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Coating Adhesion Testing using Knife/Tape

Methods
5 Comments / Coating Standards, Inspection, Instruments / By Ray Tombaugh

Introduction
Adhesion is an important physical characteristic of applied coating films and systems, and testing is
frequently used as an indicator to whether an adequate bond exists between the substrate and primer
(first coat) and/or between coats in multiple coat applications.  Adhesion testing may be a requirement of
a coating specification, or may be used for coating system performance qualification in a laboratory. 
Adhesion testing is also a valuable indicator for determining the integrity of coating systems that have
been in service for extended periods of time, may require maintenance, and overcoating is a strategy
being considered; and is frequently used during coating failure investigations. Irrespective of the
application of the test, there are standard test methods (procedures) for conducting adhesion testing that
should be followed to ensure consistency, especially when performing comparative analyses.  This article
discusses tape and knife adhesion test methods performed according to standardized ASTM
International. Tensile (pull-off) adhesion is the subject of an article by Melissa Swogger that is also
available on the KTA University site.

Test Methods

ASTM D3359, Standard Test Methods for Measuring Adhesion by Tape Test (Tape Test) and ASTM
D6677, Standard Test Methods for Evaluating Adhesion by Knife (Knife Test) are perhaps the most widely
used tests to evaluate a coatings’ adhesion to the substrate and to other coats in a multi-coat system. 
While tape and knife adhesion tests are generally regarded as more subjective than their tensile (pull-off)
adhesion test counter parts, the tape and knife adhesion tests can be much more revealing of the true
adhesion properties of a coating system.  Experience has shown that high pull-off adhesion values can be
achieved on a coating system that is easily lifted with a knife, tape or in some cases one’s fingers.  This is
primarily due to the directional forces applied to the coating system during the tests.

Adhesion testing performed according to ASTM D3359 or ASTM D6677 apply shear forces to the
coating, while the pull-off adhesion tests (performed according to ASTM D4541 or ASTM D7234)[1] use
tensile [perpendicular] forces.  The shear tests are oftentimes more definitive because they better
replicate the way in which coatings fail.  That is, coatings generally do not disbond from a substrate or
other coating as a result of forces that are exerted perpendicular to the surface.[2]  Rather, the coating
peels off of the substrate or another coat because of shear (non-perpendicular) forces exerted on the
coating system. Undercutting and peeling can occur as a result of shear forces.

Tape Adhesion Tests

Two test methods are described in ASTM D3359: Method A (X-cut), and Method B (Cross-cut).  Test
Method A is primarily intended for use on coatings/coating systems over 5 mils (125µm, while Method B
is generally used on coatings/coatings systems less than 5 mils thick Either method can be performed in
the shop, field or laboratory.

The test was developed for assessing the adhesion of coating to steel, but can be used on other hard
substrates.  The test has also been used successfully on softer substrates (e.g., wood and plaster).
 Both tests are performed by scribing the coating
to the substrate with a sharp knife blade in a
specific pattern, applying a pressure sensitive
tape and then rapidly pulling the tape from the
surface.  When the coating is greater than 5-
mils thick an X-cut (with each leg approximately
1.5-inches long) is made in the film.  When the
coating is less than 5-mils thick, a cross-cut
lattice pattern is created with either six or eleven
cuts in each direction.  For coatings up to 2.0
mils thick, eleven incisions are made that are spaced 1 mm apart. For coatings between 2.0 mils and 5.0
mils thick, six incisions are spaced 2 mm apart. For both methods, a steel or other hard metal
straightedge or template is recommended to ensure straight cuts and, in the case of the X-cut, the correct
angle at the intersection (30-45°).

Once the incisions are made, a pressure sensitive tape (with adhesive properties conforming to the
requirements of the standard; Figure 1) is applied over the incisions and pressed in place using a pencil
eraser.  Following a brief “recovery” period of about 60 seconds the tape is removed by grasping the free
end of the tape and pulling it off rapidly (not jerked) back upon itself at as close to an angle of 180° as
possible.  After removal of the tape, the amount of coating removed from the substrate or underlying
coating is rated. It is important to evaluate the coated surface and not the back of the tape, since coating
debris from the incisions is often removed by the tape.

Adhesion is rated based on the scale provided in the ASTM standard.  The scale ranges from 0 “Removal
beyond the area of the incisions” to 5 “No peeling or removal.” When Method A is used an “A” is included
after the numerical adhesion value (e.g., 3A).  Similarly, a “B” is added after the numerical value when
Method B is used (e.g., 3B).  Table 1 provides the evaluation criteria for Method A; Table 2 provides the
evaluation criteria for Method B.  The standard also contains a pictorial guide to aid in the rating of the
cross-cut (Method B).

