High Performance Building

Dow Performance Silicones

Dow Silicone Reactive Hot-Melt Adhesive

Window Assembly Sealants
Technical Manual

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Table of Contents
Introduction....................................................................................4
Product Information.......................................................................4
Quality Assurance.............................................................................................4
Industry Certifications.....................................................................................4
Substrate Selection......................................................................................... 5
Adhesion..................................................................................................... 5
Material Compatibility.................................................................................... 5
Shelf Life and Storage Conditions.............................................................. 5
Sealant Design Considerations.....................................................6
Cure Requirements......................................................................................... 6
Determining and Maintaining Sealant Joint Dimensions.....................7
Glue-line Thickness and Joint Movement Calculations................7
Determining Thermally-induced Differential Movement............ 8
Determining Sealant Glue-line Thickness....................................... 9
Bite Calculation for Wind Load............................................................ 9
Bite Calculation for Dead Load..........................................................10
Setting Blocks.................................................................................................10
Typical Yield.....................................................................................................10
Application................................................................................... 10
Safe Handling Instructions.........................................................................10
Volatile Organic Content (VOC).........................................................10
Product Handling Precautions..........................................................11
Safety Instructions.................................................................................11
Recommended Personal Protective Equipment.........................11
Quality Control................................................................................................11
Determination of Cure State...............................................................11
Substrate Preparation..................................................................................12
In-shop Application.......................................................................................12
Dispensing Equipment.........................................................................12
Glazing Table...........................................................................................12
Manufacturing Process Conditions.................................................12
Dispensing Temperatures...................................................................13
Dispensing Too Hot...............................................................................14
Dispensing Too Cold.............................................................................14
Glazing Process......................................................................................14
General Considerations for Applying DOWSIL™
InstantGlaze Window Assembly Sealants......................................14
Shut Down Considerations.................................................................15
Quality Control and Application Issues...................................................15
Bead Location.........................................................................................15
Bead Consistency and Uniformity....................................................15
Substrate Issues: Uneven Surfaces in Window Sash................16
Equipment Issues..................................................................................16
Environmental Issues............................................................................16
Deglazing and Reglazing of Window Units................................ 17
Shop Reglazing...............................................................................................17
Field Reglazing...............................................................................................17
Finished Unit Recommendations............................................... 18
Comparative Performance.......................................................... 18
Green Strength...............................................................................................18
Adhesion-in-Peel Strength.........................................................................18

pg 2
Introduction
This manual is intended to provide technical information, a translucent sealant bead or can be custom pigmented
selection and application guidelines for the DOWSIL™ brand for large volume applications. It provides instant green
of patented, neutral-cure, reactive hot-melt adhesives. These strength, a 15-minute open time, primerless adhesion and
hot-melt adhesive products are designed for automated ±50% movement capability.
back-bedding application in the assembly of windows For more information or for (Material) Safety Data Sheets,
and doors, and become part of a total manufacturing product data sheets and additional information on all Dow
productivity solution when used with standard hot-melt silicone reactive hot-melt adhesive window assembly sealants,
dispensing equipment and an automated X–Y glazing table. visit consumer.dow.com/construction.
This manual cannot be considered a comprehensive guide as
fenestration products vary in many aspects, including design,
Quality Assurance
customer requirements, manufacturing environments and end- Dow conducts quality assurance testing in its sealant
use applications. For the purpose of this manual, any reference manufacturing facilities that are certified in accordance to ISO
to windows can be considered interchangeable with doors. 9001 and Responsible Care® RC14001 requirements.

Dow technical customer service provides process Industry Certifications

workflows and resources to manage product and
Each product is approved as a bonding, back-bedding sealant
technical information inquiries from customers. These
compound by the American Architectural Manufacturers
inquiries may include but are not limited to:
Association (AAMA) and may be found on the AAMA Verified
• Product Recommendations Components List. The most recent version of this list may be
• Product Troubleshooting found on the AAMA website:
• Application Assistance www.aamanet.org /general/1/111/verified-components.
• Environmental, Health, Safety and Sustainability Data Verified components on this list are tested per AAMA 800-10,
Inquiries are received via e-mail: construction@dow.com Voluntary Specifications and Test Methods for Sealants, Section 1.1,
Back-Bedding Glazing Compounds.
As of the publication date of this manual, these products are
Product Information verified as back-bedding glazing compounds for certified windows
Dow currently offers three moisture-reactive hot-melt products and doors:
as a window assembly sealant/adhesive to meet customer • AAMA 805.2-10, Group C: DOWSIL™ InstantGlaze Sealant and
specific application needs. These products can be used in DOWSIL™ InstantGlaze II Sealant
different applications in the window industry that require
• AAMA 805.2-10, Group A: DOWSIL™ InstantGlaze III Adhesive
bonding and sealing.
The AAMA 805.2 classification is for a pumpable and
• DOWSIL™ InstantGlaze Window Assembly Sealant:
gunnable compound used to bed glass to the surrounding
This sealant is designed for use as a back-bedding sealant
substrate and is intended to bond the glass to the substrate
on most common window materials for standard and
and prevent air infiltration and water penetration. The 805.2
impact-resistant glazing, and is compatible with common
compounds cure relatively hard and stiff and permit limited
insulating glass sealants. DOWSIL™ InstantGlaze Sealant
movement without loss of bond. The performance requirements
dispenses into a crystal clear sealant bead or can be custom
for the 805.2 classification include:
pigmented for large volume applications. It provides instant
green strength, a 15-minute open time, primerless adhesion • Hardness: When tested in accordance to ASTM C661, the Shore
and ±50% movement capability. A hardness shall not exceed 70 durometer.
• DOWSIL™ InstantGlaze II Window Assembly Sealant: • Thin Film Integrity: There shall be no presence of voids within
This sealant is offered as a lower viscosity and lower the 805.2 compound when tested in accordance to AAMA
durometer alternative to DOWSIL™ InstantGlaze Sealant 800-10, Section 2.3.
for use by customers where these features are desirable. • Peel Strength: When laboratory tested for peel adhesion
DOWSIL™ InstantGlaze II Sealant dispenses into a crystal (modified ASTM C794), 805.2 compounds shall exhibit peel
clear sealant bead or can be custom pigmented for large strengths of at least 12.5 pli (lbf per inch of width).
volume applications. It provides instant green strength,
a 15-minute open time, primerless adhesion and ±50% • Failure Mode: When laboratory tested for peel adhesion
movement capability. (modified ASTM C794) or, alternatively, lap shear (modified
ASTM C961), Group C shall demonstrate predominantly
• DOWSIL™ InstantGlaze III Window Assembly Adhesive: cohesive failure (> 90%). Group A is limited to chemically
This sealant is designed for use where better resistance to curing sealants which demonstrate adhesive failure but which
creep, due to higher static loads in the window design, is have been shown to provide acceptable field performance.
desirable. DOWSIL™ InstantGlaze III Adhesive dispenses into

