Duralite

and Duraseal

Application Manual
Insulating Glass Systems
1

Table of Contents

DURASEAL

AND DURALITE

: HISTORY AND DESCRIPTION ............................................................................................. 2

BASIC USE .................................................................................................................................................................................... 2

FEATURES .................................................................................................................................................................................... 2

HOW EACH ELEMENT IN DURASEAL

AND DURALITE

FUNCTION .................................................................................. 3

PERFORMANCE .......................................................................................................................................................................... 3

GLASS CUTTING ......................................................................................................................................................................... 4

DURASEAL

AND DURALITE

STOCK AND IN-USE ................................................................................................................. 4

GLASS WASHING ........................................................................................................................................................................ 4

DURASEAL

AND DURALITE

APPLICATION AREA ................................................................................................................ 5

APPLICATION EQUIPMENT .................................................................................................................................................... 5

DURASEAL

AND DURALITE

APPLICATION ........................................................................................................................... 6

ALIGNING OF SECOND LITE ................................................................................................................................................ 15

MUNTINS ..................................................................................................................................................................................... 15

COMPRESSION EQUIPMENT ................................................................................................................................................ 15

GAS FILLING ............................................................................................................................................................................. 16

FINAL CORNER SEALS ........................................................................................................................................................... 16

DUAL-SEAL DURASEAL

AND DURALITE

UNITS ................................................................................................................. 18

RACKING & SHIPPING ............................................................................................................................................................ 19

GLAZING ..................................................................................................................................................................................... 19

RECEIVING, QC, HANDLING, STORAGE & QC TESTING OF DURASEAL

AND DURALITE

.................................... 20

QUALITY CONTROL TESTS ................................................................................................................................................... 21

DURASEAL

AND DURALITE

LINE LAYOUT GUIDE ........................................................................................................... 27

GENERAL CONSIDERATIONS WHEN DESIGNING YOUR DURASEAL

AND DURALITE

I.G. LINE .......................... 28

2

Duraseal

and Duralite

: History and Description

Quanex Building Products continues as a world leader in flexible spacer systems for insulating glass and
has introduced the most advanced warm-edge spacers in the companys history, Duraseal and Duralite.
The Duraseal and Duralite patent pending design incorporates unique materials and a breakthrough in
continuous composite manufacturing processes. Duraseal and Duralite take optimum advantage of
laminates and adhesives to reduce thermal conductivity, while improving surface and corner appearance
over other flexible spacers. This multi-layered spacer system, featuring specialized components, results in
superior window performance and aesthetics over other warm-edge spacers.

The inherent flexibility of Duraseal and Duralite allow window manufacturers to produce both standard
and specialty windows with a single spacer system, providing a simple solution for all applications and
reducing the need to segregate high volume rectangles from often profitable shapes and specials. A single
spacer system is important since the future of the I.G. market will continue to place value on the advantages
of flexible spacers that adapt to any window design.

Duraseal and Duralite have higher volume spool packaging to allow manufacturers to produce more units
with less downtime and waste. This results in fewer changeovers, which translates into higher production
efficiency. Also, additional spacer footage per spool increases the packaging density, yielding more
products per truckload and lowering freight costs.


Basic Use

By containing its own spacer and desiccant, Duraseal and Duralite enable the insulating glass manufacturer
to use one product to do the job of several components, i.e., sealant, spacer bar, corner keys, and desiccant
in producing an I.G. unit.


Features

Single component system provides everything required but the glass.
Improved productivity, efficiency, and cost effectiveness for I.G. manufacturers.
Flexible spacer, capable of conforming to any shape providing a continuous moisture vapor barrier.
Reduced edge stress flexible seal with excellent adhesion accommodates thermal movement.
Thermally broken edge seal offers improved thermal properties reducing total window U-value.
Continuous moisture vapor barrier lowers moisture vapor transmission rates.
Superior argon gas retention.
Available in black or gray.







3

How Each Element in Duraseal and Duralite Functions

The sealant is resistant to permeation by moisture vapor. This resistance is measured as moisture vapor
transmission rate (MVTR). In Duraseal and Duralite, the rate is one of the lowest achieved by any class of
I.G. sealant material. The excellent adhesion of sealant to the glass is gained by a combination of both
physical (pressure sensitive) adhesion and chemical bonding. The bond strength has a high initial value, but
increases further to reach its maximum value over a short period of time.

The spacers work in two ways:
Controlling the separation of the glass lites by maintaining the desired airspace thickness.
Acting as a total barrier to permeation of moisture vapor through this area. The corrugated nature of
the spacer provides strength and stability to the glass, as well as controls the airspace dimension of
the I.G. unit. When the corner joint is sealed, the desiccant in the sealant begins to absorb moisture
vapor from the enclosed airspace.

The desiccant keeps the I.G. units clear by trapping moisture that gets into the airspace between the glass.
Because of its long moisture vapor path (MVP), Duraseal and Duralite reduce water penetration and protect
the desiccant longer than other insulating glass edge seal systems.


Performance

Because the desiccant is encapsulated within the topcoat, the dew point develops in a controlled rate, which
is slower than if the desiccant were fully exposed to moisture vapor. The dew point ultimately falls below -
65C (-85F). How quickly the dew point falls toward this level depends on a number of factors, including:

The activity of the desiccant within the Duraseal and Duralite.
The moisture content of the air at the time when the I.G. Unit is manufactured.
The temperature at which the unit is stored.
The dimensions of the unit.

