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Sika Technicians Handbook for Commercial Vehicles

2_Sika Automotive Aftermarket

Sika Technicians Handbook

Copyright © 2010 Sika Services AG. All Rights Reserved.

The material is intended for Sika professionals. Quotation, citation, attribution, reproduction, or utilization of any property of this publication by any party other than Sika Services AG is strictly prohibited without express written permission from the Vice President Automotive Aftermarket of Sika Services AG. No part of this publication may be reproduced stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the Vice President Automotive Aftermarket of Sika Services AG. Nothing in this publication shall be deemed a warranty, implied or expressed.

Sika refers to the Swiss firm of Sika AG and other members of the worldwide Sika organization.

Sika Services AG, Tüffenwies 16, 8048 Zürich, Switzerland

Tel +41 58 436 40 40Fax +41 58 436 45 30www.sika.com

Sika Automotive Aftermarket_3


Introduction

The Sika Technician’s Handbook for Commercial Vehicles represents the current best practice for working with Sika products to ensure a common, safe, efficient and effective system and standard for commercial vehicle glass replacement. The guide goes into the specialities within commercial vehicle glass replacement and will help the technician to get the best out of the Sika product system. It provides step-by-step instructions and more detailed information about specific subjects in the tab sections to facilitate a state-of-the-art replacement job. Technicians now have all the necessary information at hand at any time.

The Sika Technician’s Handbook for Commercial Vehicles describes the procedures for safe and durable glass installation in the transportation sector, in particular for buses, coaches and trains.

The scope of this manual is to provide instructions for the replacement of bonded windows. This means that glass which was originally fixed mechanically with gaskets must be re-installed using the same fixing technology.

Always refer to the most recent local Product Data Sheet for each Sika product.



About Sika

Sika is one of the world’s foremost manufacturers of specialty chemicals. Today, Sika Industry is one of the leading suppliers of process materials in the customer groups Automotive OEM, Automotive Aftermarket, Transportation and Appliances and Components. As a producer of specialty chemicals, Sika relies on a strong and independent R&D and operates on the principle that the company bears responsibility for safety and the environment at every stage of the production and marketing cycle. Sika is committed to a comprehensive quality and service culture. Sika Management System conforms to international standards ISO 9001, ISO 14001 and QS 9000.

Disclamer:The information contained herein and any other advice are given in good faith based on Sika's current knowledge and experience of the products when properly stored, handled and applied under normal conditions in accordance with Sika's recommendations. The information only applies to the application(s) and product(s) expressly referred to herein. In case of changes in the parameters of the application, such as changes in substrates etc., or in case of a different application, consult Sika's Technical Service prior to using Sika products. The information contained herein does not relieve the user of the products from testing them for the intended application and purpose. All orders are accepted subject to our current terms of sale and delivery. Users must always refer to the most recent issue of the local Product Data Sheet for the product concerned, copies of which will be supplied on request.



Contents

Introduction 3Contents 7Important 9

Step by Step Guide1 Inspect the Vehicle 132 Selection of the Adhesive and Backfilling Sealant 153 Safe Drive-Away Time 184 Always Start with the Glass 205 Protect Vulnerable Areas of the Vehicle 216 Trim and Accessories 237 Cut Out the Glass 258 Dry Fit the Window 279 Prepare the Glass 2910 Prepare the Aperture 3311 Adhesive Application, New Screen Installation and Backfilling 3512 Post Inspection of the Vehicle 39

Detailed SectionsComplete Removal Procedure 45Corrosion Treatment 47Freshly Painted Vehicles 49Special Windscreens 51Special Weather Procedures 55Setting Blocks and Spacers 57

Appendix SectionSika Products 61FAQ 69



The work that a glass technician does is critically important to the safety and welfare of the customer and the integrity of the vehicle. Use of the wrong products and poor workmanship can and have resulted in fatal accidents that have cost the glass industry significant financial losses. Every step described in the handbook is important and must be followed as is the training provided by Sika personnel. Always refer to the latest edition of the Product Data Sheets and Material Safety Data Sheets for all Sika products before use.It is important to note that some of the instructions in the Product Data Sheets are different from what is given in this manual, e.g. flash-off times/drying times. The reason is that the Product Data Sheets are made for the general user, whereas this handbook is only intended for professional technicians trained by Sika specialists.Technicians using this handbook are expected to work to the highest standards of their profession by delivering a safe and quality-proven installation 100% of the time. Anything less may be fatal!

Safety Instructions

Pre-treatment products and adhesives are chemical products. Please follow safety instructions:

Wear chemical-resistant gloves and safety glasses. Material Safety Data Sheets and instructions for use (Product Data Sheet) must be strictly adhered to.

Important



Step by Step Guide



Before working on any vehicle, take a moment to inspect for pre-existing damage. It is recommended to do the pre-inspection together with the customer and make notes as to any scratches or dents that exist.

This step can save thousands of dollars in claims for pre-existing damage and is a professional courtesy that the insurance industry respects.

1 Inspect the Vehicle



The selection of the best suitable adhesive for a window replacement in the transportation segment depends on a variety of factors, such as Joint geometry and layout: – Is there an outer seal? – Is a “one-shot” application (bonding & sealing) possible? – Does the window have an awkward shape that requires adjustments during

the adhesive application? Window dimension and weight. Required safe drive-away time.

