The Complete Technical Guide to Duct Tape

It’s one of the most popular adhesives because of its versatility, but there are many misconceptions about the toolbox superhero called duct tape. This complete technical guide will cover everything you would ever want to know, including:


The History of Duct Tape

In 1943, Vesta Stoudt had a job in a munitions factory where ammo cases were sealed with paper tape and melted wax. Worried the cases were too hard to open on the battlefield, Stoudt proposed a fix: Use waterproof cloth tape instead.

Johnson & Johnson adapted surgical adhesive tapes to Stoudt’s specifications, and soldiers nicknamed the material “duck tape” in reference to its ability to repel moisture “like water off a duck’s back.” (They also dubbed it 100-mph tape because it could hold together a speeding jeep!)  

Following World War II, duct tape began to catch on in the U.S. as a handy tool for home construction. People were using it to hold metal air ducts together, so the company rebranded the product as “duct tape” and updated it with a matching silver color made from powdered aluminum.

Thus, duck tape became duct tape.


How Does It Work?

Duct tape relies on what’s known as a pressure-sensitive adhesive (PSA) for its inherent stickiness. PSAs are soft polymer blends that exploit van der Waals forces to join two objects together. The strength of the bond is due to the fact that the adhesive is hard enough and its viscoelastic properties are powerful enough to resist flow when stressed. This is not the same as the mechanics of structural adhesives like, say, Elmer’s glue. Those adhesives require the evaporation of a solvent to create a chemical bond.

Interestingly, its namesake usage (“duct”) is one of the few things that duct tape isn’t recommended for. Lawrence Berkeley National Laboratory conducted tests in 1998 to see how well different types of tape performed at sealing ducts, and, compared to the other products, duct tape was the clear loser.  Using duct tape on actual ductwork is now considered a code violation in many buildings.

Mythbusters has devoted three entire episodes to exploring some of duct tape’s most extreme applications. The team was able to successfully use duct tape to patch a damaged airplane fuselage, construct a functioning cannon, build a usable bridge, and lift a 5000-pound car. Of the 18 myths they tested, only one was busted (turns out you can’t use duct tape to barricade a car driving at 60 mph).


7 Types of Duct Tape — Are You Using the Right One? 

Duct tape’s initial design was simple but effective: a strong fabric bonded to polyethylene film for sealing/waterproofing, silver-gray coloring to match metal ductwork, and a thick coating of adhesive to seal the joints and make them airtight.

But people quickly determined that this specialty tape could be used for a variety of other purposes, and the boom was on. Many new versions were manufactured – each with different qualities of fabric, polyethylene, and adhesive – for many different end-uses. As a result, manufacturers now offer a wide range of grades of polyethylene/fabric types and in a wide variety of colors.

1. General Purpose

With a low fabric count, a thin polyethylene film, and a low weight adhesive, general-purpose tapes work well enough for odd jobs where long service life isn’t necessary.

2. Industrial Grade

With industrial-grade tapes, the fabric and polyethylene are upgraded, so the tape becomes more of a “workhorse” with added adhesive coating weight. One popular variation is multi-colored industrial tape that is used to seam and hold carpets at exhibitions, where the adhesive must be removed cleanly.

3. Professional Grade

Sometimes called “contractors’ grade” these tapes offer more of an upgrade to the components of the industrial-grade tape for added strength, adhesion, and durability.

4. Gaffer’s Tape

Typically, gaffer’s tape is a matte black for minimal light reflection and is used in movies, television, and photo studios to temporarily tape cables to the floor or light fixtures to vertical posts. This type of tape needs to be able to be easily torn by hand and remove cleanly.

Read more about Gaffer’s Tape vs. Duct Tape here. 

5. Stucco Tape

Stucco tape is used to attach protective polyethylene film over doors and windows during house construction prior to spraying the outside walls with stucco. Designed to be used outdoors for several days at a time, stucco duct tape must be able to resist the ultraviolet of the sun’s rays during that time – and not come apart from the vinyl window frames.

Read more about Why Stucco Tape Really Matters here.

