Soudal Soudafoam Window & Door Expanding Foam

Health & Safety Recommendations

When using Soudal Soudafoam Window & Door Expanding Foam, always follow good on site health and safety practice. Wear suitable protective gloves, safety goggles and long sleeves to prevent contact with skin and eyes, as uncured polyurethane foam is difficult to remove and can cause irritation. Use the foam only in well ventilated areas to avoid the build up of vapours, especially in confined internal spaces. Avoid breathing in aerosol mist or vapours. If foam is being blown or cut away using compressed air or similar equipment, additional respiratory protection and extraction may be required due to airborne dust and particles.

Do not smoke, eat or drink while using the product and wash hands thoroughly after use. In case of contact with skin, wipe off uncured foam immediately with a suitable PU foam cleaner and wash with soap and water. For eye contact, rinse immediately with plenty of clean water and seek medical advice. Do not attempt to remove cured foam from skin with solvents. Never burn away cured foam, as combustion can release harmful fumes. Always read the product label and material safety data sheet before use and keep cans out of reach of children.

Substrate Suitability

Soudafoam Window & Door is suitable for most common construction substrates used around window and door openings. It adheres well to brick, blockwork, concrete, stone, plaster, render, timber and many rigid plastics used in modern fenestration systems. It is designed as a professional window and door expanding foam for use around PVCu, aluminium and timber frames, where a controlled linear expansion and good bond are required.

The foam does not adhere well to polyethylene, polypropylene or PTFE and is not recommended for these low surface energy plastics. On unusual or coated substrates, such as powder coated metals, plastics with unknown composition or heavily sealed surfaces, a preliminary adhesion test is strongly advised. The substrate must be stable and strong enough to support the foam and the frame assembly; it is not intended as a structural repair for weak or friable substrates.

Surface Preparation

Correct preparation is essential for reliable window and door foam installation. All bonding surfaces must be firm, clean, dry to slightly damp, and free from dust, loose particles, grease, oil, release agents and other contaminants that might impair adhesion. Remove loose mortar, old sealant residues, flaking paint and debris from the reveal using a brush or vacuum. Check frame packers and fixings are correctly installed and that the frame is plumb, level and square before foaming, as the foam is not a substitute for mechanical fixings.

Slightly damp surfaces promote proper curing, since polyurethane foam cures by reacting with moisture. Lightly mist the sides of the joint or cavity with clean water using a fine spray bottle immediately before application. Avoid saturating the area or allowing standing water in the joint. On very smooth, non porous surfaces, such as glazed tiles or powder coated metals, light abrasion with fine sandpaper can improve mechanical key. Always ensure that adjacent finishes, glass and hardware are masked or protected where necessary, as uncured foam can be difficult to remove.

Application Method

Bring the can to room temperature before use, as performance and yield are best when the can is between about 15°C and 25°C. Shake the aerosol can vigorously for at least 20 seconds to mix the contents thoroughly. Repeat shaking regularly during use to maintain a consistent foam structure. Screw the can firmly onto a compatible foam gun, ensuring a tight seal at the adapter. Adjust the gun flow control to achieve the desired bead size before working on the frame.

With the frame already fixed mechanically and correctly packed, hold the gun with the can above it and the nozzle pointing upwards into the reveal gap. Apply the foam with the gun trigger, moving steadily along the joint. Fill joints and cavities to approximately 65% of their volume, as the foam will expand further as it reacts and cures. It is better to apply several thinner passes than one heavy, uncontrolled bead. When deeper voids need to be filled, work in layers, lightly misting with water between layers to maintain proper curing and avoid voids.

Work systematically around the frame, beginning at the bottom and progressing up the sides, finishing at the head. Avoid overfilling behind packed areas or hardware where pressure could be transmitted to the frame. After application, allow the foam to expand and cure undisturbed. Do not manipulate the frame once foaming is complete, except for minor adjustments that may be required while the foam is still soft. Respect the stated temperature range during application, with can temperature between +5°C and +30°C, ambient temperature between +5°C and +30°C, and surface temperature between +5°C and +35°C for best results.

Coverage

Coverage depends on joint dimensions and application technique, but the product has defined test yields to guide estimating. Under standard test conditions, one 750ml can of Soudafoam Window & Door typically provides a linear yield of about 22m of a standard joint bead, measured using FEICA TM1002. In free expansion tests (EN 17333-1), the same can produces approximately 28L of cured foam.

In practice, the actual coverage achieved on site will be influenced by joint width, depth, gun setting, temperature and the degree of wastage from trimming. For typical domestic window perimeters, one can will usually complete several average sized frames, but it is prudent to allow a margin for variations in gap size and the need to work in layers on deeper cavities.

Curing Time

Soudafoam Window & Door is a rapid curing polyurethane foam, but cure times are still dependent on temperature, humidity and joint geometry. Under normal conditions of around 20°C and 60% relative humidity, skin formation occurs in roughly 10 minutes. At this point the surface will no longer be tacky, but internal curing continues.

Cutting time, meaning the point at which excess foam can be trimmed cleanly with a sharp knife or saw, is typically around 25 minutes at similar conditions. Lower temperatures or low humidity will lengthen cure times, while higher humidity can accelerate curing. Full through cure of thick beads and deeper fills may take several hours. Sanding, over painting, sealing or covering should only be carried out once the foam is fully cured throughout its thickness, not just at the surface.

