Materials Science &

Engineering Div.
Highett, Victoria Australia

PP-T001

+61 3 9252 6000

PAINTING CONTRACTOR CERTIFICATION PROGRAM

TECHNICAL NOTE - CALIBRATION OF INSPECTION & TEST EQUIPMENT
Editorial Note: This version of the document amends digital hygrometers as an acceptable instrument.

1. SCOPE

c)

This Technical Note details the PCCP

requirements regarding the calibration of
inspection and testing equipment (ITE) used for the
on-site inspection of protective coatings. It is
intended to expand and elaborate on the
requirements detailed AS 3894.

d)

2. AUTHORITY & RESPONSIBILITY

1.

2.

The Executive Officer, PCCP (EO) has the

authority to implement the requirements of
this procedure.
The Technical Committee retains the
responsibility for the content of the procedure.

e)

determine if an instrument has changed since

its last calibration.
ITE Inspection and test equipment used
either on the actual job or in the site office or
in the main office for the purpose of
measuring a particular parameter to
determine
compliance
to
specification
requirements.
Primary Standards reference standards that
are maintained and housed under controlled
conditions at the principal office of the
contractor. Typically they are externally
calibrated.
Secondary Standards; working standards
generally used in the field and calibrated
against Reference standards.

Note 1: Source NATA Field Application Document (FAD)

Chemical Testing May 2011 p36

3. REFERENCED DOCUMENTS
5. INTRODUCTION
This procedure makes reference to the
following documents;
a)
b)

AS 3894 Site testing of protective coatings

AS 2886

Australian Standards are available online from

SAI-Global at http://www.sai-global.org.au
c)

NACE SP0188-2006 Discontinuity (Holiday)

Testing of New Protective Coatings on
Conductive Substrates
NACE documents are available for online
purchase from http://www.nace.org/
All PCCP documents and forms are available
for downloading from the Documents section of the
PCCP web site at;
http://www.apas.gov.au/pccp

All ITE used by a contractor is required to be

calibrated to ensure that it is capable of the
accuracy and precision required. Appropriate
handling, preservation and storage of such
equipment is maintained to preserve that accuracy.
Inspection & test equipment practices,
processes and procedures must:
a)

b)
c)
d)

4. DEFINITIONS
a)

b)

Calibration1 an operation under specified

conditions that establishes a relationship
between
values
and
measurement
uncertainties. Usually carried out by external
laboratories complying with ISO 17025 subclause 5.6.2.1 and NATA Policy Circular 12.
Checking1 the measurement of at least one
point in a range of an instrument against a
known value to confirm that it has not
deviated significantly from its original
calibrated value. Checks are used to

PCCP T001 v4
Date of issue 23/02/2012

e)
f)

g)

Be documented to ensure requirements and

practices are unambiguous and easily
understood
Describe how the calibration status of
infrequently used equipment is ensured
Establish calibration and/or checking intervals
including prior to use where appropriate.
Establish calibration and/or checking methods
such as external or internal calibration or
internal checking. ITE may be checked
against Primary Standards certified to
recognised standards. If no such recognised
standard exists, the basis used for the
calibration shall be documented.
Establish acceptance criteria for internally
calibrated or checked ITE
Ensure that all ITE is traceable back to
records showing the calibration status at the
time of use.
Ensure comprehensive records of calibration,
checking and maintenance activities are kept
and available.

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PAINTING CONTRACTOR CERTIFICATION PROGRAM
TECHNICAL NOTE - CALIBRATION OF INSPECTION & TEST EQUIPMENT

6. REQUIREMENTS
6.1 Dry film thickness gauges
c)
a) AS 3894.3 Determination of Dry Film
Thickness details the use and calibration of
various instruments used for dry film
thickness measurement. The contractor will
be required to have a set of Primary
Standards and a set of Secondary
Standards for use in the field. Both are
shims, usually of plastic or coated metal.
b) Primary (or Master) standards need to be
purchased separately in addition to those
supplied with the instrument. They need to
be kept secure and away from general
access. They are only to be used by the
calibrating officer when instrument checking
is required. Refer Appendix A below.
c) Secondary standards are usually supplied
with the instrument on purchase. Because
they are used daily in the field they are
subject to wear and tear and need to be
checked regularly to ensure continued
accuracy Refer Table 1 section A below.

