Rough and Tough, Part One

Much has changed since my early, vinyl-installation days. Life was simpler when everyone knew vinyl wouldn’t stick to such rough surfaces as brick, stucco or concrete. Customers would occasionally request their graphics be applied to such tough shapes as door handles or Volkswagen fenders. You told them vinyl manufacturers didn’t recommend or warranty applying vinyl to complex curves, and that satisfied them.

Mysteriously, the lifting of the “ban” on complex curves coincided with the development of machines that could print full wraps.

 

New opportunities, new challenges
The emergence of new technologies, films, adhesives, tools and techniques has spawned new venues for vinyl. With the development of films that conform to rough surfaces, stadiums, sidewalks, concrete pillars and brick buildings now provide suitable backdrops. Also, very pliable films now conform to the complex curves of motorcycle tanks and helmets, Beetles, Sprinters, HHR’s, Hummer H2’s and other “tough” applications.

I recently received a phone call from someone needing advice. A client wanted his shop to completely wrap a 10-ft.-tall sphere to replicate a golf ball – with no seams. I told them it was impossible, as they suspected. I suggested painting the sphere white and printing and installing graphics for the “dimples” on the ball.

Rough and tough jobs have become everyday occurrences for many vinyl shops. In addition to every vehicle, every concrete, brick and stucco surface in the world is now a “canvas,” or an advertisement waiting to happen. The obvious optimist sees opportunity and organizes his facility to optimize his offerings, while the prudent pessimist perceives that practice and perseverance will prevent problems. Keep both in mind; opportunity abounds, but caution is required.

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The rough stuff
As I wrote this column, I confirmed that 3M, Avery, FLEXcon and MACtac offer films designed for rough-textured surfaces. Manufacturers provide extensive product and installation details on their respective websites. Each film is unique, but all producers stress surfaces must be clean, with all loose particles removed, prior to installation. Some suggest power washing, while others recommend brushes, brooms or air blowers (either a compressor-driven machine or a leaf blower).

All agree the surface must be completely dry. If pressure washing is employed, it will generally take a minimum of 24 hours to adequately dry … if it doesn’t rain in that span. Applications should be performed in warmer temperatures to prevent moisture from forming under the vinyl during heating. If in doubt, try warming the surface to see if condensation occurs. If it does, it’s too cold to perform the application.

Let’s review what makes each product unique. 3M™ recommends its Scotchcal™ IJ 8624 graphic film for such moderately textured surfaces as concrete block, brick, tile, poured cement and industrial stucco. According to the company, the material will last more than two years inside for most applications and, depending on ambient conditions, three to six months outside (exposure to freeze-and-thaw conditions can reduce the lifespan).

3M’s TSA (textured surface applicator) tools apply the textured surface film with high heat. The company suggests wearing heat-resistant glove(s) for safety and setting the heat gun to 1,000° F.

Warm the vinyl up for two seconds, and roll it on immediately with TSA-1 or TSA-4 tools. When using the TSA-1 system, wear the glove on the “tool” hand only; the installer heats with one hand and rolls the film on with the other. With the TSA-4, installers hold the heat gun and roller. While wearing two gloves, installers heat and roll with two hands simultaneously.

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Generally, removals are heat-aided and adhesive-free. 3M also offers the CMP-1 Power Grip Magic Pad applicator, which conforms the media around protrusions, edges and tight areas with heat and pressure. It requires approximately the same heat as the TSA.

That’s the short version. For additional details, search for product and instructional bulletins (IB) for the 8624 film (IB 5.37) and TSA, CMP and related tools; visit http://solutions.3m.com/wps/portal/3M/en_US/Graphics/Scotchprint.

Avery Graphics markets MPI 6121 street-graphic film. Unlike others, this product is for horizontal surfaces only – for instance, sidewalks, parking lots and rougher concrete floors. Be aware, this isn’t a typical, textured-surface product. The film breaks apart as it’s installed, which allows it to conform to very rough surfaces. Print and use premask instead of laminate – laminates aren’t made to fracture the way MPI 6121 applies. Sweep the surface several times in different directions with a leaf blower to remove loose particles. Ideally, you’ll install in a 70° F environment; don’t install at less than 55° F.

To install MPI 6121, hinge an edge, remove the liner, squeegee firmly, then brush into the texture with a rivet brush or, for larger graphics or heavily textured surfaces, a very stiff broom. Remove the premask and re-squeegee, brush or sweep. On cooler days, Avery Graphics recommends using heat after installation.
To remove the film, use a pressure washer set at 2,000 psi. If possible, construct a barrier to trap residue. Depending on the surface’s roughness, a small amount of adhesive or graphic may remain.

For more information, search for PDS_MPI_6121_Street.pdf and IB6.60_Street_Graphics.pdf at www.na.averygraphics.com/AvGrNA_SF.asp.

MACtac manufactures RoughRAP™ WW100, a material that’s specifically designed for direct application onto brick walls. Using an overlaminate will extend the graphic’s life and allow easier handling during installation. Be sure the wall’s temperature exceeds 50° F. Heat up the film in small sections from left to right with a heat gun set to approximately 850° F. Then, press the heated film down into the rough texture of the brick wall with a semi-rigid, foam roller. If needed, remove all air pockets by poking with a pin (don’t use a knife) and pressing the air out with a soft cloth.

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After you’ve completed the application and removed all air pockets, heat the film to a minimum of 220° F one more time to relax and reset the film. To remove RoughRAP, heat it up and pull it off in small sections. The media will remove easily and cleanly.

To learn more about the material, search for TA2102_InstalGuide_RoughRAP.pdf or WW100 at www.mactac.com/index.php?id=40

FLEXcon offers FLEXmark® BILBRD™ BWV RTS. At 3.5 mils, this vinyl is designed for smooth or lightly textured indoor and outdoor surfaces like concrete, poured cement and concrete pillars or buildings. Install on warmer days (above 60° F) using a soft felt squeegee, foam roller or stiff brush. Don’t stretch the film. There’s a bit more information available at www.flexcon.com, but not much.

Next month, my column will cover the use of films designed to conform to vehicles’ complex curves and other challenging surfaces.