
per ASTM A123.

Q: Can I use a magnetic coating thickness gage to measure coating weight?

https://www.defelsko.com/resources/galvanizing-thickness-measurement 8/10
12/23/2018 Resources | DeFelsko

A: Magnetic coating thickness gages report measurement values in units of linear distance, not coating weight.
However, the gage reading can easily be converted to an expression of coating weight using a conversion table
or multiplication factor.
Q: What should a coating thickness gauge read on a G90 galvanized coating?

A: According to ASTM A 653, a G90 coating designation means

the weight of zinc on both sides of a steel sheet is 0.90 oz/ft 2

A magnetic thickness gauge measures only one side.

Therefore:

0.45 oz/ft 2 x 1.684 = 0.76 mils per side

0.45 oz/ft 2 x 42.78 = 19 microns per side

ASTM STANDARDS
Excerpts from ASTM A123 Standard Speci cation for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel
Products:

The specimen coating thickness shall be the average of a minimum of 5 readings at widely dispersed points.
This average value shall be not less than one coating thickness grade lower than the value listed in the appropriate
speci cation.
Thickness should be between 1.4 and 3.9 mils (35 and 100 µm) depending on the coating grade.

ASTM E 376 Standard Practice for Measuring Coating Thickness by Magnetic-Field or Eddy-Current

(Electromagnetic) Examination Methods

ASTM A123/A123M Standard Speci cation for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A153/A153M Standard Speci cation for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A653/A653M Standard Speci cation for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated
(Galvannealed) by the Hot-Dip Process

ASTM A767/A767M Standard Speci cation for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement

ASTM D7091 Standard Practice for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings
Applied to Ferrous Metals and Nonmagnetic, Non-conductive Coatings Applied to Non- Ferrous Metals


https://www.defelsko.com/resources/galvanizing-thickness-measurement 9/10
12/23/2018 Resources | DeFelsko

   EMAIL US
QUICK LINKS TOOLS C O NTA CT
PosiSoft Software Sitemap 1-800-448-3835 (USA & Canada) DeFelsko Corporation
Sales Join Our Team 800 Proctor Avenue
+1-315-393-4450
Resources Privacy Statement Ogdensburg, NY 13669-2205 USA
Fax:   +1-315-393-8471
About Us / Events Terms & Conditions
What's New PosiTrack

© 2017 DEFELSKO CORPORATION.  ALL RIGHTS

RESERVED.
   


https://www.defelsko.com/resources/galvanizing-thickness-measurement 10/10