Aga Masking 6f2xi

MASKING MATERIALS FOR PREVENTING HOT-DIP GALVANIZING BY BERNARDO DURAN, III AND THOMAS LANGILL, PHD

BACKGROUND

threads when precise fit is necessary and

Masking materials, also called stop-off

the additional width of the galvanized

materials, are products applied to steel in

coating would cause fit issues. Another

specific

reason to mask steel is to give a higher

areas

galvanizing

to

prior prevent

to zinc

hot-dip from

slip factor on some faying surfaces.

reacting with and adhering to the steel. Many different types of products have Masking is done for a myriad of reasons.

been used as masking materials. Some

For example, sometimes it is preferable

products are specifically designed for the

to prevent galvanizing on large areas of

purpose of preventing galvanizing, and

steel that will be welded, rather than

other products from other industries or

removing the zinc coating later. Masking

for other uses have been found to work

materials are also sometimes applied to Copyright © 2010 American Galvanizers Association. The material provided herein has been developed to provide accurate and authoritative information about after-fabrication hot-dip galvanized steel. This material provides general information only and is not intended as a substitute for competent professional examination and verification as to suitability and applicability. The information provided herein is not intended as a representation or warranty on the part of the AGA. Anyone making use of this information assumes all liability arising from such use.

Protecting Steel for Generations 1

well

at

masking

steel

prior

availablility and recommendations from

to

AGA .

galvanizing.

INTRODUCTION

The study consists of two phases. The

An American Galvanizers Association

goal of Phase 1 testing is to determine

(AGA)

to

the effectiveness of the various masking

determine the effectiveness of masking

products in masking the steel surface

materials at preventing adhesion of zinc

from zinc. The products that successfully

to steel during galvanizing.

masked steel in Phase 1 were included in

study

was

conducted

Phase 2 testing. The goal of Phase 2 is to This study is important because masking

determine

materials are commonly used, and until

successful materials from Phase 1 testing

now, there was no definitive study that

when

looked at the efficacy of various

Attempting

products used to prevent galvanizing.

appearance of the steel (by chemical

the

given to

performance

shorter restore

of

cure the

the

times. original

cleaning) is also a goal in Phase 2. The information obtained in this study will give galvanizers and fabricators

The masking materials were tested on

detailed facts on the performance of

three different types of surfaces; flat

various masking materials, as well as

plate, buried threaded holes, and bolt

provide data on application and removal

threads. Two types of flat plate were

of the masking materials after hot-dip

used in the study. The first type of flat

galvanizing.

plate (see Figure 1, next page) was approximately 3” x 6”. The masking

TEST PROCEDURE

materials were applied to the steel away

In this study 15 masking materials were

from the hole. The masking area had a

tested. Some of these materials are

width of 3” and a length of a little less

currently used to mask steel, and others

than 4”.

have been used in the past with some success. In addition to past performance,

All masking materials were applied to

the products were chosen based on their

the steel prior to the cleaning steps of the


the

Some of the plates were drilled and

masking materials were subjected to a

tapped to provide a plate with a buried

caustic bath, pickling bath, and flux

threaded hole to test the masking

bath. It was important to determine if the

materials (see Figure 2). The buried

masking materials could survive the

threaded holes were 2½” deep holes

cleaning chemicals, because if they

drilled into a 3” thick plate (see Figure

could survive, the masking materials

2). Buried threaded holes were used only

could be applied at the fabricator’s

in Phase 1 testing. The bolts used in the

facility, and thereby save the galvanizer

study

the time and trouble of applying the

approximately 2 ½” in length (see

materials.

Figure 3).

galvanizing

process,

meaning

were

¾”

in

diameter

and

Figure 1: Flat Plate Figure 3: Coated Bolt Threads

The masking materials were applied to the plates with a foam brush and then spread in the masked areas until an even consistency was achieved.

