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applied film thickness requirements.2

This article will discuss variousapplied film thickness measurementtechniques and how they relate topolyurea elastomer coating and liningtechnology, specifically for concretestructures, a major use of polyureacoatings. The article will focus onASTM D6132, “Standard Test Methodfor Nondestructive Measurement of

Dry Film Thickness of Applied OrganicCoatings Using an Ultrasonic Gage,” andthe new SSPC Paint ApplicationSpecification No. 9, Measurement ofDry Coating Thickness on CementitiousSubstrates Using Ultrasonic Gages.

Thickness Measurement MethodsSo just how does one measure theapplied film thickness of fast-set, plural-component polyureas on concrete? Thetraditional and easiest method recog-nized by the industry is the use of

notched gauges on the applied wet film(wet film thickness gauge).3,4 Althoughthis method is fast and economical, theapplied coating systems must remain ina liquid state for a period of time toproperly use the gauge. With fast-setsystems, like polyurea, a wet film gaugeis woefully inadequate.Because the polyurea spray elas-

tomer gels or sets very rapidly, usuallywithin 15 seconds,there is no time toplace the gauge inthe “wet” material,remove the gauge,and achieve an accu-rate reading. Also,the gauge can becomestuck or glued intothe polymer system,or it can otherwisedamage the material,leaving visible defects(Fig. 1). Dry filmthickness (dft) mea-surements can also betaken to monitorapplication. The mostcommon method ismeasuring film thick-

ness on metallic substrates using mag-netic thickness gauges. Because themajor use of polyurea is for protectingconcrete or cementitious substrates,magnetic gauges are not directly suit-able. However, contractors can use mag-netic gauges with some creativity.5 Byeither driving large head metal nails inthe concrete substrate, or by placingsmall metal panels on the surface, fol-lowed by application of the coating sys-tem, contractors can measure coatingdft using magnetic thickness gauges.

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n any coating or lining work,obtaining the specified minimumfilm thickness or the minimum

average film thickness is essential. Inaddition, the applied coating or liningmust be uniform and void free to pre-vent premature failures related to uni-formity and coverage that otherwisecan and will occur. Specifications callfor a required minimum film build, notto verify material use,but because therequirement relates tothe overall perfor-mance of the project.Knowing the appliedfilm thickness of thecoating or lining sys-tem as the job pro-ceeds also helps deter-mine if one hasobtained sufficientmaterial to successful-ly complete the appli-cation work as speci-fied.Film thickness can

also affect the color,gloss, surface finish,adhesion, flexibility,impact resistance, and hardness of acoating. The effects of film thickness areespecially critical for fast-set, plural-component polyurea spray coating andlining systems;1 however, wet filmthickness measurements used in tradi-tional coating and lining work may notreadily apply to the polyurea technolo-gy due to its unique characteristics.Failures due to low film thickness

could be avoided with proper applica-tion training and attention paid to thespecification requirements and minimal

M a i n t e n a n c e T i p s

Evaluating Techniques for Measuring Applied FilmThickness of Polyurea Elastomeric Systems

By Dudley J. Primeaux II, Primeaux Associates LLC, Elgin, TX and Kelin Bower, PolyVers International, Houston, TX

I

Fig. 1: Wet mil gauge in fast-set polyurea(inset: film defects from the gauge)Figures courtesy of the authors

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Continued

Figure 2 is a simple illustration of thatprocedure.While the procedure in Fig. 2 may

seem simple and ideal, it has some prob-lems. For example, the human factorcomes into play. If the coating applica-tor knows the purpose of the nails ormetal panels, he or she may tend to paymore attention during application toareas designated for dft measurement.This tendency may lead to the designat-ed areas being within the average mini-mum thickness requirements whileleaving other areas thinner thanrequired.The use of the nails or panels can also

