Leading Truck Manufacturer and ForzaBOND T-OS150 Case Study

Eliminating Heat-Cured Plastisol and Streamlining Truck Manufacturing

A leading manufacturer of heavy-duty commercial vehicles continuously evaluates opportunities to improve production processes while maintaining the durability required for demanding transportation environments.

Sealing technologies play an important role in truck manufacturing, protecting assemblies from moisture intrusion, vibration, and environmental exposure. However, some traditional sealing systems introduce process limitations that can add complexity to the production line.

When the manufacturer began evaluating alternatives to a plastisol sealant used in part of their manufacturing process, they partnered with Forza to investigate a room-temperature curing solution capable of maintaining performance while simplifying production.

The result allowed the manufacturer to eliminate a major piece of curing equipment from their manufacturing operation.

The Challenge

Plastisol sealants have long been used in automotive and transportation manufacturing because of their durability and sealing performance. However, plastisols require elevated temperatures to cure properly, meaning parts must pass through a curing oven before the sealant develops its full properties.

In this production process, sealed components had to travel through a 40-foot curing oven before the sealant could fully set.

While the system functioned reliably, it introduced several manufacturing challenges.

Large Equipment Footprint

The curing oven occupied a substantial portion of the production floor. In modern manufacturing environments, large fixed equipment can limit workflow flexibility and reduce available space for other operations.

Energy Consumption

Maintaining consistent curing temperatures requires continuous energy input. Over time, this contributes to both operational costs and facility energy demands.

Added Process Complexity

Because the sealant required thermal activation, the curing step had to be integrated into the production line. Parts could not move beyond this stage until the curing cycle was complete.

Engineers began exploring whether a room-temperature curing alternative could deliver the same sealing performance without the need for heat-activated curing.

The Solution: ForzaSEAL® T-OS150

After evaluating the application, Forza introduced ForzaSEAL® T-OS150, a self-leveling performance polymer designed for industrial sealing applications across a wide range of substrates.

Unlike plastisol systems, T-OS150 cures through ambient moisture exposure, allowing it to develop strength without requiring elevated temperatures. This characteristic made it possible to eliminate the thermal curing stage entirely.

T-OS150 provides durable adhesion and flexibility across many common manufacturing materials, including steel, aluminum, glass, concrete, and plastics.

The sealant’s self-leveling viscosity allows it to flow into seams and joints during application, helping ensure consistent coverage and sealing performance.

From a manufacturing standpoint, T-OS150 can be applied using standard extrusion methods and typically requires minimal surface preparation beyond ensuring that substrates are clean and free of contaminants.

Because the sealant cures through moisture exposure, the majority of its strength develops within the first 24 hours under normal environmental conditions.

Results Achieved

After implementing ForzaSEAL® T-OS150 in the assembly process, the manufacturer realized several important operational improvements.

Elimination of the Curing Oven

With T-OS150 curing at ambient conditions, the 40-foot plastisol curing oven was no longer required, freeing valuable floor space within the manufacturing facility.

Simplified Production Workflow

Removing the thermal curing stage streamlined the production process. Components could move through assembly without waiting for a dedicated curing cycle.

Reduced Energy Requirements

Eliminating the oven removed the continuous energy demand required to maintain elevated curing temperatures.

Reliable Seal Performance

T-OS150 forms a flexible, weather-resistant seal capable of accommodating vibration and thermal movement common in heavy-duty transportation environments.

The result was a simpler manufacturing process that maintained the sealing performance required for commercial truck production.

Why ForzaSEAL® T-OS150 Performs

ForzaSEAL® T-OS150 is a self-leveling performance polymer sealant engineered to deliver long-term durability while remaining flexible across changing environmental conditions.

Key technical properties include

Tensile strength of 261 psi

Elongation at break of 150%

Shore A hardness of 28

Skin formation in approximately 41 minutes

• Service temperature range from –75°F to 400°F for limited exposure

These characteristics allow the sealant to maintain adhesion while accommodating vibration, temperature fluctuations, and mechanical movement typical in commercial vehicle assemblies.

Additionally, T-OS150’s weather resistance, UV stability, and non-yellowing formulation help ensure long-term durability in demanding operating environments.

The Lasting Impact

By replacing a heat-activated plastisol sealant with ForzaSEAL® T-OS150, the manufacturer simplified their manufacturing process while maintaining the durability required for heavy-duty vehicle applications.

The change removed large curing equipment, reduced energy consumption, and freed valuable factory space while delivering a flexible, weather-resistant seal designed to perform under demanding transportation conditions.

The project demonstrates how modern polymer sealant technology can help manufacturers streamline production processes while maintaining the performance standards required in high-reliability industries.