How to Prevent Adhesive and Sealant Failure: Key Storage and Handling Factors Affecting Performance

Photo: Craftsman Concrete Floors / Unsplash

Adhesives and sealants are key components in many industrial applications, from construction to the automotive industry. However, their performance depends not only on selecting the right type but also on the conditions under which they are stored and handled. Even a high-quality product can lose its properties if exposed to unsuitable temperatures, humidity, or contamination. In this article, we will focus on the specific factors affecting the stability of these materials and provide practical recommendations on how to minimize the risk of failure and extend their shelf life.

Temperature and Humidity: The Invisible Enemies of Adhesive Properties

Adhesives and sealants are sensitive to storage conditions, with temperature and humidity being among the most critical factors. Most industrial adhesives require storage at temperatures between 15–25 °C. At temperatures below 10 °C, thickening or crystallization of some components may occur, particularly in reactive systems based on epoxies or polyurethanes. Conversely, temperatures above 30 °C accelerate polymerization, shorten shelf life, and may lead to premature curing before application. In the case of cyanoacrylate adhesives (so-called instant adhesives), high temperatures can cause spontaneous polymerization even in the packaging.

Humidity is equally insidious—especially for one-component polyurethane adhesives and sealants, which react with water vapor from the air. When stored in environments with relative humidity above 60%, a gradual reaction occurs, leading to loss of adhesion and the formation of bubbles in the material. For sensitive products, storage in hermetically sealed containers with desiccants (e.g., silica gel) is recommended. Conversely, for water-based adhesives, excessively low humidity causes drying and loss of application properties. Regular monitoring of temperature and humidity in the warehouse using dataloggers helps prevent unnecessary losses.

Proper Sealing and Handling of Containers: Prevent Contamination and Degradation

Even a high-quality adhesive or sealant will lose its properties if the container is contaminated or improperly sealed. Every time a container is opened, there is a risk of moisture, dust, or other impurities entering, which can disrupt the chemical stability of the product. In reactive adhesives (e.g., epoxies or anaerobic adhesives), contamination may cause premature polymerization or reduced bond strength. Therefore, it is crucial to use only clean tools and to seal the container thoroughly immediately after use.

For multi-component adhesives (e.g., two-component epoxies), it is crucial to maintain the correct mixing ratio and prevent cross-contamination between components. Even a small amount of the second component in the wrong container can cause an undesirable reaction. For long-term storage, it is recommended to transfer residues into smaller, airtight containers to minimize contact with oxygen. For sealants in cartridges, it is important to remove product residues from the neck after each use and close it with the original cap. Always follow the manufacturer's instructions when handling containers and use personal protective equipment, especially with low-viscosity adhesives that may cause skin burns.

Photo: Craftsman Concrete Floors / Unsplash

Adhering to expiration dates and batch records: When to discard a product

Every adhesive and sealant has a limited shelf life, which depends on its chemical composition and storage conditions. Exceeding the expiration dates can lead to irreversible deterioration of properties – reduced bond strength, extended curing time, or complete loss of adhesion. In reactive adhesives (e.g., polyurethanes or silicones), polymerization gradually occurs even in a sealed container, which manifests as thickening or gel formation. Water-based adhesives, on the other hand, may dry out or develop mold.

To minimize risks, it is essential to implement a batch tracking system that allows monitoring the production date and expiration of each product. It is recommended to store adhesives and sealants following the FIFO (First In, First Out) principle to prevent the use of older batches. Before use, always check the consistency, color, and odor of the product – any deviations from the original state may indicate degradation. If in doubt, perform a test application on a material sample. For critical applications (e.g., in construction or the automotive industry), it is advisable to conduct regular bond strength tests according to standard test methods.

Workplace Safety: How to Minimize Risks When Handling Adhesives and Sealants

Handling adhesives and sealants requires adherence to safety rules to prevent health risks and workplace accidents. Many industrial adhesives contain volatile organic compounds (VOCs), which can cause respiratory irritation, dizziness, or allergic reactions. When working with these products, it is essential to ensure adequate ventilation or use local exhaust systems. For adhesives with a high solvent content (e.g., contact adhesives), fire safety measures must be observed, as the vapors may be flammable.

