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Testex® Replica Tape

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 a precision digital or analog micrometer or electronic PosiTector RTR Replica Tape Reader
  • Less than 30 seconds required for most replicas
  • Only surface profile measurement method recognized by ISO, ASTM, and AMPP
Made in USA flag with black text below
Conforms to ASME B46, ASTM D4417, ISO 8503-5, NACE SP287, SSPC-PA 17, SP5, SP6, SP10, SP11-87T, and others

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 for most replicas
  • Measure using a precision Digital Micrometer, Analog Micrometer, or PosiTector RTR Replica Tape Reader
  • Ideal for measuring on round surfaces and other challenging locations
  • Complete Kits available with everything needed for testing
  • NEW Easy open/close fully-recyclable carton
  • Quantitative test - no need to interpret or compare measurements
  • Only surface profile measurement method recognized by ISO, ASTM, and AMPP
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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 (140° F)
  • Long shelf life with no expiration date
  • Durable custom case included with Micrometers and Kits with storage for Micrometer, replica tape, and High Accuracy Burnishing Tool
  • NEW improved strip format wih easy-remove corner
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Accurate

  • Same trusted Coarse and X-Coarse replica foam in a NEW strip format
  • NEW High Accuracy Burnishing Tool provides up to +/- 8 µm (0.3 mil) accuracy and consistent results, regardless of operator experience or burnishing technique
  • Proven technique with accuracy and repeatability validated by numerous independent studies
  • 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
Replica Tape Grade
Precision
Accuracy
Coarse
± 2 µm (± 0.1 mils)
± 8 µm (± 0.3 mils)
X-Coarse
± 6 µm (± 0.2 mils)
± 8 µm (± 0.3 mils)
X-Coarse Plus
± 8 µm (± 0.3 mils)
± 10 µm (± 0.4 mils)

Press-O-Film® Replica Tape

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).

Conventional Testex Press-O-Film Tape Grades

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).

Grade
Range
Order Code — 1 Carton
Measurement Tool
Order Code — Pack of 6 Cartons
---
Coarse Minus
0.5 to 1.0 mils
12 to 25 µm
Testex Digital Micrometer
Testex Analog Micrometer
PosiTector RTR H
RTC6
RTXC6
Coarse
0.8 to 2.0 mils
20 to 50 µm
X-Coarse
RTCMIN
1.5 to 4.5 mils
38 to 115 µm
RTXCPLUS6
X-Coarse Plus
4.0 to 6.0 mils
100 to 150 µm
RTC
RTXC
RTXCPLUS
*6-Pack includes 6 cartons of replica tape, a High Accuracy Burnishing Tool, and a Quick Guide instruction pamphlet

Optical Grade Testex Press-O-Film Tape Grades

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.

Order Code
Grade
Range
Measurement Tool
RTCOG
Optical Grade Coarse
0.8 to 2.5 mils     20 to 64 µm
PosiTector RTR 3D
RTXCOG
Optical Grade X-Coarse
1.5 to 4.5 mils     38 to 115 µm

Legacy Testex Press-O-Film Tape Grades

All tape grades are available in the legacy roll format. Instructions and Standards will continue to support both methods and burnishing tools.

Micrometers

Testex Digital Micrometer Thickness Gage

The Testex Digital Micrometer makes using Testex Replica Tape even easier. It is custom-deigned to be the optimal tool for measuring replica tape, and makes taking measurements and creating reports easier than ever.

Easy to Use

  • Bright, high-contrast digital color display with large numerals for easy viewing in bright or dark environments
  • Measures in both Microns and Mils
  • Built-in memory for up to 250 readings with on-screen statistics. View and download measurements on any computer using the included USB cable. No software required.
  • Durable, all-metal housing
  • Powered by a single AAA battery
Testex Replica Tape

Designed for Replica Tape

  • Simply select the appropriate replica tape grade to automatically apply the appropriate conversion factor and subtract the 50 µm (2 mils) backing thickness
  • In 'Average mode', the Micrometer prompts the user and averages two readings, in compliance with international standards
  • A traceable Certificate of Calibraion is inclded with each digital micrometer

Download to a PC or Mac

  • Fully compatible with powerful PosiSoft Software for archiving and reporting measurement data
  • USB Drive mode retrieves data in a manner similar to a flash drive in .csv format. No software to install or internet connection required.

