Soudal Soudafoam FR HY - HIGH YIELD Fire Rated Expanding Foam

Health & Safety Recommendations

Read the product label and Safety Data Sheet before use and follow all site safety rules for passive fire protection work. Soudal Soudafoam FR HY is a gun grade polyurethane foam that cures by moisture, so always wear suitable gloves and eye protection and avoid skin contact with uncured foam. Use only in well ventilated areas and take extra care in confined spaces, service risers and ceiling voids where vapours can build up.

When working at height around door heads, lintels, soffits or ceiling penetrations, ensure safe access equipment is in place and the working area is kept clear. If drilling or preparing adjacent substrates, use suitable dust control and respiratory protection. If vapourising product using specialist equipment such as a compressor, additional safety measures are required and only competent users should carry out that method.

Do not smoke, eat or drink during use. Keep the can away from heat sources, sparks and open flames, and store and use it within the stated temperature ranges. If uncured foam contacts skin, clean immediately in line with the Safety Data Sheet. Cured foam must be removed mechanically and must never be burnt away.

Substrate Suitability

Soudal Soudafoam FR HY is designed for primerless adhesion on most common construction materials typically found in fire rated jointing and sealing work, including masonry, concrete, brick, block, timber, many metals and rigid plastics used in building assemblies. It is suited to static joints and void filling where movement is limited and where the detail is part of a tested passive fire protection approach.

It is not suitable for low surface energy plastics such as PE, PP and PTFE. Where substrates are unusual, contaminated, friable, heavily painted, or where the joint is part of a compliance-critical fire stopping system, carry out a preliminary adhesion and compatibility test and ensure the overall joint design matches the required fire resistance specification.

Surface Preparation

Ensure the joint, opening or cavity is structurally sound and correctly formed before foaming. All surfaces must be clean, stable and free from dust, loose particles, oil, grease, release agents and standing water. Remove old failing sealant, loose debris and crumbling material so the foam bonds to a firm edge rather than to contamination.

For best curing and cell structure, lightly moisten the surfaces with a fine water mist before application, particularly in dry environments, on absorbent masonry, or where the air is low in humidity. Do not soak the area, the aim is a light film of moisture to support controlled moisture curing. If applying in layers, re-moisten lightly between layers to support even cure through the foam body.

Application Method

Soudal Soudafoam FR HY is gun grade and should be applied using a suitable professional applicator such as the Soudal Profi PU Expanding Foam Gun or the Soudal Red PU Expanding Foam Gun. Bring the can to a stable working temperature within the recommended range and shake vigorously for at least 20 seconds to ensure the contents are fully mixed and ready to dispense consistently.

Attach the can securely to the foam gun, keeping the can upright during fitting. Adjust the gun’s flow control so output can be controlled smoothly, then test dispense onto waste material to confirm an even foam structure. Insert the nozzle into the opening or joint and apply steadily, working from the deepest point outwards where possible to reduce voiding and improve continuity of the seal.

Fill holes, cavities and joint spaces to approximately 65% of their volume, as the foam will expand during curing. For wider or deeper voids, apply in controlled layers rather than attempting to fill in one pass, allowing the foam to expand and stabilise before applying the next layer. Lightly mist each layer before continuing, then keep the bead continuous and even along the full joint run to avoid gaps. Where the detail forms part of a fire rated joint configuration, ensure the geometry, depth and backing materials follow the tested system detail, and do not rely on foam alone where a multi-component fire stopping arrangement is required.

Coverage

Coverage depends on joint size, depth, application technique, substrate condition and site temperature. As an indicative guide, a 750ml can yields approximately 44L of foam under EN17333-1 box yield testing, with a joint yield of approximately 35M under EN17333-1, reflecting the high yield nature of FR HY. In practice, always allow for variation on site, particularly where voids are irregular or where the foam is being used as a large gap filler within passive fire protection detailing.

For ordering and job planning, treat the yield figures as a benchmark rather than a guarantee, and factor in additional material where the joint configuration requires deeper fills, multiple layers, or where wastage is expected during trimming and finishing.