Personal protective equipment (PPE) is a fundamental prerequisite for safe work. When handling adhesives and sealants, use protective gloves (most commonly nitrile or butyl, depending on chemical resistance), safety goggles, and, if necessary, protective clothing. For adhesives with corrosive properties (e.g., acidic silicone sealants), it is also necessary to protect the skin of the face and neck. Always follow the instructions provided in the Safety Data Sheet (SDS) under REACH and CLP/GHS regulations, which contain information on risks, protective measures, and first aid. Regular training of employees on the safe handling and storage of chemical products is key to accident prevention.

Photo: Craftsman Concrete Floors / Unsplash

Impact of mechanical stress and vibrations on the stability of adhesive systems

Adhesives and sealants are often exposed to mechanical stress during storage and transportation, which can subtly affect their performance. Vibrations, shocks, or improper stacking of packaging can lead to component separation, especially in two-component systems or products with fillers. For example, in epoxy adhesives, filler sedimentation occurs at the bottom of the container, making subsequent mixing difficult and potentially causing uneven curing. Similarly, in polyurethane sealants, mechanical stress can disrupt the polymer structure and reduce its elasticity.

To prevent these issues, it is crucial to follow the manufacturer's instructions for handling packaging. Packages containing adhesives and sealants should be stored on a flat surface, ideally on pallets that dampen vibrations. During transportation, it is advisable to use fixing systems to prevent package movement. For sensitive products, such as anaerobic adhesives, it is recommended to store them in their original cardboard boxes, which provide additional protection. Regularly checking the product's consistency before use will help detect any changes caused by mechanical stress.

Protection from UV Radiation and Light: Why Some Adhesives Require Dark Storage

Ultraviolet radiation and visible light can cause premature degradation of certain types of adhesives and sealants, particularly those based on polymers sensitive to photochemical reactions. For example, cyanoacrylate adhesives or some types of polyurethane sealants undergo polymerization or loss of adhesive properties when exposed to light for extended periods. UV radiation initiates radical reactions that lead to the formation of undesirable bonds and material embrittlement, resulting in reduced joint strength or sealant cracking.

To minimize these risks, it is essential to store sensitive products in opaque or dark containers, or in enclosed warehouses without direct sunlight. If the manufacturer specifies particular light-protection requirements, these must be observed even during handling – for example, during outdoor application. For some products, such as UV-curable adhesives, light is necessary for activation, but even here, premature exposure to light can lead to unwanted curing before application. It is therefore always important to follow the technical data sheets and safety instructions.

Monitoring and Maintenance of Storage Conditions: Tools and Procedures for Ensuring Quality

Proper storage conditions are not a one-time matter but require regular monitoring and maintenance. Dataloggers are effective for tracking temperature and humidity in storage areas, as they continuously record conditions and alert to deviations. For products sensitive to temperature fluctuations, such as reactive adhesives or sealants, it is advisable to place sensors directly near the packaging. Humidity can be controlled using dehumidifiers or air-conditioning systems to maintain relative humidity within the recommended range, typically between 30–60%.

In addition to technical measures, warehouse organization is also important. Products should be arranged by type and sensitivity, with the most sensitive materials placed in the most stable conditions – for example, further from doors or heat sources. Regular inventory checks and visual inspections of packaging help detect potential leaks, deformations, or signs of degradation. For products with limited shelf life, implementing a FIFO (First In, First Out) system minimizes the risk of using expired material. Documentation of storage conditions and inspection procedures is also crucial for demonstrating compliance with quality standards in the event of complaints or audits.

Need advice on selection or storage?

Each raw material requires an individual approach – from proper storage conditions to safe handling. GCG Group provides detailed safety data sheets and technical specifications for every product, and our experts are happy to advise you on the specific requirements for your application. Contact us – or browse our catalogue of over 1,300 products.