6. True Duct Tape

This one lives up to its name – duct tape is truly intended for sealing air ducts. Duct tape must be permanent and able to withstand the prolonged heat and air pressure for the lifetime of the duct. It may even need to be flame retardant to meet some building codes. Duct tape is the true top of the line, a high tensile, hardworking tape.

7. Coated Cloth Tape

A roll of coated cloth tape has gone with every U.S. manned space launch, and is also commonly known as “Mission Tape.” This tape played an essential role in the construction of the carbon dioxide absorbers which saved the lives of the three astronauts in the ill-fated Apollo 13 mission.

With such a wide variety to choose from, start by considering exactly what you expect your tape to do. Then, evaluate the right polyethylene/fabric backing judged by tensile strength, as well as the right adhesive coating thickness, judged by adhesion level, for the best performance with the lowest cost.

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Common Adhesive Problems

Believe it or not, standard-issue duct tape is not as versatile as you think. It has its uses—making permanent repairs on the spot —but the following is a list of surfaces that are problems for duct tape.

  1. Wet surfaces: While duct tape is water-resistant, it should only be used for emergency leak repairs. Prolonged submersion in water will cause the adhesion to peel away.
  2. Hot surfaces: Surfaces that reach temperatures over 140°F cause the adhesive to soften, lose its strength, and slip from the attachment.
  3. Cold surfaces: Similarly, duct tape does not work well in extreme cold. Freezing temperatures cause the adhesive to harden which diminishes its sticking power.
  4. Surfaces with Prolonged Exposure to UV Light: UV light can break down the tape’s adhesive bond over time. If you need the tape to remain exposed to direct sunlight, it’s best to use a product that’s been specially treated for UV protection.
  5. Uneven Surfaces: Duct tape has trouble sticking to rough surfaces such as concrete and stucco. Because it has a thin adhesive layer, this specialty tape is only able to make contact with the high points of a surface, which produces a weaker bond.
  6. Dirty Surfaces: In order to achieve maximum adhesion, surfaces must be clean, dry, and dust or oil-free.
  7. Corrugated Cardboard: Don’t use duct tape to seal cardboard boxes. These porous surfaces contain many small fibers on the surface that break away and cause the adhesive bond to fail.
  8. Materials with Low Surface Energy: Materials, like Teflon, have low surface energy, which means it prevents the adhesive from “wetting out” or spreading out to form a strong bond.
  9. Painted Surfaces: Applying duct tape to a surface that’s been painted or treated with another sealant means that the tape is only adhering to the surface layer and not the actual substrate.

When Duct Tape Fails:  6 Reasons To Choose A Different Tape

Duct tape is often cited as being the top go-to, all-purpose repair tape. It can do anything from patching to joint sealing to bundling lumber. However, this versatile tape does have its limits. Here are the top six conditions where duct tape falls short and what you should be using instead.

1. Heat

Despite its name, regular off-the-shelf duct tape is not a good choice for sealing or repairing heating and ventilation ducts. The heat softens the adhesive, causes it to lose its strength and slip from the attachment. It also carries no safety certification, which means it may burn and produce toxic smoke. (For that reason duct tape is not allowed at all on ducts in states such as California.)

As an alternative, consider All Purpose Aluminum Foil Tape, which works up to 248° F and is flame-retardant

2. Water

Duct tape is water resistant, not waterproof. It will work in a pinch until a more permanent solution can be applied, but over time the adhesion will peel away when completely submerged in water.

Consider  All Leak Repair Tape instead;  a permanent adhesive that forms a watertight seal and works in both extreme heat and cold.

3. Temporary Repairs

Think twice about using duct tape for temporary uses such as sealing a windowpane or hanging plastic sheeting. In certain situations, it makes an excellent stopgap until a more permanent solution can be applied. But this type of adhesive will leave behind a sticky residue when removed.

A better option would be All Purpose Repair Tape, which  maintains a strong grip while removing cleanly from any surface

4. Uneven Surfaces

Standard duct tape has a thin layer of adhesive so it adheres best to smooth, even surfaces. Applying it to rough or irregular surfaces means the tape will only make contact with the high points thereby lessening the strength of its bond.

Consider Outdoor Stucco Duct Tape; a thicker layer of adhesive means it’s able to connect with more surface area and maintain a stronger hold.