pg 3
• Vehicle Migration: There is no vehicle migration from an 805.2 Based on historical testing, some common materials, such as
compound edge when tested in accordance with a modified silicone weather seals, silicone insulating glass sealants,
ASTM D2203 (AAMA 800-10, Section 2.8.1). polyurethane foam tape and vinyl extrusions, are found to
be compatible with DOWSIL™ InstantGlaze Window Assembly
• Low Temperature Flexibility: 805.2 compounds shall have no
products with no discoloration or cure inhibition.
cracks and/or loss of adhesion from the test panel when tested
in accordance with a modified ASTM C734 (AAMA 800-10, Other materials, such as ethylene propylene diene monomer
Section 2.9.1). (EPDM) rubber, neoprene, Santoprene® , Kraton® and other
similar organic materials are typically found to cause slight
• Water Resistance: 805.2 compounds shall demonstrate no
discoloration of light-colored sealants. These materials are
presence of voids, cracks, separation or breakdown when
usually approved for incidental contact with glazing-type
tested in accordance to AAMA 800-10, Section 2.11.1.
silicones of all colors; but pigmented sealants may be
Substrate Selection preferable if the sealant line is visible or if any potential
discoloration needs to be masked.
DOWSIL™ InstantGlaze Window Assembly products are
suitable for back-bedding applications utilizing, but not Contact a Dow application engineer for questions regarding
limited to, the following substrates: compatibility and testing. Standard tests require four weeks
from receipt of test samples. Dow can accommodate non-
• Aluminum
standard tests with sufficient lead times, which may be
-- Anodized
subject to a service fee. Test reports from Dow should not
-- Mill finished
be interpreted as approvals.
-- Kynar® (polyvinylidene fluoride) finish
-- Duranar® finish Shelf Life and Storage Conditions
• Fiberglass and other composite materials
• Glass It is important to use any Dow product within its recommended
• Polyvinyl Chloride shelf life. The expiration date (EXP DATE) is clearly displayed on
• Wood the packaging label. DOWSIL™ InstantGlaze Window Assembly
-- Clad products should be stored in their original, unopened containers
-- Primed or unprimed in a clean and dry environment below 90°F (32°C). These products
-- Treated have a shelf life of 12 months from the date of manufacture
when stored below 90°F, and are packaged in air-tight containers
Adhesion because of its reactivity to atmospheric moisture.
All DOWSIL™ window assembly sealants are designed to
exhibit excellent adhesion to common substrates over a
wide temperature range and do not require surface priming. Sealant Design Considerations
Substrates may be subject to further treatment and coating to Properly installed and fully cured back-bedding sealants
enhance durability. All substrates should be tested as part of the allow the window unit to hold up to a wide range of weather
sealant selection process. Consult a Dow application engineer conditions and pass design pressure testing. The sealant serves
when substrates change or non-typical finishes are specified. a primary purpose as a weatherseal to prevent air infiltration
The Dow test laboratory located in Midland, Michigan offers a and water penetration. The sealant is designed to adhere and
variety of capabilities to ensure that a particular sealant will meet absorb stresses between the window sash and the glass as a
a customer’s design requirements for the window application. consequence of movement from thermally induced expansion
The adhesion of Dow products to a customer-specific substrate or contraction and wind loads. The movement capability
is evaluated using a modified version of ASTM C794 Standard Test of a fully-cured sealant helps absorb these stresses, rather
Method for Adhesion-in-Peel of Elastomeric Joint Sealants. than distribute them throughout the window unit to other
components, such as the glass.
Material Compatibility The glue-line thickness of a cured sealant must be designed
The Dow test laboratory conducts compatibility testing to accommodate joint movements due to differences in the
according to ASTM C1087 Standard Test Method for Determining thermal expansion of the different materials in the window
Compatibility of Liquid-Applied Sealants with Accessories Used in unit. The joint bite—the minimum width or contact surface
Structural Glazing Systems. In addition to the suitability of of the sealant on both the window sash and glass—must be
substrates for adhesion, components such as setting blocks, designed to accommodate both dead loads and dynamic loads
weather stripping, gaskets and other window accessory such as from thermal fluctuations, wind or impact. In all
materials must be compatible with DOWSIL™ sealants. cases, opposite-side mechanical supports such as glazing beads are
Chemical incompatibilities between materials may result required as the products in this manual are not considered
in discoloration, loss of adhesion and/or inhibit the cure structural sealants as defined by ASTM C1184 Standard
of the silicone sealant. Specification for Structural Silicone Sealants.

pg 4
Cure Requirements Figure 1: Typical cure-in-depth rates for DOWSIL™
InstantGlaze Window Assembly products at three
All DOWSIL™ one-part window sealants cure by reacting with
different sets of temperatures and relative humidities
moisture in the atmosphere. The rate of cure depends on the
diffusion of atmospheric moisture through the interface of the
0.6
exposed sealant within the sealant joint. Therefore, one-part 32°C, 60% RH
sealants cure from the outside surface inward. The rate of 0.5
moisture diffusion is affected by several factors including:

Cure-in-Depth, cm
25°C, 50% RH
0.4
• Partial Pressure of Water Vapor: This depends on
temperature and humidity in the immediate surroundings, 0.3
16°C, 30% RH
and is the driving force for diffusion. Increasing
temperature without changing the water content in the 0.2
atmosphere (such that the relative humidity decreases) will
0.1
not accelerate cure.
• Dimensions of the Sealant Joint: The diffusion rate of 0.0
0 6 12 18 24 30 36 42 48
moisture obeys Fick’s law and is proportional to the square
Elapsed Time After Glazing Window, hours
root of time. Therefore, the length of time needed for the
one-part sealant to fully cure increases significantly with an
increasingly deeper sealant joint. 7/32 90°F, 60% RH

• Joint Configuration or Joint Design: Areas such as corner 3/16

keys and windows with tight clearances may not afford 5/32
77°F, 50% RH

Cure-in-Depth, in
one-part sealants with sufficient exposure to atmospheric
moisture, and tight clearances with little access to the 1/8
60°F, 30% RH
atmosphere will slow the cure process. Conversely, porous 3/32
substrates will interfere less with the cure process and
small amounts of absorbed moisture (such as with wood 1/16
substrates) may accelerate the cure process. 1/32
• Sealant Composition: Silicones are more permeable than 0.0
organic materials. To improve mechanical strength, silicone 0 6 12 18 24 30 36 42 48
sealants are formulated with inorganic fillers, which Elapsed Time After Glazing Window, hours
decrease the moisture diffusion rate. This decrease will
While sealant green strength does allow for improved man-
depend on the type and the amount of filler in the sealant.
ufacturing throughout, care should still be taken to ensure
Figure 1 provides unidirectional cure-in-depth profiles for window units are not allowed to rack during the packaging or
three different sets of conditions over the first 48 hours after shipping process. If the sealant is not fully cured, units that
application that may be expected from DOWSIL™ InstantGlaze become out-of-square can set into this distorted shape due to the
Window Assembly products. The actual cure performance may racking forces overcoming the green strength of the material.
vary depending on joint design.
All DOWSIL™ InstantGlaze Window Assembly products Determining and Maintaining
provide instant green strength. Green strength can be described Sealant Joint Dimensions
as the initial shear strength before the sealant starts to exhibit Note: It is the responsibility of the window manufacturer to determine
sufficient cure that, in turn, builds mechanical and adhesion the appropriate bead size that will deliver the necessary joint dimensions
strength. The green strength of these hot-melt products will for each product design, joint configuration and application based on the
reduce hold times in the window assembly process necessary sealant properties provided in the product data sheet. It is incumbent on
for sufficient cure to occur. Units made with DOWSIL™ the window manufacturers to rely on their experience and to validate
InstantGlaze Window Assembly products have been successfully product design by performing the necessary unitized industry tests.
tested for air infiltration and water penetration within hours
of manufacture according to ASTM E283 Standard Test Method for Glue-line thickness is defined as the sealant thickness
Determining Rate of Air Leakage through Exterior Windows, Curtain necessary to absorb movement expected between the window
Walls, and Doors Under Specified Pressure Differences Across the sash and the glass due to climatic-induced loads. To determine
Specimen and ASTM E331 Standard Test Method for Water Penetration glue-line thickness, the first step is to identify the direction and
of Exterior Windows, Skylights, Doors, and Curtain Walls magnitude of the movement. The sealant generally undergoes
by Uniform Static Air Pressure Difference. the most movement in the direction of the longest dimension
of the window.