Simplified Adhesive Selection GuideThe following table shows the appropriate adhesive for the applications shown.Manufacturers of trains and trams often specify an aftermarket adhesive for a given application. Sika recommends that the following manufacturer's specifications are used.

Bus or Truck Train or Tram

Standard Adhesive SikaTack® MOVE Transportation

Sikaflex®-265

Adhesive for faster SDAT SikaTack® Plus Booster SikaTack® Plus Booster

2 Selection of the Adhesive and Backfilling Sealant



The following table shows a brief comparison of the three glazing adhesive systems:

SikaTack® MOVE Transportation

SikaTack® Plus Booster

Sikaflex®-265

Description One-component polyurethane adhesive. Cures with air moisture.

Accelerated polyurethane adhesive.Cures independently from moisture.

One-component polyurethane adhesive.Cures with air moisture.

Application in Rail -- Recommended, aftermarket system of choice of most rail manufacturers.

Application in Truck and Bus

Recommended aftermarket solution for large windscreens in the truck and bus market.

--

Open Time 15 minutes 8 minutes 30 minutes

Application Tem-perature

Cold applied(+5 °C to +35 °C)

Hot Applied(+80 °C) with Booster

Cold applied(+5 °C to +35 °C)

Suitable for Backfilling

Yes (not recom-mended for rail)

No Yes (including rail market)

Safe Drive-Away Time

Short for small screens.

Short for small and large screens.

Long

Ideally suited for Small screens. Larger screens if short drive-away time is not required.

Small and large screens.

Can be used in combination with other products increasing initial strength.

Applications in the rail market.

The backfilling material requires high weather resistance.



For backfilling of open joints it is essential to use a product with enhanced resistance to weathering. For glass replacement in the rail market, only Sikaflex®-265 must be used. The following table provides a guide to backfilling:

Bus or Truck Train or Tram

Backfill Application SikaTack® MOVE Transportation Sikaflex®-222 UV Sikaflex®-265

Sikaflex®-265

Sikaflex®-265 is the solution of choice for backfilling in the rail market, as it is more resistant to the aggressive cleaning fluids that are used here. In all other cases, choice can be extended to Sikaflex®-222 UV or SikaTack® MOVE Transportation. Due to its lower viscosity, Sikaflex®-222 UV could be the optimal choice for applications at low temperatures.



3 Safe Drive-Away Time

To allow adequate time for the polyurethane adhesive to build-up strength and secure the windshield, the adhesive manufacturer’s installation procedures and prescribed Safe Drive-Away Times (SDAT) must always be strictly adhered to. Environmental factors also have an effect on curing times where the adhesives are moisture-curing. Vehicle owners must be informed that compliance with the SDAT allowance is a requirement. The vehicle must remain out of service and NOT be operated until the appropriate SDAT has been reached.

In the repair market for buses, coaches and trucks, there are no crash test standards that the SDAT can refer to. Instead, the calculated SDAT is based solely on the reactivity of the adhesives. The different tensions and loads on the bond line when the vehicles are in service can only be estimated. The following SDAT times (for supported window*) are based on green strength development and slip down (creep modulus during the curing process) strength of the adhesives.

* A “supported window” in this regard means that the weight of the window is permanently supported by

mechanical means (spacers or setting blocks). For more details see picture on the next page.

Safe Drive-Away Times +5 °C to +35 °C (for Supported Windows)

Glass Size SikaTack® MOVE Transportation

SikaTack® Plus Booster

Sikaflex®-265

Weight < 40 kgPerimeter < 6 m

2 hours 2 hours 9 hours

Weight 41–75 kgPerimeter 6 – 8 m


Weight 76 –100 kgPerimeter > 8 m




If the values for glass dimensions are not available, it is recommended that the following Safe Drive-Away Times are used: 2 hours for SikaTack® Plus Booster. 4 hours for SikaTack® MOVE Transportation. 12 hours for Sikaflex®-265 .

In the case of unsupported windows, it is recommended that SikaTack® Plus Booster is used and a minimum time of 2 hours is allowed before removing fixing aids and releasing the vehicle for service. If use of accelerated adhesives is not possible, it is recommended that the indicated Safe Drive-Away Times should be doubled.

Supported and Unsupported Windows

Cleaning operations (bus-wash plant, pressure washer) must not be carried out during the first 24 hours after window installation.

Adhesive

Spacer

Window

Frame/Flange

Window

Adhesive

Frame/Flange

Supportedwindow:

Spacer takesstatic load

from windowweight

Freely suspendedwindow



Never begin work on a vehicle prior to cleaning and inspecting the glass component that is to be installed. In this respect, the quality should be checked, as well as suitability of the selected glass for installation on the vehicle.

Is it the correct glass for the vehicle? Is the glass free of scratches or blemishes? Does it have the right colour?

UV Protection GuidelinesIt is mandatory to only use glass conforming to the original OEM specification especially with regards to type and placement of ceramic coating, insulating glass edge seal etc. to ensure proper UV protection of the bond line.Additional UV protection such as covering profiles or gaskets must be installed exactly as defined in the OEM specification.

4 Always Start with the Glass



It is recommended that every part of the vehicle (seats included) that could be damaged during the window cut-out procedure, or soiled during the window bonding procedure, is protected using masking foils, tapes, etc.

Never leave tools or equipment on painted surfaces, seats or dashboards to avoid damage or loss.