Curing Time

Soudafoam FR HY cures by moisture, so curing speed is influenced by humidity, temperature, bead thickness and whether the surfaces have been misted correctly. Skin formation is approximately 6.5min under standard conditions and the foam can typically be cut after approximately 20min, helping maintain efficient progress on site.

Full cure will take longer than cutting time and increases as bead thickness increases. Avoid heavy loading, sealing over, or enclosing the foam until it has cured sufficiently for the application. If the foam is being used as part of a fire rated joint arrangement, do not disturb or compress the foam after expansion, and complete any associated fire sealing steps in accordance with the system specification.

Cleaning

Fresh, uncured foam can be removed from tools and non-porous surfaces using Soudafoam Gun & Foam Cleaner. Always test Soudal Gun & Foam Cleaner on sensitive substrates first, as some plastics, lacquers and painted finishes can be affected. Keep the gun and nozzle clean during use to prevent build-up that can affect flow control and bead quality.

Cured foam can only be removed mechanically by trimming and scraping. Where additional assistance is required for cured residue, use Soudal Cured PU Remover, following the product instructions and testing first on delicate surfaces. Do not attempt to burn off cured foam.

Limitations

Soudafoam FR HY is not UV-resistant, so exposed cured foam must be protected from sunlight by overpainting, sealing with a compatible sealant, or covering with a suitable finishing material. It is intended for static joints and is not suitable for joints subject to significant movement, abrasion, or continuous water immersion.

Do not use on PE, PP or PTFE, and avoid application to contaminated, oily, dusty or unstable substrates. Fire performance depends on joint configuration, substrate type and the overall tested system detail. Although the product is tested for fire resistant jointing and can achieve up to 4 hours depending on configuration, it must be used in suitable joint designs and in accordance with the relevant passive fire protection specification. Never assume a single product will deliver compliance in every penetration or joint without reference to the correct tested detail.

Other Information

Apply only within the recommended temperature ranges: can temperature +5°C to +30°C, ambient temperature +5°C to +30°C, and surface temperature +5°C to +35°C. The foam delivers strong thermal and acoustic benefits once cured, including thermal conductivity of approximately 0.036W/m.K and sound insulation of 60dB, making it useful for sealing gaps where heat loss and noise transfer are concerns alongside fire rated detailing.

Once cured, the foam remains stable with shrinkage after curing below 2% and expansion after curing below 2%, supporting long-term seal integrity when installed correctly. Temperature resistance of the cured foam is approximately -40°C to +90°C. For best results in passive fire protection work, ensure the full joint line is planned before application, including corners, junctions and penetrations, and maintain consistent application depth and continuity so the sealing line performs as intended.

Q) What is Soudal Soudafoam FR HY High Yield Fire Rated Expanding Foam?

A) Soudal Soudafoam FR HY High Yield Fire Rated Expanding Foam is a one-component, gun grade polyurethane foam made for high performance gap filling and sealing, including passive fire protection detailing. It is applied into static joints and voids where it expands to fill and insulate, then cures by moisture to form a stable, closed cell structure. The High Yield formulation delivers more than 25% higher yield than standard Soudafoam FR, helping you complete more work per can. Once cured, it provides strong thermal and acoustic performance, dependable adhesion to most common building materials without primer, and very good dimensional stability with minimal shrinkage and post expansion.

Q) What does “High Yield” mean on Soudafoam FR HY, and how does it benefit a job?

A) High Yield means you get more usable foam output from each can, so you can seal more joints and fill more gaps before changing cans. Soudafoam FR HY is designed to deliver over 25% higher yield than standard Soudafoam FR, which helps maintain momentum on repetitive work such as frame perimeters, connection joints and service openings. In practical terms, a 750ml can is quoted with a box yield of about 44L and a joint yield of about 35m under EN17333-1 testing, depending on joint size and site conditions. Fewer changeovers can also mean more consistent workmanship, especially where joint continuity and neat finishing matter.

Q) Is Soudafoam FR HY suitable for fire rated sealing and passive fire protection work?

A) Soudafoam FR HY is developed for fire rated jointing applications when used within suitable tested details. It is tested for fire resistant jointing to EN1366-4 and classified to EN13501-2, giving confidence that the product has been assessed for passive fire protection joint use rather than being a general purpose foam. Fire resistance can achieve up to 4 hours depending on the joint configuration and how the system is built. That detail matters, because fire performance depends on joint width, depth, substrates, backing materials and any associated sealants specified in the tested arrangement. For compliance critical work, follow the correct system detail, not just the product label.

