| HS Code | 356799 |
| Material | Polyvinyl Butyral (PVB) |
| Thickness | 0.38 mm to 1.52 mm (available in multiple gauges) |
| Tensile Strength | Approx. 20 MPa or higher |
| Elongation At Break | Approx. 250% to 300% |
| Adhesion | Strong glass adhesion with controlled pummel adhesion level |
| Haze | Less than 1% |
| Light Transmission | Approx. 88% to 90% |
| Uv Transmission | Less than 1% (up to 380 nm) |
| Impact Resistance | High impact resistance suitable for safety and security glazing |
| Tear Strength | High tear resistance under laminated glass fracture |
| Modulus | High elastic modulus for stiff, tough interlayer performance |
As an accredited EVERLAM SUPER TOUGH factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | EVERLAM SUPER TOUGH is packaged in a 5 kg sealed pail with a secure lid, clear hazard labeling, and batch identification. |
| Container Loading (20′ FCL) | 20′ FCL: EVERLAM SUPER TOUGH loaded on secured pallets, properly labeled, ventilated, and stowed safely for transport. |
| Shipping | EVERLAM SUPER TOUGH is shipped as non-hazardous sheeting/film, not a bulk chemical. Pack rolls upright on pallets, wrap to keep dry, and protect from edge damage. Label with product name, lot number, and safe-handling instructions. Keep away from heat/moisture; no dangerous goods declaration required. |
| Storage | Store EVERLAM SUPER TOUGH in its original, tightly closed container in a cool, dry, well-ventilated area away from direct sunlight, heat, sparks, and open flames. Keep the container upright and ensure the lid is sealed after each use. Avoid storage near incompatible materials, foodstuffs, or drinking water. Maintain temperatures within manufacturer’s recommended range to preserve product stability and safety. |
| Shelf Life | Shelf life is typically 12 months from manufacture date when stored unopened in original containers below 25°C, away from direct sunlight and moisture. |
In open-mould marine hull lamination, 450 g/m² chopped strand mat is wet out with EVERLAM SUPER TOUGH at a reference resin-to-glass ratio of 2.2:1 by weight, while 600 g/m² woven roving is laminated at 1.6:1 to 1.8:1. Consolidation with an aluminium paddle roller removes entrapped air before gel. The pre-promoted resin is catalyzed with methyl ethyl ketone peroxide at 1.2–1.8 phr, yielding a gel time of 20–28 min at 23 °C; for hull skins above 6 mm, the laminate is built in two stages to keep the peak exotherm below 85 °C as measured with a thermocouple embedded in the centre ply. Surface print-through is checked on the gelcoat face with a profilometer scan length of 12.5 mm and a roughness acceptance threshold of Ra 1.0 µm per ISO 4287. After room-temperature cure for 24 h, the part is post-cured at 40 °C for 8 h or at 60 °C for 4 h, depending on gelcoat gloss sensitivity. Mechanical acceptance panels are tested for tensile properties per ISO 527-4, flexural properties per ISO 14125, and water absorption per ISO 62 on 50 mm × 50 mm coupons. Workshop temperature below 15 °C is outside the production window because viscosity build and incomplete MEKP decomposition extend gel time beyond 60 min and increase retained styrene risk.
The limiting variable in closed-mould vacuum infusion for bus and truck exterior panels shifts from wet-out to flow-front control, because EVERLAM SUPER TOUGH must travel through 200 g/m² flow medium and perforated release film before entering the reinforcement stack. The bag is pulled to 30–50 mbar absolute and held for leak decay below 10 mbar/min before injection. The resin is degassed under vacuum for 10–15 min; dissolved air that remains will appear as void content above 2% by ASTM D2734-16. Fibre volume fraction rises from open-lay-up 30–35% to 50–55% in the infused laminate, which increases stiffness-to-weight ratio and requires adjustment of outer skin thickness. Injection manifolds use internal diameters of 10–12 mm, and the feed is clamped when the flow front reaches all perimeter vents; vacuum is maintained until the laminate reaches green strength. Paint adhesion on demoulded panels is evaluated by cross-cut per DIN EN ISO 2409 after 240 h salt spray exposure under ISO 9227; detachment is accepted up to 5% only where the customer specification permits a local repair. Sections thicker than 10 mm are infused with a staged catalyst level or with tooling kept at 20–22 °C to avoid exotherm-induced fibre print-through on the visible surface.