Cover parts to be protected. Use seat covers. Mask adjacent surfaces prior to any activating/priming/bonding operation.

5 Protect Vulnerable Areas of the Vehicle



Check the specific vehicle information for trims and accessories before starting to dismantle.

Gaskets must be reinstalled on the new glass immediately after glass preparation OR after the removal of trims. Always wear nitrile rubber gloves during installation to avoid leaving any fingerprints on the bonding area.

Check the specific vehicle information for trims and accessories.

Ensure availability of all necessary spares and accessories.

Carefully remove all fitted trim and accessories and store them in a safe area.

Try to re-use as many of the removed items as possible.

6 Trim and Accessories



Always wear safety glasses and cut-resistant gloves during window removal. Use tools appropriate to the type of window to be removed (cold or vibrating knives, wires, etc.)

There are two main methods for cutting out the glass.

Full Cut Removal Method Complete Removal Method

Use the full-cut removal method when: The old adhesive is a polyurethane.

For instructions on detection of other materials such as butyl and silicone please refer to: Identification of Butyl, Silicone and Polyurethane

The existing bead of cured adhesive is well bonded to the flange and is in good condition.

There are no signs of corrosion There was no damage during the

removal procedure.

In all other cases use the complete removal method. Please see the indicated tab section:

Complete Removal Method

If the surface is rusty, please refer to:

Corrosion Treatment

7 Cut Out the Glass



Full-Cut Removal Procedure: Wear personal protective equipment. Cut out glass. Clean the bonding area with SikaClean® Glass.

Trim the existing bead of adhesive down to a thin layer of 1 to 2 mm on the flange.

If the installation requires backfilling it is advisable to mask the edge of the flange adjacent to the backfill area with suitable masking tape during this phase.



It is recommended that the glass be dry-fitted in order to verify correct positioning and to make fitting marks, thereby allowing a fast and precise operation once the adhesive is applied to the glass.

Dry fit glass.Use a suitable masking tape to make marks to allow fast positioning ot the

glass.

8 Dry Fit the Window



For additional information regarding insulated glass units or cassette windows, please refer to:

Special Windows

Laminated safety glass normally consist of two thin glass panes bonded together by a layer of polyvinyl butyral (PVB), which has a tendency to absorb water by wicking. This manifests as a haze on the glass edge. It is therefore essential to minimise the risk of water infiltration by taking the following precautions:

Trim down any protruding part of the PVB to the edge of the glass. Apply a layer of Sika® Primer-206 G+P to the edge of the lamination.

This has the benefits of: Water-proofing the PVB layer. Improving the adhesive performance of the edges. Preserving the optical integrity of the glass.

For laminated safety glass, cut back the protruding layer of PVB foil.

9 Prepare the Glass



If contaminated, clean the bonding area with Sika® Cleaner S (II).

Apply small dots to the ceramic frit.Scrub the Sika® Cleaner S (II) using

a paper tissue into the contaminated area.

Apply adequate pressure with a clean, dry paper rag to wipe it off.

Clean the entire glass with Sika® CleanGlass.

Activate bonding surface with Sika® Aktivator PRO. Let it dry for a minimum of 3 minutes.



If laminated safety glass is to be fitted, apply a protecting layer of Sika® Primer-206 G+P onto the edge of the glass and let it dry for a minimum of 10 minutes.

If the installation requires backfilling, mask the edge of the glass adjacent to the backfilling zone with suitable masking tape during this phase.



For other cases use the full cut method, as follows:

Activate bonding surface with Sika® Aktivator PRO and let it dry for a minimum of 3 minutes.

For rusty surfaces, damaged pinchwelds and indications that the old adhesive is not polyurethane, continue with the complete removal procedure. For details refer to:

Complete Removal Procedure

If, during the removal of the old glass, the paint, base coatings or any other corrosion protection layers have been chipped off exposing areas of bare metal or glass-reinforced plastic:

10 Prepare the Aperture

Remove all traces and particles of detached coatings. Clean the area with Sika® CleanGlass. Activate the surrounding area (with an overlap of minimum 5 mm) using

Sika® Aktivator PRO and let it dry for a minimum of 3 minutes.



For further information please refer to:

Corrosion Treatment

Freshly Painted Vehicles

Using a brush, apply a thin continuous coat of Sika® Primer-206 G+P on the damaged area and let it dry for a minimum of 10 minutes.



11 Adhesive Application, New Screen Installation and Backfilling

Position suitable spacers on the lower edge of the frame to support the glass weight during adhesive curing.

Position suitable spacers on the part where the adhesive will be applied in order to guarantee the required thickness of the adhesive bead.

For details on setting blocks and spacers refer to:

Setting Blocks and Spacers

Using a triangular nozzle apply the adhesive.

On the glass:– If the open time of the

selected adhesive allows the adhesive application and the glass installation without any problem.

– If the edge of the flange is too difficult to reach to guarantee the correct positioning of the adhesive bead.

On the frame:– If the open time of the selected

adhesive does not allow a proper adhesive application and glass installation.



Adhesive

Frame/Flange

Window

Spatula

Never pull back the glass once it has been pressed down.

If backfilling press the adhesive into the joint with a suitable spatula.

Install the glass and press down to reach the required thickness as set by the spacers.



BackfillingThis operation can be performed after the adhesive has attained sufficient strength and the temporary fixing aids such as stetting blocks and adhesive tapes have been removed.