For the buried threaded holes the masking products were simply poured or squeezed into the holes. Figure 2: Buried Threaded Holes Plate

For the bolt threads, the masking materials were applied by either dipping Protecting Steel for Generations 3

the bolts directly into the bottle of the

•

Duct Tape

material, if there was enough room, or

•

Kapton Tape

spread onto the threads using a foam

•

VHT Header Paint (tested only

brush. The material was spread onto the

on flat plate)

threads to achieve even thickness.

•

Dow Corning Compound #111

•

DAP

The masking materials for all surface

Household

Adhesive

Sealant

types were applied prior to the chemical

•

Stop Galv

cleaning

galvanizing

•

NAPA RTV Red

process. This ensured the masking

•

GE 100% Silicone Caulk

materials could stand up to the cleaning

•

Galva Stop

agents and would remain on the steel

•

Valmont Masking Compound

prior to galvanizing.

•

Macropoxy 846

•

3M High Temperature

steps

of

the

Masking products were removed by using

a

metal-bristled

brush.

Aluminum Tape

The

materials were scrubbed off the surface and then compressed air was used to blow off the debris. In Phase 2 testing,

•

Maskote Zinc Stop-Off

•

ZYP Boron Nitride Lubricoat

•

ZYP Boron Nitride Hardcoat

scrubbing the cleaned steel with a nylon Determining the effectiveness of each

bristled brush and Simple Green solution

masking

was also performed to determine if the

material

came

down

to

observing how much of the masked area

original steel finish could be restored. A

galvanized. The smaller the area that

grinder was also tested in Phase 2 for

galvanized, the more effective the

removing the materials on flat plate.

masking material. PHASE 1 TESTING For flat plate, greater than 90% of the

MASKING MATERIAL TESTING

masked area had to remain ungalvanized

Fifteen different masking materials were

to proceed to Phase 2 testing. For buried

tested in Phase 1, including:

threaded

holes,


almost

the

entire

threaded area needed to remain free of

Six products successfully prevented zinc

galvanizing. If a few small spots of zinc

coating on the buried threaded holes,

were observed, the masking material was

including:

still considered effective. For bolt

•

threads, the same criteria applied as that

DAP

Household

Adhesive

Sealant

for buried threaded holes – almost the

•


entire

•


•


•

Macropoxy 846

•


threaded

area

must

remain

ungalvanized to be considered effective.

TEST 1 RESULTS On the flat plate, nine products failed to prevent galvanizing on a minimum of

Six of the 14 products failed to prevent

90% of the masked area. Six products

galvanizing

successfully prevented zinc coating a

masking materials that did prevent zinc

minimum of 90% of the masked area on

coating on bolt threads include:

flat plates including:

on

•

Galva Stop

bolt

threads.

•

Stop Galv

•

Stop Galv

•


•

DAP

•

NAPA RTV Red

•

Galva Stop

•

NAPA RTV Red

•


•


•


•

Macropoxy 846

•


Household

The

Adhesive

Sealant

Only 14 of the masking materials were tested on buried threaded holes and bolt

The

threads. The VHT Header Paint was not

bolts

masked

with

Valmont

Masking Compound were lost during the

tested because paint cannot be easily

galvanizing process during testing.

removed from threaded areas. For more detailed information on how Eight products failed to prevent zinc

each masking material performed on the

coating on the buried threaded holes.

various surface types, and application


and removal data, please see the charts

manufactures

in Appendix 1.

achieve optimum performance.

PHASE 2 TESTING

The second goal of Phase 2 testing was

curing

instructions

to

SHORTER CURE TIME TESTING

to determine if the original steel finish

AND CLEANING

could be restored after removing the

The first goal of Phase 2 testing was to determine

how

the

products

masking materials from the steel.

that

performed well in Phase 1 testing

The

performed were applied using shorter

effectiveness of these masking materials

cure times. Products tested in Phase 2

in Phase 2 testing was the same as in

included:

Phase 1 Testing. Ninety percent or more

•

Stop Galv

of the masked area on plates had to

•

Galva Stop

remain free of galvanizing to be

•


considered successful. For bolts, only a

•

NAPA RTV Red

few small areas of zinc on the masked

•


threads were allowed for the material to

•

DAP

be considered successful.