pg 5
As a basis for determining the appropriate glue-line thickness expansion (CTE) are known. Linear CTE values for typical
when using DOWSIL™ InstantGlaze Window Assembly window sash materials in the proximity of 77°F (25°C) are
products, it is recommended to start with a 3/16-inch (5 mm) listed in Table 1.
nominal bead diameter. The initial bead diameter will contract Table 1: Linear coefficient of thermal expansion for
in volume by approximately 6% as it cools down from its typical window sash materials
recommended dispensing temperature. This bead diameter,
assuming no squeeze out, results in a typical bite (contact
Linear Thermal Expansion Coefficients
width) of approximately 1/2 inch (13 mm), and a compressed
Material
sealant glue-line thickness of approximately 0.055 inch (1.3 10–6 in/in∙°F 10–6 m/m∙K
mm). While DOWSIL™ InstantGlaze Window Assembly products
Aluminum 12.3 – 13.2 22.2 – 23.8
may in some applications exhibit sufficient stiffness between
the window sash and the insulating glass (IG) unit, this behavior Fiberglass 6.5 11.7
cannot be solely relied upon to maintain glue-line thickness. Float Glass 5.0 – 5.1 9.0 – 9.2
Bumpers, such as those used in aluminum applications, and/or PVC 28 50.4
glazing legs, such as those seen in vinyl and wood applications,
Wood 2.1 – 3.0 3.8 – 5.4
are required to maintain the appropriate glue-line thickness
and to minimize excessive squeeze out. Dow recommends
glue-line thickness requirements be assessed by conducting The maximum thermal movement (expansion or contraction) for
movement capability tests and/or finite element analysis for a particular material from a change in temperature ΔT can be
each window design. calculated as follows:
Attention should next be given to the application process to Movement (in) = Length (in) × CTE (in/in∙°F) × ΔT (°F)
verify that a sufficient, uniform and consistent bead is applied
Figure 2 compares the movement, either contraction or
around the entire perimeter of the glazing leg with no skips,
expansion, for every 10 lineal inches of typical window
thin spots or shallow areas. If the application equipment
materials resulting from a 10°F (5.6°C) change in temperature
is not robust enough to ensure a consistently applied
using the average linear CTE data from Table 1.
minimum glue-line profile (bite and thickness) according
to design calculations, a safety factor should be applied to
increase the overall bead size so that the design requirements Figure 2: Movement for every 10 lineal inches of typical
are met in worst-case situations or locations. window materials due to a 10°F (5.6°C) change in
temperature
Care should also be taken in the dispensing process to
ensure the glue-line thickness does not fall below the design
3.0
requirement. Excessive sealant compression after bedding the 1 mil = 0.001 in
glass and installing opposite-side glazing beads may reduce the 2.5
Movement, mil

glue-line thickness such that severe climatic induced movements 2.0

may exceed the sealant’s movement capability. Wood, vinyl and 1.5
fiberglass sash profiles typically have glazing dams to establish 1.0
and maintain the design glue-line thickness. It is unacceptable
0.5
for glass to make contact with aluminum sash profiles such that
tapes and bumpers are occasionally used to ensure and maintain 0.0
Aluminum Fiberglass Float PVC Wood
the appropriate glue-line thickness. Regardless of the method to Glass
maintain glue-line thickness, the main takeaway should be that a
definable thickness is required to allow the sealant to perform its
designed functions.

Glue-Line Thickness and Joint Movement Calculations

A properly designed glue-line thickness will facilitate the
assembly process of window units and minimize stresses
on the sealant joint and interfaces resulting from movements
due to thermal expansion and wind loads. Glazed windows
undergo expansion and contraction movements due to diurnal
temperature cycles, heat traps, wind loads and proximity to
heating and air conditioning vents. The glue-line should
be designed to accommodate these movements in order to
minimize stress and prevent the glass from breaking.
Thermally-induced movement may be estimated for any
window sash profile or IG unit if its length (longest
dimension), composition and linear coefficient of thermal

pg 6
Determining Thermally-induced Differential Movement Figure 3: Thermally-induced movement as a function of
window height and ΔTglass where ΔTsash is assumed to be
Glazed windows undergo expansion and contraction movements
10°F cooler
due to diurnal temperature cycles, heat traps and proximity
to heating and air conditioning vents. The glue-line should
PVC – Glass
be designed to accommodate these movements to minimize
stress and prevent the glass from breaking. Thermally-induced 0.20
differential movement may be estimated for any window sash

Thermal Movement, in
profile and IG unit if its length (longest dimension), composition 0.15
and CTE are known. CTE values for typical window sash material
compositions in the proximity of 77°F (25°C) are listed in Table 1. 0.10
Because IG units are almost always supported on the bottom by
setting blocks, and because aspect ratios are such that windows 0.05
are typically taller than they are wide, the largest magnitude
of thermal movement is typically in the vertical direction. The 0.00 80
thermally-induced movement in the vertical direction v may 9 8 7 70
6 5 60
be estimated by the following formula where h is the height Window 4 50
Height 3 2 40 , °F
of the window unit; CTEsash and CTEglass the linear CTE of the h, ft ΔT glass
window sash and glass lite, respectively; and ΔTsash and ΔTglass
the differential temperature of the window sash and glass lite,
respectively, relative to when the window unit was assembled Aluminum – Glass
during the manufacturing process.
0.06
v
= h ∙ (CTEsash ∙ ΔTsash – CTEglass ∙ ΔTglass)
Thermal Movement, in 0.05
Assuming a window is free to expand and contract in both
horizontal directions from its centerline, thermally induced 0.04
movement w experienced by the sealant across the width from
the centerline of the window may be estimated by the following 0.03
formula where w is the width of the window unit.
0.02
w
= (w/2) ∙ (CTEsash ∙ ΔTsash – CTEglass ∙ ΔTglass)
0.01
In determining thermally-induced movement in a window unit,
the designer seeks the result with the higher magnitude for the 0.00 80
purpose of calculating the glue-line thickness. Unless the width 9 8 7 70
6 5 60
Window 4 50
of the window unit is more than twice its height, in almost all Height 3 2 40 , °F
cases the movement in the vertical direction is going to be the h, ft ΔT glass
value of higher magnitude.

pg 7
Sample Calculations • The total movement of this glue-line profile due to a 40°F
A window manufacturer is assembling a series of windows change in temperature is:
intended for use in an environment where the expected 0.074 – 0.050
maximum and minimum temperatures are 140°F (60°C) and 100% = 48%
0.050
–15°F (–26°C), respectively. The factory where the units are
manufactured is maintained at 65°F (18°C). Therefore, the Consult the product data sheet for the movement capability
temperature differential is greatest during the cold condition, rating of any back-bedding sealant to determine if the glue-line
(65°F – (–15°F) = 80°F). Because the IG unit has insulating thickness to be used is suitable for the design of the window unit.
capability, it is expected to be warmer than the window sash. Following ASTM C719 Standard Test Method for Adhesion and
Figure 3 shows the resulting movement for different window Cohesion of Elastomeric Joint Sealants Under Cyclic Movement (Hockman
heights when ΔTglass is varied from 40°F to 80°F. The temperature Cycle) protocol, the movement capability for all DOWSIL™
of the window sash, either PVC (top graph) or aluminum InstantGlaze Window Assembly products is ±50%. Using
(bottom graph), is assumed to be 10°F (5.6°C) cooler. the relationship between a and c as it relates to movement
capability M, the maximum value for c can be determined.
Determining Sealant Glue-line Thickness
c = a(1+M/100%)
The required glue-line thickness a for a differential movement
b can be calculated using the Pythagorean Theorem (Figure 4). Therefore, c = 1.5a for a back-bedding sealant rated with ±50%
Likewise, the allowable movement b for a particular glue-line movement capability, and the minimum glue-line thickness
thickness a can be calculated. The deformed glue-line dimension that will be able to accommodate a maximum allowable
c will be limited by the movement capability of the sealant movement b due to a change in temperature is:
undergoing shear in the joint configuration. a = b2/1.25
Figure 4: Schematic diagrams for the dimensions used to Figure 5 shows the effect of glue-line thickness a on the
calculate movement in the joint configuration. maximum allowable movement b for a back-bedding sealant
rated with ±50% movement capability.
Pythagorean Theorem: a2 + b2 = c2
Movement direction should also be taken into consideration. In
c a = Original glue-line thickness
a the worst case scenario, thermally-driven movement will occur
b = Joint movement in one direction due to setting blocks preventing any downward
c = Deformed glue line after joint movement
movement of the IG unit. In a system where the IG unit is not
b
supported by setting blocks, the IG unit may move in both
b
directions.
Insulating Glass Unit
Some variability in the window sash surface flatness should be
Sealant a
anticipated. The process equipment that extrudes the sealant
Window Profile bead can also be expected to demonstrate variability. Hence,
a minimum glue-line thickness of 0.035 in (0.9 mm) should be
observed regardless of the calculations.
Sample Calculations
Joint Movement: Figure 5: Allowable joint movement as a result of a
change in temperature as a function of the glue-line
• For a 3 ft × 5 ft glass lite fixed at the sill and a temperature thickness of a back- bedding sealant rated with ±50%
change of 40°F over the course of a 24-hour day, the glass movement capability
(CTE ~ 5.1 × 10–6/°F) will exhibit a maximum joint movement
0.14
b of:
Allowable Joint Movement, in