5. Cold

If you’re working in cold conditions, repairing vinyl siding or refrigeration hoses, duct tape is not the answer. Extreme cold hardens the adhesive and diminishes sticking power of existing duct tape. And if you are applying the tape under cold conditions, it may not stick at all.

We have a number of cold-weather solutions, but All Weather Repair Tape lasts in temperatures as low as -30°F!

6. UV Light

Over time exposure to sunlight will cause duct tape’s adhesive to dry out and become brittle or delaminate. For outdoor projects that require tape, it’s best to choose one that’s been treated to resist the effects of ultraviolet light, like Premium Grade Stucco Duct Tape. 


A Bigger, Better Duct Tape

The Complete Technical Guide to Duct Tape | via ECHOtapeWhat started as a battlefield repair tool has truly become an iconic American fix-all, helping DIYers, professionals, and dads out of sticky situations throughout the years.

But with so many options already on the shelves, how do you make a better duct tape?? 

“The inspiration for CL-W6064 is the culmination of 40 years of experience combined with the frustrations professional contractors encounter daily on the job site,” says Risa Edelstein. “We wanted to create a material that was strong but lightweight, industrial quality without requiring industrial equipment to use and took advantage of the inherent versatility of duct tape.”

ECHOtape CL-W6064 strikes a delicate balance between strength and usability, providing the maximum amount of sticking power without sacrificing ease of use. How did we make that happen? By using a new, advanced technology — a two head coating process.  The first coat ensures high sheer strength, and the second coat, high initial tack.  The result is a beautifully streamlined piece of tape that is lighter, yet stronger than you would imagine, and easy to unwind. Read more about CL-W6064 here.    

With such a wide variety to choose from, start by considering exactly what you expect your tape to do. Then, evaluate the right polyethylene/fabric backing judged by tensile strength, as well as the right adhesive coating thickness, judged by adhesion level, for the best performance with the lowest cost.

Whether you’re looking for a type of duct tape or a different adhesive tape, ECHOtape can help. Contact us today for help in selecting the right tape for your next job.


Duct Tape vs Gaffer’s Tape

Gaffer’s tape or Duct tape? Both are multi-purpose, pressure-sensitive tapes with a strong hold due to fabric reinforcement. But do you know which one is best for construction? Which one is more heat tolerant? Water-resistant? Tearable? Knowing the specific characteristics between duct tape and gaffer’s tape will ensure you choose the right tape for your job. Let’s break it down.


What Is Gaffer’s Tape?

Gaffer’s tape (also known as gaff tape) is a heavy cotton cloth pressure-sensitive tape with strong adhesive qualities. It is most commonly used in theatre, photography, movie and television production, as well as industrial staging work. In fact, when cables are taped down onto a stage or other surface, either to prevent tripping hazards or hide them from the view of the audience or camera, they are said to be “gaffed” or “gaffered,” which is how the tape got its name.

While similar to duct tape, and frequently confused with it, gaffer’s tape is made from a fabric material rather than vinyl or other plastics; it is more resistant to heat; it doesn’t harm the surface to which it adhered. Meaning, gaffer’s tape can be removed without leaving behind an adhesive residue, and it doesn’t reflect light.

 


What Is Duct Tape?

Well known for its versatility and strength, duct tape is a cloth tape coated with a polyethylene resin on one side and an aggressive, rubber-based adhesive on the other. Unlike other tapes, the fabric backing gives duct tape strength, yet allows it to be easily torn and adhered to a variety of surfaces.

Its initial design was simple but effective: a strong fabric bonded to polyethylene film for sealing/waterproofing, silver-gray coloring to match metal ductwork, and a thick coating of adhesive to seal the joints and make them airtight. But people quickly determined that duct tape could be used for a variety of other purposes, and the boom was on.  There are no less than eight different types of duct tape  – each with different qualities of fabric, polyethylene, and adhesive – for many different uses. It will hold together almost everything, making it a very reliable tape to use when you want to be sure that your project doesn’t fall apart. Duct tape’s high adhesion properties mean it typically will leave behind residue, so it’s not the best choice when you need to remove the tape once your job, event or project is over.


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Gaffer’s Tape or Duct Tape—Which Is Best?