result in raised or higher levels of theapplied coating. Aesthetic issues andperformance concerns can result if traf-fic or mechanical movement is presentin a raised area. For instance, if metalpanels are not permanently bonded tothe substrate, large areas of de-bondingcould occur, especially if multiple loca-tions are used for overall thickness mea-surements, such as in SSPC-PA 2 orSSPC-PA 9.6,7 So the use of magneticgauges on coatings over nails or metalon concrete is not always a goodapproach.Although destructive, other methods

suitable for concrete substrates can

include the P.I.G. or Tooke gauge fordft.8 While these methods are typicallyused on thinner film coating systems(< 10 mils or 254 µm), they can be usedon the thicker film coating systems.However, it has been shown in somecases that when using this technique onthe thicker applied polyurea elastomer-ic systems, the resilient qualities of thefilm build do not allow for a clean cut,and inconsistent readings can occur.Moreover, some may actually not becuttable because they are soft, and read-ing of the cut angle is useless for evalua-tion. Another disadvantage to usingdestructive measurements is that thetest area must be repaired.Relatively new to the arsenal of the

coatings applicator and inspector is theultrasonic gauges for use on concreteand cementitious substrates.9 Thesegauges work by sending a signal (ultra-sound) pulse through the applied coat-ing system and measuring the timerequired for the signal to bounce backfrom the substrate. Using data gatheredthrough ultrasound, the gauge then cal-culates the coating thickness.Some writers have discussed why

ultrasonic gauges do not work well forapplied fast-set polyurea spray elas-tomer systems.10 One limitation, as is

claimed, results from the microcellularmakeup of the applied polyurea. Thehigh-pressure impingement mixingneeded to apply the coating can causethe coating’s microcellular characteris-tic, which interferes with the ultra-sound signal. The coating also may bedeformable under the load of the testprobe.While some of the objections to using

ultrasound techniques might be true toa minor degree, some other characteris-tics of polymers in polyurea systemscan help overcome the objections. Forexample, one characteristic of polyureaspray technology, aside from the possi-ble microcellular nature, is that its poly-merisation produces higher molecularweights at the outer surfaces of thecross section of the polymer film11,12

compared to outer surfaces ofpolyurethanes and epoxy systems thatpossess relative uniform polymer mole-cular weight distribution throughout across section of the polymer film.Because ultrasonic units work bychanges in density, the unit “sees” theapplied layers (or spray passes), oftencausing confusion on thickness evalua-tions of applied polyurea spray sys-tems.

Fig. 2: Polyurea applied over nail or metal plate

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M a i n t e n a n c e T i p s

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To avoid confusion, it is very impor-tant to calibrate the ultrasound instru-ment and to verify its calibration beforeusing the unit on the project.Calibration must be re-affirmed throughout themeasurement process.Initial spot measurementsshould be made to give onean idea of the applied coat-ing thickness range. Oncethe range is confirmed, thegain can be adjusted on theunit to evaluate the thick-ness range, thus overcom-ing confusion relating tochanges in density.Furthermore, one can getan idea of howmany passesor layers have beenapplied. ASTM D6132,Section 3.3.3, notes thatnon-uniform coating densi-ty can influence accuracy.The proper transducer

probe use is essential forpolyurea systems. It hasbeen found that the “D”probe is the optimum andsuggested probe to use when evaluatingapplied film thickness for fast-setpolyurea spray elastomer systems.

Concrete Coating and LiningMeasurement Testing

As mentioned, one of the largest usesfor the polyurea spray elastomer tech-nology is in the coating or lining of con-crete substrates.13 With that in mind, itis very important that proper appliedfilm thickness be observed to insure

performance in these application areas.To illustrate the usefulness of the ultra-sonic gauges, a series of experimentaltest panels was prepared.