0.12
5 ft ∙ (12 in/ft) ∙ 5.1 × 10–6 in/in∙°F ∙ 40°F = 0.012 in
• A vinyl sash profile (CTE ~ 28 × 10–6/°F) will expand by 0.067 0.10
in from an increase of 40°F 0.08
• Differential movement b is 0.067 – 0.012 = 0.055 in 0.06

Sealant Movement: 0.04

• For a differential movement b = 0.055 in, a back-bedding 0.02

sealant with an initial glue-line thickness of a = 0.05 in will 0.0
deform to the following dimension: 0.035 0.050 0.075 0.100 0.125
Glue-line Thickness, in
c= (0.050)2 + (0.055)2 = 0.074 in

pg 8
Bite Calculation for Wind Load products have been tested and approved for chemical
compatibility. The primary function of setting blocks is the
Aside from thermal stresses, the bond should be able to ac-
support of both the inboard and outboard lites of glass on
commodate dynamic loads due to wind, impact from flying
the same horizontal plane. This ensures a shearing stress does
objects or normal operation of windows. The following
not occur due to one of the lites being supported only by the
procedures can be applied to calculate the minimum bite
IG sealant system. Excessive loading on the IG sealant system
(contact width) necessary to simultaneously withstand both the
may lead to failure of the IG seal and ultimately IG failure. By
weight of the IG unit and any wind load.
supporting the IG unit along the bottom with a minimum of
Note: The provided bite calculations are guidelines and each window two setting blocks, vertical loads in the IG unit are transmitted
manufacturer should decide if additional structural support is needed to entirely to the window sash for support. However, this practice
retain the IG unit based on knowledge of the specific finished product and results in the thermally-induced movement of both the window
intended application. sash and glass to be in the vertical direction. Since most windows
have aspect ratios where height exceeds width, this movement is
The minimum sealant bite w necessary to resist a given wind
usually the greater in the vertical dimension (height).
load can be approximated using the following formula where
w and the shorter dimension of a rectangular IG unit have the Typical Yield
same unit of length (in or mm), and wind load and stress have
the same unit of pressure. The amount of DOWSIL™ InstantGlaze Window Assembly
product required to meet a target manufacturing number of
Shorter dimension of IG unit × Wind load window units will depend on the bead size of the sealant and
w=
2 × Maximum allowable design stress the perimeter length of the unit. Once bead size and glue-
For example, the maximum allowable design stress for line thickness are established by the window manufacturer,
DOWSIL™ InstantGlaze Window Assembly products is 20 psi (0.14 Table 2 can be used as a guide to estimate the lineal coverage
MPa). For a 6 ft × 8 ft IG unit with an applied wind load of 40 of a gallon of sealant for different bead sizes. The number of
psf, the sealant bite dimension will be: identical window units that can be manufactured per gallon
of sealant can then be calculated if the perimeter length of the
6 ft × 12 in/ft × 40lbf /ft2 × 1 ft2/144 in2 window unit is known.
w= = 0.50 in
2 × 20 psi
To anticipate bead size variability during sealant bead extrusion, Table 2: Effect of bead size on lineal coverage
regardless of the calculation output, a minimum bite of 3/8 in per gallon of sealant
(9.5 mm) should always be observed.
Initial Bead Linear Coverage per Gallon2
Bite Calculation for Dead Load Size,1 inch inches feet

The weight of the IG unit acts as a dead load for the sealant Application
1/8 0.125 18,800 1,500
bond when a window is opened. The following formula 3/16 0.188 8,400 660
can be used to calculate the minimum bite dimension w to 1/4 0.250 4,700 380
accommodate this dead load where the weight of the IG unit
3/8 0.375 2,100 170
is based on a glass density of 0.090 lb∙in3 (2500 kg∙m3) and
1
Based on a circular cross-section
gravitational acceleration is 386 in∙s–2 (9.81 m∙s–2). 2
Calculated with consideration to waste due to start-up and purging

Weight of IG unit × Gravitational acceleration

w=
Perimeter of IG unit × Max allowable design stress
Application
For example, the maximum allowable design stress for a
constant load for DOWSIL™ InstantGlaze Window Assembly Safe Handling Instructions
products is 1.0 psi (0.007 MPa). For a 3 ft × 5 ft IG unit (192-in Before handling a DOWSIL™ InstantGlaze Window Assembly
perimeter), the minimum bite dimension for a dead load of 50 product, review the product and safety data sheets and the
lbf is 0.26 in (6.60 mm). container label for safe use, physical and health hazard
In almost all applications, the IG unit should be supported on information. Any exposure of opened containers to air is
the bottom by appropriately placed setting blocks per industry discouraged because these products will react with moisture
accepted practices found in the Glass Association of North in the atmosphere and begin to cure on the material surface.
America (GANA) manual. Where IG units are supported by The presence of local exhaust ventilation should be discussed
setting blocks, the sealant does not experience any dead load with your safety department. Be aware that air drafts from
and only experiences dynamic stresses such as thermal and ventilation systems in the proximity of the dispensing nozzle
wind loading conditions. may affect its temperature, which will in turn impact bead size
consistency and sealant wet-out on the window sash.
Setting Blocks The product and safety data sheets are available from
Setting blocks are almost always required by window consumer.dow.com/construction. Copies may also be
industry IG manufacturers. Always ensure setting blocks in obtained from your local Dow sales representative
contact with the DOWSIL™ InstantGlaze Window Assembly or distributor.

pg 9
Refer to “In-shop Application” of the dispensing equipment for Determination of Cure State
recommendations on the safe operation of the bulk melter. Dow packages its products in containers that are properly
Volatile Organic Content (VOC) sealed, but events may occur, such as mishandling of containers,
that may compromise the integrity of the seal. A compromised
• Non-hazardous Formulation
seal may allow air ingress into the container. The moisture in
• Low VOC < 15 g/L the air will produce the detrimental effect of curing the surface
(exempt from California VOC regulations) of the product before it can even be dispensed by the customer.

Product Handling Precautions DOWSIL™ InstantGlaze Window Assembly products do not

change in appearance before, during or after they are fully
The product is generally dispensed around 248°F (120°C). The
cured. The products undergo a change from a gum-like
use of personal protective equipment to prevent con-tact of
consistency in the uncured state at room temperature to a
hot material or hot equipment surfaces with skin or eyes
cross-linked rubber-like material when cured.
is recommended.
To ensure that DOWSIL™ InstantGlaze Window Assembly
Safety Instructions products can be pumped, a pick test was developed to
Safety instructions contained in this manual apply to tasks determine if the surface of the product in its container is
that may be performed with DOWSIL™ InstantGlaze Window cured (Figure 6).
Assembly products. It is important that these safety instructions Using a screwdriver or similar tool, stab the surface of the hot-
are followed to protect employees, operators, and equipment. melt product and attempt to ‘pick’ up (remove) a portion of the
• Become familiar with and follow all safety instructions material. The top photograph in Figure 6 shows what will happen
prescribed by your company, general accident prevention if the product is uncured: the screwdriver head is able to pick up
regulations and government safety regulations. a small amount of material as the screwdriver is pulled quickly
away from the surface. The bottom photograph shows what
• Become familiar with and follow all safety instructions will happen if the product is cured at the exposed surface: the
prescribed by the equipment manufacturers. small amount of material that is picked up by the tool will resist
• Schedule periodic safety inspections to ensure required separating from the bulk in the container. Any occurrence of cure
material and equipment practices are followed. in the container will not allow the product to be properly pumped
and dispensed. A video of the pick test may be found on the
• Provide appropriate emergency and first-aid equipment
YouTube website at: www.youtube.com/watch?v=R95sUPaB_Hc.
in the production workspace.
Figure 6: Determination of the cure state of DOWSIL™
Recommended Personal Protective Equipment
InstantGlaze Window Assembly products using a pick test
Product and dispensing system are both hot and pressurized.
• Safety glasses with side shields or goggles
• Cut-resistant gloves when handling scrapers or
deglazing tools
• Glass handling jackets and/or sleeves
• Heat-resistant gloves to protect against burns when
working with hot materials and equipment
• Steel-toed shoes when handling product containers
and window units Good – Acceptable:
Uncured product is gummy, separates easily and remains on the tool
Quality Control when pulled away from the surface.

