Professional Documents
Culture Documents
FOR PREVENTING
HOT-DIP GALVANIZING
BY BERNARDO DURAN, III AND THOMAS LANGILL, PHD
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.
1
PHASE 1 TESTING - OVERVIEW OF SUCCESSFUL MASKING MATERIALS
FLAT PLATE BURIED THREADED HOLES BOLT THREADS
Standardized Application Removal Application Removal Application Removal
Product Price Success Success Success
Price Time Time Time Time Time Time
DAP 100%
6 mins., 12 mins., 5 9 mins., 4 mins.,
Silicone $3.98 / 2.8 oz. tube $1.42 / oz - N/A N/A Yes Yes
30 secs. secs. 30 secs. 22 secs.
Adhesive
2 mins., 2 mins., 6 mins.,
Galva Stop $48.00 / liter $1.42 / oz Yes - N/A N/A Yes 3 mins.
21 secs. 38 secs. 50 secs.
GE 100% 1 min., 1 min., 5 mins., 10 mins., 7 mins.,
$4.97 / 10.1 oz. tube $0.49 / oz Yes 1 min. Yes Yes
Silicone Caulk 22 secs. 15 secs. 18 secs. 30 secs. 30 secs.
Valmont
2 mins., 10 mins., 5 mins.,
Masking $4.75 / small tube $0.37 / oz Yes 1 min. Yes - N/A N/A
32 secs. 30 secs. 28 secs.
Compound
(31/32 mins. Poured onto the surface and Used a small metal-bristled brush
Macropoxy 846 - About 15% of the area galvanized 1 min.. 37 secs.
spent on prep spread with a foam paint brush. to scrape the material off.
time for epoxy)
Maskote Zinc Very runny - dries very quickly, making it hard to Entire area was completely free Used a big metal-bristled brush.
2 mins., 37 secs. Yes 1 min.
Stop - Off spread around. Used a foam brush for spreading. of galvanizing; very clean. The material came off very easily.
Used a caulk gun, then spread using a foam Almost the entire area Used a big metal-bristled brush
NAPA RTV Red 1 min., 32 secs. Yes 1 min.
brush. Went on easy, but kind of thick. remained free of galvanizing to scrape away the material.
Used a small metal-bristled brush to scrape the
Poured the product on, spread with a foam paint
Stop Galv 4 mins., 26 secs. Yes Very slight seepage at perimeters. 5 mins., 48 secs. material off. The material adhered to the surface
brush. Product went on thick and dried quickly.
tenaciously, which required much harder scraping.
Valmont Masking Very thick, like a paste. Used a Entire area was completely Used big and small metal-bristled brushes
2 mins., 32 secs. Yes 1 min.
Compound foam brush to spread around. free of galvanizing. to scrape material off the metal.
Applied 2 coats of paint. Allowed N/A - product
VHT Header Paint 1 hr., 33 mins. - All the plates galvanized N/A
for dry time between coats. failed completely.
Two minutes of application time was to stir The burned product adhered to the steel very well. I
ZYP Boron Nitride
3 mins., 48 secs. the product. Poured onto the surface - About 20% of the area galvanized. 2 mins., 32 secs. had to score it with the edge of a flathead screwdriver
Hardcoat
and spread with a foam paint brush. and then scrape it with a small metal-bristled brush.
Poured onto the surface and spread with a foam
ZYP Boron Nitride paint brush. Material had the runniness of paint
4 mins., 16 secs. - The entire area galvanized. N/A N/A
Lubricoat and was very messy. 3 minutes of the application
time was due to stirring the product like paint.
BURIED THREADED HOLES - PHASE 1 TESTING
Product Application Application Notes Masking Notes Removal Removal Notes
Time Success Time
3M HIgh 4 holes galvanized completely,
9 mins., Balled up tape, hammered it into 6 mins., Used flathead screwdriver and small,
Temperature - the other 2 had considerable
41 secs. hole using a wooden dowel. 17 secs. metal-bristled brush to pry out the tape.
Aluminum Tape amounts of zinc in each.