Gaffer’s tape is the best choice for the arts and entertainment industry, as it removes from carpets, cables, stages, and other surfaces easily without causing damage or leaving adhesive residue. Duct tape is great for making permanent repairs and waterproofing. But it’s not always that simple.  Understanding the difference between these two types of tape will prevent frustration and ensure positive results for your application. We’ve compiled the best questions for contractors and building professionals to ask when choosing between duct tape and gaffers tape on the job site.

Do You Need Permanent or Temporary Adhesive?

Duct Tape: permanent and/or semi-permanent
Ideal for: Making long-lasting general repairs on the spot. Fun fact: Our CL-W6064 Industrial Strength Duct Tape can provide a permanent adhesive alternative on some applications, but it is removable if need be. For example, in the abatement/remediation industry, after the job is complete, the duct tape holding up the poly film for the containment room must be removed.
Gaffer’s Tape: removable, temporary adhesive
Ideal for: Temporary uses especially when you can’t damage the surface beneath the tape. CL-W6033 Matt Black Gaffer’s Tape is perfect for things like trade shows when you need to remove tape from the convention center floor or in the entertainment industry for marking positions on a stage.  It conforms well to irregular surfaces without twisting or curling.

Does It Need to be Hand Tearable?

Duct Tape: scissors or can be torn by hand
Ideal for: Situations where you have some basic tools on-hand to complete the job. Some duct tape can be torn by hand, making it convenient for working on the fly. However, some duct tape products have extra reinforcement, which will require scissors or hand-tools to cut.  ECHOtape’s new professional duct tape, CL-W6064, has a fine mesh easy-tear backing which gives you a crisp clean edge when torn by hand.

Gaffer’s Tape: easily torn by hand
Ideal for: Working on the fly.

Is Duct Tape Resistant to Heat and Water?

Duct Tape: Waterproof and weather-resistant
Ideal for: Patching and seaming. It’s important to note that duct tape is not very heat resistant. Under extreme heat conditions, duct tape adhesive typically becomes extremely gummy and may slide and or dry up really fast, taking the integrity out of the tape and possibly making it fail.
Gaffer’s Tape: Water resistant; able to resist high heat temperatures
Ideal for: Securing cables and props that are exposed to the bright, hot lights of camera work.  Please note:  Because it does not have a polyethylene backing, gaffer’s tapes are not waterproof, but the barrier properties in the coated cloth backing does make gaffer’s tape moisture resistant in most cases. For example, CL-W6033 has excellent water, vapor and abrasion resistance, which makes it suitable in humidity and moist environments.

Which is more flexible: Duct Tape or Gaffer’s Tape?

Duct Tape: very flexible and easy to stretch
Ideal for: Situations in which the tape must fit into tight areas or hug irregular surfaces and contours.
Gaffer’s Tape: less flexible than duct tape
Ideal for: Situations in which you need the tape to hold its shape (it won’t stretch like duct tape) or when a tight fit is less critical.

What kind of finish do you need… Matte or Reflective Finish?

Duct Tape: CL-W6064 comes in 7 colors with a reflective finish
Ideal for: Color coding and labeling things.
Gaffer’s Tape: CL-W6033 comes in matte black. The matte finish stops the tapes from reflecting light making it blend in with a normal stage background or floor. It is sold in a range of widths from 1/4″ to 4″, with the 1″ and 2″ the most common.
Ideal for: Securing cables or props that need to remain invisible under the lights of a photography or film set.

How Much Does Duct Tape Cost?

Duct Tape: less expensive; $7.99 for 60 yards
Ideal for: Go-to everyday general repair tape.
Gaffer’s Tape: more expensive; $19.99 for 60 yards
Ideal for: Circumstances where the unique properties of gaffer’s tape (especially the removability) warrant the higher cost of the tape. However, because gaffer’s tape is more easily removable, with less residue, there will be minor savings on labor cost for cleanup.

Choosing the right tape for your job is extremely important.  At ECHOtape, we’ve made it our passion for more than 40 years to help professionals with their sticky issues.  For more in-depth information on duct tape, check out our Complete Technical Guide to Duct Tape to learn the top 6 conditions where duct tape can fall short and what adhesive tape you should be using instead. If you still aren’t sure, feel free to contact us with your challenge.  We would love to help!