Customers should examine the expiration date (EXP DATE)

displayed on the packaging label to verify the product is
within its shelf life. These products have a shelf life of 12
months when stored in a properly sealed, air-tight container
at temperatures below 90°F (32°C). The product should be
inspected for traces of cure upon opening the container for the
first time; refer to the section “Determination of Cure State”.
Any attempt to pump cured material will impact bead
quality and could eventually lead to pump deterioration and
malfunction.
Reject – Unacceptable:
Cured product displays rubbery features, stretches and resists
separation when pulled away from the surface.

pg 10
 Substrate Preparation into consideration before selecting the appropriate hose
length and diameter. Hoses should be designed to be as short
DOWSIL™ InstantGlaze Window Assembly products do not
in length and as small in diameter as possible, and must not
require primers to promote adhesion to common fenestration
have so much of a pressure drop so as to starve the delivery of
substrates. Special surface preparation procedures, such as
material at any point during the dispensing phase. Hoses that
solvent wiping, are usually not required when applied to
are too long and too large in diameter can make maneuvering
clean, dry substrates. The window manufacturing process
the gun or dispensing head difficult. Longer hoses require
should therefore be set up in a manner wherein the window
higher pressures to maintain target flow rates, and increase
sash and IG are kept clean and free of dust and debris prior
radiant heat loss.
to the sealant being applied. It is recommended to clean the
substrate when in doubt. Air flow around the dispensing nozzle will be much cooler than
the hot-melt material exiting the hose. Variations in ambient
When a cleaning solvent is used, the proper choice of solvent
temperature may affect bead consistency unless heated
is an important part of the surface preparation requirements
nozzles are used or the nozzle has enough bulk to maintain a
for substrates that are to be bonded. Cleaning solvents differ in
reasonably consistent temperature.
effectiveness in removing contaminants. Be aware that the use
of aggressive solvents like methyl ethyl ketone can adversely Glazing Table
affect finishes such as polyester powder-coated aluminum.
An automated X–Y glazing table is the most efficient
Milder cleaning solvents such as isopropyl alcohol (IPA) and
method for applying glazing sealants to maintain bead
high-quality (greater than 98% purity) white/mineral spirits
consistency, reduce labor and minimize waste. Consult your Dow
can be used without damaging the substrate surface.
sales representative for contact information for manufacturers
Before bedding an IG unit, the glass edge of the outer pane of melter and table equipment. Automated glazing tables
must also be prepared for bonding. This entails ensuring the apply sealant in the most consistent manner, but problems can
glass edge is clean and dry. The IG unit should be free of any occur. Routine operational audits and preventive maintenance
cutting oils, grease, dirt and other forms of contamination schedules can help ensure consistent sealant delivery.
which might otherwise prevent proper adhesion and adversely
To assist with sealant application filling issues, it is good
impact the long-term durability of the bond.
practice to have a compatible silicone sealant available in
Dow recommends checking with the substrate supplier and IG cartridge form that can be dispensed using a caulk gun for
manufacturer for the compatibility of cleaning solvents. Always remedial glazing, or supplement sealant to thinly applied,
follow manufacturer/supplier safe handling recommendations as shallow or skipped areas of the glazed unit prior to bedding
well as local, state and national regulations. the glass. DOWSIL™ 1199 Silicone Glazing Sealant Clear,
DOWSIL™ 9-1350 Silicone Glazing Sealant or DOWSIL™ 791
In-shop Application Silicone Weatherproofing Sealant can be used in such situations.
Dispensing Equipment
Manufacturing Process Conditions
DOWSIL™ InstantGlaze Window Assembly products are
DOWSIL™ InstantGlaze Window Assembly products depend
designed for dispensing from automated, high-volume bulk
on moisture in the atmosphere to completely cure the sealant
melters (or hot-melt pumping systems) for 5-gallon/20-liter
bead even though they provide instant green strength.
or 55-gallon/200-liter containers in conjunction with auto-
The atmosphere in the manufacturing and any staging
mated robotic or hand-assist equipment. Dow can provide
areas should have a minimum relative humidity of 30% and
engineering assistance in the design of a delivery system.
preferably 50–60%. The cure rate of these products will be
Equipment suppliers of bulk melters typically provide
affected as temperature and relative humidity vary due to
design, installation, operation and maintenance training.
normal seasonal fluctuations.
Hot-melt pumps can be run either under constant flow
The temperature around the glazing process should be
or constant pressure. Dispensing product under constant
within 65°F (18°C) and 90°F (32°C). Colder temperatures
pressure usually leads to more consistent flow. However,
will reduce cure speed and adhesion development. Hotter
this can lead to slight variations in flow when changing
temperatures will initially reduce green strength and may
containers due to batch-to-batch viscosity variations. To
promote squeeze out; however, cure speed may increase.
maintain constant volumetric flow, the best solution is to
run the hot-melt pump at constant pressure and to install a The surface temperatures of the glass and window sash must
metering (gear) pump just before the nozzle. The volumetric not fall substantially below the recommended manufacturing
output depends on temperature and can be adjusted with the process temperature. Lower temperatures may lead to
help of the equipment supplier and Dow technical service condensation or wet substrate surfaces which may influence
personnel during the start-up phase. bead quality or inhibit cure.

The hose is an important component of a pump and gun The manufacturing environment should be dust free.
delivery system. The planning and design of the production
area where the sealant will be applied should be first taken

pg 11

0
 Dispensing Temperatures from the uninsulated metal nozzle. This is generally acceptable
since the residence time of the hot melt flowing through the
The dispensing temperature is critical for the proper
nozzle is relatively short. Maintain nozzle temperatures at the
application of DOWSIL™ InstantGlaze Window Assembly
lowest possible temperature which produces consistent hot-melt
products. Figure 7 shows the effect of temperature on the hot-
flow and bead dimensions. Take advantage of any equipment
melt viscosity of these products, which should not be exposed
operational safety feature that will protect the hot-melt
to sustained temperatures above 285°F (140°C).
product from overheating. This will also extend the service life
Table 3 lists recommended temperature ranges for different of o-rings and seals used in the dispensing equipment.
zones in the bulk melter and is between 248°F (120°C) and
The hot-melt viscosity of DOWSIL™ InstantGlaze Window
266°F (130°C). At 248°F, the viscosities of DOWSIL™ InstantGlaze
Assembly products will also depend on shear rate, which is
II Sealant and DOWSIL™ InstantGlaze III Adhesive are similar
proportional to the volumetric flow rate coming out of the
and approximately 75% lower than that of DOWSIL™ InstantGlaze
nozzle. Figure 8 shows how the hot-melt viscosity changes with
Sealant. The smaller volume zones closer to the nozzle may be
shear rate at 120°C (248°F) and 130°C (266°F). For the sealant bead
set at higher temperatures to increase flow at the nozzle but
sizes listed in Table 2, the shear rate can be expected to vary
should not exceed 285°F (140°C). The nozzle temperature may
between 10 and 200 s–1 in the hose and between 100 and 1,000 s–1
need to be set higher than zone temperatures but should not
exceed 285°F (140°C) depending on air drafts and heat losses in the nozzle.

