Same trusted Coarse and X-Coarse replica foam in new strip format
Simple technique: place on the surface, press/burnish it into the surface, remove, and measure
Proven technique with accuracy and repeatability validated by numerous independent studies
Less than 30 seconds required per test
Testex Replica Tape measures surface profile by creating a replica of the surface, which can be measured using a micrometer
- Same trusted Coarse and X-Coarse replica foam in new strip format
- Simple technique: place on the surface, press/burnish it into the surface, remove, and measure
- Proven technique with accuracy and repeatability validated by numerous independent studies
- Measure using an analog precision micrometer or electronic PosiTector RTR Replica Tape Reader
- Less than 30 seconds required per test
- Only surface profile measurement method recognized by ISO, ASTM, and AMPP
Conforms to ASME B46, ASTM D4417, ISO 8503-5, NACE SP287, SSPC-PA 17, SP5, SP6, SP10, SP11-87T, and others
Testex Press-O-Film Replica Tape consists of a layer of compressible foam affixed to an incompressible polyester substrate of highly uniform thickness. When pressed against a roughened steel surface, the foam collapses and forms an impression of the surface. Placing the compressed Testex tape between the anvils of a micrometer thickness gage and subtracting the thickness of the incompressible substrate gives a measure of the surface profile.
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Features
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Simple
- Simple technique: place on the surface, press/burnish it into the surface, remove, and measure
- Less than 30 seconds required per test
- Measure using an analog precision micrometer or electronic PosiTector RTR Replica Tape Reader
- Ideal for measuring on round surfaces and other challenging locations
- Complete Kits available with everything needed for testing
Durable
- Option to retain a permanent physical replica of the surface after measurement for archival reporting
- Withstands nearly any environment, including temperatures up to 60° C
- Long shelf life with no expiration date
- Hard-shell plastic case included with Replica Tape, Micrometers, and Kits
Accurate
- Proven technique with accuracy and repeatability validated by numerous independent studies
- Quantitative test - no need to interpret or compare measurements
- Only surface profile measurement method recognized by ISO, ASTM, and AMPP
- Measures over a relatively large area for high repeatability
- Generate high-resolution 3D images of the surface using Optical Grade Replica Tape and the PosiTector RTR 3D
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Conventional Testex Press-O-Film Tape Grades - Models
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Testex Press-O-Film replica tape is available in a variety of thickness ranges for measuring substrate roughness from 0.5 - 6 mils (12 - 150 µm).
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Optical Grade Testex Press-O-Film Tape Grades - Models
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Testex Press-O-Film Optical Grade replica tape, when used with PosiTector RTR 3D models, provides higher quality surface data files (.SDF) than conventional replica tape. Optical Grade Replica Tape is available in Coarse or X-Coarse.
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Legacy Testex Press-O-Film Tape Grades - Models
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All tape grades are available in the legacy roll format. Instructions and Standards will continue to support both methods and burnishing tools.
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How It Works
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DeFelsko PosiTector RTR H - Digital spring micrometers measure and record surface profile parameters using Testex Press-O-Film™ replica tape—producing a more accurate peak-to-valley height measurement
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F.A.Q.
What is replica tape?
Testex Press-O-Film replica tape consists of a layer of crushable plastic microfoam coated onto polyester film of highly uniform thickness. It is sold in a number of grades to accommodate measurements in different profile ranges.
What is Press-O-Film HT?
Testex Press-O-Film HT is an improved version of Press-O-Film (discontinued in 2010). Press-O-Film HT (High Temperature) is formulated for better performance at high temperatures (up to 140°F or 60° C) encountered in the most challenging environments.
How does replica tape work?
Replica tape consists of a layer of compressible foam affixed to an incompressible polyester substrate. When pressed against a roughened (steel) surface, the foam collapses acquiring an impression of the surface. Placing the compressed tape between the anvils of a micrometric thickness gage, and subtracting the contribution of the incompressible substrate (50 µm or 2 mils), gives a measure of the surface profile. Consequently, the thickness of the compressed tape equals the average maximum peak-to-valley profile plus the thickness of the incompressible polyester substrate. A spring-loaded micrometer gage is used to measure the thickness of the replica.
How accurate is Testex Press-O-Film Replica Tape?
There are multiple ways of expressing the accuracy or precision of an instrument or test method. The most common method in our industry is to measure on traceable standards in a calibration laboratory. This is challenging for surface profile measurement instruments because no traceable surface profile standards exist. For some instruments, such as depth micrometers (ASTM D4417 Method B), accuracy can be estimated using calibrated height standards. For replica tape, the ASTM D01.46 committee used a set of panels blasted with a range of surface profiles, and compared the results from replica tape against measurements taken on the same panels using a calibrated drag stylus micrometer (ASTM D4417 Method D). Across the 0.8-4.5 mil (20-115 micron) primary range of replica tape, the readings differed by less than ± 0.3 mils (± 9 microns), as summarized in the table below.
