STP 1453 Durability of Building and Construction Sealants and Adhesives Andreas .T Wolf, Editor ASTM Stock Number: STP1453 @. ASTM 001 Ban" Harbor Drive PO Box C700 West Conshohocken, PA 19428-2959 ~lrlgmlUl/ Printed in the U.S.A. Library of Congress Cataloging-in-Publication Data Durability of building and construction sealants and adhesives / Andreas .-1" Wolf, ed. .p cm.- (STP ; 1453) Includes bibliographical references and index. ISBN 0-8031-3480-0 .1 Building materials--Testing--Congresses. 2. Sealing compounds--Testing---Congresses. 3. Sealing compounds--Deterioration--Congresses. 4. Adhesives--Testing--Congresses. 5. Adhesives--Deterioration--Congresses. .I Wolf, A.T. )."1"saerdnA( .1I Series: ASTM special technical publication ; 1453. TA418.36.D87 2004 691'.99--dc22 2004027225 Copyright (cid:14)9 2004 AMERICAN SOCIETY ROF TESTING AND MATERIALS INTERNATIONAL, West Conshohocken, .AP All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronicf,i lm, or other distribution and storage media, without the written consent of the publisher. Photocopy Rights Authorization to photocopy items for intemal, personal, or educational classroom use, or the internal, personal, or educational classroom use of specific clients, is granted by the American Societyf or Testing and Materials International (ASTM) provided that the appropri- ate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923; Tel: 978-750-8400; online: http://www.copyright.com/. Peer Review Policy Each paper published ni this volume was evaluated by two peer reviewers and at least one edi- tor. The authors addressed all of the reviewers' comments to the satisfaction of both the technical editor(s) and the ASTM International Committee on Publications. To make technical information available as quickly as possible, the peer-reviepwaepde rs in this publication were prepared "camera-reedy" as submitted by the authors. The quality of the papers in this publication reflects not only the obvious efforts of the authors and the technical editor(s), but also the work of the peer reviewers. In keeping with long-standing publication practices, ASTM International ~ains the anonymity of the peer reviewerTsh.e ASTM International Committee on Publications acknowledges with appreciation their dedication and con- tribution of time and effort on behalf of ASTM International. Printed ni Bridgeport, JN 4002 Contents Overview viii FIELD EXPERIENCE WITH SEALED JOINTS AND ADHESIVE FIXATIONS Secondary Drainage System for Architectural Panel Systems---L. .O YRABRAC AND M. W. RYAN 3 Lock-Strip Gasket System Retrofit: A Case History--M. .K TDIMHCS 41 Durability by Design: Load Carrying Silicone Bonding, Herz Jesu Church, Mnnich--A. LGAH 24 Structural Glazing Failure--Five Case Studies--M. .E REKAB 37 Quality Control Guidelines for Factory Applied Structural Silicone Glazing-- L, D. CARBARY AND J. GUSTAFSON 45 Historical Development and Future Prospects of Structural Silicone Sealants in China--Y.-L. WANG, H.-M. WANG, AND L.-M. WU 56 FACTORS INFLUENCING THE DURABILITY OF SEALED JOINTS AND ADHESIVE FIXATIONS Influence of Polyester Powder Coating Chemistry on Adhesion Dire'ability of Silicone Sealants--F. ED LYUB 65 Water Absorption in Cold Liquid-Applied Waterproofing--J. c. GNORTS DNA J. R. KOVACH 88 Effects on Silicone Sealant Adhesion Buildup on Float Glass Substrates-- J. T. MA, S. S. CHEN, W. ZHOU, AND S. WANG 97 Moisture Conditions of Substrates and Effect on Adhesive Bond of Sealants-- M. E. KENNEY AND R. J. KENNEY 113 Silyl-Terminated Polyurethanes for Construction Sealants---A. .E RONNOC'O 341 AND T. KINGSTON Estimation of the Fatigue Resistance of Sealants to Movement at Intersections of Sealed Joints and Improvements in the Joint Design Method-- .H IHCUAYIM DNA .K AKANAT 156 vi CONTENTS DURABILITY STUD1ES OF SEALANTS AND ADHESIVES Effect of Foam Backer Rod on the Deep Section Cure of One-Part Sealants-- S. IGLAUER, A. R. HUTCHINSON, AND T. C. P. LEE 171 Effect of Foam Backer Rod on the Mechanical Performance of Sealed Joints-- S. IGLAUER, A. R. HUTCHINSON, AND T. C. P. LEE 184 Artilicial Weathering and Cyclic Movement Test Results Based on the RILEM TC139-DBS Durability Test Method for Construction Sealants-- H. MIYAUCHI, N. ENOMOTO, S. SUGIYAMA, AND K. TANAKA 206 Sealant Longevity for Residential Ducts--l. s. REKLAW DNA .M .H NAMREHS 213 Insights into the Use of Biocides in Silicones Sealants: Test Methods And Durability Aspects--F. ED LYU8 DNA .H IDLATSAG 228 Effect of Float Glass Surface Composition on Silicone Sealant Adhesion Tested After Simultaneous Exposure to Hot Water and Ultraviolet Light-- A. T. WOLF, C. S. McMILLAN, W. STIELL, AND K. LIEB 252 Comparison of Butyl versus Modified Asphalt Window Flashing Adbesives-- A. D. Z1MA, JR., T. A. WESTON, J. D. KATSAROS, AND R. HAGOOD 262 Durability of Horizontal Sealant Joints--D. H. N/CASTRO AND V. D. GORMAN 280 Durability and Adhesion Rate of One-Part Silicone Sealants to Silicone Rubber Extrusions for New and Remedial Glazing and Weatherproofing Applications--L. .D YRABRAC DNA .E .A REMMIZ 303 Sealant Failure Morphology--The Important Criterion of Equipment Selection for Weathering Studies--G. ,HCVPYW s. ,IKSREBUK DNA E E.LF 310 DEVELOPMENT OF NEW TEST METHODS AND PERFORMANCE-BASED SPECIFICATIONS Issues Related to the Mechanical Property Characterization of Sealants-- C. C. WHITE AND D. L. HUNSTON 325 Nondestructive Field Testing of Installed Weatherproofing Sealant Joints--- ~D HUFF 335 Developing a Performance-Based Joint Sealant Specification for Airport PCC Pavements--M. .A ESSACAL DNA J.