Figure 7: Effect of dispensing temperature on the hot-melt Figure 8: Effect of shear rate on the hot-melt viscosity of
viscosity of DOWSIL™ InstantGlaze Window Assembly DOWSIL™ InstantGlaze Window Assembly products at 120°C
products (1,000 cP = 1,000 mPa∙s = 1 Pa∙s) (top) and 130°C (bottom). 1,000 cP = 1,000 mPa∙s = 1 Pa∙s

Temperature, °C 200,000
T = 120°C (248°F)
100 110 120 130
150,000
600,000
Viscosity, cP

500,000 100,000
Viscosity, cP

400,000
300,000 50,000
200,000
0
100,000 10 100 1000
0 Shear Rate, s–1
210 220 230 240 250 260 270
Temperature, °F
200,000
T = 130°C (266°F)
DOWSIL™ InstantGlaze Sealant
DOWSIL™ InstantGlaze II Sealant 150,000
Viscosity, cP

DOWSIL™ InstantGlaze III Adhesive

100,000
Table 3: Recommended zone temperatures
for hot-melt unloader
50,000
Temperature
Zone 0
°F °C 10 100 1000
Platen 248 – 266 120 – 130 Shear Rate, s–1
Hose 248 – 266 120 – 130 DOWSIL™ InstantGlaze Sealant
Gun Body/Valve 248 – 266 120 – 130 DOWSIL™ InstantGlaze II Sealant
Metering Pump 248 – 266 120 – 130 DOWSIL™ InstantGlaze III Adhesive

Nozzle1 248 – 285 120 – 140

1
May exceed 266°F (130°C) depending on drafts, ambient temperature and heat loss through the nozzle.

pg 12
Dispensing Too Hot • Install setting blocks and spacers to control the position
of the glass in the window sash. To allow for placement of
Caution: Maintaining the material at temperatures over 266°F
setting blocks, glass may be shifted slightly if necessary
(130°C) over extended periods of time may have the following
by applying a slow, steady force with a thin, hard plastic
detrimental effects:
spatula. If glass shifting, repositioning or any reworking
• Reduced Tackiness is required, it should be done within the first five minutes
• Bead Dragging Around the Corners after dispensing the sealant.
• Bubbles in Sealant • Apply opposite-side glazing beads prior to leaning the
window away from the sealant. If production will not
• Reduced Pot Life
allow for this, store the window unit either flat or with
• Excessive Fluidity the weight of the glass leaning on the sealant.
Dispensing Too Cold
Figure 9: Typical changes in bead temperature as a
Operating at too low a temperature will increase the viscosity, function of time elapsed after wetting out typical
leading to predictable problems: window sash substrates (top) and when squeezed
between substrate and glass (bottom)
• Difficulty Pumping
• Uneven Flow from Nozzle
220 110

Hot-melt Bead Temperature, °F

Hot-melt Bead Temperature, °C

• Build-up of Material on the Side of the Nozzle PVC
Causing Offset Dispensing Wood 90
• Stringiness Behind the Nozzle Aluminum
160 70
Drafts or atmospheres lower than typical room temperatures
[65°F (18°C)] may contribute to adverse dispensing 50
performance at the nozzle tip. 100
30
After a DOWSIL™ InstantGlaze Window Assembly product has
been dispensed at 248°F (120°C), it will take approximately five 10
minutes for the bead to cool down to ambient temperatures. 40
0 1 2 3 4 5
Figure 9 shows typical changes in bead temperature as a function
of time elapsed after wetting out typical window sash substrates. Elapsed Time, min
The temperature profile depends on the thermal conductivity of
220 110
the substrate(s); for example, wood and PVC (and silicones) have

Hot-melt Bead Temperature, °C

Hot-melt Bead Temperature, °F

PVC and Glass

similar thermal conductivities (~ 0.2 W∙m–1∙K–1) compared to
Wood and Glass 90
window glass (~ 1 W∙m–1∙K–1) and aluminum (~ 200 W∙m–1∙K–1).
Aluminum and Glass
160 70
Glazing Process
• Open time is defined as the maximum elapsed time after 50
dispensing the sealant for completing all manufacturing 100
steps on each unit. DOWSIL™ InstantGlaze Window 30
Assembly products have up to a 15-minute open time at
10
room temperature. This provides processing flexibility 40
and robust manufacturing options. The 15-minute open 0 1 2 3 4 5
time allows the glass to be realigned or reworked during Elapsed Time, min
installation, and allows installation of setting blocks and
spacers, as well as opposite-side glazing beads and other General Considerations for Applying DOWSIL™
components, without adversely affecting the properties InstantGlaze Window Assembly Sealants
of the sealant. Follow the manufacturer recommendations for material
• Once sealant is applied to the window sash, the glass, dispensing and pump operation.
setting blocks and spacers should be installed and Initial Start-up Tips
positioned within 15 minutes. If the sealant is left for longer
than 15 minutes without the glass being installed, the • Disconnect the hose at the glazing table and position into
sealant should be removed from the window sash and a an empty drum to capture purge material and ensure all
fresh bead should be applied. contaminants (such as assembly lubricants and test fluids)
are cleared from the pumps and hoses prior to proceeding
• Ensure the glass is bedded directly on the sealant and
with production.
not bound in direct contact with the window sash.

pg 13
• Reconnect the hose and begin purging material through Shut Down Considerations
the nozzle. Collect material into a suitable waste container
• Nozzle tips left exposed to air after shutting down
until all visible contamination, such as oils and/or air
production will cure any hot-melt product left over
bubbles, are no longer present and material is extruding
within the nozzle. At the end of a production run, apply
smoothly from the nozzle.
MOLYKOTE™ 111 Compound to the nozzle tip. Immersion of
• Run test beads of material to ensure uniform bead the nozzle tip in any viscosity grade of silicone oil will also
application on the substrate. work. Upon start-up, small amounts of cured material from
Container Changeover within the nozzle tip can usually be dispensed during the
purge cycle.
• Test a newly opened container for cure. Refer to the
• For shutdown intervals in excess of 24 hours, powering
section "Determination of Cure State".
down the equipment is required. This will save energy,
• Ensure the follower platen is wiped free of dirt, dust or oils
extend the service life of the o-rings and seals in the
prior to pumping material.
dispensing equipment and avoid exceeding product pot
• Grease the gasket on the follower platen with MOLYKOTE™ life. Remove the nozzle while warm and use a pipe
111 Compound (or other silicone-compatible, high- plug to cap the application head and the hose.
temperature greases).
• Provided the product remains sealed within its container
• After opening and testing for cure, place the container and equipment, the pump can be restarted normally
under the heated platen. without any adverse effects.
• Open the vent valve on the platen to allow trapped air to
purge from the container as the platen is being lowered Quality Control and Application Issues
into the container. Bead Location
• Start the heat cycle and wait for the platen to reach the • The sealant bead should be located on the glazing leg,
target dispensing temperature. Refer to the section parallel with the glazing leg, and within the dimensions
"Dispensing Temperatures" for more information. of the glass unit.
• Apply down-force pressure (make sure the direction • Bead locations not parallel to the glazing leg or outside of
switch for platen is in the down position) and purge any the dimensions of the glass unit may not contact the glass
remaining air through the vent valve. It is recommended at some locations of the glass perimeter.
that any purged material be collected in a suitable waste
• Other issues that could cause bead location errors may
container for proper disposal.
include the operator not placing the window sash squarely
• Shut the vent once hot-melt material is flowing through on the table or the table not ‘seeing’ or sensing the
the vent valve with no air bubbles. window sash properly.
• Start the pump to begin dispensing the material through
the nozzle. Collect material in a suitable waste container Bead Consistency and Uniformity
until material is running smoothly. Bead consistency and uniform bead dimensions are important
• Run test beads of material to ensure uniform bead for good sealant wet-out and consistent bite. The consistency
application on the substrate. of the bead must be checked on every window sash. If bead
Time at Temperature Considerations inconsistencies occur, determining and correcting the root
cause will be necessary. Aside from the nozzle opening, flow
• In a sealed system, DOWSIL™ InstantGlaze Window rate – pump pressure, and table speed will define bead size.
Assembly products are stable for up to 24 hours at 248°F If the bead size is inconsistent, this may indicate a change in
(120°C). If the glazing process is not to be used for an pump pressure, temperature variations especially at the nozzle
extended period, up to and including 24 hours, the pumps tip, improperly sized hoses, or a problem with the pump.
and heating zones can be shut down or the temperatures
lowered without detrimental effects on the sealant. Below are some examples of bead inconsistencies and
suggested remedies.
• For shutdown intervals in excess of 24 hours, powering
down the equipment is required. Provided the product Skip – An area where the X–Y glazing table does not apply
remains sealed within its container and equipment, the any back-bedding sealant:
pump can be restarted normally without affecting material.
• Apply DOWSIL™ 1199 Silicone Glazing Sealant Clear (or
Approximate heat-up time is 30 to 60 minutes depending
other sealants, such as DOWSIL™ 9-1350 Silicone Glazing
on equipment type and manufacturer recommendations.
Sealant or DOWSIL™ 791 Silicone Weatherproofing Sealant)
• Exposure of opened containers to air should be minimized to the skip location.
because DOWSIL™ InstantGlaze Window Assembly products
will react with moisture in the atmosphere.

