1 AS 3894.

2—2002
TM
Australian Standard
AS 3894.2

Site testing of protective coatings

Method 2: Non-conductive coatings—Continuity
testing—Wet sponge method

PREFACE

This Standard was prepared by the Australian members of the Joint Standards
Australia/Standards New Zealand Committee CH-003, Paints and Related Materials, to
supersede AS/NZS 3894.2:1991. After consultation with stakeholders in both countries,
Standards Australian and Standards New Zealand decided to develop this Standard as an
Australian Standard rather than an Australian/New Zealand Standard.
The term ‘informative’ has been used in this Standard to define the application of the
appendix to which is applies. An ‘informative’ appendix is only for information and
guidance.

CONTENTS

Page
1 SCOPE ........................................................................................................................ 2
2 REFERENCED DOCUMENTS .................................................................................. 2
3 DEFINITIONS ............................................................................................................ 2
4 PRINCIPLE ................................................................................................................ 3
5 MATERIALS AND REAGENTS ............................................................................... 3
6 APPARATUS ............................................................................................................. 3
7 ELECTRICAL SAFETY............................................................................................. 4
8 CALIBRATION.......................................................................................................... 4
9 TESTING CONDITIONS ........................................................................................... 4
10 PRELIMINARY INSPECTION OF TEST ITEM ....................................................... 4
11 FIELD CHECKING OF TEST EQUIPMENT ............................................................ 4
12 PROCEDURE ............................................................................................................. 5
13 REPORT ..................................................................................................................... 5

APPENDIX A A SAMPLE REPORT FORM FOR CONTINUITY TESTING..................... 7

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 AS 3894.2—2002 2
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METHOD
1 SCOPE
This Standard provides a practical test method for the on-site determination of the presence
of pinholes, holidays, cracks and other discontinuities that penetrate to the substrate in a
non-conductive, protective thin film coating of less than 250 µm thickness, or where metal
particles protrude through the coating (see Note 1).
This test will not detect areas of low film thickness or inclusions in the coating. For a test
method that accurately detects areas of low film thickness or inclusions, see
AS/NZS 3894.1.

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This Standard is applicable to coated metal items, equipment or structures that may be
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subjected to long-term burial or immersion, are in continuous contact with a moist,

chemically aggressive environment, and require a greater degree of protection than is

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normally necessary for items exposed to the atmosphere. Examples of such items include
structural steel, pipelines, storage vessels, bridges and mobile/transportable containers. The
Standard is not intended to apply to coating types incorporating components that conduct an

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electric current, such as zinc dust and aluminium flakes. The method is confined to
measuring instruments that provide a maximum voltage of 90 V d.c.
Although it may be used in the laboratory for inspecting panels and relatively small test
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items, the method is intended for use in the field (see also Clause 9).
NOTES:
1 Where coatings are greater than 150 µm thick, an alternative method such as the high voltage
(brush) method may be used.
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2 This test is not recommended for use on intermediate coats of a multicoat system, as intercoat
adhesion may be affected.
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2 REFERENCED DOCUMENTS
The following documents are referred to in this Standard:
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AS/NZS
1580 Paints and related materials — Methods of test
1580.101.5 Method 101.5: Conditions of test, temperature and humidity control
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2243 Safety in laboratories

2243.7 Part 7: Electrical aspects
2310 Glossary of paint and painting terms
3100 Approval and test specification—General requirements for electrical
equipment
3108 Approval and test specification—Particular requirements for isolating
transformers and safety isolating transformers
3894 Site testing of protective coatings
3894.1 Method 1: Non-conductive coatings—Continuity testing—High voltage
(brush) method
3894.6 Method 7: Determination of residual contamination
ISO
9001 Quality management systems — Requirements
NACE
RP 0188 Discontinuity (holiday) testing of protective coatings
3 DEFINITIONS
For the purpose of this Standard, the definitions of AS/NZS 2310 and those below apply.

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 3 AS 3894.2—2002

3.1 Coating
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A material applied to a surface at a specified film thickness, which is intended to protect it

from corrosive elements or conditions such as moisture, gases, and abrasion by wind-blown
or water-borne particles. A coating may also insulate the substrate from temperature
extremes.
3.2 Continuity
The quality of a coating, which determines its freedom from those defects that increase its
electrical conductivity.
3.3 Defect
A detectable weakness or discontinuity in a coating, which brings into question its ability to

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protect the substrate from corrosion during its normal service life.