Using a standard nozzle with tip cut to the desired width, fill the joint taking care to avoid trapping any air.

With a suitable spatula remove the excess adhesive and smooth the surface of the joint.

Remove masking tape within the skin formation time of the product used.



After installation is complete inspect and clean all areas affected by your work. Glass, carpets, seats, dashes and all painted surfaces around the new glass unit must be cleaned and/or vacuumed. Defroster ducts must be blown out and free of any possible glass fragments.

12 Post Inspection of the Vehicle



Detailed Sections



Iden

tifica

tion

of B

utyl

, Si

licon

e an

d Po

lyur

etha

ne

When installing a windscreen, it is important to know that the bonding is directly to polyurethane. SikaTack® and Sikaflex® polyurethane direct glazing adhesives develop very strong adhesion to many different brands of polyurethanes and to some of the newer MS Polymer direct glazing adhesives as well. However, if the existing material on the pinchweld, is a butyl or silicone, it must be completely removed. SikaTack® or Sikaflex® polyurethane direct glazing adhesives do not adhere to butyls or silicones. If left on the surface, the silicone or butyls could even interfere with the adhesion of the ceramic coating or paint!

How can it be Determined if it is a Polyurethane Adhesive Bead? Press very firmly with the fingernail into the existing material. If it is a polyurethane or a direct glazing MS Polymer, it should not be possible

to make an indentation into the material. If it is a butyl or silicone, it should be possible to press half way into the

material or possibly all the way through to the pinchweld. If it is a butyl, there should be an indentation at the point of depression. The

butyl should retain a finger mark in it, where it does not regain its original shape.

If it is Still Unidentified… Cut out a long piece of the material and pull it apart. If it is polyurethane, a great amount of force will need to be applied in order to

pull the material apart and break it. If it is a silicone, it will stretch a great distance, without exerting too much

force. It will also be “snappy”, where it will stretch back and forth rather easily. If it is a butyl, it should pull apart very easily.

If it Remains Unidentified… Completely remove the old adhesive and follow the procedures as indicated in

the following section.

Identification of Butyl, Silicone and Polyurethane



Wear personal protective equipment. Cut out glass. Completely remove the existing bead of adhesive by mechanical means

(e.g. abrading). Clean the bonding area with Sika® CleanGlass. If the installation requires backfilling, it is advisable to mask the edge of the

flange adjacent to the backfilling zone with suitable masking tape during this phase.

Prepare the Aperture

Complete Removal Procedure

Activate bonding surface with Sika® Aktivator PRO. Let it dry for a minimum of 3 minutes.

Com

plet

e Re

mov

al

Proc

edur

e



Using a brush apply a thin contin-uous coat of Sika® Primer-206 G+P on the bonding area and let it dry for a minimum of 10 minutes.

Remove all traces and particles of detached coatings. Clean the area with Sika® CleanGlass. Activate the surrounding area (with an overlap of minimum 5 mm) using

Sika® Aktivator PRO. Let it dry for a minimum of 3 minutes.

For further information please refer to

Corrosion Treatment


If during the removal of the old glass, paints, base coatings or other corrosion protection layers have been chipped off leaving areas of bare metal or glass reinforced plastic:



If there are small areas of corrosion or oxidation on the flange after glass removal, those patches must be removed before proceeding with the new glass installation process.It is preferred to remove these areas by sanding or abrading while leaving as much as possible of the original paint or base coating on the flange intact and of good integrity. “Intact and of good integrity” is defined as being unable to scrape or chip off the coating and that there are no blisters or bubbles beneath the paint. The remaining surface should be smooth, uniform, and completely rust- and/or oxide-free. Paint coatings and other corrosion protection is designed to provide good long lasting protection against corrosion for the majority of the vehicle’s life. Therefore, it is ideal to have the paint, base coat or corrosion protection remain on the vehicle’s flange.

Corrosion Treatment

Mechanically remove rust or oxidised layers with suitable scouring pads. Clean the area with Sika® CleanGlass.

Activate the surrounding area with Sika® Aktivator PRO. Let it dry for a minimum of 3 minutes.


Corr

osio

n Tr

eatm

ent



If the technician discovers that there is heavy corrosion on the flange, the corrosion protection must be carried out in the body shop by professionals. If there is not enough time for this or the customer does not accept the charges for paint shop work Sika recommends a written disclaimer from the operating company for any future corrosion problems. Sika® Primer-206 G+P can reduce corrosion, but should not be used as a corrosion protective system.

For further information please refer to:


Using a brush apply an initial thin continuous coat of Sika® Primer-206 G+P and let it dry for 3 minutes.

Apply a second thin continuous coat of Sika® Primer-206 G+P and let it dry for a minimum of 10 minutes.



If the bond is to be made to a freshly painted vehicle and it is uncertain which paint or paint drying system was used or the correct paint drying times are unknown, allow the paint to dry for 24 hours first before treating the aperture. If the figures are known, use to the paint shop regulations & proceed as follows:


Activate the bonding area with Sika® Aktivator PRO and let it dry for

a minimum of 3 minutes.


Clean the flange with Sika® CleanGlass. Abrade the bonding area with a suitable scouring pad or very fine grade

sandpaper (grade 120).

Using a brush, apply a thin continuous coat of Sika® Primer-206 G+P and let it dry for a minimum of 10 minutes.

