Butyl, thanks to its exceptional flexibility, long-term aging resistance, and high adhesion to various substrates, is one of the most widely used sealing materials in construction, industry, and technical applications. However, choosing the right form of butyl – sealant, tape, cord, or sheets – is crucial for the durability and effectiveness of the seal. Each form addresses different technical and operational needs, so it is worth knowing which one to apply in specific conditions.
1. Butyl Sealant – Precise Sealing and Filling
Butyl sealant is the most plastic and versatile form of this material. It can be applied manually or mechanically, allowing for precise filling of gaps with irregular shapes.
When to use it:
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sealing sheet metal joints and façade elements,
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filling spaces around technical penetrations,
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securing hard-to-reach gaps,
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applications requiring a flexible, non-curing seal.
The sealant remains tacky and elastic for many years, effectively compensating for structural movements. However, it is not the best choice where flawless aesthetics or dimensional repeatability is required.
2. Butyl Tape – Fast and Clean Linear Sealing
Butyl tape is the most convenient form for linear connections. Its main advantage is ease of application, strong adhesion, and predictable thickness of the sealing layer.
When to use it:
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roofs: sheet metal joints, flashings, gutters, chimneys, skylights,
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sealing under photovoltaic installations,
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window and door installation,
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joining roofing and façade membranes.
Butyl tapes adhere excellently to metal, PVC, glass, and concrete, making them indispensable in industrial construction. However, they are less suitable for highly irregular gaps – in such cases, sealant or butyl cord performs better.
3. Butyl Cord – Ideal for Deep Gaps and Structural Joints
Butyl cord comes in cylindrical form with a defined diameter, allowing precise control of the amount of material used. Its key advantage is the ability to fill deeper or wider gaps without the risk of material squeeze-out.
When to use it:
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installation of PVC and aluminum joinery,
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as a sealing base under panels and cladding,
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expansion joints and technological gaps,
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areas where consistent geometry of the seal is required.
The cord is resistant to compression and deformation, making it an excellent preliminary hydroisolating barrier in multilayer constructions.
4. Butyl Sheets – Large Surfaces and High Sealing Performance
Butyl sheets, often reinforced with aluminum or PE films, are used on larger surfaces requiring a continuous waterproofing layer.
When to use it:
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sealing flat roofs, panel joints, and expansion joints,
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insulating HVAC installations,
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moisture protection in wet zones,
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waterproofing containers, trailers, and modular structures.
Sheets allow for fast installation of large, uniform sealing surfaces. However, they are not suitable for complex details – in such cases, tapes or sealant will work better.
Summary
The choice of butyl form depends primarily on the type of joint, required application precision, and the size of the area being sealed. Sealant works best in irregular areas, tape in linear joints, cord in gaps with consistent cross-section, and sheets for large surfaces requiring complete tightness.