A series of concrete blocks, 8 in. x 16in. (20 cm x 40.6 cm) was prepared witha profile of CSP 2 to CSP 3.14 The tophalf of each block was primed with anepoxy primer system. In the center ofeach block, a metal coupon 3 in. x 5 in.(7.6 cm x 12.7 cm) was used for thick-ness measurement using magneticgauges. The top portion of the couponwas taped off to allow for conventionalmicrometer testing of applied dft (Fig.3). The metal coupons had a surface pro-

file of 3 to 4 mils (76 to 101 µm), asillustrated in Fig. 3.The four blocks were coated with one

coat, two coats, three coats, and fourcoats respectively, of a fast-set spray polyurea elas-tomer system, with a geltime of about 10 secondsand tack free time of about30 seconds. The polyureasystem was applied with aplural-component, high-temperature/high-pres-sure proportioning unit, fit-ted with a mechanicalpurge impingement mixspray gun. After one hourof application of thepolyurea system, each sam-ple was evaluated for sys-tem uniformity and appliedfilm thickness.A visual observation of

the coated concrete panelsrevealed that the one-coatapplication gave poor,incomplete coverage overthe unprimed and primedconcrete area, while the

two-coat application showed incom-plete coverage over only the unprimedconcrete area. For each of the fourmetal samples, complete coverage wasnoted for the one- to four-coat applica-tions (Fig. 4).

ResultsMicrometers, Type 2 magnetic gauges,and an ultrasonic gauge, were used tomeasure the applied dft of the polyureaspray elastomer system. Table 1 showsthe results.Very good consistency in the mea-

sured dft was obtained from the differ-ent test methods, including the ultra-sonic gauge. However, the results arenot exact between methods used.Discrepancies can be explained by thecharacteristics of the applied polyureasystem and the surface profile of the

Continued

Fig. 3: Concrete test samples

Fig. 4: (L to R) Coated concrete test samples, one coat to four coats

*values reported are in mils (thousands of an inch)

Table 1: Applied Dry Film Thickness Results*

Sample

#1, 1 coat

#2, 2 coats

#3, 3 coats

#4, 4 coats

MicrometerTape area

13

20

34

55

Type 2, #1

Metal

10

18

29

43

Tape area

11

19

30

47

Type 2, #2Metal

10

21

28

44

Tape area

12

19

31

50

Ultrasonic, ConcretePrimed

13

25

28

52

Unprimed

13

25

28

51

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M a i n t e n a n c e T i p s

substrate.Fast-set polyurea systems are not

paint materials. Applied polyureashave surfaces that are level but with anorange-peel finish, and the orange peelcan cause some measurement issues.15

Depending on where one places thegauge probe, varying thicknesses can bemeasured, and averaging will “smoothout” the results, though the numberswill not be exact. (See ASTM D6132,Section 3.3.2.)Compared to metals, concrete sub-

strates have a higher profile and poros-ity, which can account for large spreadsin dft evaluations. Use of a primer sys-tem is mainly for improved adhesionand other minor issues, but can also pre-vent penetration of the coating systeminto the substrate.

Application and Field Useof Ultrasonic Techniques

The successful field use of ultrasonicthickness measurements for an appliedpolyurea system to concrete was con-firmed in the following examples.The concrete floor of a decommis-

sioned facility, once used for manufac-ture and repair of large electrical trans-formers but then scheduled for demoli-tion, was contaminated with polychlori-nated biphenyls (PCBs), a known healthhazard. To protect the demolition crewand minimize the transfer of contami-nants, a polyurea spray technology wasspecified as a floor/capping system.The specification called for a minimumaverage coating thickness of 60 mils(1.5 mm) in light areas and a minimumaverage of 120 mils (3.0 mm) in heavyconstruction equipment areas on the28,000 ft2 (2,600 m2) facility.To confirm that the specified film

thickness was achieved, an ultrasonicgauge was used to verify the coatingthickness and measurements weretaken, using the SSPC-PA 2 procedurefor frequency characterization (becauseSSPC-PA 9 had not yet been published).Measurements taken throughout the

project were found to meet the mini-mum specified film thickness in thenoted areas. However, the specifierexpressed some doubt about the validi-ty of the results, so to confirm the read-ings, micrometer measurements of thethickness of removed blisters weretaken. The micrometer measurementscorrelated with the results of the ultra-sonic gauge.16