Fres

hly

Pain

ted

Vehi

cles



Plastic windscreens can be found on:Building machines.Special-purpose vehicles (BGS, Police).Light-weight construction vehicles.

Typical materials are PMMA (Polymethylmethacrylate) and PC (Polycarbonate). In the manufacturing process, many polycarbonate sheets are coated with a scratch resistant surface. Unlike standard float glass, plastic windscreens have a much higher coefficient of thermal expansion, resulting in greater movement (expanding and contracting of the window.)

In addition, plastic windscreens are missing the ceramic coating on glass windscreens that provide UV-protection to the adhesive bond-line. For these reasons, the following procedures must be followed when bonding plastic windscreens:

Permanent Glazing: Pre-Treatment PC or PMMA Windscreen If there is an unknown coating, it is recommended that the surface be tested before bonding (contact Sika), otherwise use the following procedure:

Sika® Primer-206 G+P must be used for bonding plastic windscreens. Black-primerless bonding is not possible.

Special WindscreensBonding Plastic Windscreens (PMMA and PC)

Step 1 Abrade bonding area with 120 grit sandpaper .

Remove scratch resistant coating.

Step 2 Remove dust (Note: only oil free compressed air or wipe with a clean paper towel).

Clean surface from dust.

Step 3 Wipe on with Sika® Aktivator PRO.Flash-off for 3 minutes.

Clean and activate the surface.

Step 4 Apply Sika® Primer-206 G+P. Flash-off time 10 minutes.

Create a suitable surface for bonding. Note: Primerless bonding is not possible.

Step 5 Application of Sikaflex®-222 UV. Layer thickness according to Table below.

Bonding.

Spec

ial W

inds

cree

ns



Adhesive Thickness

Largest Windscreen length

Triangular Bead Required Adhesive Bead Dimension*

L [m] H [mm] B [mm] D [mm] B [mm]

0.5 8 6 3 8

1.0 8 8 4 8

1.5 12 10 6 10

2.0 16 12 8 12

Over 2.0 Meter contact Sika

*Important: Adhere to minimal adhesive thickness, D.

UV-ProtectionTo ensure a durable bond, transparent windscreens must have protection against UV on the surface. Possible solutions are:Suitable print color.Protective metal or opaque plastic trim.Sika UV Shielding Tape.

Without this protection, Sika® Primer-206 G+P will eventually detach from the plastic windscreen. The exact period until failure depends strongly on the weather, the synthetic material quality and the general load.

LDH

BB



Surrounding Conditions and Safe Drive-Away Time Sika recommends that the bonding of the plastic windscreens be carried out at a temperature of +10 °C to +35 °C. Furthermore it is important to adhere to the recommended flash-off time (see pre-treatment). The vehicle must not be moved for 16 hours after the replacement.

Remarks Sika recommends Sikaflex®-222 UV for the durable long term bonding of plastic windscreens. This adhesive is low modulus (soft) and can handle the thermal extension of the windscreen without a mechanical over-load resulting.PMMA is particularly sensitive to stress cracks. For this reason, windscreens should remain flat and not bent during the bonding process. If there are larger than specified dimensions of PC or PMMA to be bonded, please contact Sika before commencing work.

Temporary Glazing of PC or PMMA WindscreensThis procedure is used when a short-term application is required for plastic windscreens. Temporary glazing is carried out if the original glass windscreen is not available at the time of the repair. At the most, this temporary glazing is only to be used for two weeks until the correct glass windscreen can be installed.

Temporary Glazing: Pre-Treatment PC or PMMA Windscreens Clean the entire part with Sika® CleanGlass. Activate the bonding surface with Sika® Aktivator PRO. Let it dry for a minimum

of 3 minutes. Apply a layer of Sika® Primer-206 G+P onto the bonding area. Let it dry for a

minimum of 10 minutes. Bond the part using the adhesive selected in point No. 2 of the installation

manual and refer to the indicated drive-away times.

Sika® Primer-206 G+P must be used for bonding plastic windscreens. Black-primerless bonding is not possible.



Insulating Glass Unit and Cassette WindowsIn the transportation market, special types of windows (e.g. insulating glass units, cassette windows,) are used.

For technical reasons, it is essential to use only insulating glass units designed and manufactured specifically for the intended application and that conform to the original OEM specification. This means that the type of glass, the edge sealing system, the spacer, the seal height etc., must exactly correspond to the original double glass unit.

Due to the large variety in prefabricated windows, having different sliding, collapsing and other functionalities (“cassette windows”), the manufacturer’s instructions must be consulted to identify replacements. Only spare parts conforming to the original OEM specification should be used.



Special Weather Procedures

General Precautions Store all chemical products in an area above +5 °C for an adequate period

before use! Bear in mind that push-in trim will be more difficult to fit at low temperatures

because the adhesive is stiffer. Use extra care when removing and replacing scuttles and trim pieces as they

become more brittle below freezing point. As bonding cannot take place in air temperatures below -10 °C, the vehicle

should be stored somewhere with a higher air temperature or the job postponed.

Cold TemperatureAdditional measures must be taken when bonding glass at temperatures between +10 °C and +5 °C so that the glass can be bonded safely by all methods.

Sika® CleanGlass If air temperature is below -5 °C the glass cleaner will freeze when it comes in

contact with the glass and will malfunction. In such a case move the glass to a warmer environment.