Household

Adhesive

criteria

for

determining

the

Sealant For the flat plate specimens, each Although Valmont Masking Compound

masking material was applied to the

did well in Phase 1 testing, it was not

same areas used in Phase 1 testing. The

included in Phase 2 testing. Also, as

plates had been stripped of all zinc and

mentioned earlier, buried threaded holes

remaining residues from Phase 1 testing.

were not tested in Phase 2.

Masking products were applied to only one side of the plates to decrease

Shorter cure times were tested in Phase

application time. Cure times included 1

2. These tests demonstrated the limits of

and 2 hours for flat plate specimens.

the masking materials. However, it is important to note these materials should

For bolt threads, the masking materials

be

were applied to the same bolts as those

used

in

accordance

with

the


used in Phase 1 Testing. The bolts had

TEST 2 RESULTS

been stripped of all galvanizing and

FLAT PLATE

debris from the Phase 1 tests. Three

For the 1 and 2 hour cure times only

different cure times were tested on the

Stop

bolt threads; 30 minutes, 1 hour, and 2

successful at preventing galvanizing.

Galv

and

Galva

Stop

were

hours. Some ashy material from Stop Galv and For both the flat plate specimens and the

Galva Stop remained on the plates even

bolt thread areas, cleaning the baked on

after scrubbing with a metal-bristled

masking materials after galvanizing was

brush.

attempted by scraping the steel with a

Cleaning the plates with the Simple

metal-bristled brush and then scrubbing

Green solution had a negligible effect on

with a nylon brush and Simple Green

removing the debris left from the

solution (see Figure 4). The goal of

masking materials.

cleaning with the Simple Green solution was to determine if the original finish of

Using a grinder to remove the baked-on

the steel could be restored after the

masking materials was excessive and is

various masking materials had baked on

not

the surface while going through the

immediately went through the masking

galvanizing process. Cleaning with a

materials

grinder was attempted on the flat plate

underneath.

recommended.

and

The

attacked

grinder

the

steel

specimens only. BOLT THREADS Three different cure times were tested for each masking material on bolt threads, including 30 minutes, 1 hour, and 2 hours. For the 30 minute cure time Galva Stop and NAPA RTV Red were the only products that successfully prevented galvanizing. Figure 4: Simple Green and Nylon Brush


For the 1 hour cure time, five of the six

Cleaning with the Simple Green solution

masking materials were successful at

was done after the 1 hour curing time. If

preventing galvanizing, including Galva

the masking materials had been given

Stop, Maskote Zinc Stop-Off, DAP

their full recommended curing time it is

Household Adhesive Sealant, NAPA

likely the products would have been

RTV Red, and Stop Galv.

easier to remove and would have cleaned even better.

For the 2 hour cure time all six masking materials

successfully

prevented

Cleaning the masking materials from the

galvanizing on the bolt threads.

bolt threads with a grinder was not

After galvanizing, a metal-bristled brush

attempted because it would damage the

was used to scrape the big chunks of

threads.

baked-on masking material from the threads. A Simple Green solution and

CONCLUSION

nylon brush were then used to remove

The goal of this study was to determine

the remaining baked-on debris. The

which commercially available masking

appearance of the bolt threads was

materials

improved for all the masking materials

galvanizing on masked areas.

work

best

at

preventing

after cleaning with the Simple Green Six commercially available masking

solution.

materials were identified to successfully The cleanest bolts were those masked

prevent galvanizing on one or more

with Maskote Zinc Stop-Off, GE 100%

surface types, including flat plate, bolt

Silicone Caulk, and DAP Household

threads, and buried threaded holes. The

Adhesive Sealant. It was necessary to

successful masking materials included

wash the bolts masked with NAPA RTV

(in no particular order):

Red twice because of the gummy

• Stop Galv

residue.