Polyurea was specified as the liningfor a concrete secondary containmentarea in the diesel, jet fuel, and MOGASstorage area of a major Air ForceFacility. The specification called for aminimum average thickness of 80 mils(2.0 mm), applied over a failing epoxylining system. Ultrasonic thickness test-ing was again used to monitor theapplied film build. To confirm the thick-ness measurement of the ultrasonicgauge, caliper measurements were takenfrom samples obtained from destructivepull-off adhesion testing, as was speci-fied for certain areas of the project.17 Inthis work, the adhesion testing affordedthe ability to confirm the applied filmthickness noted with the ultrasonicgauge by use of micrometers. Of course,these test areas required repair of thelining system before the customer wouldaccept the project.

ConclusionIn order to insure performance of aninstalled coating or lining system, moni-toring of applied film thickness is cru-cial to success. Many physical andappearance properties of the finishedcoating or lining are affected by appliedfilm thickness. These include color,gloss, surface finish, adhesion, flexibili-ty, impact resistance, hardness, and “fit”of coated pieces. The coating and liningapplicator and inspector have a varietyof tools to monitor applied coatingthickness. While tools are readily avail-able and easy to use for film thicknessmeasurements on metallic substrates,measurement on concrete or othercementitious substrates is more diffi-

cult. However, work described in thearticle has shown that ultrasonic gaugesand the related industry test proce-dures are in fact effective measuringtools, even for the fast-set polyureaspray elastomer technology.

References1. Primeaux II, D.J., “Specifications

and Polyurea Elastomeric Coating/Lining Systems,” “Bet onSuccess” 2003 PDA AnnualConference, Reno, NV, August19–21, 2003, pp. 1–16.

2. Polyurea Applicator Spray Course,Polyurea Development Associ-ation, Kansas City, MO.

3. ASTM D4414 (latest version),“Standard Practice for Measure-ment of Wet Film Thickness byNotch Gages,” ASTM International,West Conshohocken, PA.

4. ASTM D1212 (latest version),“Standard Test Methods forMeasurement of Wet FilmThickness of Organic Coatings,”ASTM International, WestConshohocken, PA.

5. ASTM D7091 (latest version),“Standard Practice forNondestructive Measurement ofDry Film Thickness ofNonmagnetic Coatings Applied toFerrous Metals and Nonmagnetic,Nonconductive Coatings Appliedto Non-Ferrous Metals,” ASTMInternational, West Conshohocken,PA.

6. SSPC Paint Application Specifica-tion No. 2, “Measurement of DryCoating Thickness with MagneticGauges,” SSPC: The Society forProtective Coatings, Pittsburgh,PA, 2004.

7. SSPC Paint Application Specifica-tion No. 9, “Measurement of DryCoating Thickness on CementitiousSubstrates Using Ultrasonic Gages,”SSPC: The Society for ProtectiveCoatings, Pittsburgh, PA, 2008.

Continued

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PREQUALIFICATIONOF PROSPECTIVE BIDDERS: The New Jersey TurnpikeAuthority is seeking Contractors to become prequalified under Classification 9,Painting and Classification Rating H, Unlimited, utilizing the Authority’s Pre-qualification process in anticipation of the referenced contract.

GENERAL DESCRIPTION OFWORK: TheWashington Memorial Passaic RiverBridge is located on the New Jersey Turnpike Easterly Alignment between In-terchange 15E in the City of Newark, Essex County and the Hackensack RiverBridge in the Town of Kearny, Hudson County and has an estimated AADT ofnearly 130,000 vehicles per day. The bridge measures 6,948 feet long and car-ries three (3) lanes with a full shoulder in the Northbound and Southbound di-rections.