d)

e)

f)
g)

h)

6.2 Thermometers
a)

b)

c)

d)

Contractors should have access to, or have

purchased
a
calibrated
reference
thermometer with a calibration certificate. As a
Reference instrument it needs to be kept
securely in the main (calibrating officers)
office.
The Reference Thermometer will need to be
recalibrated externally every 5 to 10 years
depending on its level of use.
Field thermometers and surface temperature
gauges need to be calibrated annually against
the Reference Thermometer.
Records of the calibration results shall be
kept.

6.3 Humidity measurement

a)

b)

j)
k)

l)

Relative humidity is a difficult parameter to

measure accurately. The most accurate of
instruments (digital or analogue) will only
measure to 5% and outside the range 30 to
90% relative humidity, the readings are even
less accurate.
A study of electronic hygrometers by the
South Australian Department of Transport,
Energy and Infrastructure has determined that

PCCP T001 v4
Date of issue 23/02/2012

i)

these instruments suffer from not only

unacceptable levels of accuracy of readings
but also of inconsistency of the inaccuracy ie
today they might be out by +10%RH whereas
yesterday they were out by -5%RH.
The only reliable way to measure relative
humidity is to use a sling psychrometer which
consists of two matched thermometers.
The sling psychrometer is more reliable
although they require skill and training to use.
They also are more fragile than their
electronic counterparts, requiring greater care
in handling.
There is no Australian Standard for humidity
measurement but BS2842, ISO 2842 and
ASTM E337 describe the method. Calibration
requirements are dependent on the type of
instrument used. Suggested calibration
frequencies are detailed in Table 1 below.
If the sling psychrometer is to be the chosen
instrument for humidity measurements on site,
the calibration needs to be in compliance with
Appendix B below and the frequency of
calibration shall be as per Table 1 below.
If an electronic (hand-held) hygrometer is to
be used, it is necessary to establish the
accuracy and consistency of the instrument
prior to use. This will involve taking many
readings over a period of several weeks at
different time of the day to build up a picture
of the instruments accuracy and consistency.
The readings shall be compared against a
known reliable standard instrument.
Acceptable standard instruments are;
i)
a calibrated sling psychrometer or
ii)
a nearby (within a 25km radius)
Bureau of Meteorology (BoM) reading
station. Access to these readings is via
the BoM web site.
Records of the determination of the accuracy
and consistency of readings shall be kept.
Where comparative readings indicate that the
instrument is inaccurate but consistently
inaccurate, a correction factor may be able to
be applied to readings.
Where comparative readings indicate that the
instrument is inaccurate and inconsistently
inaccurate, the instrument must not be used
to make decisions on whether or not to
commence painting operations.

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PAINTING CONTRACTOR CERTIFICATION PROGRAM
TECHNICAL NOTE - CALIBRATION OF INSPECTION & TEST EQUIPMENT

6.4 Pinhole & holiday testing

6.4.1 Low Voltage Wet Sponge Method
The low voltage wet sponge holiday detector
is used for testing for pinholes and holidays in nonconductive coatings of thickness up to 250m.
Calibration of these instruments is usually not
necessary. If required, NACE SP-0188 describes a
procedure. However, verification of proper
operation should be regularly carried out. This is
done by touching the damp sponge to a section of
bare metal to which the ground wire has been
attached.
6.4.2 High Voltage Spark Tester
High voltage spark testers are used to check
for discontinuity in thick coatings above 150m.
The test method and calibration requirements are
described in AS 3894.1. Essentially the calibration
details the detection of a fault at the
commencement of each shift (Appendix B of
AS3894.1) and the voltage checked annually. The
voltage is checked using a special high voltage
voltmeter (Crest Meter) which has been calibrated
within the last two years by a laboratory certified
for that purpose.