Top 10 Surfaces that Are Problems for Duct Tape

It’s been said that duct tape is the #1 all-purpose repair tape. And while it is a lifesaver in a number of situations, there are times when duct tape falls short. Believe it or not, standard issue duct tape is not as versatile as you think. It has its uses–making permanent repairs on the spot–but the following is a list of surfaces that are problems for duct tape.

  1. Wet surfaces: While duct tape is water resistant, it should only be used for emergency leak repairs. Prolonged submersion in water will cause the adhesion to peel away.
  2. Hot surfaces: Surfaces that reach temperatures over 140°F cause duct tape’s adhesive to soften, lose its strength, and slip from the attachment.
  3. Cold surfaces: Similarly, duct tape does not work well in extreme cold. Freezing temperatures cause the adhesive to harden which diminishes its sticking power.
  4. Surfaces with Prolonged Exposure to UV Light: UV light can break down the tape’s adhesive bond over time. If you need the tape to remain exposed to direct sunlight, it’s best to use a product that’s been specially treated for UV protection.
  5. Uneven Surfaces: Duct tape has trouble sticking to rough surfaces such as concrete and stucco. Because it has a thin adhesive layer, duct tape is only able to make contact with the high points of a surface, which produces a weaker bond.
  6. Dirty Surfaces: In order to achieve maximum adhesion, surfaces must be clean, dry, and dust or oil free.
  7. Corrugated Cardboard: Don’t use duct tape to seal cardboard boxes. These porous surfaces contain many small fibers on the surface that break away and cause the adhesive bond to fail.
  8. Materials with Low Surface Energy: Materials, like Teflon, have a low surface energy, which means it prevents the adhesive from “wetting out” or spreading out to form a strong bond.
  9. Painted Surfaces: Applying duct tape to a surface that’s been painted or treated with another sealant means that the tape is only adhering to the surface layer and not the actual substrate.
  10. Your Bottom Lip: As demonstrated here, duct tape is not ideal for use in kidnappings.

To learn more about using duct tape in the field or on the job site, check out our Complete Technical Guide to Duct Tape.

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At ECHOtape we offer a full range of specialty tapes that can work in all kinds of circumstances, including many listed above. Feel free to contact our ECHOtape team with your tape request if you want help determining which product is best for your particular project.


Introducing CL-W6064: Not Your Father’s Duct Tape

What started as a battlefield repair tool has truly become an iconic American fix-all, helping DIYers and professional contractors out of sticky situations throughout the years.  But this isn’t just another duct tape.  CL-W6064 is better. Much, much better.  


Remember that story about the pilot in Alaska who repaired his bear-ravaged plane with duct tape to fly home? Or the time astronauts used duct tape to save the Apollo 13 space mission?

What started as a battlefield repair tool has truly become an iconic American fix-all, helping DIYers, professional contractors and dads out of sticky situations throughout the years.

But this isn’t your father’s duct tape. CL-W6064 is better.  Much, much better. 

Our proprietary, industrial-strength, utility-grade tape is a 21st-century duct tape designed to tackle 21st Century challenges.

“The inspiration for CL-W6064 is the culmination of forty years of experience in pressure-sensitive adhesives combined with the frustrations professional contractors encounter daily on the job site,” says Risa Edelstein. “We wanted to create a material that was strong but lightweight, industrial quality without requiring industrial equipment to use and took advantage of the inherent versatility of duct tape.”

Indeed, when it comes to high-performance building, the average duct tape just doesn’t cut it.  

ECHOtape CL-W6064 strikes a delicate balance between strength and usability, providing the maximum amount of sticking power without sacrificing ease of use. How did we make that happen? By using new, advanced technology — a two head coating process.  The first coat ensures high sheer strength, and the second coat, high initial tack.  The result is a beautifully streamlined piece of tape that is lighter, yet stronger than you would imagine, and easy to unwind.

Furthermore, we implemented a special quality control process where testing the thickness of the adhesive happens inline – during the manufacturing process. This allows the tape to be made precisely to spec and provides better quality control.