Q) What types of jobs is Soudal Soudafoam FR HY most commonly used for?

A) Soudafoam FR HY is commonly used for sealing and insulating gaps around door and window frames, construction connection joints, and service penetrations where joints are largely static. It is also used to close irregular voids in walls, floors and ceilings where a controlled, gun applied foam helps create a continuous seal. Alongside its fire rated intent, it is valued for improving air tightness, reducing draughts and limiting sound transfer through leaky junctions. Because it has strong dimensional stability and low shrinkage, it is well suited to details where long term seal integrity matters. It is a contractor style option for programmes where speed, yield and neat finishing all count.

Q) What materials does Soudafoam FR HY stick to, and are primers needed?

A) Soudafoam FR HY has strong primerless adhesion to most common construction materials, which helps reduce preparation time on busy sites. Typical compatible substrates include brick, block, concrete, masonry, timber and many metals, plus rigid plastics used in building assemblies. Like most polyurethane foams, it is not suitable on low surface energy plastics such as PE, PP and PTFE, and adhesion can be unreliable on dusty, oily, greasy or friable surfaces. For best results, clean back to a sound edge and remove loose material so the foam bonds to stable substrates rather than contamination. If you are working on unusual surfaces, do a small compatibility test first, especially where the detail is fire rated.

Q) Can Soudafoam FR HY be used for door and window frame installation work?

A) Yes, Soudafoam FR HY is well suited to sealing around frames where you want a stable, insulating perimeter seal and controlled application through a foam gun. Its high yield helps on repetitive openings, and its dimensional stability helps reduce the risk of shrinkage opening up small gaps later. Apply in a measured bead rather than overfilling, because the foam expands substantially as it cures. Once cured, it can be trimmed flush for finishing. For fire door frames or fire rated assemblies, the key point is to follow the required tested detail for the door set, including any required backing materials, packers, fixings and sealants. Foam can be part of a compliant approach, but it should not replace specified system components.

Q) How much does Soudafoam FR HY expand, and how do you avoid overfilling?

A) Soudafoam FR HY expands approximately 35 to 40 times its initial volume, which is great for filling voids efficiently but means controlled dosing is essential. As a simple rule, fill the joint or cavity to roughly 65% of its volume and allow expansion to complete the fill. For deeper voids, apply in layers rather than trying to fill everything in one pass, letting the first layer expand and stabilise before adding the next. A foam gun helps you control flow, bead size and placement, especially in narrow joints or around delicate frames. Good control reduces waste, improves finish quality, and helps keep joint geometry closer to the intended design for fire rated sealing details.

Q) What is the recommended application temperature range for Soudafoam FR HY?

A) For reliable dispensing and cure behaviour, use Soudafoam FR HY within the stated temperature ranges. Typical guidance is can temperature from +5°C to +30°C, ambient temperature from +5°C to +30°C, and surface temperature from +5°C to +35°C. Within these ranges you are more likely to get predictable expansion, consistent cell structure and steady flow through the foam gun. Cold conditions can slow cure and affect foam structure, while very warm conditions can increase expansion and make bead control harder. Wherever possible, bring the can to a stable working temperature before use and avoid applying onto frozen or heavily chilled substrates. Consistent conditions help deliver a neater finish and reduce the chance of voids.

Q) What surface preparation is needed before applying this fire rated expanding foam?

A) Good preparation is mainly about clean, stable surfaces and sensible joint planning. Remove dust, loose mortar, flaking paint, grease and any friable material so the foam bonds to a sound edge. If the joint is part of a fire rated detail, confirm the required depth, backing and joint geometry first so you do not rely on foam where the system requires other components. Lightly misting the substrate with a fine water spray can help curing, especially in dry conditions, because the foam cures by moisture. Do not saturate the area, just add a light film of moisture. Mask delicate finishes if needed, because uncured foam can smear. Clear access makes consistent bead placement much easier.

Q) Do I need a specific foam gun for Soudal Soudafoam FR HY High Yield Fire Rated Expanding Foam?