The benefits of the ultra low MVTR of Duraseal and Duralite coupled with a controlled rate of dew point
development allows these spacers to be handled during production without special protection.

The key is the spacers ability to minimize the rate that new moisture enters the airspace allowing this
phenomenon to continue uninterrupted for a longer period of time. This can be attributed to both the
MVTR and the length of the moisture vapor path (MVP) created in units fabricated with Duraseal and
Duralite.





4

Glass Cutting

It is recommended that the glass cutter be used with a water soluble or full flash lubricant to prevent
residual oil contamination after glass washing, which may inhibit sealant adhesion to the glass.
Additionally, any oil contamination of the glass may cause a discoloration or halo effect on Low E
coatings. Reference Quanex Technical Bulletin G005 for a list of approved cutting fluids.

It is important that the glass edge quality is monitored. Poor glass edge quality or damage is indicated by a
rough or uneven cut, chipped edges, fish eyes, or other similar characteristics. Glass edge damage leads to
a significantly higher glass breakage rate in I.G. unit handling, in the glazing operation, as well as in
service. The cause of any noted glass edge damage should be determined and efforts made to eliminate the
damage immediately. For more information pertaining to glass edge quality, refer to SIGMA Technical
Report TR-3401-96, Preventing Glass Breakage During I.G. Design, Manufacture, Transport,
Installation, and Use.


Duraseal and Duralite Stock and In-Use

Proper stock rotation is recommended to ensure consistent freshness of Duraseal and Duralite. The shelf
life of these spacers is one year from the date of manufacture while in an unopened package. Duraseal and
Duralite should be stored at application temperature (70 - 80 F for automated or hand tool application, 65
- 85 F for manual application). It is recommended that all packages of Duraseal and Duralite be stored in a
covered area in order to prevent exposure of the packaging to wet environmental conditions, which may
reduce the shelf life by increasing the potential for moisture entry into the packaging. Boxes, as well as half
drums, should be stored on pallets or otherwise kept off the floor or slab to reduce heat transfer between the
boxes and the floor.

Reseal opened Duraseal and Duralite spools at the end of the working day to protect the desiccant from
ambient moisture. At the end of the workday, partially used spools should be returned to either their
original packaging, or placed in half drums, preferably storing reels horizontally (available from Quanex
Customer Service). Resealing the bags protects the product's desiccant from moisture entry. Improper
sealing will reduce the Duraseal and Duralite ability to dry the hermetically sealed airspace of an I.G. unit
and excessive moisture entry will affect dew point development and possibly reduce I.G.unit life
expectancy.


Glass Washing

Ensure that the Glass Washing equipment is functioning per the manufacturers specifications. The wash
water temperature should be maintained at 120 - 140 F (50 - 60 C) to optimize the glass washers
performance. Many Low-E glass manufacturers recommend temperatures from 130 - 140 F to properly
clean the glass. Your glass supplier should provide the correct temperature range based on the type of glass
used. Approved glass detergents should be used in moderation to minimize residue left on the glass.
Glass suppliers generally recommend detergents for use with their products; a list of Quanex approved
detergents is provided in Technical Bulletin G006.
5

Wash water, re-circulating rinse water, and clear final rinse water should flow freely through all spray
nozzles in the glass washer, and with enough volume to flood the glass surface. Water flow through the
spray nozzles should be checked daily to ensure proper operation of the washer. In addition, no detergent
froth should be visible in the re-circulating rinse water tank. If froth does appear, change the rinse water
immediately to avoid detergent contamination of the glass. For more information regarding the effect of
water quality on sealant adhesion to glass, please refer to Quanex Tech Bulletin No. G002.

For areas where the water quality is hard (high level of dissolved solids -- >200 ppm), it is
recommended that de-ionized or de-mineralized water be used at least for the final rinse system. The
dissolved solids in the water may cause a film to form on the glass surface, which can interfere with the
sealant bond to the glass surface.

As always, make sure the glass exits the washer clean and dry. NO water should be seen on the glass
after exiting the washer. Water will add moisture loading on the desiccant system and hinder the adhesion
of the I.G. sealant to glass. NO detergent film should be on the glass surface after the exiting the washer.
A detergent film will compromise the adhesion of Duraseal and Duralite to glass. To test for detergent
contamination of the glass, conduct a Slosh Test, as outlined in the QC Section of this manual.


Duraseal and Duralite Application Areas

The application area should be isolated from the rest of the production operation, in order to maintain a
clean environment. A positive pressure environment is suggested for the application area in order to
maintain a clean environment. The floor in this area should be sealed or painted and the environment
should be temperature controlled. For hand tool application, the temperature should be maintained
between 70 - 80 F (21-27 C), or for manual application, the temperature should be between 65 - 85 F
(18-29 C).


Application Equipment

The spool support stand must dispense the spacers easily, creating no marks or damage to the bonding
surfaces. The I.G. line layout should ensure that a good flow of materials can be achieved for all glass sizes
used. Air float tables should be maintained in accordance with the manufacturers instructions. All filters,
compressed air bowls and safety devices should be inspected daily. Compressed air used in the clean room
must be kept clean and dry an in-line air drier or desiccated trap is recommended. The application area
and equipment should be kept clean at all times to avoid contamination of the Duraseal and Duralite
bonding surfaces.






6

Duraseal and Duralite Reel Conversion

Horizontal reel stands will generally be used for spacer application.