7. CALIBRATION FREQUENCY
a)
b)

The frequency of calibration or checking shall

initially be as specified in Table 1 below.
Where four (4) or more consecutive
calibration or checking results indicate
identical results, the calibration or checking
frequency may be increased by one interval
eg if monthly temperature readings against
the
Reference
Thermometer
indicate
compliance within the specified tolerance for 4
consecutive months, the next readings can be
taken at 2 month intervals.

8. ACKNOWLEDGMENT
This technical note is based on AS 3894 and
NATA calibration requirements for chemical
testing.

PCCP T001 v4
Date of issue 23/02/2012

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PP-T001
PAINTING CONTRACTOR CERTIFICATION PROGRAM
TECHNICAL NOTE - CALIBRATION OF INSPECTION & TEST EQUIPMENT

9. TABLE 1 CALIBRATION REQUIREMENTS

Instrument

Calibration or checking method

Initial Checking frequency

A. Dry Film Build measurement

1. Electronic DFB
gauge

As per Appendix A (9.3A) below.

2. Secondary Standards
(working shims)

Either;
As per Appendix A (9.3B) below
or
Externally using an accredited facility
Either:
External calibration with supplied certificate

3. Primary Standards
(reference shims)

At start and end of each

group of readings or each
hour of readings.
Annually
Annually
5-yearly if used more
frequently than once a month
10-yearly if used less
frequently than once a month

or
Against externally calibrated micrometer
4. Vernier calipers

Either;
As per Appendix A (9.3B) below
or
Externally using an accredited facility

10 yearly

Annually
Annually

B. Humidity measurement
1. Electronic gauge
2. Sling psychrometer

As per Appendix B (10.3B) below.

As per Appendix B (10.3A) below.

Weekly
Annually

C. Temperature measurement
1. Working (liquid in
glass) thermometers
2. Working electronic
(IR) or other surface
(eg magnetic)
thermometer
3. Reference
thermometer

As per Appendix C (11.3A) below.

Annually

As per Appendix C (11.3B) below.

Monthly

External calibration with supplied certificate.

10 yearly

D. Linear measurement
1. Tape measures

Visual only; legibility of readings; freedom of

movement.

On use

Against the Telstra talking clock for 30 secs.

6 monthly

E. Time measurement
1. Digital or analogue
timer

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PAINTING CONTRACTOR CERTIFICATION PROGRAM
TECHNICAL NOTE - CALIBRATION OF INSPECTION & TEST EQUIPMENT
10. APPENDIX A SUGGESTED CHECKING METHOD FOR DRY FILM THICKNESS
10.1 Scope
This document suggests a method to be used for the verification or checking of the accuracy of an
electronic instrument for the measurement of dry film builds (DFB). Although this method is satisfactory for
PCCP use, there may be other methods that would also provide the same level of surety of readings.

10.2 Apparatus
The following apparatus, plant or equipment is needed to carry out this checking of DFB instrument;
a) An electronic DFB instrument needing checking
b) A set of checking shims (Secondary Standards, typically supplied with the instrument)
c) A set of Primary Standards shims with a valid external calibration certificate.

10.3 Process
A. Daily checking
a) Prior to beginning taking the days first reading on a surface with dry paint film on it, the instrument
needs to be checked according to the manufacturers directions as supplied with the instrument.
b) Frequency of checking shall be as nominated in Table 1 above and shall include a zero check.
c) Repeat at the frequency nominated in Table 1 above.
B. Annual checking
a) Place the instrument, its Secondary Standards and the Primary Standards in the same room with a
constant temperature and allow their temperatures to stabilise for 30 mins minimum.
b) Zero the instrument using its designated probe.
c) Take readings on the first Primary Standard shim. Record the readings and the average reading on a
suitable calibration form/document.
d) Take readings on the closest corresponding thickness Secondary Standard shim. Record the readings
and the average reading on the same form/document.
e) Calculate the difference in readings in microns & percent (using the formula;
100(T1 T2) / T1
where T1 = thickness of the Primary Standard
and T2 = thickness reading obtained on the Secondary Standard).
f)

Repeat steps c) to e) for each of the shims applicable to the range of coating thicknesses likely to be
encountered in jobs the organisation normally undertakes.
g) Repeat at the frequency nominated in Table 1 above.