A) Soudafoam FR HY is gun grade, so it should be used with a professional foam gun that allows controlled flow and accurate placement. A good quality applicator helps you regulate output, maintain a consistent bead, and reach into deeper joints without messy over-application. Before starting, shake the can well, attach it securely to the gun, then test dispense onto waste material to confirm steady flow. Adjust the flow control so you can work smoothly, especially around frames and narrow joints where precision matters. Using a gun also helps reduce waste compared with straw application and supports better workmanship in compliance focused details. Keep the nozzle clean during use so flow stays consistent across the job.

Q) How quickly does Soudafoam FR HY skin over, and when can it be cut?

A) Soudafoam FR HY is designed for speed on site, with rapid skin formation and fast cutting times under typical conditions. Skin formation is around 6.5 minutes, which helps the foam stabilise quickly and reduces the risk of disturbance while work continues nearby. Cutting time is around 20 minutes, allowing trimming and follow-on works to proceed sooner. Keep in mind these figures depend on temperature, humidity, bead thickness and whether the surface has been lightly misted. Thicker sections take longer to cure internally, even if the surface skins quickly, so avoid enclosing or heavily loading the foam until it has cured sufficiently through its depth. For fire rated details, avoid compressing the foam after expansion, as joint geometry matters.

Q) How stable is Soudafoam FR HY once cured, and does it shrink over time?

A) Once cured, Soudafoam FR HY offers very good dimensional stability, which is important for maintaining seal integrity in static joints. The product data highlights minimal shrinkage after curing below 2% and controlled expansion after curing below 2%, helping reduce the risk of gaps forming later due to movement in the foam itself. That stability supports long term air sealing, acoustic performance and thermal insulation, particularly around frames and service openings where small gaps can become problem areas. It also means trimming and finishing are more predictable, because the foam is less likely to pull back after cutting. Even with stable foam, remember that substrate movement or joint movement can still affect performance, so it is best used where movement is limited and detailing is correct.

Q) Does Soudafoam FR HY improve insulation and help reduce draughts?

A) Yes, Soudafoam FR HY is designed to fill voids and create a continuous seal, which helps reduce draught paths and cold bridging around typical leakage points. Its thermal conductivity is approximately 0.036W/m.K to EN 12667, which is strong for a cured foam and useful where small gaps around frames or penetrations are creating local heat loss. Sealing these interfaces can improve comfort and reduce unwanted air leakage. The key is continuity: a well applied, uninterrupted foam line around an opening performs better than patchy filling. Apply in controlled beads, avoid voids, and trim flush only after the foam has stabilised. If the foam will be exposed, protect it with a suitable finish, because UV exposure can degrade foam over time.

Q) How effective is Soudafoam FR HY for acoustic sealing and noise reduction?

A) Soudafoam FR HY can contribute significantly to acoustic performance because air gaps are a common route for sound leakage. When used to seal joints and voids in static details, it helps reduce airborne noise transfer through openings around frames, service penetrations and connection joints. Independent acoustic reporting supports a sound insulation rating of 60dB to EN ISO 717-1, which highlights its potential value as part of a sealed construction approach. The practical outcome depends on the overall build-up, because sound can still travel through flanking paths, weak linings and unsealed junctions elsewhere. For best results, focus on continuity, seal the full perimeter, and avoid leaving small voids or missed sections. Combine with correct linings and detailing where acoustic separation is a key project requirement.

Q) Can cured Soudafoam FR HY be painted, plastered over, or covered?

A) Soudafoam FR HY should be protected and finished where it will be exposed, particularly because polyurethane foams are not UV-resistant. Once the foam has cured fully, it can usually be trimmed flush and then covered with a suitable finishing material such as plaster, paint, render, boards or sealants, depending on the detail. The finish choice should match the joint purpose, especially for fire rated assemblies where the system detail may specify a particular over-seal or facing. Allow the foam to cure properly before finishing, because cutting time is not the same as full cure through thicker sections. Ensure the surface is clean and stable, and avoid finishes that could be undermined by residual movement or moisture. Proper finishing improves durability and protects the seal long term.

Q) What are the main limitations of Soudafoam FR HY in real-world use?

