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 areas prior to hot-dip reason to mask steel is to give a higher
galvanizing to prevent zinc 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
 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.

$89.78 / 32 mins., 8 mins., 37 mins., 1 min.,

Macropoxy 846 $0.35 / oz - N/A N/A Yes Yes
gal. of Part A & B 26 secs. 40 secs. 10 secs. 11 secs.

Maskote Zinc 2 mins., 37 5 mins., 5 mins., 3 mins.,

$120.00 / gal. $0.94 / oz Yes 1 min. Yes 3 mins. Yes
Stop - Off secs. 13 secs. 12 secs. 5 secs.
11

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.

4 mins., 5 mins., 10 mins.,

Stop Galv $45.00 / qt. $1.41 / oz Yes - N/A N/A Yes 5 mins.
26 secs. 48 secs. 20 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

ZYP Boron 3 mins., 7 mins.,

$170.00 / gal. $1.33 / oz - N/A N/A Yes - N/A N/A
Nitride Hardcoat 24 secs. 52 secs.
 FLAT PLATE - PHASE 1 TESTING
Product Application Application Notes Masking Notes Removal Time Removal Notes
Time Success
3M High About 12% of the area
Used a flathead screwdriver to scrape
Temperature 17 mins., 26 secs. Thoroughly ensured the edges were sealed. Almost galvanized. Seepage at ends 9 mins., 24 secs.
the tape and then pulled it off.
Aluminum Tape caused galvanizing in those areas.
Squirted the product onto plates, then One plate galvanized completely
DAP Household Scraped off with a small metal-bristled brush.
3 mins., 20 secs. spread it with a foam paint brush. - and the two other plates had 2 mins., 11 secs.
Adhesive Sealant The material was very gummy and hard to remove.
Material was very easy to work with. large areas that galvanized.
Squirted the product onto plates, then spread
Dow Corning
3 mins., 42 secs. around with a foam paint brush. Material spread - At least 80% of the area galvanized. 40 secs. Scraped with a small metal-bristled brush.
Compound #111
easily, but was messy because it does not dry.
Scraped off burnt tape with a metal-bristled
Duct Tape 25 mins. Wrapped 2 times around plates. - Less than 90% remained bare 10 mins., 52 secs.
brush. Scraped off very easily.
Used a small metal-bristled brush to scrape
Shook can, poured, then spread Entire area was completely
Galva Stop 2 mins., 21 secs. Yes 2 mins., 38 secs. since the big metal-brush was innefective. Had
using a foam brush. free of galvanizing
to scrape very hard to get this material off.
GE 100% Used a caulk gun, then spread using a The material prevented galvanizing, Used big and small metal-bristled brushes to
1 mins., 22 secs. Yes 1 min.
Silicone Caulk foam brush. Went on very thick. but the surface was stained black. scrape away the product. It came off fairly easily.
2 wraps. Tape did not stick well, much Scored tape with a flathead screwdriver, then used a
Kapton Tape 30 mins. - Less than 90% remained bare 18 mins., 39 secs.
harder to work with than the duct tape. metal-bristled brush to scrape away remaining debris.
32 mins., 14 secs.
12

(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.

11 mins., Used a metal-bristled brush to scrub the

Stop Galv 4 mins. Poured into holes. - 1 of the 6 holes galvanized
30 secs. material out. Holes were charred black inside.
In addition to masking intended
Valmont Masking 10 mins., Had to cut into the side of the roll, since an 5 mins., Used flathead screwdriver to break apart material, then used a
Yes areas, it caused bare spots
Compound 30 secs. industrial size caulk gun was not available. 28 secs. small metal-bristled brush to scrape out remaining material.
in surrounding areas.

VHT Header Paint N/A N/A N/A N/A N/A N/A

None of the holes galvanized, but

2 minutes of application time was due to there was some frozen zinc inside Used flathead screwdriver to break apart hard ash, then
ZYP Boron Nitride 3 mins., 7 mins.,
stirring product. Poured material into Yes the holes that had to be wedged used small metal-bristled brush to scrape out the rest.
Hardcoat 24 secs. 52 secs.
the holes. Material dried fast. out. Wedging out the zinc might not Some small particles remained inside the holes.
always be possible for all fabrications.
ZYP Boron Nitride 4 mins., 3 minutes of application time was due
- All of the holes galvanized 100%. N/A N/A - all holes galvanized 100%.
Lubricoat 16 secs. to stirring the product. Poured into holes.
 BOLT THREADS - PHASE 1 TESTING
Product Application Application Notes Masking Notes Removal Time Removal Notes
Time Success
3M High Many areas galvanized.
11 mins., 16 Wrapped tape around bolts 3 times. Adhesive is Scraped tape w/ a flathead screwdriver
Temperature - Some bare areas, but about 7 mins., 55 secs.
secs. very sticky, and difficult to get off roll and apply. until it could be peeled off.
Aluminum Tape half of threads galvanized.
DAP Household 9 mins., 30 Very thick, messy. Smelled awful. Smeared on A few small areas picked up Used big metal-bristled brush to scrape away material.
Yes 4 mins., 22 secs.
Adhesive Sealant secs. w/ foam paint brush. Dried hard, like caulk. a little zinc. Got 5 bolts back. Threads were very clean after scraping material off.
Dow Corning Squeezed material onto threads, smeared on w/ All bolt threads galvanized to Crusty white material came off very
8 mins. - 2 mins., 40 secs.
Compound #111 foam paint brush. Had wet, waxy feeling after drying. some extent. Got 4 bolts back. easily w/ a small metal-bristled brush.
5 mins., 30 Had large bare areas, but Used a big metal-bristled brush to scrape away the
Duct Tape Wrapped 5-6 times around each bolt. - 5 mins., 44 secs.
secs. many areas still galvanized. material, which came off very easily.
Dipped bolts into bottle to apply material.
Brushed off black ashy material very
Galva Stop 3 mins. Hardened, but still flexible. Will stick to Yes A few tiny areas did galvanize. 6 mins., 50 secs.
easily with a big metal-bristled brush.
itself if it touches other coated products.

