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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.
Each carton of Testex Tape includes 50 pieces (impressions).
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).
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 X-Coarse.
All tape grades are available in the legacy roll format. Instructions and Standards will continue to support both methods and burnishing tools.
A variety of micrometer thickness gages are available for measuring blast steel profile using Replica Tape. Select from digital micrometers, analog dial thickness gages (snap gages) and digital replica tape readers.
The Testex Digital Micrometer makes using Testex Replica Tape even easier. It is custom-designed to be the optimal tool for measuring replica tape, and makes taking measurements and creating reports easier than ever.
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Includes digital micrometer, instruction manual, USB Cable, Certificate of Calibration, one AAA battery, and a custom case.
Testex Micrometer Dial Thickness Gages are the only analog gages specifically designed for use with replica tape having the correct accuracy, closing force, anvil/contact point dimensions, and parallelism specifications required for accurate measurement of replica tape.
Includes choice of snap gage, instruction manual, carrying case, and one (1) year warranty.
Replica tape readers, such as the PosiTector RTR H and PosiTector RTR 3D, use Testex Press-O-Film replica tape to measure and record surface profile parameters.
All gages come complete with High Accuracy Burnishing Tool, 5 cleaning cards, check shim(s), surface cleaning putty, protective rubber holster, wrist strap, 3 AAA alkaline batteries, instructions, nylon carrying case with shoulder strap, protective lens shield, Long Form Certificate of Calibration traceable to PTB, USB cable, PosiSoft Software, two (2) year warranty on body and probe.
Digital spring micrometers measure and record surface profile parameters using Testex Press-O-Film replica tape—producing a more accurate peak-to-valley surface profile height measurement for blasted steel and textured coatings.
Digital replica tape imagers measure and record peak height, peak density, and 14 common 2D/3D surface profile parameters (Ra, Rq, Rz, Rp, Rv, Rt, Rpc [2D], and Sa, Sq, Sz, Sp, Sv, and Spd [3D]) using Testex Press-O-Film™ replica tape. Download high resolution .SDF files for further analysis (Advanced models only).
Testex Digital Micrometer Thickness Gage Kit includes everything required to measure the surface profile using replica tape. Includes digital micrometer, three cartons of replica tape – Coarse, X-Coarse, and X-Coarse Plus, two burnishing tools – High Accuracy Burnishing Tool and classic burnishing tool, instruction manual, USB Cable, Certificate of Calibration, one AAA battery, and a custom case.
Testex Micrometer Analog Dial Thickness Gage Kits include everything required to measure the surface profile using replica tape. Includes choice of micrometer, two cartons of Testex Press-O-Film tape (Coarse and X-Coarse), two burnishing tools – High Accuracy Burnishing Tool and classic burnishing tool, instruction manual, and a hard shell case.
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Use cleaning putty to remove dust, debris, or residual blast media from the measurement site by firmly pressing the putty onto the surface to be tested using your fingers and remove.
Select the appropriate grade of replica tape, then pull a single piece of tape free of its release paper and apply to blasted surface.
Firmly compress replica film using burnishing tool by applying sufficient pressure in a circular and x-y rubbing motion. When complete, remove tape from surface.
Insert the compressed replica tape between the micrometer's measurement anvils and take a reading.
Ensure the tape is properly positioned so that the burnished region is centered in the anvils with the adhesive side down.
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.
Replica tape consists of a layer of compressible foam affixed to an incompressible polyester substrate. When pressed or “burnished" against a roughened (steel) surface, the foam collapses and creates an impression of the surface. Placing the burnished 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 average maximum peak-to-valley height of the surface profile.
In 2024, a comprehensive study was performed to determine an accuracy statement for replica tape. That study determined the following accuracy and precision statements:
The study, and the above accuracy statements, were determined under the following conditions:
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 readings improves repeatability and accuracy.
The Testex Digital Micrometer features an Average Mode which prompts the user to average two readings in compliance with international standards.
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 blasting the surface with abrasive. The height of the surface profile has been shown to have a significant impact on coating adhesion and resistance to corrosion.
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.
For more information, consult the Testex Press-O-Film Replica Tape Instruction Manual.
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.
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:
Returning Features
Burnishing tool includes a built-in spring mechanism ensuring that consistent force is used, regardless of
how hard the tool is pressed against the surface
Used to verify the accuracy and operation of Testex and other spring micrometer replica tape readers
To clean the surface of debris prior to burnishing
Used to verify the accuracy and operation of all Testex micrometers. Ideal for fulfilling both ISO and in-house quality control requirements. Includes Certificate of Calibration traceable to PTB.
Round-end plastic rubbing tool to compress replica film on the blasted surface