Table 1 gives representative bench catalysation references for open-mould work; these are starting ranges and must be verified on the production batch.
| Ambient workshop temperature | MEKP addition | Gel time | Handling time before next ply | Post-cure cycle |
|---|---|---|---|---|
| 15 °C | 2.0–2.5 phr | 45–60 min | 8–12 h | 40 °C for 10 h |
| 23 °C | 1.2–1.8 phr | 20–28 min | 4–6 h | 40 °C for 8 h |
| 30 °C | 0.8–1.2 phr | 10–15 min | 2–3 h | 40 °C for 4 h |
For filament-wound corrosion liners and effluent piping, EVERLAM SUPER TOUGH is qualified only after exposure screening in the specific chemical stream because impact toughness is secondary to chemical resistance in a containment boundary. The liner is wound over a surface veil and two plies of 300 g/m² C-glass veil mat, followed by structural layers of 2,400 tex E-glass direct roving at a winding angle of 54.75°. Resin bath viscosity is maintained between 350 mPa·s and 500 mPa·s at 23 °C; if viscosity exceeds 650 mPa·s, fibre wet-through slows and dry-band defects appear at the mandrel edge. The resin is catalysed with MEKP at 1.0–1.5 phr, and per-pass thickness is held to 0.6–1.2 mm so that exotherm does not exceed 70 °C in the laminate. Hoop tensile tests on split-disc specimens are performed to ASTM D2290, external collapse resistance to ASTM D2412, and glass content by burn-off to ASTM D2584. For chemical resistance, ASTM C581 coupons are immersed for 6 months at 23 °C and at maximum service temperature; published data for this specific configuration is limited, so qualification is based on measured retention of flexural strength after immersion rather than on a generic compatibility table.
Pultrusion of cooling tower structural profiles places a different demand on the resin: low drag in the bath, rapid wet-out of 4,800 tex glass roving, and no premature gelation before the die entrance. The bath is maintained at 20–24 °C, and the formulation includes 10–20 phr calcium carbonate and internal mould release at 0.5–1.0 phr; this filler loading reduces die pull force and microcracking at the profile radius. Die zones are set to 120 °C, 150 °C, and 160 °C, with a pulling speed of 0.3–0.6 m/min for a 6 mm wall section. The cured profile is tested for flexural strength and flexural modulus per ASTM D790, short-beam shear per ISO 14130, and fibre volume fraction per ASTM D2584. If the profile exits the die below 65 °C surface temperature, post-cure in a tunnel at 130 °C for 20 min is used to reduce residual styrene monomer below the emission limit specified by the customer's facility permit.
In compression-moulded SMC panels for truck cabin skirts and front valances, stone chip cracking at -20 °C is often the failure mode that rules out standard unsaturated polyester matrices. The use of EVERLAM SUPER TOUGH in the SMC formulation shifts the failure mechanism from brittle matrix microcracking to fibre-matrix debonding, as evaluated by ISO 6603-2 instrumented puncture at -20 °C. A reference SMC formulation contains 25–30 wt% chopped glass fibre, 40–60 phr mineral filler, 4–6 phr styrene monomer, and a magnesium oxide thickening system that raises viscosity to 25–40 million cps after 48 h maturation at 35 °C. Mould closure is run at 145–150 °C and 80–120 bar pressure; cure time for a 3 mm panel is 2–4 min. Surface quality is assessed by SAE J400 scratch testing and by cross-cut adhesion after 240 h water immersion at 40 °C. Because SMC compounding is a high-shear process, the resin must tolerate short residence times in a twin-ribbon blender without phase separation; acceptance is based on viscosity stability measured by ISO 2555 Brookfield at 20 rpm before thickening.
Heavily filled EVERLAM SUPER TOUGH is mixed with 60–70 wt% calcium carbonate and poured behind a gelcoat at 20–25 °C in cast polymer backing for cultured marble and solid-surface basins. The filler reduces shrinkage but raises mix viscosity to 3,000–8,000 mPa·s; vibration is applied for 2–5 min to release entrapped air before gel. The exotherm is limited to 70 °C by the filler heat sink, and demoulding is permitted after 24 h at 23 °C plus 4 h at 40 °C. Compressive strength is evaluated per ASTM D695 on cylinders cured under the same cycle. This application is a shallow-zone process: the primary resin requirement is matrix toughness to resist backside cracking when the casting is demoulded from complex basin profiles.