[1] ASTM D4541,

Standard Test Method
for Pull-Off Strength of
Coatings Using Portable
Adhesion Testers and
ASTM D7234, Standard
Test Method for Pull-Off Strength of Coatings on Concrete Using Portable Adhesion Testers

[2] The exception to this is osmotic blistering, where the coating is pushed off the surface as a result of
vapor pressure from below the coating.  However, the subsequent delamination is a result of shear forces.
 When appropriate, the
nature and location of the
separation is
documented.  A cohesive
separation is one that
occurs within a coating
layer; an adhesive
separation is one that
occurs between coating
layers or between the coating and the substrate.   Generally, adhesion ratings of 4 and 5 are considered
good, adhesion values of 2 and 3 are considered marginal and adhesion values of 0 and 1 are considered
poor.

Knife Adhesion Tests

Similar to the tape adhesion tests, the Standard Test Method for Evaluating Adhesion by Knife (ASTM
D6677) can be used to evaluate coating adhesion to steel and other hard substrates.  Precautions are
included regarding the use of the test on coatings with a high cohesive strength that may appear to have
worse adhesion than one that is brittle and fractures easily.  In addition, the method is not to be used on
overly thick coatings that cannot be cut to the substrate with a utility knife blade in one stroke.

The knife adhesion test is conducted similarly to Method A of the tape adhesion tests in that incisions are
made in the shape of an “X” (each leg 1.5-inches in length, with an angle of 30o – 45o) through the coating
film down to the substrate.  The tip of a knife blade is then inserted into the intersect of the two incisions
and used to attempt to lift the coating from the substrate or an underlying coating.

Adhesion is rated on an even number scale between 0 and 10, with 10 having the best adhesion and 0 the
worst.  A description of the adhesion criteria is included in Table 3.

Generally,
adhesion
ratings of 8
and 10 are
considered
good,
adhesion
values of 4
and 6 are considered marginal, and adhesion values of 2 and 0 are considered poor.

Interpreting Adhesion Test Results

The Tape and Knife adhesion test procedures described herein include specific language to address
“gray areas,” which require agreement between parties that are either requiring or performing the tests. 
There are circumstances and situations that do not allow standard procedures and methods to provide an
accurate representation of coating adhesion.  For example, laboratory testing is typically conducted
under “standard” laboratory conditions of temperature and humidity; however, field testing conditions
vary with the prevailing weather and are largely uncontrolled.  Variations in temperature and humidity can
affect the efficacy of the method employed.

Heavily chalked paints typically show very good tape adhesion properties, since only the friable chalk
layer is removed by the tape (the weakest plane), leaving the coating system intact.  The adhesion by
knife test may provide a more accurate picture of the actual adhesion characteristics. If the tape adhesion
test is required, the chalking should be removed from the area prior to performing the test.

Adhesion testing conducted on acrylic elastomeric coatings applied to cement or stucco cannot be
evaluated using the tape adhesion test. Further, the results of any knife adhesion tests performed on
these coatings must be carefully considered.  Acrylic elastomeric coatings have high cohesive strength
and, once cut, can often be removed by pulling on the leading edge with one’s fingers.  Never the less, the
adhesion is oftentimes considered to be acceptable under these conditions.

Adhesion tests that consistently reveal an adhesive break between coats or a cohesive break within a
coat do not provide any information relative to the adhesion of the coating (or coating system) to the
substrate.  Knife adhesion tests may be used to assess the bond to the substrate when the tape adhesion
test results revealed a break somewhere higher up in the coating system.

Simply stated, the ASTM standard test procedures have limitations that need to be considered when
making judgements or decisions based on the test results.  Make sure that any “gray areas” are
considered and addressed by the stakeholders before testing is performed.

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5 thoughts on “Coating Adhesion Testing

 using Knife/Tape Methods”

SHIVAJI BANERJEE
MARCH 3, 2018 AT 12:27 AM

Great article . Thanks for the post.

INVESTIGATOR
APRIL 7, 2018 AT 6:11 AM

Good write up shame the coating company’s don’t follow procedures correctly rather than to make a
quick buck. Time and time again, I see these guys taking short cuts, or the platform general manager on
construction doesn’t really understand the corrosion effect.. thinking it’s only paint. Recently, have seen
hubs in service within one year showing heavy signs of spots, blisters, etc due to coatings applied at low
temperatures at the construction stage. Compliance concerns here maybe need further investigation
before final releases. Its a major concern.

EUGEN ORANICI
AUGUST 7, 2018 AT 8:25 AM

Hi,

You mention on this article that:

Experience has shown that high pull-off adhesion values can be achieved on a coating system that is
easily lifted with a knife, tape or in some cases one’s fingers. This is primarily due to the directional forces
applied to the coating system during the tests.

It is correct this affirmation?

Eugen
 JASON WESLAGER
AUGUST 8, 2018 AT 8:19 AM

Eugen,

The following comes from the author:

That is a correct statement. Tensile adhesion tests exert a force perpendicular to the coating system.
Tape and knife adhesion exert a prying type of force. The latter represents the way coatings typical fail
and are more indicative of a coating’s adhesion. In many instances a coating system can have excellent
tensile adhesion but poor shear adhesion. In order to be successful a coating system has to have both
good tensile and shear adhesion.

EUGEN ORANICI
AUGUST 22, 2018 AT 11:34 AM

Jason,

Thank you for confirmation.

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