The typical bridge cross section consists of four (4) main deck girders withfloorbeams and stringers. The five span main river unit consists of a three spancontinuous unit with suspended approach spans attached with pin andhanger connections. The south suspended span is 190 feet long and has aminimum vertical clearance of 110 feet above ground. The north suspendedspan is 190 feet long with a minimum vertical clearance of 98 feet above rail-road tracks. The main river unit is 985 feet long and crosses railroad tracks witha vertical clearance of 113 feet, and the Passaic River with a vertical clearanceof 110 feet above a 270 foot wide shipping channel. The south approach con-sists of 19 simple spans that range from 76 to 160 feet in length and that crossroadways (3 spans), railroad tracks (3 spans), and Turnpike and private ROW (13spans). The south approach also passes under the Pulaski Skyway with a 15foot minimum vertical clearance above the deck. The north approach consistsof 24 simple spans that range from 92 feet to 136 feet in length and that crossroadways (2 spans), railroad tracks (1 span), and open areas of NJ Turnpike andprivate ROW (21 spans). Riveted fabrication of painted carbon and silicon steelis used throughout the original center section of the structure, and bolted fab-rication of weathering steel is utilized throughout widenings of the bridge inboth directions.

Contract No. T100.116: Work shall include the removal of approximately1,750,000 SF of existing lead based paint to a near-white (SSPC SP-10) blastcleaning standard utilizing a full containment system during all blasting andrepainting. The work will also involve abrasive blasting (SSPC SP-10) and paint-

ing of approximately 185,000 SF of weathering steel within the widened por-tion of the structure. The work on the weathering steel will specifically involvethe beam-ends, areas below bridge deck joints and areas as directed in thefield during construction. The existing paint system will be replaced with aNew Jersey Turnpike Authority approved three coat system (Zinc Primer /Epoxy Intermediate / Aliphatic Urethane Finish). Work shall also include Main-tenance and Protection of Traffic and other incidental work called out in thecontract documents. Estimated Construction Cost: $40M-$50M.

PREQUALIFICATION PROCEDURE: A copy of the “Procedure for Prequalifica-tion and Award of Construction Contracts” is available at:http://www.state.nj.us/turnpike/Contractor-prequalification.pdf. The packagewill be furnished upon written request to: New Jersey Turnpike Authority; En-gineering Department; P.O. Box 5042;Woodbridge, New Jersey 07095-5042;Attn: Mrs. Jane Pietraska, Bid Supervisor; 732-750-5300, ext. 8253.

Please provide your e-mail address, mailing address, telephone number, con-tact person and title with your request. The completed“Procedure for Prequal-ification and Award of Construction Contracts”package and supporting“Contractors Qualifying Statement”are due by April 9, 2009.

GENERAL INFORMATION:Evaluation: The evaluation is solely for the purpose of determining, in a timelymanner, bidders who are deemed qualified under NJAC 19:9-2.7 for the typeand scope of work included in the project. The contract will be awarded to theprequalified bidder submitting the lowest responsive bid.Authority’s Reservation of Rights: The Authority reserves the right to rejectany or all responses to prequalification submissions and to waive non-materialirregularities in any response received.Confidentiality: All information submitted for prequalification evaluation willbe considered official information acquired in confidence, and the Authoritywill maintain its confidentiality to the extent permitted by law.

NEW JERSEY TURNPIKE AUTHORITYRichard J. Raczynski, P.E.Chief Engineer

REQUEST FOR CONTRACTOR PREQUALIFICATION • REPAINTING STRUCTURAL STEELNEW JERSEY TURNPIKE STRUCTURE NO. E107.88 • WASHINGTON MEMORIAL PASSAIC RIVER BRIDGE

CONTRACT NO. T100.116

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8. ASTM D4138 (latest version),“Standard Practices for Measure-ment of Dry Film Thickness ofProtective Coating Systems byDestructive, Cross-SectioningMeans,” ASTM International, WestConshohocken, PA.

9. ASTM D6132 (latest version),“Standard Test Method forNondestructive Measurement ofDry Film Thickness of AppliedOrganic Coatings Using anUltrasonic Gage,” ASTMInternational, West Conshohocken,PA.