Manual Duraseal and Duralite Reel Conversion check list. OLD BILLCO STAND

BILLCO

Newer style Billco reel stand will work without
modification.
Modify old Billco reel stand model with the addition
of 2 collar.

BESTEN

Purchase newly configured Besten reel stand model
universal to Quanex flexible spacers.
Conversion kit for old Besten reel stand.


Duraseal and Duralite Application

Spacer application may be completed effectively either manually, with a Flexible Spacer PRO tool or via
T.A.P.E. Manual application may be more appropriate for very small units, while PRO tool and T.A.P.E
application will provide a faster, more consistent, and higher quality application for standard size units. A
Specials tool is available for shape units.


Manual Duraseal and Duralite Application

Duraseal and Duralite should be handled on the
inside/outside surfaces, taking care not to contaminate
or mar the bond surface (the edges of the Duraseal and
Duralite that will bond to the glass surface). Bondline
contamination or deformation may result in areas of seal
weakness due to incomplete wet-out of the glass by the
sealant during compression.

When beginning the application, ensure that the Spacer
tail is cut squarely, as shown to the right in Figure 1.

Figure 1

7

For air filled units, start the tape application about
1/4" to 5/16 from the edge of glass, as shown in
Figure 2. Starting the application too far from the
lite edge can hinder the final corner closure, while
starting the application too close to the lite edge can
reduce the bondline moisture vapor path.






Figure 2





Lay the Duraseal or Duralite about 1/16 in and
parallel to the glass edge, or at the inset set by the
Flexible Spacer PRO tool. The spacers should be
applied 90 to the glass surface, as shown in
Figure 3, and checked prior to topping the I.G.
unit. This ensures that the fluted shim will
properly maintain the units air space.



Figure 3




To form corners, first tack the
Duraseal or Duralite firmly onto
the glass, just before the corner.
Next, bend the spacer back to the
corner, as shown in Figure 4.






Figure 4


8


Then, fold the spacer so it points to the opposite corner,
and pinch the backside of the Duraseal or Duralite to
form a sharp corner as shown in Figure 5. Set the
Duraseal or Duralite firmly on the glass to secure the
finished corner.

Continue manual application around the straight sides
and corners until the final corner is reached.


Figure 5





At the final by-pass corner for air-filled units,
ensure that there is a minimal-gap (1/16 +/-1/32)
to minimize bondline shear during corner closing,
as shown in Figure 6. Trim the Duraseal or Duralite
flush with the glass edge as shown.

NOTE JOINING TWO TAPES TOGETHER:
When joining two tapes together on a unit, always
make the joints at a corner. For odd shapes start
at the sharpest corner to ensure a complete fourth
corner seal.


Figure 6


















9

Odd Shaped Units

Always start Duraseal or Duralite application
at the sharpest corner of an odd-shaped unit,
as shown in Figure 7.









Figure 7




To seal a sharp pointed corner unit, pinch the
corner from both sides as shown in Figure 8,
ensuring that the hair line interface voids are
eliminated. Fill in the point of glass with the
extra mastic to help prevent glass-handling
damage.






Figure 8





Use of Flexible Spacer PRO Tool for Duraseal and Duralite Application

Flexible Spacer PRO Tool Setup for Duraseal or Duralite:

INSET - The Flexible Spacer PRO tool (Generation III shown) is designed to apply two insets, 1/16 and
1/8, but can be modified to accommodate others. Generation IV is available with a variable-inset movable
base plate. The inset is determined by the position of the horizontal guide wheels, as shown in Figure 9.
The horizontal guide wheels consist of a plastic or brass rim and two rubber O-rings. The guide wheels are
attached to the base plate with a hub and bolt. All horizontal guide wheels must be in the same inset holes
(either the 1/8 inset holes OR the 1/16 inset holes) of the base plate. The O-rings experience significant
wear as part of normal usage. As a result, these parts should be inspected and maintained daily.

10


NOTE: Additional inset adjustments can be
made by shimming the base plate from the tool
head/handle.




Figure 9


PIVOT PIN - The pivot pin, shown in Figure 10, is the long pin wrapped in a silicone sheath at the head of
the Flexible Spacer PRO tool that facilitates corner forming. The pivot pin is held firmly in place by the
pivot pin-retaining bracket. Ensure that this bracket locks to the head of the pivot pin at the notch. The
pivot pin will rotate freely when installed properly.


Figure 10 - Flexible Spacer Pro and Pro V Hand Tools

PRESSURE WHEEL ADJ USTMENT - The pressure wheel is adjusted with a spring loaded bolt
mechanism for both the Black Flexible Spacer PRO tool as well as the Flexible Spacer PRO V tool. This
adjustment allows different airspace thickness of Duraseal or Duralite to be used on the same PRO tool with
only minor tool adjustments. The pressure wheel should be adjusted to give approximately 1/32
compression of the Duraseal or Duralite in a static position. This will impart enough downward pressure
during application to place and tack down the spacer without marring the Duraseal or Duralite bonding
surfaces.

GLASS THICKNESS ADJ USTMENT - This adjustment will set the height of the pivot pin and vertical
guide wheel so it is 1/16 to 1/8 above the surface of the glass as shown in Figure 11. This adjustment is
done with two thumb-tight bolts that attach the head and handle of the Flexible Spacer PRO base.

NOTE: This adjustment should be done with the air float of the application table on and the glass attached
to the suction cup. This adjustment is not available for the Flexible Spacer PRO V tool.