Squeezed material out of tube and into Scraped blob of material out with flat-head screwdriver. Used
DAP 100% 6 mins., 12 mins.,
holes. Hardened like caulk, still flexible. Yes None of the holes galvanized. a metal-bristled brush to scrape the rest of the material out.
Silicone Adhesive 30 secs. 5 secs.
Material remained waxy after 14 hours. Consistency of dry caulk. Some small crumbs remained.
Dow Corning Squeezed product out of tube and into holes. The 3 mins., Scraped product out with flat-head screwdriver.
3 mins. - 4 out of 6 holes did galvanize
Compound #111 material was very hard to squeez out of the tubes. 50 secs. Hard, flexible consistency like dry caulk.
Scraped w/ metal-bristled brush. Some
6 mins.,
Duct Tape 5 mins. Balled up tape, then stuffed in the holes. - 5 of the 6 holes galvanized unmasked areas around holes did not galvanize,
17 secs.
which could fail inspection after galvanizing.
In 5 of the 6 holes, a small
2 mins., 8 mins., Used a metal-bristled brush to scrape
Galva Stop Poured into holes - area galvanized. The area
30 secs. 26 secs. material out, which was very hard to do.
was about 10% of the holes.
The very top of one hole galvanized
GE 100% 1 min., a tiny bit, but it could have been 5 mins., Used flathead screwdriver to break apart material, then used a
Squirted into holes w/ a caulk gun Yes
Silicone Caulk 15 secs. an application error, as the hole 18 secs. small metal-bristled brush to scrape material out.
was not filled to the very top.
Used flat-head screwdriver to scrape out tape, then used a metal-
Slightly harder to work with than duct tape. 5 mins.,
13
Kapton Tape 8 mins. - 3 out of the 6 holes galvanized bristled brush to get the rest. Some unmasked areas around holes
Balled up, then stuffed in the holes. 40 secs.
did not galvanize, which could fail inspection after galvanizing.
Used flathead screwdriver to break apart material inside the
32 mins., Preparation time for product took 31 minutes. 8 mins., holes. Material was extremely hard, required considerable
Macropoxy 846 Yes None of the holes galvanized.
26 secs. Poured into holes; very runny and messy. 40 secs. force. Used a small metal-bristled brush to scrape out rest of
the material, which also required considerable effort.
Maskote Zinc 5 mins., Poured into holes; runnier than Galva Stop or None of the holes galvanized. Used a small metal-bristled brush to clean material
Yes 3 mins.
Stop - Off 13 secs. Stop Galv. Dries faster than other products, too. Holes looked very clean. out of the holes. Material came out very easily.
2 of the holes galvanized completely, 5 mins., Used flathead screwdriver to pry out material, then used a small
NAPA RTV Red 1 min. Squirted into holes with a caulk gun -
4 holes galvanized partially. 51 secs. metal-bristled brush to clean the rest of the material out.
GE 100% 10 mins., 30 Smeared material on w/a foam paint brush. Threads Used a small metal-bristled brush to scrape
Yes 7 mins., 30 secs.
Silicone Caulk secs. Somewhat easier to handle than NAPA RTV red. were completely bare. away the material, which came off pretty easily.
NAPA RTV Red $14.19 / 11 oz. tube $1.29 / oz - - Yes Yes Yes
All five of the bolts A few small specs of Applied w/ a foam brush. Went on slightly thicker than Galva
Stop Galv - Yes Yes
galvanized to some extent. zinc here and there. Stop and seemed to cover surfaces better than Galva Stop too.
Appendix 2.
Pictures of Masking Materials During Phase 1 Testing
18
3M High Temperature Aluminum Tape
19
DAP Household Adhesive Sealant
20
Dow Corning Compound #111
21
Duct Tape
22
Galva Stop
23
GE 100% Silicone Caulk
24
Kapton Tape
25
Macropoxy 846
26
Maskote Zinc Stop-Off
27
NAPA RTV Red
28
Stop Galv
29
Valmont Masking Compound
30
VHT Header Paint
31
ZYP Boron Nitride Hardcoat
32
ZYP Boron Nitride Lubricoat
33
Additional Pictures
34