Sika® Cleaner S (II) If air temperature is below -5 °C the Sika® Cleaner S (II) will freeze when it

comes in contact with the glass and it will malfunction. In such a case move the glass to a warmer environment.

Sika®®Aktivator PRO Condensation on the glass is not an issue with Sika® Aktivator PRO. Below -10 °C at least 10 minutes flash-off time must be allowed for instead of

the standard 3 minutes.

Sika® Primer-206 G+P Below -10 °C at least 20 minutes flash-off time must be allowed if it is used

for bonding purposes! Tip: Warming up the primer until it is “touch” dry will save considerable time!

Adhesives It is recommended that the adhesives are pre-conditioned to minimum

+5 °C prior to application. With products approaching their expiry date, the higher viscosity combined with the low temperature can create a risk of unsatisfactory setting properties resulting in bad adhesion.

Spec

ial W

eath

er P

roce

dure

s



Hot Temperature To avoid bubble formation in the adhesive bead, it is recommended that when replacing the glass at air temperatures greater than +35 °C, the glass components and vehicle’s aperture are not exposed to direct sunlight during the process.

Another important fact is that, at higher temperatures chemical reactions work faster, and the open times can be reduced down to less than 5 minutes. It is therefore essential that the windscreen be installed within this period in order to ensure a good bond between the polyurethane adhesive and the aperture/glass. This is necessary to prevent leaks and for customer safety.



Setting blocks and spacers have the following functions: Setting minimal bond line and sealant thickness.Vertical load support: vertical load of window weight is taken by spacers.Elimination of slip down (creep) of windows during the curing process.

Setting Blocks and Spacers

Please noteThe Shore A hardness of spacers must be similar to the hardness of the

adhesives. Hardness differences between spacers and adhesives can create stresses which can cause the glass to break.

Where possible spacers should be positioned outside the bond line in order to eliminate bond line interruptions. Apart from the obvious undesirability of water ingress within the vehicle, any breaches of the bond line can also cause corrosion, leakage, turn laminated security glass milky white, etc.

Never use cyanoacrylate glues to fix spacers or setting blocks: vapours released could impair a proper adhesion of the polyurethane adhesive in the surrounding area. To prefix spacers or setting blocks use Sikaflex® or SikaTack® adhesives.

Correct Wrong

Interruption of beadInterruption

of bead

Adhesive

Window

Frame/Flange

Spacer

Spacer

Frame/FlangeFrame/Flange

Adhesive

Adhesive

Spacer

Spacer

No interruption of the bead Window

Setti

ng B

lock

s an

d Sp

acer

s



Appendix Section



Sika® CleanGlassSika® CleanGlass has been designed for the cleaning of glass surfaces. It can also be used for cleaning other hard, non-porous materials. Surfaces must be allowed to dry completely before the next step in surface preparation (e.g. application of Sika® Aktivator PRO).

Application Moisten a dry, clean paper tissue with the product

and wipe the entire surface until it is dry.Or spray the product onto the surface and wipe

until it is dry using a clean paper tissue.Dispose the paper tissue properly after each use.

If air temperature is below -5 °C, Sika® CleanGlass will freeze when it comes in contact with the glass and it will malfunction. In such temperatures, allow the glass to normalise in a warmer environment.

Sika Products



Sika® Cleaner S (II) Sika® Cleaner S (II) is a cleaning paste for heavily soiled bonding substrates, especially for windscreens and glass. Sika® Cleaner S (II) can either be generally used or applied specifically to the soiled areas only.

Application Apply small dots of Sika® Cleaner S (II) around the

perimeter of the bonding area. Use a clean, dry paper tissue and moderate

pressure to scrub Sika® Cleaner S (II) into the contaminated area.

Use a fresh clean, dry paper tissue to remove any excess Sika® Cleaner S (II).

Spray Sika® CleanGlass onto the part and wipe it dry and clean.

After using Sika® Cleaner S (II) the part must be cleaned with Sika® CleanGlass to remove any remaining contaminants.Do NOT use Sika® Cleaner S (II) on porous substrates.



Application Moisten a dry, clean and lint-free paper tissue or

cloth with Sika® Aktivator PRO. Apply the Sika® Aktivator PRO by dragging the

cloth in one direction around the perimeter of the bonding area.

When the cloth requires re-wetting, always expose a clean portion of the cloth to the Sika® Aktivator PRO can.

Dispose of the cloth properly after each use. Always close the Sika® Aktivator PRO can

immediately after use. The flash-off time for Sika® Aktivator PRO is 3

minutes at temperature between -10 °C and +45 °C.

Sika® Aktivator PRO must NEVER be applied with a brush or dauber. Do not use Sika® Aktivator PRO on porous substrates like foam, tapes, etc.

Used correctly, Sika® Aktivator PRO will remove small quantities of dust, oil and other contaminants, which could cause a bond to fail. Unlike some glass cleaners and primers, Sika® Aktivator PRO will not harm the topcoat of car finishes.

Sika® Aktivator PROSika® Aktivator PRO is used to give improved adhesion on glass, ceramic coated glass, the cut face of old polyurethane adhesive beads, polyurethane coated window glass and paints. Sika® Aktivator PRO is an important process step in the SikaTack® System, because it has been designed to ensure a strong, durable bond between the polyurethane direct glazing adhesive and the windscreen.



