The Tale of the TapeASTM D 3359

Mike O'Brien

"Measuring Adhesion by Tape Test" (ASTM D 3359) is one of the oldest and more commonly used methods for determining the adhesion of a coating system on a metal substrate. In fact, the test method is older than most of the people reading this article, dating back to the 1930s. The reason for its popularity is simple. The ASTM D 3359 test method is quick, inexpensive, and relatively easy to perform; however, there are also several major limitations and potential procedural problems associated with its use. Since ASTM D 3359 is used so frequently in the field by inspectors and others to make decisions about the adhesion of coatings, it is important to understand some of the factors and variables that affect the results. The ASTM D 3359 standard contains two test methodsMethod A and Method B. The dry- film thickness generally, but not always determines which method to use. For dfts greater than 130 m (5 mils), Method A is generally chosen; however, although many inspectors may be unaware of it, the standard does allow the use of Test Method B for films thicker than 130 m (5 mils). Use of Method B for films greater than 130 m (5 mils) is subject to agreement between the purchaser and the seller and is allowed only if wider spaced cuts are employed. Unfortunately the width of the alternate spacing is not mentioned so this must be agreed upon by the parties involved. Test Method A is primarily intended for job site use while Test Method B is normally utilized in labs. Since Test Method A is used more frequently in the field, it is the primary focus of this article. ASTM D 3359 recognizes that many variables affect the result. In the Appendix, X1.6.1 states the following: "The accuracy and precision depend LARGELY upon the skill of the operator and the operators ability to perform the test in a consistent manner." Some of the factors that affect the results include, but are not necessarily limited to, the following: Condition of the cutting blade Angle of the cut Sharpness of the blade Skill of the operator Operators ability to perform the test in a consistent manner Adhesive properties of the particular tape selected Batch of the tape Tapes storage time and temperature Type of coating Bond strength of coating Extremes in temperature or humidity

Additional detailed information on some of these items is found in the non-mandatory Appendix section of ASTM D 3359. In reference to the tape used to conduct the test, the standard states the following four criteria: 1. 2.5 cm (1.0 in.) 2. Semitransparent 3. Pressure sensitive 4. Agreed upon by the supplier and the user

In reference to the tape, the Appendix of the standard states, "no single tape is likely to be suitable for testing all coatings." It goes on to say that, "differences in tapes can lead to different results as small changes in backing thickness and adhesion rheology cause large changes in the tension area." Certain coatings, such as inorganic zincs and other products that contain substantial amounts of metallic pigments or glass flake, are inherently difficult to cut through using ASTM D 3359, particularly when Method B is used. The standard does not address this issue directly although it is a problem in the field with certain coatings. Some coatings, primarily water-based acrylics, can take several weeks to achieve full cure and adequate adhesion in certain conditions, namely in environments with high-relative humidity and high-temperature. At the time of application these types of products generally consist of approximately 60% solvent (mostly water). Since water-based acrylics dry very quickly, especially when the steel temperature is high, owners and inspectors sometimes wrongly assume these coatings also cure quickly. If the ASTM D 3359 test is performed on these types of coatings prematurely, that is, before the water leaves the film, the coating will often peel off in sheets when ASTM D 3359 testing is performed. The standard mentions that before conducting the test in the field the surface must be "clean and dry"; however it does not require that the coating be cured. If water-based products are not cured adequately before testing, false assessments resulting in serious consequences and premature mandates may result. Based on poor adhesion ratings from ASTM D 3359 tests, some owners have insisted that "all the coating be removed by the contractor and reapplied." For water-based products that cure by coalescence, the higher the relative humidity, the longer it takes for the water to leave the film and therefore the longer it takes to cure. Unfortunately the water-based acrylics dry very quickly on the top layer, especially when they are exposed to direct sunlight in the hot summer months. This causes the upper layer of the paint film to dry rapidly even though a significant amount of moisture remains in the coating. Perhaps a practical, real-life example best demonstrates the unique challenge of performing ASTM D 3359 tests on water-based acrylic coatings in climates where the two Hshigh relative humidity and high surface temperature, are present. Several years ago, an irate client called the author to investigate a reported coating failure. The information provided over the phone indicated that the water-based acrylic, applied three days previous, peeled off in sheets when their inspector performed the adhesion test (ASTM D 3359) as required by the specification. The inspector rated it as a 0A in his report "Removal beyond the area of the X." The owner was insisting that all the coating be blasted off and reapplied. Their facility was located in central Virginia. The steel was painted inside their plant and then moved outside to dry in the hot Virginia summer sun. The daytime air temperatures at that time of year often reached into the 90s with relative humidity hovering in the upper 80s to low 90s. The steel temperature approached 57C (135F) during the early afternoon. After surveying the steel and examining the samples that were removed the previous day by their inspector, considerable effort was exerted by the author in a futile attempt to explain to the Quality Control Manager why water-based acrylics can take two or three weeks to cure when the humidity is high. The QC Manager was informed that the coating would eventually cure and would most likely pass the Adhesion-by-Tape Test (ASTM D 3359) with an acceptable adhesion rating if they just waited another two to three weeks before performing the test again. Initially the QC Manager would not accept the explanation about how coalescence worked. Like many people who have not taken CIP Session I, he did not understand curing mechanisms. He expressed his opinion that the paint was as dry as it was ever going to get. However he finally agreed to wait two weeks before retesting the steel, confident that he would be proven right. In two weeks, when the test was redone, to his surprise, all the coating passed with a 5A rating"No peeling or removal." This true story illustrates a good lesson for all of us as inspectors. If you are working on projects with water-based products, in conditions of high-humidity, and you are required to perform adhesion tests shortly after the paint is applied, alert the owner and or specifier to the potential problem and encourage them to wait to conduct the test. Obviously the best time to do this is at the pre-job conference.