A high-rise building experiencing curtainwall leakage was targeted for remedial repairs to correct the problem. The cost of a conventional repair using a new mullion cover and sealant detail was judged to be prohibitively high, and an alternate design was sought. The alternate design selected required no new extrusions and incorporated a modified fillet bead with a foam bond-breaking tape. As this was an unproven detail, a test program was initiated to compare its performance to that of the mullion cover repair. Both repair designs were subjected to the equivalent of five years expansion and contraction at twice the anticipated extension range. Both designs performed without adhesive or cohesive failure of the sealants observed during the test period. The alternate design was judged to be comparable in extension performance and a viable substitute for the more expensive mullion cover repair.
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