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.

Tape was nearly

Could not remove masking material. Unable to remove tape from threads. This material
6 mins., 30 impossible to
Kapton Tape N/A - One bolt was lost during would not work as a masking material, as it
secs. remove from
the galvanizing process. cannot be removed w/o damaging the threads.
threads
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.

Three minutes of application time All bolts picked up excessive zinc.

ZYP Boron Nitride 5 mins., 14
was stirring the product. Dipped bolts - A lot of the zinc was just frozen, N/A N/A
Lubricoat secs.
into masking material to apply. but many areas galvanized too.
 PHASE 2 TESTING - OVERVIEW
FLAT PLATE BOLT THREADS
1 Hour Cure 2 Hour Cure 30 Min. Cure 1 Hour Cure 2 Hour Cure
Product Price
Time Success Time Success Time Success Time Success Time Success
DAP Household Adhesive Sealant $3.98 / 2.8 oz. tube - - - Yes Yes

Galva Stop $48.00 / liter Yes Yes Yes Yes Yes

GE 100% Silicone Caulk $4.97 / 10.1 oz. tube - - - - Yes

Maskote Zinc Stop - Off $120.00 / gal. - - - Yes Yes

NAPA RTV Red $14.19 / 11 oz. tube - - Yes Yes Yes

Stop Galv $45.00 / qt. Yes Yes - Yes Yes

15
 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

Galva Stop $48.00 / l. $1.42 / oz Yes Yes Yes Yes Yes

GE 100% Silicone Caulk $4.97 / 10.1 oz. tube $0.49 / oz - - - - Yes

Maskote Zinc Stop - Off $120.00 / gal. $0.94 / oz - - - Yes Yes

NAPA RTV Red $14.19 / 11 oz. tube $1.29 / oz - - Yes Yes Yes

Stop Galv $45.00 / qt. $1.41 / oz Yes Yes - Yes Yes

16
 BOLT THREADS - PHASE 2 TESTING
30 MINUTE CURE TIME 2 HOUR CURE TIME 2 HOUR CURE TIME

Product Success Notes Success Notes Success Notes

DAP Household
Material was gummy and Applied w/ a foam brush. One bolt out of the 5 had a little zinc
Adhesive - 2 of the 5 bolts galvanized Yes Yes
took a long time to remove. on it. The material was very gummy and took longer to remove.
Sealant
1 bolt galvanized a little less Applied with a foam brush. Went on very thin. The outermost
One bolt had a tiny
Galva Stop Yes Yes than 10%. Other bolts had Yes part of the threads looked like very little if any material went
spec of zinc on it.
miniscule amount of zinc. on those areas. The product still prevented galvanizing though.
3 of the 5 bolts had zinc between
GE 100% the threads at the top 25% of Applied with a foam brush. One bolt out
- 3 of the 5 bolts galvanized - Yes
Silicone Caulk the threads. Material was of the 5 had a little zinc on it.
gummy and hard to remove.
Applied with a foam brush. One bolt out of the 5 galvanized
about 10-15%. This material dries extremely fast, which
Maskote The product scraped off the bolts
- 3 of the 5 bolts galvanized Yes Yes can make working with it hard. After applying masking
Zinc Stop - Off very easily.
material the outer edges of the threads appeared to be bare.
It still masked the zinc effectively though.
None of the bolts galvanized,
Material was very gummy Applied with a foam brush. Material was the
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

Protecting Steel for Generations

18
3M High Temperature Aluminum Tape

Protecting Steel for Generations

19
DAP Household Adhesive Sealant

Protecting Steel for Generations

20
Dow Corning Compound #111

Protecting Steel for Generations

21
 Duct Tape

Protecting Steel for Generations

22
 Galva Stop

Protecting Steel for Generations

23
GE 100% Silicone Caulk

Protecting Steel for Generations

24
 Kapton Tape

Protecting Steel for Generations

25
 Macropoxy 846

Protecting Steel for Generations

26
 Maskote Zinc Stop-Off

Protecting Steel for Generations

27
 NAPA RTV Red

Protecting Steel for Generations

28
 Stop Galv

Protecting Steel for Generations

29
Valmont Masking Compound

Protecting Steel for Generations

30
 VHT Header Paint

Protecting Steel for Generations

31
ZYP Boron Nitride Hardcoat

Protecting Steel for Generations

32
ZYP Boron Nitride Lubricoat

Protecting Steel for Generations

33
 Additional Pictures

Protecting Steel for Generations

34