-F. NOSSAM 346 Harmonization and Optimization of Weathering Test Methods for Building and Construction Sealants and Adhesives--N. .D ELRAES 355 CONTENTS vii Material Properties for Use in FEA Modeling: Sealant Behavior with Ambient Laboratory Climate Aging--A. .T FLOW DNA .H .L TSOH-DNALELC 372 Concepts for Development of a Service Life Prediction Methodology for Sealed Building and Construction Joints--Review and Roadmap for Future Research--A. .T FLOW 385 Index 104 FIELD EXPERIENCE WITH SEALED JOINTS AND ADHESIVE FIXATIONS Lawrence D. Carbary I and Michael ..VI Ryan 2 Secondary Drainage System for Architectural Panel Systems REFERENCE: Carbary, L. D., and Ryan, M. W., "Secondary Drainage System for Architectural Panel Systems," Durability of Building and Construction Sealants and Adhesives, ASTM STP 1453, A. T. Wolf, Ed., ASTM International, West Conshohocken, PA, 2004. ABSTRACT: In conjunction with the exterior cladding system, field applied architectural joints sealant are the primary source of resistance against air and water intrusion on most high-rise residential and nonresidential commercial structures. Jobsite practices and quahty in workmanship will dictate deficiencies in application of the high performance sealants specified for this purpose. When these deficiencies allow water and air to enter the structure, or when water condenses and collects behind the walls, damage caused by water detrimental is to the structure. The condition known as percolation, where outside positive pressures associated with Heating Ventilation and Air (HVAC) Conditiofiing systems in combination with wind driven rains literally vacuum water into the building, further amplifies this problen~ The damages attributed to water and air infiltration can be corrosion of structural anchors, reduction in insulation efficiency, damage to interior walls, damage to floor coverings and mold growth. This paper reports on the design, development and testing of a state of the art secondary drainage system that is used behind prefabricated panelized Glass Fiber Reinforced Concrete (GFRC), Architectural Precast Concrete (APC), Architectural Composite Precast (CAP), and natural stone on truss systems. This system consists of silicone extrusions, tubes and joint protection collection reservoirs with one way valves (JPCROV) that are attached to the back of the concrete or stone panels using adhesive attachments, which are compatible and marry intimately into the exterior architectural sealant joints. Unique designs of gutters that are resistant to jobsite debris that can clog drains and render them inadequate are presented along with the JPCROV that prevents percolation and allows water to weep out of the These system- additional materials within the wall cavity also must have benign fire properties due to the concern for toxic gasses and smoke in the event of a fire. The technology of the silicone extruded gutters, tubes and percolation boxes is most suitable for the alkaline variable temperature and humidity environment found in these wall cavities. Silicone adhesive technology of one-part neutral cure RTV silicone sealant is used to mount the secondary drainage system within the wall to provide a long-term performing solution. Durability data is presented on the bonds between the silicone extrusions and concrete substrates for this application. Modified ASTM Standard Test Method for Apparent Shear Strength of Single-Lap-Joint Adhesively Bonded Metal Specimens by Tension Loading (Metal-to-Metal) (D1002-99) data aider room temperature cure, water immersion, and both elevated temperature and high humidity is presented as data simulating the actual application. design System capacities proper and installation for maximum coverage are presented. also KEYWORDS: exterior cladding, infiltration, drainage system, silicone extrusion, durability, ASTM .2001D Introduction Modem mid- to high-rise buildings are predominately comprised of a structural steel or cast in place concrete framing system upon which all other building elements are supported. Walls, Associate Industry Scientist, 1 Dow Coming Corporation, P.O. Box 994, Midland, MI 48686-0994, U.S.A. 2 Chief