11


Glass thickness
adjustment bolt









Figure 11



Once the tool is adjusted to the desired glass thickness, a shim or spacer block should be installed between
the front base plate arm and the top of the notch for this arm on the Flexible Spacer PRO tool head. This
will eliminate any possible slippage during use. Also included with tool is a set screw that can be inserted
below the glass thickness adjustment bolt (instructions are included with tool).


Flexible Spacer PRO Tool for Duraseal or Duralite Application

Duraseal or Duralite should be handled on the
inside/outside surfaces, taking care not to contaminate
or mar the bond surface (the edges of the spacer that
will bond to the glass surface). Bond line contamination
or deformation may result in areas of seal weakness
due to incomplete wet-out of the glass by the sealant
during compression.

When beginning the application, ensure that the Duraseal
or Duralite is cut squarely, as shown in Figure 12.


Figure 12












12

For air filled units start the spacer application
approximately 1/4" to 5/16 from the edge of
glass, as shown in Figure 13. Starting the
application too far from the lite edge can hinder
the final corner closure, while starting the
application too close to the lite edge can prevent
proper unit venting during compression.




Figure 13




Hold the Duraseal or Duralite lightly and
slightly above and off the glass edge. Lay the
Duraseal or Duralite about 1/16- 1/8" in and
parallel to the glass edge, or at the inset set by
the Flexible Spacer PRO tool. The spacer
should be applied 90 to the glass surface, as
shown in Figure 14, and checked prior to
topping the I.G.unit. This ensures that the
stabilizer will properly maintain the units air
space.


Figure 14




EDGE APPLICATION - When applying the spacer to
the glass edge with any of the Flexible Spacer PRO
tools, the Duraseal or Duralite should be lightly held
(not stretched), slightly above and off the edge of the
glass as shown in Figure 15. This allows the vertical
guide wheels and pressure wheel to consistently
perform their functions.


Figure 15






13

When applying the Duraseal or Duralite to the sides,
ensure that all three of the horizontal guide wheels are
against the glass edge as shown in Figure 16.







Figure 16





CORNER FORMING - To form the applied corner,
back the Flexible Spacer PRO tool away from the
corner, hold the corner point and rotate the glass while
using the other hand to pull the spacer from the spool
as shown in Figure 17.



Figure 17






Bring the Flexible Spacer PRO tool to the glass edge
so that the pivot pin rests at the glass edge, as shown
in Figure 18.




Figure 18










14

CORNER FORMING MECHANICS - Rotate and pull back on Flexible Spacer PRO tool while holding the
Duraseal or Duralite tape up and over the glass edge, as shown in Figures 19a and 19b.











Figures 19a & 19b




Bring the spacer back off the edge of glass and
apply to the side. See Figure 16. Pinch the corner
to sharpen the angle, as shown in Figure 20.







Figure 20






FINAL CORNER LAYUP - Continue Flexible Spacer
PRO tool application around the straight sides and
corners until the final corner is reached. At the final
corner of an air-filled unit, ensure that a no gap (zero
gap) remains to minimize bond-line shearing as the
units 4th corner is closed, as shown in Figure 21. Also
trim the Duraseal or Duralite flush with the glass edge, as
shown in Figure 21.

NOTE JOINING TWO TAPES TOGETHER:
When joining two tapes together on a unit, always
make the joints at a corner. Cut the Duraseal or
Duralite flush with the glass edge.
Figure 21
15

Aligning of Second Lite

When topping the I.G. unit, ensure that the lites of glass are square to each other and the Duraseal or
Duralite remains perpendicular to the glass lites. A few methods recommended for alignment include:

Pop up aligning pins or bars at the aligning station.
A tilt table with aligning stops for the larger lites of glass.
An off line aligning rack.
An automatic topper.


Muntins

Quanex recommends that any system installed inside an I.G. units air space be clean, dry and free of
contaminating chemicals, which may affect the units aesthetic quality and/or seal integrity. Aluminum
muntins are acceptable, but plastic or PVC muntins are generally not recommended, as these materials may
release chemical vapors that will fog the inside of the window. A PERIMETER FRAME must NOT be
used in the muntin assembly, as it will prevent proper drying of the I.G. units air space.

Gridloc end clips are required in order to position grids properly in the cavity. Reference Gridloc
application charts to select the correct Gridloc end clip.

Touch-up paint should be avoided. When used, apply sparingly and allow solvent to dry before unit
assembly.

Please see the Quanex Muntin Manual for more details.


Compression Equipment

Conveyor speeds should be set to achieve the desired overall thickness while maintaining a Duraseal
or Duralite exit temperature between 110-120 F (43-49 C). The press should be calibrated such that
the dial gauge reading gives the same reading as the measurement of the overall I.G. thickness. After
calibration, the gap at the exit roll set should be approximately 0.040 to 0.050 (1-1.25mm) less than the
dial gauge readout. Conveyor speed may require adjustment throughout the day, depending on
environmental conditions as well as I.G. unit volume. Duraseal exit temperatures should be checked
periodically during production. Calibration of the press should be confirmed daily by measuring the overall
thickness of the exiting I.G. units and comparing to the gauge setting. Proper compression will optimize
Duraseal performance and prevent difficulties in glazing. Duraseal or Duralite exit temperature can be
measured with an infrared temperature probe (such as a Raytek MiniTemp).