• GE 100% Silicone Caulk

Some

baked

on

masking

material remained on the bolts masked

• Maskote Zinc Stop-Off

with Galva Stop and Stop Galv.

• NAPA RTV Red • (cont. on next page)


• Galva Stop

COSTS OF THE MASKING MATERIALS

• DAP Household Adhesive

The masking materials tested in this study have a wide range in price, which

Sealant

can be found in Appendix 1. In addition Additional and detailed performance

to the purchase price, additional costs to

data is presented in the charts in

be considered include labor time for

Appendix 1 and additional pictures are

applying and removing the materials.

presented in Appendix 2.

Detailed application and removal times are included in the charts in Appendix 1.

SAFETY AND HEALTH INFORMATION Material Safety Data Sheets (MSDS) should be obtained and adhered to when using

these

materials.

Necessary

personal protective equipment should be employed when appropriate. Almost all of

these

masking

materials

had

nauseating smells and should be used only in well ventilated areas. It is important to note some of these products were not designed to be used in the temperature ranges of the galvanizing process.


Appendix 1. Detailed Performance Data of Masking Materials


11

$4.75 / small tube

$170.00 / gal.



$120.00 / gal.

Maskote Zinc Stop - Off

$45.00 / qt.

$89.78 / gal. of Part A & B

Macropoxy 846

Stop Galv

$4.97 / 10.1 oz. tube


$14.19 / 11 oz. tube

$0.35 / oz

$48.00 / liter

Galva Stop

NAPA RTV Red

$0.49 / oz

$3.98 / 2.8 oz. tube

DAP 100% Silicone Adhesive

$1.33 / oz

$0.37 / oz

$1.41 / oz

$1.29 / oz

$0.94 / oz

$1.42 / oz

$1.42 / oz

Price

Product

-

Yes

Yes

Yes

Yes

-

Yes

Yes

-

N/A

N/A

1 min.

5 mins., 48 secs.

4 mins., 26 secs. 2 mins., 32 secs.

1 min.

1 min.

N/A

1 min., 32 secs.

2 mins., 37 secs.

N/A

1 min.

2 mins., 38 secs.

2 mins., 21 secs. 1 min., 22 secs.

N/A

N/A

Standardized Application Removal Success Price Time Time

FLAT PLATE

Yes

Yes

-

-

Yes

Yes

Yes

-

Yes

Success

3 mins., 24 secs.

10 mins., 30 secs.

N/A

N/A

5 mins., 13 secs.

32 mins., 26 secs.

1 min., 15 secs.

N/A

6 mins., 30 secs.

Application Time

7 mins., 52 secs.

5 mins., 28 secs.

N/A

N/A

3 mins.

8 mins., 40 secs.

5 mins., 18 secs.

N/A

12 mins., 5 secs.

Removal Time

BURIED THREADED HOLES

-

-

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Success

PHASE 1 TESTING - OVERVIEW OF SUCCESSFUL MASKING MATERIALS

N/A

N/A

5 mins.

9 mins., 45 secs.

5 mins., 12 secs.

37 mins., 10 secs.

10 mins., 30 secs.

3 mins.

9 mins., 30 secs.

Application Time

BOLT THREADS

N/A

N/A

10 mins., 20 secs.

4 mins., 18 secs.

3 mins., 5 secs.

1 min., 11 secs.

7 mins., 30 secs.

6 mins., 50 secs.

4 mins., 22 secs.

Removal Time

12 Poured onto the surface and spread with a foam paint brush.

32 mins., 14 secs. (31/32 mins. spent on prep time for epoxy)

2 mins., 37 secs.

1 min., 32 secs.

4 mins., 26 secs.

2 mins., 32 secs.

1 hr., 33 mins.

3 mins., 48 secs.

4 mins., 16 secs.

Macropoxy 846


NAPA RTV Red

Stop Galv


VHT Header Paint



-

-

Applied 2 coats of paint. Allowed for dry time between coats. Two minutes of application time was to stir the product. Poured onto the surface and spread with a foam paint brush.