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3.4 Holiday
A localized defect, which is characterized by a coating having areas of insufficient

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thickness, including the point where parts of the substrate may be uncoated.
3.5 Pinhole

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A minute hole in a dry coating, which is formed during the application and drying of the
coating material.
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4 PRINCIPLE
A damp sponge electrode is passed over the surface to be tested. The location of any defect,
as indicated by the instrument's response, is then highlighted on the surface of the test area
with a specified marker.
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5 MATERIALS AND REAGENTS

5.1 Cleaning solutions/agents
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Alkaline oil emulsifiers in solution, or a solvent recommended for this purpose by the
manufacturer of the coating.
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Potable water shall be used throughout the test (for example, for preparing solutions or
rinsing operations). The water shall be free of any levels of impurities that would affect the
outcome of the test as revealed during calibration of the instrument (see Clause 10).
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5.2 Marker
A suitable marker such as chalk or a spirit pen is used to mark the position of defects.
Crayon or grease-based materials shall not be used.
5.3 Wetting solution
A suitable non-foaming solution of non-ionic wetting agent, or surfactant diluted to 0.25 to
1% with potable water, shall be used to saturate the sponge electrode and aid the wetting of
any pinholes.
NOTE: Distilled or deionized water should not be used.
6 APPARATUS
6.1 Extra-low-voltage wet sponge holiday detector
A holiday detector tester having the following features:
(a) An electrical energy source of less than 90 V d.c., such as a battery.
(b) An exploring electrode having a sponge dampened with the wetting solution (see Clause 5.3).
(c) An audible indicator to signal a defect in the coating on a metal substrate.
(d) Ground wire connecting the detector to the metal substrate.

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 AS 3894.2—2002 4

6.2 Thermometer
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To measure the surface temperature of the test area to an accuracy of ±1°C.

6.3 Dewpoint apparatus
Capable of determining the dewpoint of the air in the vicinity of the test surface in
accordance with AS/NZS 3894.7 to an accuracy of ±1°C.
NOTE: This apparatus is recommended for use in the field to assist in determining the suitability
of conditions for testing.
6.4 Resistors
Capable of checking the operation of the instrument.
7 ELECTRICAL SAFETY

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Where the extra-low-voltage detector unit incorporates a power supply, rectifier or

transformer, the equipment shall be constructed in accordance with the requirements of
AS/NZS 3100 and AS/NZS 3108, where appropriate.

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The safety inspection and maintenance procedures of AS/NZS 2243.7 for portable
equipment shall be followed.
8 CALIBRATION
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At periods not greater than two years, the instrument shall be calibrated in accordance with
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AS/NZS ISO 9001.
NOTE: The National Association of Corrosion Engineers recommended practice (NACE
RP 0188) may provide guidance on appropriate calibration procedures.
9 TESTING CONDITIONS
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9.1 Field testing

Ensure that the surface is clean and free of oil, water, condensation, dust and other
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contaminants, and that the surface temperature is at least 3°C above the dewpoint (see
Clause 6.3).
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9.2 Laboratory testing

When conducting tests in a laboratory environment, the test conditions shall be in
accordance with AS/NZS 1580.101.5 for routine testing.
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10 PRELIMINARY INSPECTION OF TEST ITEM

Prior to testing, the test item shall be inspected and any visible defects shall be clearly
highlighted with the specified marker (see Clause 5.2). Although the rest of the work may
be tested, any identified visible defect shall not be tested until the fault has been rectified.
11 FIELD CHECKING OF TEST EQUIPMENT
Prior to use, to ensure that it is operable, the instrument shall be checked as follows:
(a) Test the battery for correct voltage output. Refer to the manufacturer’s instructions.
(b) Switch the instrument to ‘on’ or ‘calibrate’, whichever is applicable.
(c) Using the appropriate resistors, check the operation of the instrument, in accordance
with the manufacturer’s operating instructions. The alarm should actuate if the
instrument is operating correctly.
(d) Saturate the sponge with a wetting solution consisting of potable water and a wetting
agent (see Clause 5.3).
(e) Connect ground cable to instrument ground output terminal.

© Standards Australia [Link]

 5 AS 3894.2—2002

(f) Touch the ground connection with the wetted sponge. The instrument signal should
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actuate in accordance with the instrument manufacturer’s instructions.

(g) If the instrument fails to signal, it shall be considered defective.
12 PROCEDURE
The procedure shall be as follows:
(a) Allow sufficient drying and curing of the coating prior to conducting a test. The length of
time required shall be obtained from the coating manufacturer.
(b) Ensure that the surface is dry and free of all contaminants (see Clause 9.1).
(c) Measure the film thickness of the coating with a non-destructive dry film thickness
gauge. If the thickness of the coating film exceeds 250 µm, use the procedures for

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high voltage spark testing described in AS/NZS 3894.1.
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(d) Test the instrument for correct operation (see Clause 11).