Sika® Primer-206 G+PSika® Primer-206 G+P is a one-component, black, moisture-curing liquid primer specifically formulated for the treatment of bond faces in direct glazing work. It is used to give improved adhesion to glass, ceramic coated glass, paints and other substrates such as plastics and metals and can be used to inhibit corrosion where scratches on bare metal of the window frames become visible during the installation process. Sika® Primer-206 G+P can also be applied on poor quality ceramic coatings (non-uniform glass and continuous opaque, mineral-based ceramic frit) to provide supplemental UV protection or if the ceramic frit is not applied correctly, (no frit on the glass edges) provide a uniform aspect to the glass.

Application Before opening, shake the can vigorously until the

ball-bearing rattles and then continue for a further 10 seconds.

Apply Sika® Primer-206 G+P, using a clean brush, into the scratches wherever bare metal or glass-reinforced plastic is visible on the window frames.

Apply Sika® Primer-206 G+P on the glass or window frames, when used as the bonding surface, with a dauber in a thin even coat.

Close both the inner liner and outer cap of the can immediately after each use.

Sika® Primer-206 G+P requires a flash-off time of 15 minutes at temperatures above +5 °C.

Sika® Primer-206 G+P must NOT be used on the old polyurethane bead as it reduces the bonding strength as compared to un-primed interfacial adhesion. Do not dilute primers with solvents.



SikaTack® MOVE TransportationSikaTack® MOVE Transportation is a moisture-curing one-component polyurethane (PUR) adhesive with a high initial strength. The temperature range for SikaTack® MOVE Transportation is between +5 °C and +35 °C.

Overview of features and benefits of the SikaTack® MOVE Transportation system:

SikaTack® MOVE TransportationOne Component Adhesive ✓

High Initial Strength ✓

Excellent non-sagging properties ✓

Very short cut-off string ✓

Black-primerless bonding ✓

No heating required ✓

Unipacks 600 ml

Shelf Life 12 months

Good weathering and chemical resistance ✓

Suitable for gap filling (open joints) ✓

Good working and tooling properties ✓

Good adhesion on a large variety of bonding and sealing substrates which are used in the bus and truck business.

✓



Sikaflex®-265 Sikaflex®-265 is a moisture-curing one-component polyurethane adhesive with high initial strength. It can be used for bonding and back filling. It is used in the OEM production of trains.

Overview of features and benefits of the Sikaflex®-265 adhesive system:

Sikaflex®-265

One Component Adhesive ✓

High Initial Strength ✓

Good non-sagging properties ✓

Short cut-off string ✓


Suitable for backfilling ✓

Application Temperature +5 °C to +35 °C

Unipacks 400 ml / 600 ml

Good weathering and chemical resistance ✓

Good working and tooling properties ✓

Good adhesion on a large variety of bonding and sealing substrates used in the rail business.

✓



SikaTack® Plus BoosterSikaTack® Plus Booster is an accelerated one-component polyurethane adhesive with high initial strength. It can be used for bonding applications and is used in the OEM production of trains and trams.

Overview of features and benefits of the SikaTack® Plus Booster adhesive system:

SikaTack® Plus Booster ooster

Accelerated one-component polyurethane adhesive ✓

High Initial strength ✓

Good non-sagging properties ✓

Short cut-off string ✓


Suitable for backfilling Not suitable

Application temperature 80°C

Unipacks 600 ml

Good adhesion to a large variety of bonding substrates used in the transportation industry

✓

When using unipacs for SikaTack® Plus Booster on Booster applications, the hot adhesive softens the plastic adapter between the two units. Sika supplies parts to strengthen the softened adapter. Please contact the local Sika organization for more information.



Use of Booster-Accelerated Adhesives

The adhesive must be heated up to the recommended temperature (consult the relevant PDS) for a minimum of 1 hour in a dedicated oven.

Screw on the nozzle and cut in the necessary dimension on the booster pack.

When the adhesive is warm, open the unipack, mount the adapter and screw on the booster pack.

Apply a small amount of adhesive to a piece of carton.

Apply the adhesive.

The warm accelerated adhesive has a limited open time, care must be taken that everything is ready and at hand in order to avoid unnecessary loss of time. A booster pack contains the required amount of booster paste to accelerate 600 ml of adhesive. However the product will partially cure in the static mixer placed on top of the booster pack. Hence it is not possible to use the same booster pack for more than one job. After application, the booster pack (even if only partially empty) must be discarded.

Consult the relevant Product Data Sheet for further information.



FAQ

A Can SikaTack® polyurethane adhesives be applied to wet surfaces? No. Polyurethane can not be applied onto wet surfaces because a reaction with

water can cause the polyurethane to lift from the surface. All surfaces must be dry.

B Can Sika® Aktivator PRO be used in damp conditions? Yes, Sika® Aktivator PRO can be used in damp conditions, e.g. on windscreens

with condensation. (In this application, ‘damp’ refers to any humid condition where water droplets are NOT present, either as condensation or as spots of rain).

C How long will primers and cleaners last after they have been opened? All Sika cleaners and primers have a reduced shelf life when opened. With

proper storage conditions, they will remain usable up to 1 month after opening, or until the expiration date, whichever comes first. Always tightly reseal both the inner liner and outer cap after each use. If the product becomes thick or cloudy, or inhomogeneous, immediately discard according to the information provided in the Material Safety Data Sheet.