Poured onto the surface and spread with a foam paint brush. Material had the runniness of paint and was very messy. 3 minutes of the application time was due to stirring the product like paint.

Yes

Poured the product on, spread with a foam paint brush. Product went on thick and dried quickly. Yes

Yes

Used a caulk gun, then spread using a foam brush. Went on easy, but kind of thick.

Very thick, like a paste. Used a foam brush to spread around.

Yes

Very runny - dries very quickly, making it hard to spread around. Used a foam brush for spreading.

-

-

2 wraps. Tape did not stick well, much harder to work with than the duct tape.

30 mins.

Kapton Tape

Yes

1 mins., 22 secs.


Used a caulk gun, then spread using a foam brush. Went on very thick.

2 mins., 21 secs.

Galva Stop

Yes

25 mins.

Duct Tape

-

Squirted the product onto plates, then spread around with a foam paint brush. Material spread easily, but was messy because it does not dry.

Shook can, poured, then spread using a foam brush.

3 mins., 42 secs.


-

Squirted the product onto plates, then spread it with a foam paint brush. Material was very easy to work with.

-

3 mins., 20 secs.

DAP Household Adhesive Sealant

Almost

Masking Success

Thoroughly ensured the edges were sealed.

Application Notes

Wrapped 2 times around plates.

17 mins., 26 secs.

Application Time

3M High Temperature Aluminum Tape

Product

The entire area galvanized.

About 20% of the area galvanized.

All the plates galvanized

Entire area was completely free of galvanizing.

Very slight seepage at perimeters.

Almost the entire area remained free of galvanizing

Entire area was completely free of galvanizing; very clean.

About 15% of the area galvanized

Less than 90% remained bare

The material prevented galvanizing, but the surface was stained black.

Entire area was completely free of galvanizing

Less than 90% remained bare

At least 80% of the area galvanized.

One plate galvanized completely and the two other plates had large areas that galvanized.

About 12% of the area galvanized. Seepage at ends caused galvanizing in those areas.

Notes

FLAT PLATE - PHASE 1 TESTING

N/A

2 mins., 32 secs.

N/A - product failed completely.

1 min.

5 mins., 48 secs.

1 min.

1 min.

1 min.. 37 secs.

18 mins., 39 secs.

1 min.

2 mins., 38 secs.

10 mins., 52 secs.

40 secs.

2 mins., 11 secs.

9 mins., 24 secs.

Removal Time

N/A

The burned product adhered to the steel very well. I had to score it with the edge of a flathead screwdriver and then scrape it with a small metal-bristled brush.

N/A

Used big and small metal-bristled brushes to scrape material off the metal.

Used a small metal-bristled brush to scrape the material off. The material adhered to the surface tenaciously, which required much harder scraping.

Used a big metal-bristled brush to scrape away the material.

Used a big metal-bristled brush. The material came off very easily.

Used a small metal-bristled brush to scrape the material off.

Scored tape with a flathead screwdriver, then used a metal-bristled brush to scrape away remaining debris.

Used big and small metal-bristled brushes to scrape away the product. It came off fairly easily.

Used a small metal-bristled brush to scrape since the big metal-brush was innefective. Had to scrape very hard to get this material off.

Scraped off burnt tape with a metal-bristled brush. Scraped off very easily.

Scraped with a small metal-bristled brush.

Scraped off with a small metal-bristled brush. The material was very gummy and hard to remove.

Used a flathead screwdriver to scrape the tape and then pulled it off.

Removal Notes

13

Balled up tape, then stuffed in the holes.

Poured into holes

3 mins.

5 mins.

2 mins., 30 secs.

1 min., 15 secs.


Duct Tape

Galva Stop


5 mins., 13 secs.

1 min.

4 mins.

10 mins., 30 secs.

N/A

3 mins., 24 secs.

4 mins., 16 secs.

