Why the Right Sealant Makes the Difference in Long-Term Performance and Weatherproofing in Metal Buildings

by David Flaherty | 29 July 2025 12:54 pm

[1]

In the construction of modern metal buildings, long-term performance hinges on more than just the structural design—it depends on what seals everything together. While often overlooked, non-skinning sealants are critical in maintaining weather-tightness, energy efficiency, and durability, particularly in insulated metal panels (IMPs) and standing seam roof (SSR) systems.

Key challenges in metal building construction

Metal buildings are designed for strength, efficiency, and longevity; however, achieving those outcomes requires more than precise installation—it demands the right sealing solutions to combat:

• Thermal movement, which causes panels to expand and contract
• Moisture infiltration through laps, joints, and penetrations
• Air leakage, reducing insulation effectiveness and increasing energy costs
• Exposure to harsh environments, including UV, wind, and temperature swings

These challenges make the selection of high-performance sealants critical to ensure a weather-tight building envelope and protect structural integrity over the building’s lifespan.

The role of sealants in metal installation applications

Sealants are widely trusted in metal building systems for their strong adhesion, long-term flexibility, and resistance to the elements. Unlike traditional caulks or hardening sealants, butyl-based and non-skinning sealants maintain performance without cracking or drying out over time. They provide a consistent, long-lasting barrier against moisture and air infiltration, which is critical in factory-assembled and field-installed systems.

What happens when the proper sealant isn’t used

Using the wrong sealant—or skipping sealant altogether—can lead to:

• Water penetration and corrosion
• Loss of thermal performance
• Premature material degradation
• Increased maintenance and repair costs
• Voided warranties and failed inspections

Types of Sealants & Their Application Areas

Metal building sealants generally fall into two categories: butyl tape sealants and non-skinning sealants, each suited to specific needs in metal construction.

Butyl tape or non-skinning sealants: What’s the difference?

Feature	Butyl Tape Sealants	Non-Skinning Sealants
Application Areas	Rib joints, end laps, roof curbs, and skylights	Panel joints, concealed seams, and roll-forming joints
Form	Pre-formed tape rolls	Fluid sealant (packaging options: caulk tube, sausage pack, pail, or drum)
Installation	Peel-and-stick; tool-free	Requires gunning or pumping
Movement Tolerance	Moderate – conforms to the surface	High – ideal for dynamic joints
Repositioning Ability	Limited after initial application	Easily repositionable during installation
Mess/Cleanup	Clean, minimal residue	Clean application; no stringing or webbing
Priming Required	No priming required	No priming required
Best For	Simple joints, exterior sealing, and easy installs	High-movement areas, factory/field panel joints
Flexibility	Maintains shape; flexible	Non-hardening and fully flexible over time
Appearance	Hidden between joined surfaces	Hidden within seams or panels

Butyl tape sealants are ideal for sealing metal rib and end joints, standing seam roof end laps, and around roof curbs, jacks, and skylights. They are highly tacky, adhere to common metal coatings like Kynar, Galvalume, and Zincalume, and apply easily without tools—even in temperatures from -5°F to 120°F. Permanently flexible and UV/weather-resistant, butyl tapes will not crack or flow under stress. With an 18-month shelf life and various sizes, they’re a proven, reliable choice across metal building types.

Non-skinning sealants are designed for more dynamic applications, such as IMP joints, standing seam concealed seams, and roll-forming lines. Their non-hardening formula stays flexible over time and allows repositioning during installation. Easy to apply with no priming or cleanup required, they bond well to clean surfaces and adapt to joint movement from thermal expansion. Available in tubes, pails, or drums, they offer clean, efficient sealing for factory and field use.

Conclusion

Choosing the proper sealant is essential for protecting a metal building from the start. With proven performance, flexibility, and weather resistance, butyl-based sealants—tape and non-skinning varieties—are critical tools in the contractor’s arsenal. Whether sealing a cold storage facility or installing a standing seam roof, using the correct product ensures fewer callbacks, lower lifecycle costs, and higher customer satisfaction.

[2]Quenton Roehricht is a product manager at Amrize Building Envelope, bringing over 20 years of experience in the building materials industry. With a strong background in marketing and product management, he has spent the past two years leading the adhesives and sealants category for the Gaco brand. His portfolio includes GacoBond, GacoSeal, American Safety Technologies, and Tacky Tape, where he drives product strategy and innovation.

Source URL: https://www.metalconstructionnews.com/articles/the-right-sealants-for-metal-buildings/

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