10.4 Acceptance Criteria

a) Acceptance criteria can be set by the organisation but criteria outside the limit of 5% may need to be
technically justified to PCCP.

10.5 Actions on non-Acceptance

a) Where an instrument or its shims fail to fall within the organisations acceptance limits, the senior
Manager responsible for technical matters shall be informed and a decision on actions to be taken
shall be made.
b) Such decisions may include concessional acceptance (where the outlier results are minor deviations),
purchase of new shims or instrument.
c) Where new shims are purchased, retirement of the former Primary Standards to Secondary Standards
is possible if the newly purchased shims are certificated.
PCCP T001 v4
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PAINTING CONTRACTOR CERTIFICATION PROGRAM
TECHNICAL NOTE - CALIBRATION OF INSPECTION & TEST EQUIPMENT
11 APPENDIX B SUGGESTED CHECKING METHOD FOR HUMIDITY METERS
11.1 Scope
This document suggests a method to be used for the verification or checking of the accuracy of electronic
dew meters or hygrometers. External calibration by a suitably accredited organisation is equally acceptable in
technical terms but may not provide the company with sufficient financial savings or turn around times to
satisfy their internal objectives.

11.2 Apparatus
The following apparatus, plant or equipment is needed to carry out this checking of the electronic dew
meter instrument;
a)
b)
c)
d)
e)
f)
g)

An electronic dew meter or hygrometer needing checking

A certificated reference thermometer
A sling (or whirling) psychrometer
A calibration room any room free of drafts will suffice. Refer also Note 1 below.
A dew point chart
Distilled water
Ice made from distilled water.

11.3 Process
A. Calibration of the sling psychrometer
a) Place some distilled water, ice, the Reference Thermometer and the two thermometers from the sling
psychrometer into a container and allow to stabilise for 10 minutes in a room with constant (ambient)
temperature (the calibration room).
b) Record the readings on each of the three (3) thermometers on a suitable calibration form/document.
c) Remove the thermometers and dry. Place them on a surface in the room within 5cm of each other but
not touching, cover with a clean rag or paper towel to exclude any drafts and allow to stabilise for 10
minutes.
d) Record the readings on each thermometer and any resulting calibration decision on a suitable
calibration form/document.
e) Repeat at the frequency nominated in Table 1 above.
B. Verification of electronic hygrometers
a) Place the hygrometer to be checked in the calibration room and switch on. Allow to stabilise for
15mins.
Note 1: The calibration room to be used can be any suitable room inside a building and complying with 10.2d)
above, if a calibrated sling psychrometer is to be used as the standard instrument. If data from a BoM web site
is to be used a the standard, the calibration room shall be outside in the open but as free of drafts as
practicable.
b) Record the temperature and relative humidity on both the standard instrument and the test
hygrometer.
c) Repeat step 10.3Bb) at least twice during the first day with at least 3h between readings.
d) Repeat steps 10.3Bb) and c) for additional days until a clear picture of the accuracy and consistency is
achieved.
Note 2: A greater number of readings will be required to establish a case for high consistency, typically 50+
readings. If it is clear that the readings are inaccurate and inconsistent, a lower number of readings is
required.
e) Repeat steps 10.3Bb) to d) monthly and record results including verification or otherwise of accuracy
and consistency.

