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Bonding and Sealing Plastic Windows

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Marine Application Guide

Bonding and Sealing Organic Windows

Application Description
Most of the organic glazing materials used in boat building are either clear acrylic sheet (PMMA), widely marketed under trade names such as
Perspex and Plexiglas (the latter manufactured by Rohm and Haas), or polycarbonate (PC), marketed by Bayer GmbH as Makrolon and by General Electric as Lexan or scratch-proof
Margard.
All plastic glazing products possess certain characteristics that must be clearly understood before they are installed or bonded with adhesives. In general, incorrectly installed plastic glazing panels are prone to environmental stress cracking (ESC). This can be aggravated by the use of the wrong adhesives.

Sika Transportation_99

Plastic glazing products have a higher coefficient of thermal expansion than conventional glass.
Therefore, when designing glazing installations, an expansion gap of at least 10 mm all round the periphery must be incorporated between the window rebate and the plastic glazing panel to accommodate thermal movement. Similarly, any clearance holes for fixing screws must be drilled oversize; slightly larger than the diameter of the screw shank.
To minimise the risk of environmental stress cracking, flat sheets of plastic glazing material should be installed completely flat; they should

not be forced to take up a curvature by the use of mechanical fastenings. When the design calls for curved glazing panels, these should be prefabricated to order and properly tempered by a specialist supplier to ensure installation with no resulting stresses.
As many varieties of organic window exist, it is recommended to ensure that the specific grade selected is suitable for use with Sikaflex®-295
UV. Please note that the extruded type of organic glazing (XT) exhibits a higher tendency to environmental stress cracking than the cast type (CS).
Please contact your local Sika Company for technical advice.

Marine Application Guide

Bonding and Sealing Organic Windows

Pre-treated Flange
Sikaflex®-295 UV Backfill
UV Protection
Sikaflex®-295 UV
Pre-treated Window Pane

Fig. 122 Examples of one of the many decorative glazing applications inside a luxury liner

Fig. 124 Typical construction of a window with outer UV protection

Fig. 123 (a, b & c) Examples of adhesively bonded organic glazing using Sikaflex®-295 UV in conjunction with UV Shielding Tape

100_Sika Transportation

Marine Application Guide

Procedure for Bonding and Sealing Organic Windows
Substrate Preparation
Fiberglass Frame

Organic Window

Lightly abrade the gelcoat of the contact area with a very fine sanding pad

Abrade the bond area with abrasive paper or very fine abrasive pad. Abrade the bonding periphery with 80 grit sandpaper if the organic glazing panel has a scratch proof coating

Remove the dust with a vacuum cleaner

Remove the dust with a vacuum cleaner
Mask off any areas that need it

226
Aktivator

226

Flash-off: 10 minutes (min) to 2 hours
(max)

209 D

Aluminium Frame
Mask off any areas that need it

Lightly abrade the contact area with a fine sand pad
Remove the dust with a vacuum cleaner

205
Aktivator

Pretreat with with Sika® Aktivator or Sika®
Aktivator 205, using a clean, lint-free rag or paper towel. Change the rag frequently!
Sika® Aktivator must be applied with the wipe on/wipe off method.
Flash-off: 10 minutes (min) to 2 hours
(max)

206
G+P
210

Apply a thin, continuous coat of Sika®
Primer-206 G+P or Sika® Primer-210, using a clean brush or felt applicator

Drying time: 10 minutes (min) to 24 hours
(max)

Sika Transportation_101

Pretreat the substrate with Sika® Aktivator or Sika® Aktivator 205, using a clean, lint-free rag or paper towel. Change the rag frequently! Sika® Aktivator must be applied with the wipe on/wipe off method.
Flash-off: 10 minutes (min) to 2 hours
(max)

Apply a thin, continuous coat of
Sika®Primer-206 G+P or Sika®
Primer-215, using a clean brush or felt applicator Drying time: 30 minutes (min) to 24 hours
(max)

205

Pretreat the substrate with with Sika®
Aktivator or Sika® Aktivator 205, using a clean, lint-free rag or paper towel. Change the rag frequently! Sika® Aktivator must be applied with the wipe on/wipe off method. Flash-off: 10 minutes (min) to 2 hours
(max)

Aktivator

206
G+P
215

Mask off any areas that need it

Aktivator

Mask off any areas that need it
Pretreat the substrate with Sika® Aktivator or Sika® Aktivator 205, using a clean, lint-free rag or paper towel. Change the rag frequently! Sika® Aktivator must be applied with the wipe on/wipe off method.

Two-Part Lacquer Coated Frame
(Timber or Aluminum)

Apply a continuous coat of Sika®
Primer-209 D, using a clean brush or felt applicator Drying time: 10 minutes (min) to 24 hours
(max)

For the preparation of other substrates, please refer to the Primer Chart available at www.sikaindustry.com

Marine Application Guide

Bond Line Protection

Place spacers in position. Depending on the size of the glazing panel, the thickness of the spacer should be chosen accordingly; approximately 30 Shore A hardness As with conventional glass, plastic glazing panels generally do not protect the adhesive face from damage by UV radiation. Therefore, the bond line must be protected from direct sunlight using one of the methods recommended.

Avoid interruption of the bead by the spacers Plastic Windows with a Transmission of >0.5% in UV Range
ƒƒ

295
UV

Apply Sikaflex®-295 UV to the frame rebate or glazing panel using a triangular nozzle with a bead width of at least 10 mm Assemble all components within 20 minutes of applying the adhesive
To prevent slip down of vertical glazing panels, distance blocks (wood or plastic) must be placed in the lower rebate during installation. After curing, these must be removed. The back-fill gap must be at least 10 mm (see Fig. 125)

Clamps and other fastening aids can be removed after 24 hours. After this time, the expansion gap between glazing panel and the back-fill gap should be filled and completely sealed with Sikaflex®-295
295
UV. This sealant joint can be tooled to a
UV
smooth finish using an appropriate tooling agent. Do NOT use alcohol or alcohol containing solvents. Tooling must be
Tooling carried out before skinning of the sealant

External cover dimensions strip

ƒƒ

Sika® UV Shielding Tape of appropriate dimensions ƒƒ

Use ONLY Sika Primer-209 D
16

Pane thickness (D)
Pre-treated
Pane

If required, apply a commercial UV shielding tape, rubber gasket, or frame

OK

12

8

Too small

4

UV Protection
Overlap (O)
0 1 2 3
Largest pane dimension (m)

Sikaflex®-295 UV

Fig. 126 Back-fill gap to window size ratio
UV Protection
Sikaflex®-295 UV backfill Pre-treated flange

Uncured Sika adhesives or sealants may be removed with Sika® Remover-208 or mineral spirits
Do not use Sika® Aktivator, Sika® Aktivator
205, or any other cleaning agent or solvent for cleaning purposes

20

®

Bond line thickness (mm)

208

appropriate

Commonly, the edge of the window will be cosmetically finished with Sikaflex® products.
The preparation of the surfaces must be identical to that used for bonding. Edge sealing ensures both the prevention of standing water on or near the bond and helps cosmetically finish the window. Fill up the joint completely, ensuring there is no space between the adhesive bead and the joint. The following diagram illustrates the required dimensioning of the back-fill gap for plastic window panels using Sikaflex®-295 UV.

Plastic Windows with a Transmission…...

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