Air barrier testing guide
How to Do an ABAA T0002 / ASTM D4541 Air Barrier Adhesion Pull Test
By the Force-Test team, St. Petersburg, FL · Last reviewed October 2026
To run an ABAA T0002 adhesion pull test, bond a 2-1/4 in (60 mm) disc to the fully cured air barrier, cut through the membrane down to the substrate around the disc, then pull the disc straight off with a calibrated digital pull tester, turning the crank no faster than half a turn every 5 seconds. Record the peak force and divide it by the disc area to get psi. With a 4 sq in ADH-4 disc, just divide the reading by 4: 64 lbf is 16 psi. Three pulls in one 1 m × 1 m area count as one test.
What you need
- Digital pull tester accurate to 0.5% of full scale, with a dated calibration no older than 12 months (ABAA T0002 requires a digital gauge). Our ABAA tester kit meets this.
- Adhesion discs, 60 mm (2-1/4 in) diameter. Our ADH-4 aluminum discs have a 4 sq in face and are reusable.
- Adhesive: two-part epoxy or hot glue that will not attack the membrane.
- High-tack tape to hold discs while the adhesive cures (avoid masking tape).
- Cutter: a utility knife or the FCC-2.25 core cutter to cut cleanly around the disc.
- Thermometer and hygrometer, since temperature and humidity go in the report.
Step-by-step: the ABAA T0002 pull test
Step 1: Confirm the membrane is fully cured
Check the air barrier manufacturer’s cure time for the current temperature and humidity. Testing too early gives low, misleading results.
Step 2: Pick the test area and three pull spots
Choose a flat, rigid 1 m × 1 m (39 in × 39 in) area. Mark three representative spots, spaced farther apart than the tester’s base.
Step 3: Clean the surface and the disc
Clean each spot without damaging the membrane or leaving residue. Clean (or lightly abrade) the disc face so the bond doesn’t fail at the disc.
Step 4: Bond the discs
Mix the adhesive per its instructions and cover 100% of the disc face. Press the disc onto the membrane parallel to the substrate, tape it in place and let the adhesive fully cure.
Step 5: Cut around each disc
Once cured, cut through the membrane at the edge of the disc all the way down to the substrate, so only the material under the disc is tested.
Step 6: Set up the tester
Center the tester over the disc, shim the base if needed so it pulls perpendicular to the surface, and connect the grip without bumping or bending the disc. On walls, support the tester so its weight isn’t on the disc.
Step 7: Take up slack and zero
Turn the crank until the grip just starts to pull, then zero the gauge.
Step 8: Pull at a steady rate
Turn the crank smoothly, no faster than ½ turn per 5 seconds, until the disc comes off. The gauge holds the peak.
Step 9: Record and convert
Write down the peak lbf and divide by the disc area. With ADH-4 discs, divide by 4. Note where the failure happened (see the failure mode table).
Step 10: Average, report and repair
Average the three valid pulls; that average is one test result. Repair the tested spots per the membrane manufacturer’s instructions.
How to convert lbf to psi with the 4 sq in ADH-4 disc
Pull testers read force in pounds-force (lbf). Specs ask for adhesion in pounds per square inch (psi), so divide the force by the disc’s face area.
psi = peak force (lbf) ÷ disc area (sq in)
With ADH-4 (4 sq in): psi = lbf ÷ 4
kPa = psi × 6.895
Quick conversion for 4 sq in discs
| Gauge reading | Adhesion (psi) | Adhesion (kPa) |
|---|---|---|
| 40 lbf | 10 psi | 69 kPa |
| 64 lbf | 16 psi | 110 kPa |
| 80 lbf | 20 psi | 138 kPa |
| 100 lbf | 25 psi | 172 kPa |
| 150 lbf | 37.5 psi | 259 kPa |
| 200 lbf | 50 psi | 345 kPa |
| 400 lbf | 100 psi | 690 kPa |
| 1,000 lbf | 250 psi | 1,724 kPa |
A 2-1/4 in disc is about 3.98 sq in, so dividing by 4 reads about half a percent low, which errs on the conservative side. For other disc sizes, area = 3.1416 × diameter² ÷ 4.
Reading the failure mode
ABAA T0002 labels the layers A (substrate), B (membrane), C (adhesive) and D (disc), and records where the break happened. Only two kinds of failure count toward the result.
| Failure location | Code | Counts? |
|---|---|---|
| Between substrate and membrane | A/B | Yes |
| Within the membrane | B/B | Yes |
| Within the substrate | A/A | No, retest |
| Between membrane and adhesive | B/C | No, retest |
| Within the adhesive | C/C | No, retest |
| Between adhesive and disc | C/D | No, retest |
ABAA T0002 key requirements at a glance
| Requirement | ABAA T0002 | Force-Test equipment |
|---|---|---|
| Force gauge | Digital, 0.5% of full scale | SP1-1KD digital, 0.5% FS |
| Calibration | Within last 12 months, dated | New certificate with each tester; $150 recalibration |
| Disc | 60 mm (2-1/4 in) metal or plywood | ADH-4 aluminum, 4 sq in face |
| Pull rate (crank) | Max ½ turn per 5 seconds | Hand crank with ACME lead screw |
| Pulls per test | 3 in a 1 m × 1 m area | Kit includes 10 discs |
| Valid failures | A/B or B/B only | — |
ABAA Adhesion Pull Tester Kit
$1,800 with 10 ADH-4 discs, case and calibration certificate. Questions? Call 727-421-3093.
Frequently asked questions
Because the ADH-4 disc face is 4 square inches. Adhesion in psi is force divided by area, so a 64 lbf reading on a 4 sq in disc is 16 psi.
Your project specification sets the pass value. Many specifications use 16 psi (110 kPa), the value ABAA uses in its material approval criteria, which is 64 lbf on an ADH-4 disc.
No. ABAA T0002 calls for a digital force gauge accurate to 0.5% of full scale. Analog testers are fine for many roofing tests but not this method.
ASTM D4541 is the general pull-off test for coatings. ABAA T0002 is the air barrier association’s method written for adhered air and water resistive barriers, with a set disc size, gauge accuracy, pull rate and three pulls per test. Use whichever your specification names.
As long as the adhesive manufacturer recommends for the conditions on site. The membrane itself must also be fully cured before you bond the disc.
A failure in the adhesive or at the disc (C/C or C/D) doesn’t measure the air barrier, so it is discarded. Clean the disc and repeat the pull nearby.
Yes. They are aluminum. Remove the old adhesive and membrane, clean the face, and bond again.
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This guide summarizes the published test methods for practical field use. It does not replace the standard itself; always follow the current edition and your project specification.