Testex Digital Micrometer Specifications

Measuring Range
0 - 40 mils
0 - 1000 μm
Accuracy
0 - 10 mils: ±0.2 mils
10 - 40 mils: ±(0.2 mils + 1%)
0 - 250  μm:  ±5 μm
250 - 1000 μm: ±(5 μm + 1%)
Resolution
0.1 mils
1 μm
Closing Force
1.1 N
Anvil Diameter
0.25"
6.35 mm

Includes digital micrometer, instructional manual, USB Cable, Certificate of Calibration, one AAA battery, and a custom case.

Analog Dial Thickness Gage

Testex Micrometer Dial Thickness Gages measure the surface roughness of blast cleaned surfaces. They are the only 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.

Order Code
Description
Units
Certified
RTMMIL
Testex Micrometer Dial Thickness Gage
Mils
No
RTMMILCERT
Testex Micrometer Dial Thickness Gage — Certified
Mils
Yes
RTMMIC
Testex Micrometer Dial Thickness Gage
Microns
No
RTMMICCERT
Testex Micrometer Dial Thickness Gage — Certified
Microns
Yes

Digital Replica Tape Readers

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.

PosiTector RTR H Replica Tape Reader

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.

Visit the PosiTector RTR H
Product Page to Learn More

PosiTector RTR 3D Replica Tape Imager

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).

Visit the PosiTector RTR 3D
Product Page to Learn More

Replica Tape Kits

Digital Micrometer Kit

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.

Order Code
Description
Units
Certified
RTKIT
Testex Digital Micrometer Kit
Microns/Mils Switchable
Yes

Analog Micrometer Kits

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.

Select from 4 Dial Thickness Gage Kit options:

Order Code
Description
Units
Certified
RTKITMIL
Testex Micrometer Dial Thickness Gage
Mils
No
RTKITMILCERT
Testex Micrometer Dial Thickness Gage — Certified
Mils
Yes
RTKITMIC
Testex Micrometer Dial Thickness Gage
Microns
No
RTKITMICCERT
Testex Micrometer Dial Thickness Gage — Certified
Microns
Yes

How it Works

prepare the surface with cleaning putty

1

Prepare

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.

burnish the replica tape

2

Burnish

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.

measure with PosiTector RTR

3

Measure

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.

Videos

Video Thumbnail
How to Measure Surface Profile Using Replica Tape
Video Thumbnail
Cómo Medir el Perfil de Superficie Utilizando Cinta Testex

F.A.Q.

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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.

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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.

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How does replica tape work?

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.

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How accurate is Testex Press-O-Film Replica Tape?

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:

  • The procedure detailed in the instructions is followed
  • The High Accuracy Burnishing Tool is used
  • All readings are converted using a Testex Digital Micrometer, PosiTector RTR H, or conversion table
  • At least two readings were taken per measurement and averaged, in accordance with the written procedure found in the Number of Readings section of the instruction manual

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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 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.

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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.

For more information, consult the Testex Press-O-Film Replica Tape Instruction manual.

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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.

For more information, consult the Testex Press-O-Film Replica Tape Instruction Manual.

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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.

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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

Accessories

High Accuracy Burnishing ToolHigh Accuracy Burnishing Tool

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

Learn MoreLearn More
Testex Shim SetTestex Shim Set

Used to verify the accuracy and operation of Testex and other spring micrometer replica tape readers

Learn MoreLearn More
Surface Cleaning PuttySurface Cleaning Putty

To clean the test surface of debris prior to burnishing

Learn MoreLearn More
Testex Certified Shim SetTestex Certified Shim Set

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.

Learn MoreLearn More
Legacy Burnishing ToolLegacy Burnishing Tool

Round-end plastic rubbing tool to compress replica film on the blasted surface (Pack of 10)

Learn MoreLearn More

Resources

Downloads