10. Reader Response: “DFT of Coatingson Concrete,” Problem SolvingForum, JPCL, Vol 24, Number 9,September 2007, pp. 28–29.

11. Dominguez, R.J.G., “The Effect ofAnnealing on the ThermalProperties of Reaction Injection

Molded Urethane Elastomers,”Polymer Engineering and Science,Volume 21, No. 18, December,1981, pp. 1210 – 1217; discussionsand work with author.

12. Ryan, Anthony J., et. al., “Thermal,Mechanical and FractureProperties of Reaction Injection-Moulded Poly(urethane-urea)s,”Polymer, Volume 32, No. 8, 1991,pp. 1426–1439; discussions withauthor.

13. “Study of the Global PolyureaIndustry 2008,” Duker Worldwide,The Polyurea DevelopmentAssociation, Kansas City, MO.

14. “Selecting and Specifying ConcreteSurface Preparation for Sealers,Coatings, and Polymer Overlays,”Guideline No. 03732, InternationalConcrete Repair Institute, Sterling,VA, 1997.

15. Berger, D.M. and D.J. Primeaux II,“Thick-Film Elastomeric Polyure-thanes and Polyureas,” TheInspection of Coatings and Linings,2nd Edition, SSPC: The Society forProtective Coatings, 2003, Chapter5.3, pp. 115–121.

16. ASTM D1005 (latest version),“Standard Test Method forMeasurement of Dry-FilmThickness of Organic CoatingsUsing Micrometers,” ASTMInternational, West Conshohocken,PA.

17. ASTM D7234 (latest version),“Standard Test Method for Pull-OffAdhesion Strength of Coatings onConcrete Using Portable Pull-OffAdhesion Testers,” ASTMInternational, West Conshohocken,PA.

M a i n t e n a n c e T i p s

Dudley J Primeaux II, PCS, CCIDudley J. Primeaux II is a consultant and

the owner of Primeaux Associates LLC

(Elgin, TX), which specializes in the

polyurea industry, equipment, application,

training, and inspection. He is part of The

Polyurea Training Group, which provides

various training programs relating to all

aspects of polyurea technology, and he is

the instructor for the Polyurea Development Association (PDA)

Spray Applicator Course. Mr. Primeaux has an M.S. degree in

organic chemistry from Lamar University in Beaumont, TX, and

was employed by Texaco Chemical Company, Huntsman

Corporation, and EnviroChem Technologies, LLC, as a partner

before forming Primeaux Associates LLC.

Mr. Primeaux is active in SSPC, NACE, and PDA, where he is

a past-president and a member of the Board of Directors. He has

also completed the SSPC PCS Protective Coatings Specialist and

SSPC CCI Concrete Coatings Inspector certifications. He is an

inventor of 26 U.S. patents and 8 European patents on

polyurethane and polyurea foam applications, as well as

polyurea spray elastomer systems and applications. He has

authored over 40 technical papers on polyurea elastomeric coat-

ing and lining technology, as well as several chapters in SSPC

book publications.

Kelin BowerKelin Bower is the marketing director for

PolyVers International (Houston, TX), a

polyurea technology company that formu-

lates, manufacturers, and supplies

polyurea elastomeric coating and lining

systems globally.

Mr. Bower received his degree in interna-

tional business with minors in political sci-

ence and economics from Texas Lutheran University. He then

began his work with PolyVers in technical support and develop-

ment and has since transitioned into his current role. Mr. Bower

is active in SSPC, NACE, and PDA, where he is a member of the

Board of Directors. He has authored and co-authored numerous

technical presentations on polyurea elastomer technology.

Dudley J. Primeaux II

Kelin Bower

Editor’s Note: This article is based on a paper the authors gave at PACE 2009, the joint conference of SSPC: The Society forProtective Coatings and the Painting and Decorating Contractors of America, held February 15-18, 2009, in New Orleans, LA.

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