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(e) Secure the earth connection to a clean section of uncoated metal substrate using the
earth clamp supplied with the instrument. A bared section of the earth connection
shall be within easy reach of the operator throughout the test.
(f)
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If necessary, connect the sponge to the appropriate terminal.
Saturate the sponge with the wetting solution. The sponge should be sufficiently
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moist to wet the surface, but should not drip while being moved over the coating.
Replenish the wetting solution as required.
(h) Check for continuity of the circuit by touching the probe against a bared earth contact
at 1 min intervals, and when the earth clamp is relocated.
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(i) Move the sponge over the surface of the coating at a moderate rate, not exceeding
0.3 m/s, using a double pass over each area. Apply sufficient pressure to maintain a
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wet surface. If a discontinuity is detected, a corner of the sponge should be used to

determine the exact location of the discontinuity.
(j) Identify the location of any discontinuity using the marker (see Clause 5.2).
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(k) Ensure that the solution is wiped dry at a previously detected discontinuity before
continuing the test, to prevent tracking (current travelling through a moisture path to
a discontinuity, giving a misleading indication).
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(l) Count and record the number of defects found, expressing them as ‘defects per item’
or ‘defects per unit area tested’, e.g. defects per square metre.
(m) When repairing discontinuities, ensure that the surface is dry and free of all
contaminants including wetting solutions.
13 REPORT
The following information shall be reported:
(a) Name of testing laboratory/authority/inspector.
(b) Date of the test and report number.
(c) Identification and description of the work piece, substrate material, coating type,
actual and specified film thickness.
(d) A description of the location where the test was conducted, the project identification
and the test conditions.
(e) Description of the test equipment used and calibration details.
(f) Film thickness measurements and the method used for their determination.

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 AS 3894.2—2002 6

(g) Voltage selected to conduct the continuity test and calibration details.
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(h) Results of the test expressed as defects per item, or defects/m2 .

(i) Any other information or observation to assist in the correct interpretation of the
results (for example, cleaning water purity, surface conditions, any apparent factors
that may have contributed to the formation of defects, including inadequate curing).
(j) Reference to this Australian/New Zealand Standard, i.e. AS/NZS 3894.2.
(k) Any deviations from this test method.
NOTE: Appendix A provides a sample test report form.

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 7 AS 3894.2—2002
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APPENDIX A
A SAMPLE REPORT FORM FOR CONTINUITY TESTING
(Informative)

AS 3894.2 TEST REPORT

Continuity testing of non-conductive coatings—Wet sponge method

Project: ...................................................................................................................................

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Contract No.: ..........................................................................................................................

Name of testing laboratory/authority: .......................................................................................

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Date of conduct of test:............................................ Report number: ......................................
Identification/description of test item

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Substrate material: ..................................................................................................................
Description of work piece: .......................................................................................................
Coating system: ......................................................................................................................
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Method of coating application and date: ...................................................................................
Curing conditions (time/temperature): ......................................................................................
Method of cure: .......................................................................................................................
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Specified dry film thickness: ....................................................................................................

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Test procedure
Surface cleaning prior to testing: .............................................................................................
Dry film thickness—instrument used: .......................................................................................
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—results (µm): .............................................................................................

Dewpoint and surface temperature: .........................................................................................
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Brand/model of test equipment: ...............................................................................................

Date of last calibration:............................................................................................................
Test voltage selected: .............................................................................................................
Test results
Percentage of area tested: ......................................................................................................
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Number of defects detected (per item or m ): ...........................................................................
Pass To be repaired
Comments, if any, to assist in interpretation of results: .............................................................
...............................................................................................................................................
...............................................................................................................................................
Inspector's name (print): ................................................. Signature .............................................
Name of contractor's representative (print):..................................................................................
Signature of contractor's representative: ......................................................................................

[Link] © Standards Australia

 AS 3894.2—2002 8

This Australian Standard was prepared by Committee CH-003, Paints and Related Materials. It was approved on behalf of the Council of
Standards Australia on 29 March 2002 and published on 7 June 2002.
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The following are represented on Committee CH-003:

Australian Paint Approval Scheme
Australian Paint Manufacturers Federation

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AUSTROADS
Building Research Association of New Zealand

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Institution of Professional Engineers New Zealand

Master Painters Australia
National Association of Testing Authorities Australia
New Zealand Abrasive Blasting Association
New Zealand Manufacturers Federation

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New Zealand Painting Contractors Association
Surface Coatings Associatoin Australia
Telstra Corporation

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Water Corporation Western Australia
Additional interests participating in the preparation of this Standard:
Australian Institute of Protective Coatings
Blast Cleaning and Coating Association Qld
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Sydney Water Corporation
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Keeping Standards up-to-date

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Originated as AS 3894.2—1991.
Second edition 2002.

This Standard was issued in draft form for comment as DR 01386.

COPYRIGHT
© Standards Australia International
All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic
or mechanical, including photocopying, without the written permission of the publisher.
Published by Standards Australia International Ltd
GPO Box 5420, Sydney, NSW 2001, Australia
ISBN 0 7337 4477 X Printed in Australia