Estimator, Pacific, Clark River South Rd., 1900 West Sacramento, CA 95691-2888, U.S.A. 3 Copyright(cid:14)9 by ASTM International www.astm.org 4 SEALANTS BUILDING/CONSTRUCTION DNA SEVISEHDA floors, electrical, plumbing and HVAC systems all attach to this structure. The exterior of the support structure is typically clad with and supports the above-mentioned panelized systems as well as glass/curtainwall systems, metal panels, stucco, Exterior Insulation Finish Systems (EIFS) or plaster. These cladding systems must be made to pass specifications regarding air and water infiltration. Specifications have been created to minimize air and water infiltration so that buildings can operate the heating and cooling systems efficiently and remain structurally sound over the life of the building. These panelized barrier systems typically have joints between each individual panel that require a high performance sealant, a sealant that has greater than +25% joint movement ability per ASTM Standard Test Method for Adhesion and Cohesion of Elastomeric Joint Sealants Under Cyclic Movement (Hockman Cycle) (C719-93 (1998)). The purpose of the high performance sealants is to provide air and water tight panel joints on the exterior face of the panel systems. These sealants are required to have elastomeric properties to accommodate joint movements created by thermal expansion and contraction, interstory building drift due to wind or seismic movements, elastic frame shortening and creep. An elastomeric material is also referred to as a material that has elastic recovery orm emory. Elastomeric silicone sealants are commonly used in commercial buildings to protect wall systems from water intrusion. The sealant is installed over a back up or bond tape. The backer rod supports the sealant until it has cured and is typically made of polyurethane or polyethylene foam. The intended use of the backer materiails to provide a proper joint shape that allowst he sealant to expand and contract as required. Once the sealant has cured, in conjunction with the exterior cladding, it forms the primary waterproofing barrier system for the building. The main suppliers of silicone sealants typically have excellent quality control and testing procedures and utilize applicators or caulking subcontractors, trained in the use of the products. Silicone sealants have proven to be very effective when the bond line is properly detailed and the edges of the panels are cleaned and prepared allowing the sealant to develop durable adhesion to the panel substrate. Silicone sealants have proven to be excellent long lasting sealing materials well suited for providing the weatherproofing protection in barrier wall systems. The primary exterior sealant system can fail or be compromised in many ways allowing a building to leak. Sealant installation is highly dependent on skilled workmanship. Improperly detailed joints that do not allow for proper sealant installation and poor workmanship can combine, creating adhesive or cohesive failures of the sealant. Joint failures can also occur when exterior panelized systems are damaged, allowing water to bypass the sealant at the joints. Failures can also occur at the interface with glass and curtain wall systems. This interface can lead to compatibility and workmanship problems associated with the coordination of tradesmen working on the project. The proper sealant best used for architectural precast concrete joints may not be the proper sealant for an architectural precast concrete panel abutting an aluminum window mullion. These interfaces and improperly installed caulk joints may lead to potential water penetration inside the building. Joint failures from building movements due to wind- induced interstory drift or seismic events can occur. Sealants can degrade over time from exposure to the elementasn d repeated cyclic thermal expansion and contraction. Therefore, they will require replacement during the life of the building. When leaks occur, the damage caused to the building can be further amplified due to percolation. Percolation occurs when sustained high winds or a positive external pressure due to the HVAC system can vacuum water through the damaged sealant joints or cladding. The water YRABRAC AND NAYR NO A SECONDARY METSYS EGANIARD 5 will percolate or blow into the building, wetting insulation, accelerate the corrosion of structural anchors, and create unsightly stains and odors within the structure. Another source of water infiltration that is a concern is condensation on the backside of the panels. Sealants protect the interior from leaks but do nothing to protect against condensation. Under certain atmospheric conditions water can condense on the backside of the panels. Condensation issues occur when the airspace within the walls reaches 100% relative humidity andc ooling begins. The amount of condensation is