Escolar Documentos
Profissional Documentos
Cultura Documentos
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
well at masking steel prior to availablility and recommendations from
galvanizing. AGA members.
2
galvanizing process, meaning 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 were ¾” in diameter and
the time and trouble of applying the approximately 2 ½” in length (see
materials. Figure 3).
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 Household Adhesive
The masking materials for all surface Sealant
types were applied prior to the chemical • Stop Galv
cleaning steps of the 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
Masking products were removed by
Aluminum Tape
using a metal-bristled brush. The
• Maskote Zinc Stop-Off
materials were scrubbed off the surface
• ZYP Boron Nitride Lubricoat
and then compressed air was used to
• ZYP Boron Nitride Hardcoat
blow off the debris. In Phase 2 testing,
scrubbing the cleaned steel with a nylon
Determining the effectiveness of each
bristled brush and Simple Green solution
masking material came down to
was also performed to determine if the
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
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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 • DAP Household Adhesive
threads, the same criteria applied as that Sealant
for buried threaded holes – almost the • GE 100% Silicone Caulk
entire threaded area must remain • Valmont Masking Compound
ungalvanized to be considered effective. • Maskote Zinc Stop-Off
• Macropoxy 846
TEST 1 RESULTS • ZYP Boron Nitride Hardcoat
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 on bolt threads. The
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:
• Galva Stop
• Stop Galv
• Stop Galv
• Maskote Zinc Stop-Off
• DAP Household Adhesive
• NAPA RTV Red Sealant
• Galva Stop • NAPA RTV Red
• GE 100% Silicone Caulk • GE 100% Silicone Caulk
• Valmont Masking Compound • Macropoxy 846
• Maskote Zinc Stop-Off
Only 14 of the masking materials were
tested on buried threaded holes and bolt
The bolts masked with Valmont
threads. The VHT Header Paint was not
Masking Compound were lost during the
tested because paint cannot be easily galvanizing process during testing.
removed from threaded areas.
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and removal data, please see the charts manufactures curing instructions to
in Appendix 1. achieve optimum performance.
Sealant
For the flat plate specimens, each
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.
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.
be used in accordance with the were applied to the same bolts as those
6
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 Galv and Galva Stop were
bolt threads; 30 minutes, 1 hour, and 2 successful at preventing galvanizing.
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 recommended. The grinder
the surface while going through the immediately went through the masking
galvanizing process. Cleaning with a materials and attacked the steel
grinder was attempted on the flat plate underneath.
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.
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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 work best at preventing
improved for all the masking materials galvanizing on masked areas.
after cleaning with the Simple Green
solution. Six commercially available masking
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. Some baked on masking • GE 100% Silicone Caulk
material remained on the bolts masked • Maskote Zinc Stop-Off
with Galva Stop and Stop Galv. • NAPA RTV Red
• (cont. on next page)
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• Galva Stop COSTS OF THE MASKING MATERIALS
• DAP Household Adhesive The masking materials tested in this
Sealant study have a wide range in price, which
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.
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Appendix 1.
Detailed Performance Data of Masking Materials
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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.
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1 min., 9 mins., 4 mins.,
NAPA RTV Red $14.19 / 11 oz. tube $1.29 / oz Yes 1 min. - N/A N/A Yes
32 secs. 45 secs. 18 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
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(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.,
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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.
14
Received only 1 bolt back (the rest
Preparation of the product took 31 mins.
37 mins., 10 must have fallen out of the basket Used a small metal-bristled brush to scrape
Macropoxy 846 Dipped bolts into masking material to apply. Yes 1 min., 11 secs.
secs. during the galvanizing process). A away the product, which came off pretty easily.
Material was runny, like paint.
few very small areas did galvanize.
Very runny, hard to smear around. Rather
Maskote Zinc 5 mins., 12 than smearing, it dries, lumps up, and comes Used a small metal-bristled brush to scrape
Yes Some small areas did galvanize. 3 mins., 5 secs.
Stop - Off secs. off the metal. Very strong, nauseating off the material, which came off very easily.
smell - similar to nail polish remover.
Smeared material on w/ a foam paint
9 mins., 45 A few small areas picked Used a small metal-bristled brush to scrape
NAPA RTV Red brush. Applied thick in many areas Yes 4 mins., 18 secs.
secs. up a little zinc. away the material, which came off very easily.
because of product consistency.
Dipped bolts into bottle to apply material. Thicker Scraped the material off with a big metal-bristled
Got 5 bolts back. Almost all
Stop Galv 5 mins. than Galva Stop. Hardened, but still flexible. Yes 10 mins., 20 secs. brush. The material came off very easily
threads were completely bare.
Sticks to itself if it touches other coated products. and the threads had very little residue.
Goes on very thick, so it could get expensive.
Valmont Masking 9 mins., 10
Used a foam paint brush to spread around. - All bolts lost during testing. N/A N/A
Compound secs.
Need an industrial size caulk gun.
Not tested, as paint cannot be
VHT Header Paint N/A - N/A N/A N/A
easily removed after galvanizing.
Used small metal-bristled brush to scrape material
ZYP Boron Nitride Three mins. of application time due to stirring. Many areas had zinc frozen
4 mins., 5 secs. - 4 mins., 57 secs. off. Baked-on material was much harder than other
Hardcoat Dipped bolts into material. Dries very fast. between the threads.
products. Could not remove all of the product.
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PHASE 2 TESTING - OVERVIEW
FLAT PLATE BOLT THREADS
Standardized 1 Hour Cure 2 Hour Cure 30 Min. Cure 1 Hour Cure 2 Hour Cure
Product Price
Price Time Success Time Success Time Success Time Success Time Success
DAP Household Adhesive Sealant $3.98 / 2.8 oz. tube $1.42 / oz - - - Yes Yes
NAPA RTV Red $14.19 / 11 oz. tube $1.29 / oz - - Yes Yes Yes
16
BOLT THREADS - PHASE 2 TESTING
30 MINUTE CURE TIME 2 HOUR CURE TIME 2 HOUR CURE TIME
17
but the material was extremely
NAPA RTV Red Yes Yes and took a long time and Yes gummiest out of the other materials and took the
sticky and was nearly impossible
considerable effort to remove. longest time to clean from the threads.
to get off the threads.
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
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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