Follow manufacturers recommended maintenance and lubrication schedule, and keep the press clean.
Dirt on the quartz heat lamps may cause their premature failure, and dirty compression rollers can scratch,
mar, or otherwise mark the I.G. units as well as cause glass breakage during compression. If two or more
lamps are not functioning, they should be replaced immediately. It is important that all lamps are operating
to ensure proper heating of the I.G. unit, consistent overall unit thickness, and to minimize glass breakage
during compression. Even heating of the top and bottom lites is critical to even compression of I.G. unit
and optimal wet-out of bond-line sealant.
16

Check frequently that all emergency stop systems are operating correctly. The malfunction of emergency
stops may result in personal injury, equipment damage, or production downtime for repairs and clean up.


Gas Filling

A one-hole method of gas filling should be used when filling Duraseal or Duralite I.G. units. The start-
point of application from glass edge is modified from (air-filled) to 3/8 to 7/16 (argon-filled) to
achieve a 1/8 nominal gap (see Figure 13). Press in the normal fashion.

The fill wand should be inserted into the unit through the elevated open corner, and should reach to within
two inches of the bottom of the unit.

To achieve desired percent fill, ensure that the correct time is used for a given flow rate and I.G. unit
airspace and size for timer-fill systems, and that the sensor is calibrated for sensor fill systems.

For units with internal muntins, insert the wand as far as possible and double the listed time to fill (for
timer-fill systems) given the unit airspace and size. For sensor-fill systems, cycle twice.

To make the final corner seal after gas filling, use the following procedure: Reheat only the 4th corner area
with a quartz heat lamp or hot air spot heater, prior to completing the corner seal. A quartz lamp is
preferred because radiant energy is transmitted through the glass and heats the bondline and topcoat joints
directly. Then using a sharp-edged Teflon corner sealing block (available from the Besten Hard Parts
List), press the tail end of the Duraseal or Duralite application into the start end as shown in Figure 22a.


Final Corner Seals

A completed corner seal should have a moisture vapor path similar to that around the perimeter of the unit,
with a minimum width of 0.250 (6.3mm). The corner joint should exhibit no hairline voids or other
interruptions in the bond.

For units that are greater than 16 ft
2
, seal the fourth corner while the unit is standing vertically with the
fourth corner elevated, or inflate the unit using a clean, dry air source. This technique will prevent issues
from arising due to a negative pressure within the I.G. unit.

For air-filled units with one or more sides shorter than 15", the normal ability of glass to flex is
diminished by its geometric shape. Thus, increased negative pressures that result from sealing the unit hot
will result in additional stresses on the edge seal. To minimize these stresses, small units should be sealed
off-line to allow the excess heat to dissipate before sealing. Reheating of the final corner seal area is
required prior to sealing the unit. Reheat only the 4th corner area with a quartz heat lamp or hot air spot
heater, prior to completing the corner seal. A quartz lamp is preferred because radiant energy is transmitted
through the glass and heats the bondline and topcoat joints directly. To seal the final corner, first allow the
unit to cool to Room Temperature (90F/32C) or lower (measuring the glass temperature away from the
edge of glass where it will be slightly higher). Reference Quanex Technical Bulletin IG009.




17

Quanex spacers bondline temperature (measured at glass perimeter, above the seal) should be 110-120
F (43-49 C), when sealing the final corner. Then using a Teflon corner sealing block (available from the
Besten Hard Parts List), press the tail end of the Duraseal application into the start end as shown in Figure
22a. Eliminate any hairline voids by tooling with a sharp corner-sealing block. Avoid excessive wiping
action to minimize bondline shearing. Reference Quanex Bulletin IG0028 for additional details





Figure 22a: Push the tail end and start point together to
eliminate any hairline voids.















Figure 22b: The final corner inspection must
include scrutiny of three points, the two bondlines
and the topcoat joint.


Inspection can reveal an incomplete joint seal.
















18

Closing Detail at Edge for Full Ellipses and Circles






Dual-Seal Duraseal or Duralite Units

When manufacturing dual-seal Duraseal or Duralite I.G. units, ensure the spacer is inset a minimum of 1/8
when applied. When choosing a secondary sealant, refer to Quanex Technical Bulletin IG011, Dual-Seal
Technical Policy, for a listing of approved sealants, or contact your Quanex Building Products Sales or
Technical Services Representative.

Note: Do not dual-seal with silicone.

The secondary sealant must have uninterrupted contact with the glass. Any Duraseal or Duralite mastic
present on the glass outside the bondline should be removed using a razor blade or other suitable
device. The presence of mastic or other materials on the glass will prevent a full-width secondary seal.

For more details on dual-sealing Duraseal or Duralite units, refer to Quanex Technical Bulletin IG011,
Dual-Seal Technical Policy.






19

Racking & Shipping

All I.G. units should be stored and handled on 90 racks. The base
should not exceed 12 in length unless load separators are used,
and should be tilted back 5 to 7, as shown in the illustration to
the right. This will preserve the correct alignment achieved in the
I.G. manufacturing process. Regularly clean any glass chips off the
racks to prevent possible glass edge damage. When racking I.G. units,
ensure that all lites of glass are fully supported, and cushion the
edges to prevent glass edge damage. Initially store units above
32 F and ship non-glazed units at warm temperatures.