Macropoxy 846


NAPA RTV Red

Stop Galv


VHT Header Paint



-

Yes

2 minutes of application time was due to stirring product. Poured material into the holes. Material dried fast.

3 minutes of application time was due to stirring the product. Poured into holes.

N/A

Yes

-

-

Yes

Yes

N/A

Had to cut into the side of the roll, since an industrial size caulk gun was not available.

Poured into holes.

Squirted into holes with a caulk gun

Poured into holes; runnier than Galva Stop or Stop Galv. Dries faster than other products, too.

Preparation time for product took 31 minutes. Poured into holes; very runny and messy.

32 mins., 26 secs.

-

Slightly harder to work with than duct tape. Balled up, then stuffed in the holes.

8 mins.

Kapton Tape

Yes

-

-

-

Squirted into holes w/ a caulk gun

Squeezed product out of tube and into holes. The material was very hard to squeez out of the tubes.

Yes

Squeezed material out of tube and into holes. Hardened like caulk, still flexible. Material remained waxy after 14 hours.

6 mins., 30 secs.

-

Masking Success

Balled up tape, hammered it into hole using a wooden dowel.

DAP 100% Silicone Adhesive

Application Notes

9 mins., 41 secs.

Application Time

3M HIgh Temperature Aluminum Tape

Product

5 mins., 40 secs.

N/A

7 mins., 52 secs.

None of the holes galvanized, but there was some frozen zinc inside the holes that had to be wedged out. Wedging out the zinc might not always be possible for all fabrications. All of the holes galvanized 100%.

N/A

5 mins., 28 secs.

In addition to masking intended areas, it caused bare spots in surrounding areas. N/A

Used a metal-bristled brush to scrub the material out. Holes were charred black inside.

11 mins., 30 secs. 1 of the 6 holes galvanized

N/A - all holes galvanized 100%.

Used flathead screwdriver to break apart hard ash, then used small metal-bristled brush to scrape out the rest. Some small particles remained inside the holes.

N/A

Used flathead screwdriver to break apart material, then used a small metal-bristled brush to scrape out remaining material.

Used flathead screwdriver to pry out material, then used a small metal-bristled brush to clean the rest of the material out.

5 mins., 51 secs.

2 of the holes galvanized completely, 4 holes galvanized partially.

Used a small metal-bristled brush to clean material out of the holes. Material came out very easily. 3 mins.

Used flathead screwdriver to break apart material inside the holes. Material was extremely hard, required considerable force. Used a small metal-bristled brush to scrape out rest of the material, which also required considerable effort.

None of the holes galvanized. Holes looked very clean.

None of the holes galvanized.

8 mins., 40 secs.

Used flat-head screwdriver to scrape out tape, then used a metalbristled brush to get the rest. Some unmasked areas around holes did not galvanize, which could fail inspection after galvanizing.

5 mins., 18 secs.

The very top of one hole galvanized a tiny bit, but it could have been an application error, as the hole was not filled to the very top. 3 out of the 6 holes galvanized

Used flathead screwdriver to break apart material, then used a small metal-bristled brush to scrape material out.

8 mins., 26 secs.

In 5 of the 6 holes, a small area galvanized. The area was about 10% of the holes.

Used a metal-bristled brush to scrape material out, which was very hard to do.

Scraped w/ metal-bristled brush. Some unmasked areas around holes did not galvanize, which could fail inspection after galvanizing.

6 mins., 17 secs.

5 of the 6 holes galvanized

Scraped blob of material out with flat-head screwdriver. Used a metal-bristled brush to scrape the rest of the material out. Consistency of dry caulk. Some small crumbs remained.

Used flathead screwdriver and small, metal-bristled brush to pry out the tape.

Removal Notes

Scraped product out with flat-head screwdriver. Hard, flexible consistency like dry caulk.

12 mins., 5 secs.

6 mins., 17 secs.

Removal Time

3 mins., 50 secs.

4 out of 6 holes did galvanize

None of the holes galvanized.

4 holes galvanized completely, the other 2 had considerable amounts of zinc in each.