dependent on the location, typea nd/or lack of a vapor barrier. Additional factors relating to condensation include the amount and temperature of air infiltration into the building. Buildingsw ill leak eventually, some more than others, due to the service life of sealants. Most of the time the leaks are insignificant enough that the water is absorbed by the substrate and dries prior to any damage occurring. Significant uncontrolled leaks andc ondensation lead to interior damagteo the building as noted by unsightly stains and odors. One solution to this problem has been developed in the form of a secondary drainages ystem that is attached to the interior surface of the exterior panels that backs up the primary waterproofing system. This solution has come aboutd ue to numerous sealant failures, the use of inexpensive less durable cladding systems, and/or poor quality panelized systems that have resulted in the damaged parties seeking redress in high profile lawsuits. These situations have resulted in architects and exterior wall consultants mandating that a secondary drainage system be used in addition to the primary system (e.g. the sealant caulk joint) to prevent water damage to buildings. This paper is written to discuss a secondary drainages ystem that is installed as a back up to barrier wall construction utilizing precast concrete, GFRC, and natural stone on truss panel systems used in commercial construction. The system consists of extruded silicone rubber gutters, and molded parts that are part of an engineesryesdt tehma t allows water to be effectively routed out of a wall system if the primary barrier walli s breached. The extruded silicone gutters are attached with Room Temperature Vulcanizing (RTV) neutral cure silicone sealants to the backside of precast concrete, GFRC, or natural stone and must withstand the spandrel environment for years. The RTV silicone sealainst also used to attach the silicone gutters, tubes, splices and valves together. The drainage system can be placed onto concrete panels that may reach 9 m (30 feet) in width. The question of durability is brought about as the RTV neutral silicone adhesive sealant is required to form a permanent bond to the backside of preeast concrete, GFRC and natural stone. The backsides of these panels are not visible from the exterior of the building. Hence, there is little attention paid to these surfaces. Will the panel supplier be able to provide a surface suitable to apply sealants, free of loose dust, laitance, dirt, and grease? How can this be done? Will the adhesive be able to holudp in a spandrel environment witthh et hermal and humidity cycling that is present? This paper intends to address these questions using a testing methodology on real surfaces that has been put together in a logical fashion. Performance Requirements of the Gutter System The secondary drainage system is a system of horizontal gutters applied on the backside of spandrel panels to collect any condensation and water that collects and falls down the back of the panels. The system has a slope built into it that allows collected condensation and rainwater to 6 AND SEALANTS BUILDING/CONSTRUCTION SEVISEHDA drain out through engineered valve boxes placed in the exterior vertical sealant joints, see Figure FIG. l--Cut away section of the gutter system installed on a precast concrete panel (System consists of gutters attached to the backside that drain water to valve boxes mounted in the vertical joints). The gutter as designed has a mass of 0.5 grams per millimeter (0.34 lbs per foot) of length. If the gutter were to be full of water, the gutter would weigh 1.0 gram per millimeter (0.68 lbs per foot) of length. Hence the adhesive should be designed to support the weight of the gutter full of water without having any negative impact on the bond. The gutter system must be capable of removing the water resulting from leaks and condensation that can breach the primary system. The largest concrete panels that this could be used with measure 9 m x 3 m (30 ft x 10 fl). Silicone RTV sealants have not been used to attach items to concrete-based materials in the past. However, it is common in a sealant-testing laboratory to attach concrete blocks to aluminum supports that rest inside an accelerated weathering machine. Personal experience by one of the authors is documented in ASTM STP 1200 [1]. This author had 63 tensile adhesion joints made of concrete to concrete, each weighing about 250 grams (0.55 lbs), attached to aluminum with about 1250 turn 2 (2 in )2 RTV neutral cure silicone sealant. Of the 63 samples, 21 were exposed to 1000 hours, 21 were exposed to 2500 hours, and 21 were exposed to 4000 hours of 3 QU-V accelerated aging. The adhesive sealant never saw the UV light, however it did see QUV 3 gnirehtaeW Q-Panel Tester baL ,stcudorP 008 yrubretnaC ,dR OH Cleveland, ,54144 USA.