Glazing

When glazing Duraseal or Duralite I.G. units, ensure that the fourth corner is glazed in the head rather
than the sill. In addition, follow the Four Premises of Good Glazing Practice, as outlined below:

Setting blocks must be used in the glazing pocket. The setting blocks should be made of a cross-linked,
compression-resistant neoprene, EPDM, or silicone material having a Shore A hardness of 80-90
durometer. The setting blocks should be of sufficient size to fully support all lites of glass equally and to
prevent rotation of the block during shipping, handling, and installation (1 or 1-1/2 for every 10 ft
2
on
larger units). Setting blocks should be placed at the quarter points of the sash/frame or no closer than 6
from the corners of the I.G. unit.

By design, the glazing pocket must be vented to bottom at lowest possible point. The vent holes should be
a minimum 1/4 diameter or 3/16 by 3/8 slot to overcome the surface tension of water (meniscus effect)
and allow any water that enters the glazing pocket an unencumbered exit.

As an alternative, vent holes may be omitted if both the interior and exterior are fully wet sealed against
moisture entry.

Under no circumstances should the edge of an I.G. unit be allowed to sit in water.

By design, water entry into the glazing pocket from both the exterior and interior sides must be prevented.
Sealants are required to treat weak seal areas such as joints and areas of directional change.

By design, there is an interior air barrier. A continuous air barrier to the interior side of the window will
optimize the thermal performance of the window system by eliminating air transfer or leakage.

For more detail, please refer to Quanex Technical Bulletin SG002, Warranty Glazing Guidelines, or for
specific glazing system recommendations, contact your Quanex Sales Representative or the Technical
Service Group.





20

Receiving QC, Handling, Storage & QC Testing of Duraseal and Duralite

Inspection of Incoming Material

Upon receiving a shipment of Duraseal or Duralite, a visual inspection of the packages for any damage
should be conducted. Inspect for damage that may have allowed moist air to enter the packaging or would
indicate rough handling. If the inspection finds damage that may allow moisture to enter the package,
either reject the material shipment or have the damage noted on the receiving paperwork and contact the
freight carrier to file a claim.

Avoid dropping or other rough handling when unloading and transporting Duraseal or Duralite. Physical
shocks of this nature may cause loosening of the release paper from the spacer, resulting in "telescoping" of
the spools upon removal from the packaging making the product unusable. Also keep product upright as
shipped do not tip boxes on sides.




Duraseal or Duralite Storage and Stock Rotation

Proper stock rotation is recommended to ensure that the spacer material in use is fresh and that all Duraseal
or Duralite is used within its 12 month shelf life. To ensure that fresh material is in use, the following
storage procedures should be followed:

Do not open Duraseal or Duralite packaging until the material is required for production. After the
Duraseal or Duralite has been removed from the aluminized bag, reseal the bag or drum. At the end of
each production shift, reseal any unused Duraseal or Duralite in the original packaging or in a drum,
which is available through the Hard Parts List.









21

Humidity Indicator Card

Included in the package at the time of Duraseal or Duralite manufacture is a humidity indicator card. Its
purpose is to confirm that there has been a good seal against moisture entering the bag by means of a color
change in the indicating spot.

PINK indicates the Duraseal or Duralite has been exposed to moisture.

BLUE indicates the Duraseal or Duralite remains protected from moisture.

If the indicator card is pink, it is possible that the Duraseal or Duralite has suffered a loss of desiccant
activity. The desiccating ability of the Duraseal or Duralite must then be verified by evaluating the dew
point development, as described below.


Quality Control Tests
I. Dew Point Determination for Flexible Spacer I.G. Units
II. Quick Test or Ice Cube Test
III. V-45 Initial Adhesion Test
IV. Slosh Test


I. Dew Point Determination for Flexible Spacer I.G. Units:

This Quality Control Test is conducted to ensure that the desiccant in the Flexible Spacer is active and
capable of drying the hermetically sealed air space within the I.G. unit.

Purpose: To measure the rate at which spacer desiccates a standard sized airspace.

Required Materials

2 pieces of clean, dry clear float glass 5 (127mm) square.

Dew point apparatus. See Figure 23.

A thermometer with a range of at least +32 to -100 F (0 to -73 C). Dry ice (solid carbon
dioxide) -- powdered or pulverized.

Isopropyl alcohol.

A timing device with second indicating capability.

A sample of Flexible Spacer just removed from its packaging container.






22

Procedure

1. Using the two small lites of clean, dry clear float glass and the Flexible Spacer sample, assemble a small
I.G. unit. Compress the unit and seal the final corner.

2. Age the sample unit for 2 hours at 77 F (25C).

3. Prepare the dew point apparatus with isopropyl alcohol and dry ice, and adjust the system to 0 F (-
18C).

4. Apply a film of alcohol to one face of the sample unit, and then place the brass section of the dew point
apparatus in contact with this face for 3 minutes. Maintain the dew point apparatus at the desired test
temperature by the addition of more dry ice as required for this 3-minute period.

5. Remove the dew point apparatus after 3 minutes and apply another film of alcohol to the dew pointed
area, and as quickly as possible, view the sample from above by means of a light transmitted through the
sample from beneath. If condensation or frost has formed on the second surface of the top lite of glass, then
the dew point of the sample is higher/warmer than the tested temperature. See Figure 23 for a configuration
of the dew point test.

6. Repeat steps 1 to 5, adjusting the test temperature by 10 F (5 C) up or down as required, waiting 5-10
minutes between tests or until the condensation from the previous test has flashed off.

7. Repeat parts 1 to 5 after 24 hours aging at 77 F (25 C) starting at -40 F (-40 C) and adjusting the
temperature up or down as required by 10 F (5 C).