Notes

BURIED THREADED HOLES - PHASE 1 TESTING

14

Yes

Squeezed material onto threads, smeared on w/ foam paint brush. Had wet, waxy feeling after drying. Wrapped 5-6 times around each bolt.

Dipped bolts into bottle to apply material. Hardened, but still flexible. Will stick to itself if it touches other coated products.

Smeared material on w/a foam paint brush. Somewhat easier to handle than NAPA RTV red.

N/A

8 mins.

5 mins., 30 secs.

3 mins.

10 mins., 30 secs.

6 mins., 30 secs.

Duct Tape

Galva Stop


Kapton Tape

-

Not tested, as paint cannot be easily removed after galvanizing.

N/A

4 mins., 5 secs.

5 mins., 14 secs.

VHT Header Paint



-

-

Goes on very thick, so it could get expensive. Used a foam paint brush to spread around. Need an industrial size caulk gun.

9 mins., 10 secs.


Three minutes of application time was stirring the product. Dipped bolts into masking material to apply.

Yes

Dipped bolts into bottle to apply material. Thicker than Galva Stop. Hardened, but still flexible. Sticks to itself if it touches other coated products.

5 mins.

Stop Galv

-

Yes

Smeared material on w/ a foam paint brush. Applied thick in many areas because of product consistency.

9 mins., 45 secs.

NAPA RTV Red

Three mins. of application time due to stirring. Dipped bolts into material. Dries very fast.

Yes

Very runny, hard to smear around. Rather than smearing, it dries, lumps up, and comes off the metal. Very strong, nauseating smell - similar to nail polish remover.


5 mins., 12 secs.

Macropoxy 846

Yes

37 mins., 10 secs.

Preparation of the product took 31 mins. Dipped bolts into masking material to apply. Material was runny, like paint.

-

Yes

-

Yes


Very thick, messy. Smelled awful. Smeared on w/ foam paint brush. Dried hard, like caulk.

9 mins., 30 secs.

-

Masking Success


Wrapped tape around bolts 3 times. Adhesive is very sticky, and difficult to get off roll and apply.

Application Notes

11 mins., 16 secs.

Application Time


Product

All bolts picked up excessive zinc. A lot of the zinc was just frozen, but many areas galvanized too.

Many areas had zinc frozen between the threads.

N/A

All bolts lost during testing.

Got 5 bolts back. Almost all threads were completely bare.

A few small areas picked up a little zinc.

Some small areas did galvanize.

N/A

4 mins., 57 secs.

N/A

N/A

10 mins., 20 secs.

4 mins., 18 secs.

3 mins., 5 secs.

1 min., 11 secs.

N/A

Used small metal-bristled brush to scrape material off. Baked-on material was much harder than other products. Could not remove all of the product.

N/A

N/A

Scraped the material off with a big metal-bristled brush. The material came off very easily and the threads had very little residue.

Used a small metal-bristled brush to scrape away the material, which came off very easily.

Used a small metal-bristled brush to scrape off the material, which came off very easily.

Used a small metal-bristled brush to scrape away the product, which came off pretty easily.

Unable to remove tape from threads. This material would not work as a masking material, as it cannot be removed w/o damaging the threads.

Tape was nearly impossible to remove from threads

Could not remove masking material. One bolt was lost during the galvanizing process. Received only 1 bolt back (the rest must have fallen out of the basket during the galvanizing process). A few very small areas did galvanize.

Used a small metal-bristled brush to scrape away the material, which came off pretty easily.

7 mins., 30 secs.

Threads were completely bare.

Brushed off black ashy material very easily with a big metal-bristled brush.

Used a big metal-bristled brush to scrape away the material, which came off very easily.

Crusty white material came off very easily w/ a small metal-bristled brush.

Used big metal-bristled brush to scrape away material. Threads were very clean after scraping material off.

Scraped tape w/ a flathead screwdriver until it could be peeled off.

Removal Notes

6 mins., 50 secs.

