How to Apply Vinyl Graphics to Corrugations

Learn the traditional way to apply vinyl graphics to corrugated trailer surfaces.

Shortcuts can lead to problems. About 25 years ago I inspected a graphics failure on a corrugated trailer. The vinyl had lifted from the valleys of the corrugations and was cracking and peeling from the trailer surface. The installer had taken one of those shortcuts. He had tacked the graphic into position at the corners, allowing the film to bridge all corrugations. After heating the vinyl with his torch, the installer used a rivet brush to force the film into the valleys. Here’s the problem — vinyl will only stretch so far. Overstretching puts too much mechanical stress on the film. Sooner or later, the vinyl will lift or tent in corrugation valleys. To avoid these problems you should apply vinyl graphics in a relaxed state using the method described below.

Link to Vinyl Application Videos

Begin the application on the top of the crown of the corrugation, in the center of the panel. As you install the graphic from your starting point downward, the application sequence is (1) crown; (2) lower slope; (3) lower valley; (4) flat space; (5) upper valley; and upper slope.   Always start each squeegee stroke in the center of the panel, applying  pressure from the center to the outer edge.  A natural tendency is to apply strokes in one direction rather than using alternating strokes. This can cause misalignment  problems, especially when one graphics panel must match another. By applying strokes in one direction, you will most likely push the emblem in that direction, distorting the graphics panel. 

1. Starting in the center of the emblem, squeegee the film to the crown of the corrugation. For most applications, professional installers prefer hard nylon squeegees, such as the 3M gold squeegees. Softer plastic squeegees, such as the 3M blue squeegees, however, are preferred for application to corrugations. The softer squeegee will bend and conform around the curved ridge or crown of the corrugation. See photo A.

Photo A.

2.  Use the corner of the squeegee to apply the vinyl to the lower slope of the corrugation.  Some manufacturers recommend first applying the vinyl with your thumb (gloved hand) prior to using a squeegee. See photo B.

Photo B.

3. Run the edge of the squeegee in the lower corrugation valley. See Photo C.

Photo C.

4. Starting in the center in the lower valley, use overlapping downward strokes to squeegee the film to the flat area between the valleys. See Photo D.

Photo D.

5. Use the edge of the squeegee to apply the vinyl to the upper valley. See Photo E.

Photo E.

6. Use the corner of the squeegee to apply the film to the upper slope. See Photo F.

Photo F.

7. Before removing the application tape, cut the vinyl at the seams, using a utility knife. Vinyl, which is not cut, will inevitably tear as the trailer panels vibrate and flex with the movement of the trailer. Rather than tearing in a nice straight line, the vinyl rips, leaving ragged, unsightly edges.

8. After cutting the seams, remove the application tape by pulling it 180° against itself. See Photo G.

Photo G.

9. Check for air bubbles under the vinyl. Puncture an edge of the bubble with an air release tool or pin and force the air out with your thumb.  Never puncture the vinyl with a knife. A knife creates a slash, which will eventually open up. Finish your application by heating the vinyl film with a heat gun or propane torch.

10. Using an industrial heat gun or propane torch, heat the film and  run the edge of a squeegee in the corrugation valleys.  To prevent the squeegee from scratching or marring the vinyl surface, use a low friction sleeve. See Photo H.

Photo H.

11. Puncture the film in several places around the rivet heads with an air release tool or pin.  After heating the vinyl, use a rivet brush to burnish the vinyl around the rivet heads, using a circular motion. Regardless of the application technique or whether you use a rivet brush, felt squeegee or plastic squeegee, successful  graphics applications to rivets and corrugations require good mechanical pressure and the use of heat.  Heat is important in these applications, because it softens the vinyl, so it can conform to the irregular shapes of the corrugations and rivet heads.  Heat also breaks the memory of cast vinyl films, which prevents tenting around rivet heads and channeling in the corrugation valleys. Heat also softens the adhesive, which makes it flow, so it adheres faster and creates a long-lasting bond. See Photo I.

