Predicting how much sealant or caulking you need for a construction job can be difficult. To alleviate this challenge, many manufacturers and distributors offer online sealant calculators to approximate how much product is required for your application. This sealant calculator guide walks through when and how to navigate these programs so you get the most accurate estimate for your project.
Sealant calculators estimate the amount of necessary product needed for an application regardless of its technology (silicone, urethane, hybrid, etc.). Calculations are based on the volume of a traditional sealant bead, a rectangular prism that is later tooled to an hourglass shape, common in basic vertical and horizontal expansion joints, utilizing the recommended 2:1 width-to-depth ratio.
Additional calculations can be made to accommodate cove or triangle beads of sealant and expandable foam sealants that are used in control joints and window perimeters.
Sealant calculators are not suitable for detailing or flashing applications, as the product is often tooled flat so the volumetric-based calculations would not be appropriate, either significantly overestimating or underestimating your needs. Contact a Sales Representative for anticipated product needed for these or other caulking applications.
After you’ve entered your joint details, the sealant calculator will report how many tubes, cartridges, sausages, or buckets of product you will need for your application. Again, make sure you select the appropriate packaging type for what you are looking to purchase. 10 cartridges will not equal 10 sausages.
If the project has multiple joints with the same width and depth, you can add up their lengths to calculate how much product is needed for them all. However, if your joints have different widths or depths, it is best to input the values of each joint separately first and then combine the amount of product needed.
The first way to minimize unused sealant and unnecessary cost is to only purchase as much sealant as you will need. Therefore, having the exact dimensions of your joint upfront will return the most precise output of the sealant calculator.
Once you have your product in hand, there are additional strategies you can employ to decrease waste, whether due to applying too much sealant or installing it incorrectly and having to tear out and recaulk the joint. For basic steps on how to apply sealant, refer to this blog post.
It is important to note that you cannot simply tool caulking in a joint and move the remainder to another area of the job as this may cause contamination which will diminish the sealant’s elongation and durability performance, causing premature failure of the joint seal.
Proper substrate preparation and the use of primer, if needed, are indicated in the product’s application instructions and are critical to avoiding sealant waste due to lack of adhesion. To verify the adhesion of an existing joint seal, the field adhesion test can indicate the quality of the application and identify potential problems such as contaminated or expired sealant, improper cleaning, or extreme substrate movement.
In addition, the right size tool is necessary for the tooling process. Caulk spatulas and sealant finishing tools come in various shapes and sizes. For typical expansion joints, you will want a tool that just barely fits into the joint width to maintain the hourglass shape of the sealant bead.
A final consideration is the time of day that the product is installed. During the mid-point temperature of the day, the joint will be at its mean joint size, the average width during its natural expansion and contraction cycle. If you apply the product in this timeframe, the sealant will experience consistent expansion and contraction during the cure period which prevents cracking and bulging.
Sealant calculators, like the one provided by Tremco CPG, are a great tool for forecasting how much material you will need for a typical caulking joint. To best utilize these estimates, it is essential to know the joint dimensions and how to input them into the calculations. From there, proper substrate preparation and sealant application will reduce waste and ensure you have enough product for the job.