5 mins., 44 secs.

2 mins., 40 secs.

4 mins., 22 secs.

7 mins., 55 secs.

Removal Time

A few tiny areas did galvanize.

Had large bare areas, but many areas still galvanized.

All bolt threads galvanized to some extent. Got 4 bolts back.

A few small areas picked up a little zinc. Got 5 bolts back.

Many areas galvanized. Some bare areas, but about half of threads galvanized.

Notes

BOLT THREADS - PHASE 1 TESTING

15

Price $3.98 / 2.8 oz. tube $48.00 / liter $4.97 / 10.1 oz. tube $120.00 / gal. $14.19 / 11 oz. tube $45.00 / qt.

Product


Galva Stop



NAPA RTV Red

Stop Galv

Yes

-

-

-

Yes

-

1 Hour Cure Time Success

Yes

-

-

-

Yes

-


FLAT PLATE

-

Yes

-

-

Yes

-

30 Min. Cure Time Success

PHASE 2 TESTING - OVERVIEW

Yes

Yes

Yes

-

Yes

Yes


BOLT THREADS

Yes

Yes

Yes

Yes

Yes

Yes


16

Price $3.98 / 2.8 oz. tube $48.00 / l. $4.97 / 10.1 oz. tube $120.00 / gal. $14.19 / 11 oz. tube $45.00 / qt.

Product


Galva Stop



NAPA RTV Red

Stop Galv

$1.41 / oz

$1.29 / oz

$0.94 / oz

$0.49 / oz

$1.42 / oz

$1.42 / oz

Standardized Price

Yes

-

-

-

Yes

-


Yes

-

-

-

Yes

-


FLAT PLATE

PHASE 2 TESTING - OVERVIEW

-

Yes

-

-

Yes

-

30 Min. Cure Time Success

Yes

Yes

Yes

-

Yes

Yes


BOLT THREADS

Yes

Yes

Yes

Yes

Yes

Yes


17

-


-

-


Stop Galv

Yes

Galva Stop

Yes

-


NAPA RTV Red

Success

Product

Yes

Yes

Yes

3 of the 5 bolts galvanized

None of the bolts galvanized, but the material was extremely sticky and was nearly impossible to get off the threads. All five of the bolts galvanized to some extent.

-

Yes

One bolt had a tiny spec of zinc on it.


Yes

Success


Notes

30 MINUTE CURE TIME

Yes

3 of the 5 bolts had zinc between the threads at the top 25% of the threads. Material was gummy and hard to remove.

A few small specs of zinc here and there.

Material was very gummy and took a long time and considerable effort to remove.

Yes

Yes

Yes

Yes

1 bolt galvanized a little less than 10%. Other bolts had miniscule amount of zinc.

The product scraped off the bolts very easily.

Yes

Success

Material was gummy and took a long time to remove.

Notes

2 HOUR CURE TIME

BOLT THREADS - PHASE 2 TESTING

Applied w/ a foam brush. Went on slightly thicker than Galva Stop and seemed to cover surfaces better than Galva Stop too.

Applied with a foam brush. Material was the gummiest out of the other materials and took the longest time to clean from the threads.

Applied with a foam brush. One bolt out of the 5 galvanized about 10-15%. This material dries extremely fast, which can make working with it hard. After applying masking material the outer edges of the threads appeared to be bare. It still masked the zinc effectively though.

Applied with a foam brush. One bolt out of the 5 had a little zinc on it.

Applied with a foam brush. Went on very thin. The outermost part of the threads looked like very little if any material went on those areas. The product still prevented galvanizing though.

Applied w/ a foam brush. One bolt out of the 5 had a little zinc on it. The material was very gummy and took longer to remove.

Notes

2 HOUR CURE TIME

Appendix 2. Pictures of Masking Materials During Phase 1 Testing








Duct Tape


Galva Stop




Kapton Tape


Macropoxy 846




NAPA RTV Red


Stop Galv




VHT Header Paint






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