Photo I.

Application of graphics over rivets can be challenging. 

View RTape's video for tips on correctly installing vinyl films over rivets.  

12. Resqueegee all of the edges of the graphic.

13. Inspect your job and make sure that the vinyl conforms tightly to the rivets and corrugations.

14. Finally, pick up your mess.

For more information about graphics application, I highly recommend reading The Graphic Installers Handbook. This comprehensive guide to vinyl graphics installation is a “must have” resource for the beginner or seasoned professional. Written by Rob Ivers, the certification director for the PDAA (Professional Decal Application Alliance), the handbook covers every aspect of vinyl graphics installation. Contact Rob at www.robivers.com for more information about his book. Rob also offers PDAA certification classes as well as private graphics training.

Vinyl Application Videos

Squeegee Technique. Nothing is more basic in vinyl application than the squeegee. But some squeegees work better than others. And there are right ways and wrong ways to use this simple tool. This video clip reviews squeegee selection, squeegee care and squeegee technique. Click to Link

Wet Applications. Dry applications are typically recommended for most vinyl applications. For those exceptions to the rule, this instructional video explains the right way to perform a wet application. Click to Link

Application of Window Graphics. Installing vinyl graphics on glass can be challenging, because the adhesive aggressively grabs onto this high energy surface. Repositioning graphics on window is generally difficult, if not impossible. This instructional video explains how to dry apply window graphics right the first time. It also describes the necessary steps required for surface preparation. Click to Link

Transferring Frosted Window Graphics Films.  Because frosted window films are highly textured, transferring cut vinyl graphics can be problematic. This video provides direction in selection of the right application tape and how to apply these films quickly, easily and without problems. Click to Link

3-Step Surface Prep. This instructional video describes how to properly clean the surface of a vehicle before applying pressure sensitive vinyl graphics to a trailer or doing a full wrap of a car or van. This three step surface prep involves detergent washing, solvent cleaning and a final wipe down with IPA. Click to Link

Vinyl Application Over Rivets. Applying vinyl graphics on vehicle surfaces with rivets is challenging for most sign makers. Vinyl failures to these surfaces are all too common. This video demonstrates some tips and procedures, used by professional decal installers, which will make these demanding applications easier and more trouble-free.  Click to Link

Vinyl Application to Corrugations. Learn how to apply vinyl graphics to corrugations in a relaxed state. Forcing films into the valleys of corrugations puts too much mechanical stress on the film. Sooner or later, the vinyl will lift or tent in valleys. Click to Link

Applying Air Egress Vinyls. Vinyl films with air egress release liners have almost eliminated bubbles and wrinkles from applied graphics. Air egress release liners with their highly textured surface structure are problematic. Not much will stick to these liners other than the vinyl film. At RTape our best premask solution for air egress liners is a special Conform® tape called 4761RLA. Click to Link

About Jim Hingst: After fourteen years as Business Development Manager at RTape, Jim Hingst retired. He was involved in many facets of the company’s business, including marketing, sales, product development and technical service.

Hingst began his career 42 years ago in the graphic arts field creating and producing advertising and promotional materials for a large test equipment manufacturer.  Working for offset printers, large format screen printers, vinyl film manufacturers, and application tape companies, his experience included estimating, production planning, purchasing and production art, as well as sales and marketing. In his capacity as a salesman, Hingst was recognized with numerous sales achievement awards.

Drawing on his experience in production and as graphics installation subcontractor, Hingst provided the industry with practical advice, publishing more than 150 articles for  publications, such as  Signs Canada, SignCraft,  Signs of the Times, Screen Printing, Sign and Digital Graphics and  Sign Builder Illustrated. He also posted more than 325 stories on his blog (hingstssignpost.blogspot.com). In 2007 Hingst’s book, Vinyl Sign Techniques, was published.  Vinyl Sign Techniques is available at sign supply distributors and at Amazon. 

Slides of Jim's Artwork

© 2016 Jim Hingst