pg 14
Thinning – An area along the sealant line where the bead nozzle. At the end of a production run, apply MOLYKOTE™
dimension is unusually thin and non-uniform: 111 Compound to the nozzle tip. Immersion of the nozzle tip
in any viscosity grade of silicone oil will also work. Remove
• Apply DOWSIL™ 1199 Silicone Glazing Sealant Clear (or
nozzle while warm and use a pipe plug to cap the application
other sealants, such as DOWSIL™ 9-1350
head when production downtimes exceed 24 hours.
Silicone Glazing Sealant or DOWSIL™ 791 Silicone
Weatherproofing Sealant). Nozzles containing cured material can often be purged out
with fresh material. Occasionally, the nozzle may need to
• Check that the dispensing pump is powered on and
be removed and cleaned or replaced if the material cure
maintaining pressure. If thinning occurs at the end
has progressed too deep. DOWSIL™ 3522 Cleaning Solvent
of the cycle, this could be an indication that either the
Concentrated, which is based on odorless mineral spirits,
system has too much pressure drop for the flow rate
may be used to dissolve cured silicones.
required or the melt rate of the bulk melter is not
sufficient for the application rate. Hose
Tooling – An area along the sealant where the nozzle was too Plug any open-ended hose when production downtimes exceed
low (or the window sash too high) and the nozzle dragged on 24 hours or material may start to cure and affect flow in
the sealant: subsequent production runs. DOWSIL™ InstantGlaze Window
• Scrape Off the Sealant and Apply New Sealant. Assembly products do not build up on the interior hose wall,
and proper care of the outside of the hose including preventing
• Adjust the Nozzle to the Appropriate Height.
excessive tight radius bending should lead to a long hose life as
Waviness or Unevenness – An inconsistent bead that can long as the sealant is not allowed to cure on the inside.
occur when the nozzle is too high above the window sash:
Melt Platen Sealing Rings
• If the waviness results in a bead of varying height
causing wet-out to be inconsistent, scrape off the bead Avoid buildup of product residue on the melt platen surface and
and reapply. If the bead is just uneven, but the bead around the sealing rings. Any residue should be considered
height is consistent, the sealant application is acceptable cured and will reduce the seal’s effectiveness. Avoid the use
if the window manufacturer deems the waviness to of sharp tools and remove any residue before start up or when
be visually acceptable. a new container is loaded. Follow all recommendations for
lubricating the sealing rings. In some instances, the sealing ring
• Adjust the Nozzle to the Appropriate Height.
may need to be replaced.
Substrate Issues: Uneven Surfaces in Window Sash Leakage
Uneven surfaces, such as improper cleaning of welded When air or sealant leakage occurs, immediately replace the
corners or a warped window sash, can cause either tooling corresponding seal or o-ring.
or wavy sealant and can contribute to a unit that may be
Compressed Air
improperly sealed. It is vital to consistently provide a flat, even
window sash on which to apply the DOWSIL™ InstantGlaze Compressed air is used for pneumatic operations including
Window Assembly product. the aeration and deaeration of the container. Compressed air
coming into contact with the moisture-reactive product must
Equipment Issues be clean and dry.
Issues may occur even when following recommended
Environmental Issues
operational and maintenance practices. Some of these
issues may adversely affect the quality of the sealant bead Air drafts from ventilation systems in the proximity of the
being applied on the window unit. application head may affect its temperature, which will in turn
impact bead size consistency and sealant wet-out on the window
Application Head or Nozzle sash. Reduce and eliminate air flow on nozzles where possible.
• The nozzle on the application head is often uninsulated. Temperature and humidity conditions in the manufacturing area
Nozzle temperatures are often set higher than hose should be controlled year round if possible. Like other one-
temperatures, but should not exceed 285°F (140°C) to part RTV sealants, DOWSIL™ InstantGlaze Window Assembly
maintain consistent hot-melt flow and bead dimensions. products require moisture in the air to cure.
This is generally acceptable because the residence time of
the hot-melt flowing through the nozzle is short.
• A nozzle tip left exposed to air during production down
times will cure any hot-melt product left over within the

pg 15
Deglazing and Reglazing
of Window Units
Note: It is recommended that the operator wear appropriate Personal An operator should stand in an ergonomic position as to
Protection Equipment while deglazing any window and handling glass. be able to insert the blade and move it around the window
without reaching well beyond their range of motion.
Deglazing can be used to remedy manufacturing issues
associated with the back-bedding sealant and/or as a quality Deglazing can be used as a test for quality assurance.
assurance method of inspection used to confirm good During production of window units, it is a good idea to
adhesion and proper fill of the glazing joint. periodically monitor sealant performance and application.
Quality assurance tests are good practice and can alert
Window units manufactured with DOWSIL™ InstantGlaze
the manufacturer to a potential quality issue prior to
Window Assembly products as the back-bedding sealant can
manufacturing a large quantity of units. It is the prerogative
be deglazed using standard deglazing tools.
of the window manufacturer to determine the frequency of any
To remedy a manufacturing issue, the window should be test including deglazing based on quality assurance principles.
deglazed within the first 30 minutes of assembly by removing
When used as a quality assurance procedure, units should sit
opposite-side glazing beads and applying steady pressure on a
for the prescribed cure time before deglazing to check for
corner until the sealant breaks. Next, carefully apply pressure
bead quality. The sealant should be inspected for wet-out to
around the perimeter of the unit until the glass is free.
both the lite and the window sash. For best inspection results,
For cure times exceeding one hour, it may be necessary to cut the surface of the lite and/or window sash should not be
the glass out of the unit using an appropriate tool such as that damaged. The inspection should include the following:
shown in Figure 10. First, remove the opposite-side glazing
• Uniformity of Width of Sealant Bite
beads if these are present. Deglaze the window by spraying the
perimeter of the unit with a mild solvent, such as isopropyl • Wet out of Sealant on the Lite and Window Sash
alcohol (IPA), to soften the sealant and provide lubrication • Uniformity of Cure
during cutting. Insert the cutting tool between the glazing leg
on the window sash and the glass. Working the blade between • Appearance of Sealant, Including Uniformity of Color
these two surfaces is the most critical step; it is possible to for Pigmented Versions and Presence of Bubbles or
break the glass if excessive pressure is applied. Once the blade Foreign Matter
is well positioned between the glass and the glazing leg, move it
slowly around the window cutting the sealant line and finally
Shop Reglazing
removing the IG unit. Multiple passes around the unit and Window units originally glazed with silicone sealants should
additional applications of IPA may be required to completely be reglazed with silicone sealants. Glazing tapes will not
cut the unit free. adhere to a glazing leg that has had a silicone-based material
previously applied to it.
Figure 10: Deglazing tool
Once the glass is removed from the window sash, scrape away
excess beads of sealant using a putty knife or a spatula with
a finely ground sharp blade. A wide flat-head screwdriver is
frequently used. It is unnecessary to clean the glazing leg with
any chemical or to remove the sealant film. Reapply DOWSIL™
InstantGlaze Window Assembly product to the glazing leg and
follow regular glazing installation procedures.