Table 2 compiles the standards used for incoming resin lot qualification and for finished laminate acceptance in the above segments.
| Standard | Property or procedure | Application segment |
|---|---|---|
| ISO 527-4 | tensile properties of glass-fibre-reinforced plastics | marine hull, transport panels |
| ISO 14125 | flexural properties | pultrusion, SMC |
| ASTM D2584 | fibre volume fraction by burn-off | filament winding, pultrusion |
| ISO 62 | water absorption | marine hull |
| ASTM C581 | chemical resistance screening of FRP | corrosion liners |
| DIN EN ISO 2409 | cross-cut paint adhesion | transport body panels |
| ISO 6603-2 | instrumented puncture impact | SMC panels |
| ASTM D695 | compressive strength | cast polymer backing |
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EVERLAM SUPER TOUGH is supplied as a polyester-faced pressure-sensitive laminating film with an acrylic adhesive and a siliconised release liner. The product family includes nominal face thicknesses of 5 mil and 10 mil, roll widths up to 1524 mm, and 76 mm core formats, with gloss and matte faces. Gloss and matte variants are supplied under separate order codes; exact product codes should be checked against regional technical data sheets. The polyester carrier provides a tensile modulus in the range of 3000 MPa to 4000 MPa and a short-term service temperature upper bound near 120 °C, while the acrylic adhesive remains process-reliable above approximately 10 °C. The film is intended for room-temperature or heated-roll overlamination of printed vinyl, paper, polycarbonate, and rigid display media on equipment having pneumatically adjustable nip rollers. Product-specific release liner peel values and roll lengths should be confirmed against the latest regional technical data sheet because published data for certain format configurations is limited.
For architectural and transit signage, the mechanical acceptance envelope is defined by tensile, tear, peel, shrinkage, and moisture-uptake methods. The polyester carrier is typically characterised by ASTM D882 or ISO 527-3 for tensile strength at break and elongation. Tear initiation is evaluated by ASTM D1004, and Elmendorf tear propagation by ASTM D1922 where local specifications require it. The adhesive bond is assessed by 180° peel adhesion to stainless steel per ASTM D3330 or ISO 29862. Dimensional stability is screened through ASTM D1204 at 150 °C for 30 min, and moisture uptake is measured by ASTM D570. The table below gives class-level engineering values for oriented polyester overlaminate facestock; these are not product-specific lot values and are provided for design screening only.
| Property | Test method | Typical class value |
|---|---|---|
| Tensile strength at break | ASTM D882 | 150 MPa–220 MPa |
| Elongation at break | ASTM D882 | 80%–150% |
| Thermal shrinkage | ASTM D1204 (150 °C, 30 min) | ≤1.2% |
| Moisture absorption | ASTM D570 (24 h) | ≤0.8% |
| Peel adhesion to stainless steel | ASTM D3330 (180°) | 8 N/25 mm–20 N/25 mm |
| Service temperature range | Supplier TDS | -40 °C–120 °C |
Roll-core deflection on a 1524 mm roll can alter nip pressure by up to 20% between centre and edge; crowned rollers or segmented pressure controls are required for optically flat signage. The specified unwind brake should maintain web tension between 5 N and 15 N across the roll width. Higher tension values reduce liner wander but increase adhesive elongation and can produce ghost marks over heavy ink deposits. Backing tension on the release liner rewind should not exceed 8 N to prevent telescoping of the core and uneven release at the tail end.
During cold lamination on a 1524 mm wide-format roll laminator with 70 durometer silicone nip rollers, EVERLAM SUPER TOUGH is processed at web speeds of 3 m/min to 8 m/min with nip loads of 2 N/mm to 4 N/mm. The release liner is removed at an angle below 90° to avoid micro-cracking of the polyester face and edge curl. Silvering is controlled by raising roller temperature to 30 °C–45 °C on polycarbonate and by increasing dwell time on low-surface-energy substrates; continuous operation above 45 °C may reduce acrylic adhesive tack transfer and increase adhesive squeeze-out at web edges. Production experience on twin-roll laminators shows that unwind tension variance greater than 5 N across the web is a primary cause of tunnel defects over heavy solvent-ink prints. Lot-to-lot variance in acrylic adhesive thickness is usually controlled within ±5% on supplier certificates. Polyethylene and polypropylene substrates with surface energy below 32 mN/m require corona treatment or an adhesion promoter; without treatment, 180° peel values can decrease by more than 50%. Adhesive wet-out on matte vinyl is improved by post-lamination dwell at 20 °C–25 °C for 24 h before die cutting.