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PAINTING CONTRACTOR CERTIFICATION PROGRAM
TECHNICAL NOTE - CALIBRATION OF INSPECTION & TEST EQUIPMENT
Note 3: The frequency of checking of accuracy and consistency may be extended where results obtained
show good consistency eg if the inaccuracy has been consistently +4%RH for several months, The checking
frequency can be increased under certain circumstances see clause 7 above.
C. Checking of the instrument
a) Place the electronic dew meter to be checked in the calibration room and switch on.
b) Fill the (in-calibration) sling psychrometer reservoir with distilled water, insert the wick and allow 30
mins for the wick to wet completely.
c) Whirl the sling psychrometer for a period of 3 minutes and record the readings on both thermometers.
d) Repeat step g) for a further 3 minutes and record the temperatures registered. If these are different
from the first record, repeat until a constant reading is obtained.
e) From the Dew Point chart, using the stabilised temperatures, determine the relative humidity (%) and
record.
f) Record the reading of relative humidity from the electronic dew meter.
g) Calculate the difference in readings in percent (using the formula;
100(H1 H2) / H1
where H1 = relative humidity obtained from the sling psychrometer
and H2 = relative humidity obtained from the electronic dew meter)
h) Repeat at the frequency nominated in Table 1 above.

11.4 Acceptance Criteria

a) Acceptance criteria can be set by the organisation but criteria outside the limit of 5%RH may need to
be technically justified to PCCP.

11.5 Actions on non-Acceptance

a) Where an instrument fails to fall within the organisations acceptance limits, the senior Manager
responsible for technical matters shall be informed and a decision on actions to be taken shall be
made.
b) Such decisions may include concessional acceptance (where the outlier results are minor deviations),
or the purchase of new equipment.

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PAINTING CONTRACTOR CERTIFICATION PROGRAM
TECHNICAL NOTE - CALIBRATION OF INSPECTION & TEST EQUIPMENT

12. APPENDIX C SUGGESTED CHECKING METHOD FOR THERMOMETERS

12.1 Scope
This document suggests a method to be used for the verification or checking of the accuracy of
thermometers used for air or surface temperature measurement. External calibration by a suitably accredited
organisation is equally acceptable in technical terms but may not provide the company with sufficient financial
savings or turn around times to satisfy their internal objectives.

12.2 Apparatus
The following apparatus, plant or equipment is needed to carry out this checking of thermometers;
a)
b)
c)
d)

A certificated reference thermometer

Distilled water
Ice made from distilled water.
A piece of steel of at least 100 x 100 x 4mm

12.3 Process
A. Working liquid-in-glass thermometers
i) Place some distilled water, ice, the Reference Thermometer and the working thermometer in a
container so that the thermometers are submerged to at least 75mm of their length.
j) Allow to stabilise for 10 minutes in a room with constant (ambient) temperature (the calibration room).
k) Record the readings on each thermometer on a suitable calibration form/document.
l) Remove the thermometers and dry. Place them on a surface in the room within 5cm of each other but
not touching, cover with a clean rag or paper towel to exclude any drafts and allow to stabilise for 10
minutes.
m) Record the readings on each thermometer on a suitable calibration form/document.
n) Repeat at the frequency nominated in Table 1 above.
B. Infra-red thermometers
a) Place the piece of steel, the reference thermometer and the infra-red thermometer in the calibrating
room. Switch on the instrument and allow everything to stabilise for 30 minutes.
b) Record the reading on the Reference thermometer on a suitable calibration form/document.
c) Use the instrument to take several readings on the steel block and record the readings. Calculate and
record the average reading.
d) Calculate the difference in readings in percent (using the formula;
100(t1 t2) / t1
where t1 = temperature obtained from the Reference Thermometer
and t2 = temperature obtained from the instrument
e) Repeat at the frequency nominated in Table 1 above.
C. Magnetic surface thermometer
a) Use method 11.3B above but place the magnetic surface thermometer into contact with the piece of
steel.

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TECHNICAL NOTE - CALIBRATION OF INSPECTION & TEST EQUIPMENT

12.4 Acceptance Criteria

a) Acceptance criteria can be set by the organisation but criteria outside the limit of 3C may need to
be technically justified to PCCP.

12.5 Actions on non-Acceptance

a) Where an instrument fails to fall within the organisations acceptance limits, the senior Manager
responsible for technical matters shall be informed and a decision on actions to be taken shall be
made.
b) Such decisions may include concessional acceptance (where the outlier results are minor deviations),
or the purchase of new equipment.

PCCP T001 v4
Date of issue 23/02/2012

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Copyright CSIRO 2012

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