Quickly model cleaning effort before replacing critical seals. Include tools, chemicals, surface, and safety checks. Get clear time and cost outputs for crews onsite.
| Scenario | Type | Method | Area (in²) | Adhesion | Crew | Estimated Total Time (min) | Estimated Total Cost |
|---|---|---|---|---|---|---|---|
| Pump flange | RTV / Sealant | Chemical + scraping | 36 | High | 1 | ~65 | ~48 |
| Gearbox cover | Paper | Manual scraping | 25 | Medium | 1 | ~35 | ~23 |
| Aluminum housing | Rubber | Plastic scraping | 30 | Medium | 2 | ~28 | ~19 |
The calculator estimates removal time using an area-based baseline, then applies condition factors:
Gasket removal is rarely a single action; it includes isolation, bolt handling, face cleaning, wipe-down, and inspection. Tight clearances, overhead work, and awkward tooling angles can add significant minutes per joint. Use the access setting to capture scaffold time, restricted swing space, or limited lighting that slows controlled scraping.
The calculator starts with a base minutes-per-square-inch rate by gasket type, then scales by cleaning area. Adhesion level increases effort as bonded sealant resists shear and lifts in small fragments. For baked-on or seized joints, plan multiple passes and longer dwell time when chemicals are used, plus extra recheck time.
Abrasive wheels can be fast on robust steel faces, but they raise the surface risk score on aluminum, coated faces, and machined flanges. Plastic tools and chemical softening reduce gouging risk, which helps control leaks and torque relaxation after reassembly. Heat can assist on stubborn sealants, but it may affect coatings and nearby elastomers if applied carelessly.
Consumables are estimated from area-based usage rules: chemical and solvent liters, blade wear, and disc count for wheel methods. Update unit costs to reflect your local supply chain, and add disposal fees when rags or solvents are handled as waste. Tracking these inputs provides better shutdown budgeting and makes method comparisons more realistic.
A clean face is not only “shiny”; it must be free of high spots, embedded debris, and remaining sealant that can create leak paths. After cleaning, recheck flatness visually and with a straightedge where practical, then wipe with an approved solvent. Document time, risk, and recommendations using the CSV or PDF output for job records.
Use direct area mode. Estimate the cleaned face area that actually carries sealant, not the outside footprint. For rings, use the contact band width times the circumference.
Two people help, but space and task overlap limit gains. The calculator applies diminishing returns because only one person can scrape a small face efficiently at a time.
Avoid them on aluminum, coated parts, and precision-machined faces. Abrasives can round edges, remove coatings, or create grooves that lead to leaks during service.
Chemical liters are based on face area and typical application coats, with higher adhesion increasing coats. Solvent liters cover wipe-down and residue removal after softening.
It is a planning indicator from 0–100 that reflects method aggressiveness and surface sensitivity. Higher scores suggest more care, gentler tools, and tighter inspection steps.
Use the thickness that affects removal effort. For RTV or sealants, enter bead thickness. For thin paper gaskets, keep it low because scraping effort is usually adhesion-driven.
Yes. Adjust fixed minutes, method choice, and your hourly rate. If your team has measured times, switch consumables to manual and tune inputs until outputs align.
Important Note: All the Calculators listed in this site are for educational purpose only and we do not guarentee the accuracy of results. Please do consult with other sources as well.