Figure 23. After removing the apparatus, look for condensation or frosting on the inside surface of the
glass as shown.









23

Duraseal/Duralite/Edgetherm FS Performance Requirements

2 hour aged sample test should have a dew point of 20 F (-7 C) or lower.

24 hour aged sample test should have a dew point of -20 F (-29 C) or lower.

In the event that the test sample does not meet the above requirements, immediately retest this packaging 4
wraps further down in the package. If additional stock is available set aside this drum and open another
drum until the retest has been completed. In the event that the retest results do not meet the requirements,
your Quanex Sales Representative should be contacted and this packaging should be set aside.

Note #1: For a comparison evaluation, a dew point run on a single lite of glass would show a deposit at a
temperature of 32 F (0 C). See: Flexible Spacer Desiccant Dew Point Draw Down - Quick Test - (Ice
cube test).

Note #2: If the test lites of glass are not fully dried or if the samples are made during a high humidity
period, the 2-hour results may not pass. A retest should be started with added care taken regarding the
drying of the lites of glass.

Note #3: Dew Point is recorded as the last boundary at which no condensation or frost is deposited on the
2nd surface of the top lite of glass, while with a 5 F (2.5 C) drop of the test temperature, a deposit is
formed.


II. Quick Test or Ice Cube Test

This test is a quicker, yet less precise means of qualifying the dew point development of an I.G. unit than
the Dew Point Draw Down Test detailed above. It requires no dry ice or frost point device. Its purpose,
however, remains the same, and is to ensure that the desiccant in the Flexible Spacer is active and capable
of drying out the hermetically sealed air space.

Equipment and Supplies

2 pieces of clean, dry clear float glass 5 (127 mm) square.

Ice cubes with at least 1 flat side.

Water.

A timing device with second indicating capability.

A sample of Flexible Spacer just removed from its packaging container.







24

Procedure

1. Using the two 5 (127 mm) lites of clean,
dry clear float glass and the sample to be tested
of Flexible Spacer, assemble a small insulating
glass unit.

2. Compress the unit and seal the final corner.

3. Age the sample unit for 2 hrs. for Duraseal
and Duralite, 4 hrs. for Edgetherm FS, at 77 F
(25 C).

4. Place a small amount of water on the top lite of
the small sample unit and then hold the flat side of Figure 24
an ice cube (32 F / 0 C) in place on the sample
unit for 3 minutes as shown in Figure 24.

5. Remove the ice cube after 3 minutes and apply another film of water to the dew pointed area. Then as
quickly as possible, view the sample from above by means of a light transmitted through the sample from
beneath. If no condensation has formed on the second surface of the top lite of glass, then the dew point
draw down on this Flexible Spacer would be considered good. If condensation formed, the desiccant
activity of the spacer would be in question. If condensation is observed, redo the test.

6. Hold the sample unit for 24 hours and repeat the dew point test, as well as associated production.


Performance Requirements

After 2 hours for Duraseal and Duralite, or 4 hours for Edgetherm FS, there should be no condensation
formed in the sample unit. If after these times, there is condensation formed, the test should be repeated
and the first sample tested again after 24 hours aging at 77 F (25 C). If after 24 hours condensation still
forms, the associated Flexible Spacer should not be used. Contact your Quanex Sales Representative.


III. V45 Initial Adhesion Test

This test is conducted to ensure adequate initial adhesion between clean, dry glass and Quanex Flexible
Spacers bondline sealant.


Equipment and Supplies

2 pieces of clean, dry glass, minimum thickness dsb/3 mm clear float, approximately 12 (305 mm)
square.

Sample quantity of Flexible Spacer, just removed from packaging, but conditioned to 70-75 F (21-
25 C).
Note: filler strips approximate length 5 (130 mm).
25

Use of the production heated glass press.

Glass cutter.

Safety glasses, safety sleeves and gloves to safely handle glass.


Procedure

1. Apply the 12 (305 mm) sample of Flexible Spacer on two opposite edges; (a) of the clean, dry pieces of
clear float glass in the fashion used in production; on the other two adjacent sides, (b) use pieces shorter than
the glass (approximately 5 (130mm). Reference Figure 25.





Score Top
Coat







Figure 25: Assemble w/fill strips Figure 26: Example V-45 rotation in test

2. Place the lite of glass on top of the applied spacer and slightly press by hand to set the unit, and then
compress the unit to nominal using the production press. Press to the airspace dimension specific to the spacer
used, -0.008, +0.010, being sure to achieve the correct exit temperature of 110-120 F (43-49 C).

3. Allow the assembly to cool to 75 F (24 C) for approximately 30 minutes after exiting the press. Then,
wearing safety glasses, gloves, and sleeves score the top lite with glass cutter (see Figure 25 score lines) then
press up on the score lines to break the glass. Slowly hinge the unit by pulling up and rotating first one half of
the fractured lite, opening it to 45 over a full 5 seconds (see Figure 26). Check the bond line for adhesion by
examining the black bondline adhesive and comparing it to the photos.

4. Figure 27 - Acceptable, Figure 28 - Not acceptable. Note: When you perform the V-45 test you may see an
approximate .050 (1.3mm) adhesion loss to the interior of the test sample. This is the Top Coat area which is
not part of the test requirement.


