Costs: Sealant joints

Sealants are commonly used externally to weather-proof junctions between moving components. They are short-life components in a building element that, in the case of brickwork, may perform for centuries. It is important to maximise their whole-life performance.

Design issues

Guidance is given in BS 6093, the British Standard code of practice for the design of joints in building construction. Further guidance is published in the Construction Industry Research and Information Association’s Manual of good practice in sealant application and sealant joints in the external envelope of buildings. Some design issues with whole-life cost implications include:

• Joint width-to-depth ratio and sealant movement capability. It is important to minimise tensile stresses between the joint faces to reduce the risk of adhesive failure
• Consider protecting sealants from direct weathering or ultraviolet radiation but not at the cost of being unable to access the joint for maintenance or inspection
• Ensure the sealants are non–staining and compatible with adjoining materials. Tests may be needed.

Sealant options

BS 6213 provides guidance on the selection of sealants. This standard refers to ISO 11600, which classifies sealants by application and performance characteristics but does not refer to sealants by material. ISO 11600 defines 11 sealant classes, which give performance assurances with regard to elastic recovery, tensile properties, adhesion and cohesion properties at variable and constant temperatures and after water immersion, and loss of volume.

Sealants are defined by:

• The end use
• Movement capability, usually up to 25%. Before specifying sealants with movement capability greater than 25%, long-term performance should be confirmed with the manufacturer
• Elasticity. Plastic sealants do not recover their original position as well as elastic sealants after movement
• Modulus, which applies to elastic sealants. Low modulus sealants require only small forces to stretch or compress them, meaning these are most suitable where constant movement is expected or when the substrate is weak or friable.

ISO 11600 does not predict sealant durability. Long-term performance of sealants should be confirmed by manufacturers.

Silicone sealants

Acetoxy cure silicone sealants are slightly cheaper, have a quicker cure time but poorer adhesion. They release acetic acid, making them unsuitable for use with substrates affected by acids such as concrete or some metals. Neutral cure silicone sealants are more expensive and have a longer cure period, but have better adhesion and low modulus. External life expectancy is five to 20 years.

Polysulphide-based sealants

These tend to be used less as they have a high modulus and are not completely elastic. External life expectancy is 20 years.

Polyurethane sealants

These are slow curing sealants, with moderate resistance to ultraviolet radiation and chemicals. They show excellent resistance to abrasion and indentation. External life expectancy is 20 years.

MS polyether sealants

These show excellent adhesion on metals, plastics, wood and ceramics used without primers. A conservative life expectancy estimate is 15 to 20 years, although some think it could be as much as 30 years.

Installation issues

Refer to BS 8000-16. Good preparation is essential:

• Surfaces should be clean and dry
• If required, apply the correct primer, filler, back–up or bond break
• Sealants should be given the correct profile: the exposed face of triangular fillet joints should ideally be convex or flat, preferably not concave. Rectangular joints should be finished flat or slightly concave.

In–use issues

BS 6093 recommends inspection of movement joints after the first year and all joints at intervals of one–fifth of their expected service life. Maintenance may be necessary where sealants attract dust, mould or mildew. Cleaning can be minimised by appropriate selection of sealants.