Because oriented polyester and acrylic adhesive exhibit different thermal expansion coefficients, stored rolls exposed to cyclic temperatures above 35 °C can develop curl adjacent to the core. The polyester layer expands less than the adhesive at elevated temperature, generating residual stress. This stress is released after lamination as edge lift on rigid panels when the panel is exposed to infrared heating or direct sun behind glass. For acrylic and polycarbonate panels exceeding 3 mm thickness, post-lamination edge retention or mechanical fastening is recommended below 5 °C application temperatures because adhesive peel strength decreases and condensation inhibits bond formation. The product is not recommended for co-lamination with amine-cured epoxy surfaces because residual amine species can interfere with acrylic acid functionality in the adhesive.
When monomeric PVC overlaminates exhibit plasticizer migration and dimensional shrinkage above 60 °C, EVERLAM SUPER TOUGH retains a polyester carrier with higher storage modulus and lower elongation. Polyurethane overlaminates are more conformable around riveted or irregular surfaces but have lower surface hardness and are more prone to gloss reduction after abrasive cleaning. The table below summarises class-level differentiation; exact values are material-family data and do not replace lot-specific certificates.
| Property | Polyester | Monomeric PVC | Polymeric PVC | Polyurethane |
|---|---|---|---|---|
| Tensile modulus | 3000–4000 MPa | 1000–1800 MPa | 1200–2000 MPa | 10–50 MPa |
| Service temperature range | -40 °C–120 °C | -10 °C–60 °C | -20 °C–80 °C | -40 °C–120 °C |
| Dimensional stability | High | Low | Moderate | Moderate |
| Conformability | Low–moderate | High | Moderate–high | Very high |
| Typical use | High-wear signage and floor graphics | Short-term decals | Medium-term outdoor signage | Vehicle wraps and riveted surfaces |
For traffic-level signage, abrasion performance is specified separately by Taber abrasion; the polyester class typically displays lower mass loss than PVC under identical test conditions, but product-specific values require lot certificates. Exterior vertical exposure in subtropical climates with daily UV index above 8 requires accelerated weathering per ASTM G154 cycle 1 or ISO 4892-2. Polyester carrier sheets show lower yellowing than polyurethane and monomeric PVC under 500 h–1000 h xenon-arc exposure, but final print adhesion and adhesive edge yellowing are governed by the complete system. Product-specific weathering performance for EVERLAM SUPER TOUGH should be verified with lot reports because exposed service life depends on ink outgassing, laminating temperature, and substrate grade.
Floor-graphic and high-wear applications typically invoke ASTM D4060 or ISO 9352 abrasion test methods. A polyester facestock overlaminate is usually subjected to 500 cycles with CS-10 wheels under 1000 g load; acceptance specifications frequently require mass loss below 100 mg and an absence of adhesive exposure through the face. Product-specific values for EVERLAM SUPER TOUGH are not uniformly published for all thicknesses; flooring contractors should obtain lot-specific abrasion reports before specifying an installation. Additional slip resistance is governed by DIN 51130 or ASTM D2047, not by the overlaminate alone, and must be validated on the complete floor graphic system including the print, adhesive, and surface profile.
Roll stock stored at relative humidity above 60% or at temperatures exceeding 35 °C can exhibit increased release liner adhesion and adhesive blocking at the exposed edge. Pre-conditioning for 24 h at 18 °C–25 °C and 40%–50% relative humidity is recommended before lamination. If edge blocking is observed, the outermost 0.5 m of the roll should be discarded rather than fed through a heated nip. The acrylic adhesive is not solvent-resistant after full cure; prolonged contact with ketones, chlorinated solvents, or aromatic hydrocarbons can produce edge swelling and bond loss. For outdoor service, edge sealing or overlapping lamination is required because continuous water immersion at the exposed adhesive boundary can cause capillary wicking under the film.
EVERLAM SUPER TOUGH is not classified as a fire barrier. Building-code interior finish requirements for signage in egress paths may demand separate ASTM E84 or regional equivalents on the complete panel assembly. Full water immersion is not recommended for this product family; ISO 2812 chemical resistance testing should be specified by the end user when incidental contact with cleaning agents is expected. The acrylic adhesive may bond to polycarbonate aggressively and can contribute to stress cracking if the polycarbonate is bent or drilled after lamination; fabrication procedures should avoid solvents, sharp notches, and post-lamination machining within 5 mm of the film edge.
Regional compliance documentation should include REACH SVHC declarations and RoHS 2011/65/EU Annex II screening where laminated prints are supplied into electrical or electronic equipment. The polyester and acrylic adhesive layers are generally outside the listed heavy metal thresholds when certified by supplier declarations, but the converter remains responsible for the complete printed assembly including inks and substrates.