Figure 27: Acceptable Figure 28: Not acceptable
26

5. Repeat the procedure with the second half of the fractured top lite, also as shown in Figure 26.


Performance Requirements

To meet Acceptable standards as in Figure 27:

If there are areas that exhibit a bondline shown in Figure 28 Not acceptable, verify that the glass used is
completely clean and dry using the Slosh Test #IV, below. Retest by assembling another sample. Ensure that
the applicator is not touching or otherwise contaminating the bondline when the Flexible Spacer is being
applied. Ensure that the glass is opened slowly to 45 utilizing the full 5 seconds. If there is a second failure in
this test, place this material on hold and contact your Quanex Building products Sales or Technical Service
Representative.


IV. Slosh Test

The Slosh Test is an indicator of the cleanliness of glass used in the production of I.G. units. It is imperative
that glass be free of contaminants, both particulate and chemical, in order to produce high quality, durable units.
Any contaminant can affect the long-term adhesive properties of I.G. seals. Detergents can be particularly
insidious; an invisible layer of glass washer detergent that remains on the glass may cause premature failure of
the I.G. unit. Detergents dissolved in water, will froth and produce suds when the liquid is agitated. This
property can be exploited to test for glass cleanliness. Conduct the following frequently, such as at the
beginning of each shift for example.


Equipment and Supplies

2 pieces of clean, dry clear float glass for any production size.

Water.

A small, clean jar.


Procedure

Assemble a small (14 x 20 or other convenient size) Flexible Spacer I.G. unit.

After compression, leave the final corner open, and with the I.G. unit stood on end, pour clean tap water into the
hole until it is about (6mm) deep.

By manipulating the I.G. unit, run the water all over (i.e. rinse) both interior surfaces of the glass. The purpose
is to pick up any water-soluble contaminant and detergent residues that may have been deposited on the glass
surfaces.

Slosh the water back and forth within the I.G. unit in an attempt to produce froth. Alternatively, transfer the
rinse water to a clean jar that is easier to shake. If desired, a second jar can be filled with an equal amount of
clean tap water and used as a control.


27

Bubbles in clean water will disappear when shaking stops providing an effective comparison, while detergent
froth will remain visible when the agitation is stopped.

Also look for water which beads very sharply like water on a freshly waxed car. This indicates that while
detergent may be rinsed, there may be contaminants that increase surface energy, also preventing good
adhesion. Contaminants such as silicones, oils, and waxes fall into this category.


Duraseal or Duralite Line Layout Guide

Layouts developed by the Technical Services Group at Quanex are designed to optimize the production
efficiencies of an I.G. fabrication line. Sample line layouts are available, and our Technical Services Group is
available to evaluate your specific facility requirements, and to customize a line layout for these requirements.
The recommended equipment is designed to provide the most economic methods available to produce a high
quality Duraseal or Duralite I.G. Unit. The concepts behind the line layouts are to minimize glass handling,
eliminate wasted steps and motions, and to generally streamline the production of Duraseal or Duralite I.G.
units.

A clean room is a central element of the insulating glass line. The clean room allows the consistent application
of Duraseal or Duralite, while preventing contamination of the spacer, the glass, and the I.G. airspace. The
clean room should be maintained at a temperature of 75 F +/- 5 F (21 C +/- 3 C) for Flexible Spacer PRO
tool application, and 75 F +/- 10 F (24 C +/- 6 C) for manual application.

When planning the clean room, only the area where the units are fabricated should be enclosed. The outfeed of
the washer and the infeed of the press should be enclosed within the clean room. The equipment supplier
should be contacted for exact dimensions of opening sizes, ceiling height and necessary clearances for service
of the equipment.

The clean room should be large enough to store material for two days worth of production. The proper material
temperature is imperative to both the application quality of Duraseal or Duralite as well as the operational
efficiency of the glass room.




















28

General Considerations When Designing Your Quanex I.G. Line

Standard airfloat tables are 84 x 84 for application tables and 84 x 60 for aligning / topping / tilt tables.
This configuration is suitable for up to 34 x 76 patio doors and 60 x 60 picture windows. Consider the
diagonal of your largest I.G. unit to choose the most appropriately sized application table; consider the longer
dimension of your largest I.G. unit to choose the more appropriately sized topping/tilting table.

60 Topping table requires minimum height of 92 in a raised position.

The clean room should be designed using a minimum distance of six feet between the application table and the
wall behind an applicator.

Allow ample space for muntin staging at the topping station.

Typical cycle time should be 35 to 60 seconds, depending on the layout and product mix. When quoting
equipment consider these as standard:

10 ft/min on washer for U-shape line.
24 ft/min on washer for Two-sided line.
84 washer for Two-sided line.
Minimum 5 roll press.

Design line for peak volume, scale down if necessary.

Washer recommendations

Prewash.
Double heaters.
8 foot outfeed.
Flat black open caster table with under table inspection lamps.
Cut out for 60 washer exit caster table: 36x18.

Recommended size for heated roller press is 84. Consider the option of a remote speed control for press, to be
located at the takeoff end. Such an option will add approximately $300 to price (includes parts & labor), but
will enable closer control of the exit Duraseal or Duralite temperature.

The minimum recommended number of compression roller pairs is five. With an increasing number of
compression rollers, you should be able to reduce the temperature of the press, improve the uniformity of the
I.G. unit overall thickness, and reduce the stresses applied to the I.G. unit during compression.



Quanex Building Products
6680 Parkland Boulevard
Solon, OH 44139
T 888-910-5280
F 216-910-1507
www.quanex.com

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