Field Reglazing
DOWSIL™ InstantGlaze Window Assembly products are 100%
silicone: other cold-applied silicone sealants are compatible and
will adhere to it. Once the glass is removed from the window
unit, scrape away excess beads of sealant. It is unnecessary
to clean the glazing leg with any chemical or to remove any
leftover film from the sealant bead.

pg 16
Apply a fresh sealant bead to each glazing leg using either Window Assembly products exhibit peel strengths of at least
DOWSIL™ 1199 Silicone Glazing Sealant or DOWSIL™ 791 30 pli after a 7-day water immersion to a variety of common
Silicone Weatherproofing Sealant. Immediately install substrates. Refer to the section on "Substrate Selection". The
the new IG unit (before a sealant skin forms) and reinstall mode of failure is cohesive.
opposite-side glazing beads and other components as needed • DOWSIL™ InstantGlaze Sealant > 45 pli
according to the window manufacturer’s procedures. • DOWSIL™ InstantGlaze II Sealant > 41 pli
• DOWSIL™ InstantGlaze III Adhesive > 30 pli
Finished Unit Figure 11: Green strength build up of DOWSIL™
Recommendations InstantGlaze Window Assembly products configured
with a 0.10-in glue-line thickness in a single 1×1 in2
Avoid prolonged exposure to citrus-containing cleaners, overlap lap-shear joint at 24 ± 2°C and 50 ± 5% RH
solvents and solvent-based cleaners as they may damage the
cured sealant. 60

50
Comparative Performance

Green Strength, psi

40
Green Strength
30
Green strength can be described as the initial shear strength
before a sealant exhibits significant cure as to build mechanical 20
and adhesion strength. The Dow Corporate Test Method (CTM)
02431 is used to measure the amount of shear force required to 10
separate a single-lap-joint laminate under ambient conditions.
A 0.10-in glue-line thickness is used between a 1×1 in2 overlap of 0
mill-finished aluminum substrates, which are pulled apart along 15 min 1 hour 4 hours 1 day 3 days 7 days 21 days
its long axis at 2 in∙min–1 after predefined cure intervals at 24 Elapsed Time After Assembly
± 2°C and 50 ± 5% RH. The results for DOWSIL™ InstantGlaze DOWSIL™ InstantGlaze Sealant
Window Assembly products are shown in Figure 11.
DOWSIL™ InstantGlaze II Sealant
DOWSIL™ InstantGlaze III Adhesive
Adhesion-in-Peel Strength
The ability of a cured sealant to maintain an adhesive bond to a 1
CTM 0243 is based on ASTM C961 Standard Test Method for Lap Shear Strength of Sealants and ASTM
D1002 Standard Test Method for Apparent Shear Strength of Single-Lap-Joint Adhesively Bonded Metal
particular substrate while subjected to a 180° peel is evaluated Specimens by Tension Loading (Metal-to-Metal).
using a modified version of ASTM C794 Standard Test Method for
Adhesion-in-Peel of Elastomeric Joint Sealants. DOWSIL™ InstantGlaze

pg 17
Frequently Asked Questions
Q: What are the handling precautions for DOWSIL™ Q: How do I clean DOWSIL™ InstantGlaze materials
InstantGlaze Window Assembly products? off my equipment and tools?
A: Before handling, read product and safety data sheets A: Isopropyl alcohol can be applied to areas where the
and the container label for safe use. Exposure of opened sealant needs to be removed. This will soften the cured
containers to air is discouraged because these products material and allow it to be scrubbed away with an abrasive
will react with moisture in the atmosphere. The product is pad. The DOWSIL™ 3522 Cleaning Solvent Concentrated ,
dispensed under pressure at approximately 248°F (120°C), which is based on odorless mineral spirits, may also be used
and use of personal protective equipment to prevent to remove cured silicones.
contact with skin or eyes is recommended.
Q: What bead size is recommended?
Q: Is any local exhaust ventilation required?
A: Manufacturers designing and testing fenestration systems
A: DOWSIL™ InstantGlaze Window Assembly products have should determine bead size that will provide the required
a low volatile organic content of less than 15 g/L. The need sealant bite and glue-line thickness. Refer to the section
for local exhaust ventilation should be discussed with "Sealant Design Considerations" for more information.
your safety department personnel. An exhaust hood can
be integrated into the design of the bulk melter to remove Q: What can be done if the table skips or there is a gap in
vapors directly from the container. Refer to the product and the sealant bead?
safety data sheets for further information.
A: DOWSIL™ 1199 Silicone Glazing Sealant Clear can be used
Dow has an extensive Product Stewardship organization to patch gaps in the sealant. Other silicones in use
and a team of Product Safety and Regulatory Compliance in your facility may also be used (e.g., DOWSIL™ 9-1350
(PS&RC) specialists to support customers for product safety Silicone Glazing Sealant or DOWSIL™ 791 Silicone
needs. For further information, please see our website, Weatherproofing Sealant). Refer to the section "Bead
consumer.dow.com/construction, or consult your local Dow Consistency and Uniformity" for more information.
sales application engineer.
Q: Are DOWSIL™ InstantGlaze Window Assembly
Q: What purge material can be used to clean existing products compatible with clean glass?
material from dispensing equipment before using
A: DOWSIL™ InstantGlaze Window Assembly products are
DOWSIL™ InstantGlaze Window Assembly products?
approved for use with PPG Sunclean™ Glass according to
A: Dow recommends retrofitted hot-melt pumping equipment PPG. Non-pigmented DOWSIL™ InstantGlaze products
be disassembled, cleaned and rebuilt if it has been used do not contain silicone oils that can migrate to the glass,
with other types of hot-melt materials (e.g. acrylics, butyls, and exhibit ‘negligible sill effect’ and ‘negligible picture
urethanes). Dispensing hoses should be replaced. DOWSIL™ framing’ when used in back-bedding applications.
3522 Cleaning Solvent Concentrated, based on odorless
mineral spirits, may be used as a purge material and should Q: When should setting blocks be used?
be applied at room tem-perature. If you need to purge lines,
A: Dow recommends that setting blocks are always used
contact your local Dow representative.
based on Insulating Glass Manufacturers Alliance (IGMA)
and GANA guidelines. In addition to setting blocks, side
Q: How shall I conduct incoming product inspection?
placement shims may be required to hold the IG unit
A: Non-pigmented DOWSIL™ InstantGlaze Sealant and in place in the event that the window unit is tilted on
InstantGlaze II Sealant are clear, but DOWSIL™ InstantGlaze its side during production or shipment. Consult the IG
III Adhesive appears translucent in its bulk form. A typical manufacturer for additional support requirements.
bead of any non-pigmented silicone hot-melt product will
appear optically clear for desirable aesthetics.
The material, before pumping, should be pliable but not
stretchy. A stretchy response is an indication of a cured
surface due most likely to the product container seal being
compromised. Refer to the section "Determination of Cure
State" for more information.

pg 18
Sealant Profile Calculation Inputs
Largest Window Height:________________________________________________________________________________

Largest Window Width: ________________________________________________________________________________

Is the IG unit supported at the bottom by setting blocks?

Yes No

If the IG unit is not supported by setting blocks, maximum weight of IG:____________________________________

If the unit is wider than it is tall, is the IG unit free to move in both horizontal directions?
Yes No

Shop Temperature During Fabrication: __________________________________________________________________

Expected Maximum Wind Load: _________________________________________________________________________

Sash Material: Aluminum Wood Vinyl Fiberglass Other: _________________________________________________

Expected actual LOW temperature of sash, at sealant bond, during service: __________________________________

Expected actual HIGH temperature of sash, at sealant bond, during service:__________________________________

Expected actual LOW temperature of glass, at sealant bond, during service: _________________________________

DOWSIL™ Sealant choice OR movement capability of selected sealant: ______________________________________

Image: Cover – dow_ 40458040502; Page 15 – dow_40458404272

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The information contained herein is offered in good faith and is believed to be accurate. However, because DOW DISCLAIMS LIABILITY FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.
conditions and methods of use of our products are beyond our control, this information should not be used
in substitution for customer’s tests to ensure that our products are safe, effective and fully satisfactory for
®
™ The DOW Diamond, MOLYKOTE and DOWSIL are trademarks of The Dow Chemical Company
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Your exclusive remedy for breach of such warranty is limited to refund of purchase price or replacement of
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TO THE FULLEST EXTENT PERMITTED BY APPLICABLE LAW, DOW SPECIFICALLY DISCLAIMS 30023848 Form No. 63-1038-01 C