The combination of an aggressive adhesive, flexible backing and rugged all-weather shell makes it one of the few professional-grade tapes to consistently stick to smooth, rough or uneven surfaces, indoors or out. It’s completely hand-tearable, leaving a crisp, clean edge, and the uniquely engineered mesh lays flat on any surface, with no twisting or curling.

FEATURES

  • Aggressive adhesive provides superior holding power
  • Excellent quick stick to a wide variety of smooth and rough surfaces
  • Flexible backing conforms well to irregular surfaces
  • Smooth unwind makes it easier to apply in the field
  • Our fine mesh easy-tear cloth leaves a clean crisp edge when torn by hand
  • Tape lays flat so there is no twisting and curling

APPLICATIONS

  • General-purpose construction uses and repair
  • Patching and seaming a wide variety of materials
  • Temporary holding and bonding
  • Hanging and patching polyethylene sheeting
  • Sealing polyethylene waste disposal bags
  • Smooth unwind makes it easier to apply in the field
  • Maintenance applications in manufacturing environments
  • Bundling and color coding

You can purchase our CL-W6064 at our online store.  Give it a try!


8 Kinds of Duct Tape: Are You Using the Right One??

Products_ClothTape1

The term, “duct tape” is probably the single biggest misnomer in the adhesive tape industry today!

When the concept of using an adhesive tape to seal the seams of galvanized duct work first came along, this was its only intended use, and the name stuck. (Pun intended).

Its initial design was simple but effective: a strong fabric bonded to polyethylene film for sealing/waterproofing, silver-gray coloring to match metal duct work, and a thick coating of adhesive to seal the joints and make them air tight.

But people quickly determined that duct tape could be used for a variety of other purposes, and the boom was on. Many new types of duct tape were manufactured – each with different qualities of fabric, polyethylene, and adhesive – for many different end uses. As a result, duct tape manufacturers now offer a wide range of grades of polyethylene/fabric types and in a wide variety of colors.

Here are 8 different kinds of duct tape being used today:

General purpose: With a low fabric count, a thin polyethylene film, and a low weight adhesive, these general-purpose tapes work well enough for odd jobs where long service life isn’t necessary.

Industrial grade: With these tapes, the fabric and polyethylene are upgraded, so the tape becomes more of a “workhorse” with added adhesive coating weight. One popular variation is multi-colored industrial tape that is used to seam and hold carpets at exhibitions, where the adhesive must be removed cleanly.

Professional grade: Sometimes called “contractors’ grade” these tapes offer more of an upgrade to the components of the industrial grade tape for added strength, adhesion, and durability.

Gaffer’s tape: Typically gaffer’s tape is a matte black for minimal light reflection and is used in movie, television, and photo studios to temporarily tape cables to the floor or light fixtures to vertical posts. This type of tape needs to be able to be easily torn by hand and remove cleanly.

Stucco tape: Stucco tape is used to attach protective polyethylene film over doors and windows during house construction prior to spraying the outside walls with stucco. Stucco tape is designed to be used outdoors for several days at a time, so it must be able to resist the ultraviolet of the sun’s rays during that time – and not come apart from the vinyl window frames.

True duct tape: This one lives up to its name – tape that is truly intended for sealing air ducts. Duct tape must be permanent and able to withstand the prolonged heat and air pressure for the lifetime of the duct. It may even need to be flame retardant to meet some building codes. Duct tape is the true top of the line, a high tensile, hardworking tape.

Coated cloth tape: A roll of coated cloth tape has gone with every U.S. manned space launch, and is also commonly known as “Mission Tape”. This tape played an essential role in the construction of the carbon dioxide absorbers which saved the lives of the three astronauts in the ill-fated Apollo 13 mission.

Pick the Right Duct Tape for Your Job 

With such a wide variety to choose from, start by considering exactly what you expect your tape to do. Then, evaluate the right polyethylene/fabric backing judged by tensile strength, as well as the right adhesive coating thickness, judged by adhesion level, for the best performance with the lowest cost.

Whether you’re looking for a type of duct tape, or a different adhesive tape, ECHOtape can help. Contact us today for help in selecting the right tape for your next job.

1.800.461.8273 | info@echotape.com | echotape.com