Choosing the Right Sealant: What You Need to Know
When it comes to construction and industrial projects, choosing the right sealant is more than a finishing touch—it’s a critical component of long-term performance, durability, and safety. Whether you’re sealing windows and doors, bonding panels, or protecting electrical enclosures, selecting the proper sealant can directly impact the integrity and efficiency of your build.
But how do you know which sealant is best for your application? And how do sealants differ from adhesives?
Let’s break it down.
Sealants vs. Adhesives: What’s the Difference?
Although the terms are often used interchangeably, sealants and adhesives serve distinct functions:
Adhesives are primarily used to bond materials together. They’re designed to create strong structural or semi-structural connections that resist separation.
Sealants, on the other hand, are formulated to fill gaps, prevent leaks, and block environmental elements like moisture, dust, and air. While many sealants offer some adhesive properties, their main role is to seal rather than bond.
In short, adhesives hold things together. Sealants keep things out.
At InnoStar Solutions, we offer high-performance hybrid technologies—like our PURfect Hybrid line—that blend the best of both worlds: strong adhesion with exceptional flexibility and sealing capability.
Key Factors to Consider When Selecting a Sealant
Choosing the right sealant starts with understanding your specific application and performance requirements. Here are a few important considerations:
- Substrate Compatibility
Make sure the sealant adheres well to the materials being joined—metal, glass, PVC, composites, etc. Hybrid and silicone sealants are often versatile and bond well to a variety of surfaces without primer. - Movement & Flexibility
If the joint will experience expansion, contraction, or vibration, flexibility is key. Look for sealants with high movement capability (like ±25% or ±50%) for dynamic applications like curtain walls, windows, and metal buildings. - Weather & UV Resistance
For outdoor applications, a sealant must stand up to the elements. UV resistance, temperature tolerance, and moisture resistance are essential to prevent premature failure. - Cure Speed
Some projects require fast turnaround. Fast-curing sealants can reduce downtime and increase efficiency, especially in manufacturing settings. - Joint Design
All sealants and adhesives must be properly installed in a correctly designed joint to perform at their full capability. When using sealants, the joint must be designed to prevent 3-sided adhesion. - VOC Content & Sustainability
More companies are shifting toward low-VOC or VOC-free sealants to meet sustainability goals and LEED requirements. InnoStar’s Non-Skinning Butyl 110, for example, is Intertek Clean Air GOLD Certified—a distinction that supports indoor air quality and green building standards.
When to Use an Adhesive Instead
If your application requires mechanical performance of the bond—such as bonding panels to a metal frame or assembling parts in a load-bearing configuration—you’ll likely need an adhesive. While the PURfect hybrid sealants have some structural/mechanical capability, with a tensile strength greater than 150 PSI, for some jobs you will need a structural adhesive like our PURfect WELD 15 epoxy which provides superior shear, peel, and tensile strength, making it ideal for demanding mechanical applications.
Still not sure whether to use a sealant or adhesive? In many cases, a hybrid formulation can provide both sealing and bonding in one product—saving time and simplifying the process.
Need Help Deciding?
At InnoStar Solutions, we work closely with our customers to help identify the right sealant—or adhesive—for each job. We consider your materials, environment, application method, and performance goals to ensure you get the most reliable solution possible.
We also offer custom formulations to meet your exact specifications.
Explore our full line of sealants and adhesives or contact our team for a recommendation tailored to your needs. Let’s find the right fit for your next project.