D If the open time of Sika®Aktivator PRO has passed, is it ok to perform the activation step again?

Yes. It is OK to apply Sika® Aktivator PRO up to three times onto the bonding surface. It is important that the surface is clean and activated. You can tell if the surface has been activated when it has a shimmery aspect to it. If you are uncertain it is better to re-apply Sika® Aktivator PRO.

If Sika® Aktivator PRO is applied a second time without following through with the bonding, the activated surfaces must be cleaned with a solvent such as Isopropanol. After that, pre-treatment of the surfaces can start again.



E Why is the use of daubers with Sika® Aktivator PRO not recommended?1. Sika® Aktivator PRO performs a cleaning function, as well as an activating

function. Application with a dauber simply moves dirt around and does not clean it off.

2. Daubers apply too much product, which is unnecessary and wasteful.3. They can become dirty and contaminate the activator if they are dipped in the

bottle several times.4. It is difficult to cover the required area using daubers.

F Why is the use of daubers recommended for Sika® Primer-206 G+P, when applied to clear glass, but only brushes recommended for scratches on the flange?

Many prefer using the daubers for Sika® Primer-206 G+P when it is applied as the bonding surface, because of the smooth uniform application. It is recommended that a brush is used when covering scratches, because it is important that the product is applied INTO the scratch. Some installers find that the use of ear sticks or Q-tips is also effective to apply Sika® Primer-206 G+P to the scratches in the flange.

G Why does Sika® Primer-206 G+P need to be shaken? Shaking primers mixes the solids that may have settled at the bottom of the

bottle and ensures a thin, uniform mixture and coverage. All manufacturers’ primers containing solids should be shaken before use.

H Why is it not recommended to apply Sika® Primer-206 G+P onto the old PUR bead?

Cured Sika® Primer-206 G+P forms a rigid layer, which if incorporated between two soft layers (the old PUR bead and the new PUR) reduces the strength of the bond. If performing scratch treatment, it is acceptable if a small area of the old PUR bead comes into contact with Sika® Primer-206 G+P, but it must never be applied to large areas of old PUR bead.



I What happens if the recommended flash-off time of the pre-treatment products is not adhered to?

In addition to bonding products, pre-treatment products also require time to react. For example, a primer is like a diluted adhesive that also requires moisture for curing to occur. If the pre-treatment product is not allowed to fully react, it can reduce the bond strength of the system and in the worst case, the bond may fail. Lower temperatures increase the flash off time of Sika® Primer-206 G+P.

J Cutting out a windscreen has revealed that the old PUR bead contained a bubble between the adhesive and the windscreen. how can this be prevented?

This is known as ‘Tunneling’ which, in most cases, is caused by errors by the technician. When the adhesive is applied, ensure that the nozzle is at a right angle to and is in contact with the substrate. Always apply a triangular bead so that when compressed no air is trapped.

K Having cut out a windscreen, the old PUR bead contained lots of small bubbles in the adhesive bead. how can this be prevented?

The adhesive releases carbon dioxide while curing. If the adhesive bead is heated during curing, the gas is released more quickly which can result in small bubbles dispersed throughout the bead. This can happen if the car is parked with the windscreen exposed to sunlight on a warm day. Parking the car in the shade will prevent this problem.

L Are there any aggressive components in Sika® Aktivator PRO or Sika® Primer-206 G+P that could attack surfaces?

Sika® Aktivator PRO and Sika® Primer-206 G+P contain reactive components which react chemically with glass, paint and other materials. Once cured, they can only be removed mechanically and the upper layer of the substrate is damaged in the process. Care must be taken to apply Sika® Aktivator PRO only to the required areas. If the product is applied to the transparent area of the glass, it will be visible and the customer will have cause for complaint.



M What happens if too thick a layer of Sika® Primer-206 G+P is applied? Applying a thick layer of Sika® Primer-206 G+P results in a longer flash off

time. But if applied as corrosion protection on bare metal it is recommended that two thick layers of Sika® Primer-206 G+P be applied for long lasting protection.

N Is there a product for cleaning Sika® Primer-206 G+P from Interior parts? Sika® Primer-206 G+P can be cleaned using Sika® Remover-208 or

Sika® HandClean Tissues as long as it has not cured completely. Once cured, it must be removed mechanically.

O What is the minimum temperature to perform a replacement job? Sika’s products are intended for use at temperatures between +5 °C and

+35 °C. For all other conditions Sika has special hot and cold weather recommendations. While a job can be carried out at -10 °C, there is a question of adequate dexterity with cold hands. It may be too cold to carry out the job to a suitable professional standard. In which case, the job should be deferred.



Notes

www.sika.com

Our most current General Sales Conditions shall apply. Please consult themost current local Product Data Sheet prior to any use.

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SikaWorldwide

Sika is a globally active company supplying the specialty chemicals markets. It is a leader in processing materials used in sealing, bonding, damping, reinforcing and protecting load-bearing structures in construction (buildings and infrastructure construction) and in industry (vehicle, building component and equipment production).

Sika’s product lines feature high-quality concrete admixtures, specialty mortars, sealants and adhesives, damping and reinforcing materials, structural strengthening systems, industrial flooring and membranes. Subsidiaries in more than 70 countries worldwide and approximately 12,900 employees link customers directly to Sika.

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