Operable Partition Systems Manufacturer and OS2 Case Study

Eliminating Field Failures and Improving Manufacturing Reliability in Folding Wall Systems

A manufacturer of operable partition wall systems produces large folding wall assemblies used in gymnasiums, conference centers, schools, and other commercial buildings. These movable walls allow large spaces to be quickly divided while maintaining acoustic performance and structural durability.

Because the panels that form these wall systems must withstand constant movement, vibration, and handling during installation and use, the integrity of each panel assembly is critical. When the manufacturer began experiencing reliability issues tied to their existing bonding process, they partnered with Forza to evaluate a more robust solution.

The resulting change improved both manufacturing reliability and long-term performance in the field.

The Challenge

Operable partition panels are typically constructed by bonding interior board materials—such as gypsum—to metal framing structures that give the panel its strength and dimensional stability.

The manufacturer had traditionally relied on a single-component solvent-based adhesive to bond these components during assembly. While the adhesive initially appeared effective on the production line, its performance was inconsistent once the panels entered service.

Several issues emerged

Slow Curing and Handling Limitations The adhesive required significant drying time before assemblies could be confidently moved through production. In a high-throughput manufacturing environment, this created uncertainty about when panels had developed sufficient bond strength.

Flammability Concerns in Production Because the adhesive was solvent-based, it introduced flammability considerations that complicated handling, storage, and ventilation requirements within the facility.

Field Failures After Installation Perhaps most concerning, some panels experienced bond failures after installation. Panels that appeared intact leaving the factory occasionally separated in the field, creating costly warranty service calls and installation disruptions.

The manufacturer needed a solution that would eliminate reliability issues while improving safety and consistency in the manufacturing process.

The Solution: ForzaSEAL® OS2

After reviewing the application requirements, Forza introduced ForzaSEAL® OS2, a single-component moisture-curing sealant designed to provide strong adhesion while maintaining long-term flexibility across a wide range of materials.

Unlike many traditional adhesives that cure rigid and brittle, OS2 forms a durable, permanently flexible bond line capable of absorbing movement, vibration, and temperature fluctuations without cracking or losing adhesion.

Key attributes that made OS2 suitable for the application include

• Strong resistance to impact, peel forces, and flexing

High weather and UV resistance

Low-temperature flexibility retained down to –75°F

• Non-yellowing formulation that does not shrink, bubble, or crack during cure

Immediate paintability and clean finishing characteristics

In addition, OS2 is a single-component moisture-curing sealant, eliminating the need for mixing and simplifying application on the assembly line. The material can be applied by extrusion or trowel and adheres to a wide variety of substrates including metals, masonry, glass, plastics, and wood—making it well suited for the mixed-material construction typical of partition wall panels.

Results Achieved

After implementing ForzaSEAL® OS2 within the production process, the manufacturer experienced significant improvements in both manufacturing reliability and long-term product performance.

Improved Production Consistency Because OS2 develops the majority of its strength within the first 24 hours, panel assemblies achieved reliable bonding earlier in the manufacturing process, allowing production to move forward with greater confidence.

Safer Manufacturing Environment Switching away from a solvent-based adhesive eliminated the flammability concerns associated with the previous bonding process.

Dramatic Reduction in Field Failures The flexible bond line created by OS2 proved far more resilient to the vibration, movement, and environmental changes experienced by operable wall panels.

As a result, field callback rates dropped by approximately 95%, dramatically reducing costly service issues and improving product reliability.

Why ForzaSEAL® OS2 Performs in This Application

Operable partition systems experience repeated movement and dynamic stresses during normal use. In such applications, adhesives that cure into rigid structures can become susceptible to cracking or debonding over time.

ForzaSEAL® OS2 addresses this challenge by combining adhesion strength with long-term elasticity.

Technical characteristics supporting this performance include

Tensile strength of 225 psi

Elongation at break of 252%

Shore A hardness of 47

Non-sag formulation for controlled application

• Skin formation in less than 75 minutes at 77°F and 55% relative humidity

These properties allow OS2 to maintain bond integrity while accommodating the dimensional changes and stresses inherent in large movable wall systems.

Additionally, the product’s broad substrate compatibility enables bonding and sealing across materials such as aluminum, steel, glass, concrete, and wood—common components within architectural panel assemblies.

The Lasting Impact

By transitioning to ForzaSEAL® OS2, the manufacturer replaced an unreliable bonding process with a durable and flexible solution that better matched the demands of their product design.

The change delivered several lasting benefits

Dramatically reduced field failures

Improved manufacturing safety

More predictable production outcomes

Increased confidence in long-term panel performance

The project illustrates how selecting the correct adhesive chemistry—particularly one capable of accommodating movement and environmental stress—can significantly improve both manufacturing operations and product reliability.

For manufacturers working with dynamic assemblies or dissimilar materials, flexible hybrid sealant technologies such as OS2 offer a powerful alternative to traditional rigid adhesives.