A) Soudafoam FR HY is intended for static joints and controlled gap filling, so it is not the best choice where joints have significant movement, abrasion, or continuous water exposure. It is also not suitable on low surface energy plastics such as PE, PP and PTFE, and performance will suffer on dusty, oily or unstable substrates. Fire performance is configuration dependent, so you should not assume it provides the same fire resistance in every joint or penetration without using a suitable tested detail. Like other foams, it is not UV-resistant and needs covering or sealing if exposed. Overfilling is another practical limitation, because the foam expands strongly and can distort frames if applied too aggressively. Good gun control and layered application help avoid these issues.

Q) How do I clean up uncured foam, and what if it has already cured?

A) Cleanup is easiest before the foam cures. Uncured foam can be removed from tools and many non-porous surfaces using a dedicated foam cleaner such as Soudafoam Gun and Foam Cleaner, ideally while the material is still fresh. Always test cleaners on sensitive finishes first, because some plastics, coatings or painted surfaces can react. If foam has cured, it must be removed mechanically by trimming and scraping, as cured polyurethane does not dissolve with standard solvents. Where extra help is needed for cured residue, a specialist cured PU remover can assist on suitable surfaces, again with careful testing first. Plan protection in advance by masking adjacent finishes and using controlled gun settings, because prevention is far quicker than cleanup. Never attempt to burn off cured foam.

Q) How should Soudafoam FR HY be stored, and what shelf-life issues should I watch for?

A) Store Soudafoam FR HY upright in a cool, dry place away from direct sunlight and heat sources, and keep it within the temperature conditions recommended on the can. Avoid storing in hot vehicles, near radiators, or where the can could be exposed to sparks or flame, because it is a pressurised aerosol. Before use, bring the can to a stable working temperature so flow and expansion are more predictable. Shelf-life is influenced by storage conditions, so tight temperature control helps the product remain consistent. Shake well before use to ensure the contents are properly mixed and yield is optimised. If a can has been stored poorly, output can become inconsistent, which increases waste and makes bead control harder, especially on compliance focused work.

Q) Is Soudafoam FR HY low odour and suitable for indoor projects?

A) Soudafoam FR HY is described as virtually odourless in use compared with many traditional foams, and it also carries low emission credentials that support indoor specification. It is certified to EMICODE EC1 Plus and has M1 emission classification, which are commonly used indicators for very low emissions and better indoor air quality performance. Even with low emission products, good ventilation is still important during application and early cure, especially in confined areas such as service risers, ceiling voids and small rooms. Apply carefully to reduce overspray, avoid prolonged skin contact, and keep the work area controlled. Once cured, the foam forms a stable structure that supports air sealing and insulation without ongoing odour issues, provided it is finished appropriately where exposed.

Q) What safety precautions should be followed when using Soudal Soudafoam FR HY?

A) Use standard construction chemical precautions and treat the can as a pressurised, flammable aerosol. Wear suitable gloves and eye protection, and avoid skin contact with uncured foam. Apply in well ventilated areas, especially indoors and in confined spaces, and keep the can away from heat, sparks and open flames. If you are working around penetrations, voids or frames, confirm safe access and protect adjacent finishes to reduce cleanup risk. Avoid inhaling vapours and keep the work area tidy, because drips can be slippery. If uncured foam contacts skin, clean promptly following product guidance. Cured foam must be removed mechanically and should not be burned. For fire stopping work, follow the correct system detail and do not improvise around critical penetrations.

Q) What are common application mistakes with fire rated expanding foam, and how do you avoid them?

A) The biggest mistakes are overfilling, poor surface preparation, and assuming fire rating without following a tested joint detail. Overfilling is common because the foam expands 35 to 40 times, so fill to about 65% and let expansion finish the job. Poor preparation, such as dust and loose mortar, reduces adhesion and creates voids, so clean back to a sound edge and clear drill dust and debris. Another frequent issue is trying to fill very deep voids in one pass, which can trap uncured foam inside, so apply in layers and lightly mist between layers to support curing. Finally, do not treat fire performance as a generic promise. Use the correct configuration, depth and backing so the joint build-up matches the required passive fire protection detail.

Technical Data Sheet

Safety Data Sheet

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