However, this tests the accuracy of the instrument or apparatus, but not necessarily the overall test method. For most users, it is more important that measurements are consistent between the various parties (for example, the specifier or contract author, the contractor, and the inspector). Because blasted surfaces are complex, random shapes, the ability of an instrument to measure height in a laboratory is not necessarily indicative of its ability to measure surface profile in a consistent, repeatable manner in the field.
In 2011 the ASTM D01.46 committee preformed an interlaboratory study, which measured the reproducibility of measurements made by multiple users and laboratories (stated as the range that 95% of measurements from all operators across all laboratories fall within). The results are summarized as follows:
The accuracy/reproducibility values are specified at 3 mils in the above table, and typically vary across the range of an instrument. For Replica Tape:
In summary, independent studies have shown that Testex Press-O-Film replica tape is a highly accurate measurement method with industry-leading reproducibility
Why is measuring surface profile important?
Industrial steel in bridges, ships, railcars, etc., is almost always painted or otherwise coated to prevent corrosion. Before they can be painted, these metal surfaces must be cleaned and roughened to ensure that the paint adheres. This is usually done by grit or shot blasting the surface. If the resulting surface is too smooth, the paint or coating will not stick. If the surface is too rough, the peaks may poke through the coating allowing rusting to occur.
Is it necessary to average the measurements from two pieces of replica tape?
Most international standards instruct users of replica tape to take two replica tape readings in each measurement area, and average those two readings together to yield a 'Profile Measurement'. As with any test, averaging multiple measurements improves repeatability and accuracy.
If a measurement made with either Coarse or X-Coarse replica tape is in the 'overlap range' of 38 to 64 µm (1.5 to 2.5 mils), a second measurement should be taken in the same spot with the other grade of tape. If BOTH readings are in the above Overlap Range, record the average of the two measurements as the peak-to-valley roughness. If EITHER reading is outside of the Overlap Range, record it as the profile height.
Do I need to use two different grades of replica tape to take a measurement?
In 2024, a peer-reviewed study introduced improvements to the replica tape test method including an increased range for Coarse, X-Coarse, and X-Coarse Plus replica tapes and a new conversion technique. The resultant conversion table can be used with analog micrometers and provides a simpler alternative to the legacy ‘averaging’ technique. The conversion table is not required for the Testex Digital Micrometer as it makes the calculations automatically.
Previously, if readings made with either the legacy Coarse or X-Coarse replica tape fell within the 'overlap range' of 38 to 64 µm (1.5 to 2.5 mils), a second reading was be taken in the same spot with the other grade of tape. If BOTH readings were within the above 'overlap range’, the average of the two readings were recorded as the ‘Profile Measurement’. If only one reading was outside of the Overlap Range, it was recorded as the first reading and a second reading was taken with the same grade of replica tape. Averaging those two readings together yielded a 'Profile Measurement'. The legacy averaging technique is still valid and supported by international standards.
What is the High Accuracy Burnishing Tool?
The High Accuracy Burnishing Tool includes a spring-loaded burnishing ball which is depressed into the base of the tool exerting the perfect amount of pressure to burnish (create) a replica. It reduces operator influence, providing an extended range and ±8 µm (0.3 mil) accuracy for Testex Replica Tape.
For concave surfaces, the narrower curved top of the tool can be used to create replicas.
The Classic Stick-type Burnishing Tool remains a valid measurement practice and is recognized by international standards. Care should be given to avoid applying too much force. Excessive force can lead to inaccurate measurements
What has changed with the new replica tape format and packaging?
All versions of Coarse and X-Coarse replica tape use the same trusted replica foam, incompressible backing, and HT (high temperature) formulation that have been sold for decades. There is no functional difference between the legacy rolls of Coarse and X-Coarse replica tape, and the new strips of Coarse and X-Coarse replica tape that are packaged in cartons.
The new 'strips' of Coarse and X-Coarse replica tape simply feature a modernized design and packaging.
Strips of X-Coarse Plus replica tape feature thicker foam to allow an increased measurement range of 100-150 µm (4.0-6.0 mils). Strips and rolls of X-Coarse Plus replica tape should not be used interchangeably.
Improvements include:
- Easy-Open, Easy-Close Carton
- Improved 'Strip' format with Easy-Remove 'Peel-Here' Tab
- Increased X-Coarse Plus Range—100-150 µm (4.0-6.0 mils).
Returning Features
- Same trusted Coarse and X-Coarse replica foam
- Same High Temperature (HT) Formulation for better performance on hot surfaces
- 50 strips (impressions) per carton/roll