Cleaning

Fresh, uncured foam can be removed from tools, guns and most non absorbent surfaces with a dedicated PU foam cleaner such as Soudafoam Gun and Expanding Foam Cleaner. Always test the cleaner on a small, inconspicuous area first, because certain plastics, lacquers and paint finishes can be sensitive to solvent. Wipe away uncured foam carefully with a cloth dampened with cleaner, replacing cloths frequently to avoid smearing.

Once cured, polyurethane foam can no longer be dissolved by standard cleaners and must be removed mechanically by careful cutting, scraping or sanding. For difficult residues on some substrates, Soudal Cured PU Foam Remover may be used in accordance with its instructions. Do not attempt to clean cured foam by burning, grinding aggressively or using highly reactive chemicals, as this can damage the substrate and create safety risks.

Limitations

Soudal Soudafoam Window & Door Expanding Foam is not UV resistant in its cured state. Prolonged exposure to sunlight will cause yellowing and eventual degradation of the foam surface. All exposed foam must therefore be protected after curing by over painting, covering with plaster or trim, or sealing with a suitable sealant such as silicone, polyurethane, acrylic or hybrid polymer, chosen to suit the application and substrates.

The product must not be used on polyethylene, polypropylene, PTFE or other very low surface energy plastics where adhesion is poor. It is also not a fire rated or intumescent foam and must not be relied upon where a fire resisting seal is specified. The foam is not a substitute for mechanical fixings, and frames must always be fixed in accordance with relevant standards and manufacturer guidance. Use only within the stated temperature ranges for can, ambient and substrate.

Do not apply in persistently wet or underwater conditions, and avoid use where the substrate is saturated or there is visible running water. The product contains isocyanates; users with known sensitivity should take additional precautions or avoid contact. Always follow site specific risk assessments and method statements when using expanding foam on construction projects.

Other Information

Soudafoam Window & Door Expanding Foam is supplied with DuraValve technology, which helps maintain consistent performance and yield across the entire shelf life, including when cans are stored or transported on their side. Store cans upright where possible, in a cool, dry and well ventilated place, away from direct sunlight and sources of heat or ignition. Do not expose cans to temperatures above 50°C and never puncture or incinerate the container, even when empty.

The cured foam has very good thermal and acoustic insulation characteristics and good mechanical strength, including compressive, shear and tensile resistance, making it suitable as an insulating and sealing infill around windows, doors and other construction details. It is a single component, moisture curing polyurethane material and should be used in accordance with Soudal’s technical data sheet and local building regulations. For more specialised requirements, such as fire resistance or specific acoustic ratings, consult Soudal or a qualified specifier to confirm suitability or to select an alternative PU foam from the range.

Q) What is Soudal Soudafoam Window & Door Expanding Foam and what is it designed for?

A) Soudal Soudafoam Window & Door Expanding Foam is a professional gun grade polyurethane expanding foam formulated specifically for installing and sealing PVCu, aluminium and timber window and door frames. It is a one component, moisture curing foam that expands linearly along the joint to seal perimeter gaps safely without distorting frames. Once cured, it forms a rigid, low density infill with excellent thermal and acoustic performance and strong adhesion to masonry, timber and many rigid plastics. It is intended for professional window and door installation work, but is also suitable for competent DIY users with a foam gun.

Q) How does Soudal Soudafoam Window & Door Expanding Foam differ from general gap filling foams?

A) Soudal Soudafoam Window & Door Expanding Foam is tuned for controlled linear expansion rather than aggressive three dimensional expansion. General gap filling foams expand strongly in all directions, which can generate outward pressure on frames if overfilled. This window and door foam is formulated so that most expansion follows the direction of the bead, filling the joint while limiting lateral stress on PVCu, aluminium and timber frames. It also offers high dimensional stability with no post expansion or shrinkage once cured, which helps to maintain frame alignment, airtightness and long term weather tightness at the perimeter.

Q) Where is Soudal Soudafoam Window & Door Expanding Foam typically used on a window or door installation?

A) Soudal Soudafoam Window & Door Expanding Foam is mainly used to fill and insulate the perimeter gap between the window or door frame and the surrounding reveal. This includes the head, jambs and sill areas around PVCu, aluminium and timber frames set into brick, block or concrete openings. It is also used around frame packers, fixings and local voids to avoid cold bridges, and around associated service penetrations near openings. Beyond fenestration work, it can be used in compatible roof, wall and partition details where a controlled expanding foam with good thermal and acoustic performance is required.

Q) Which substrates are suitable for Soudal Soudafoam Window & Door Expanding Foam and which should be avoided?

A) Soudal Soudafoam Window & Door Expanding Foam adheres well to most common building materials used around frames, including brick, blockwork, concrete, stone, plaster, render, timber and many rigid plastics associated with modern window systems. It is formulated to bond directly without primer on these surfaces. It does not adhere well to low surface energy plastics such as polyethylene, polypropylene or PTFE and should not be used on these materials. On unusual or coated substrates, such as some powder coated metals or plastics of unknown composition, a small adhesion test is recommended before full application.

Q) How should surfaces be prepared before applying Soudal Soudafoam Window & Door Expanding Foam?

A) Surfaces must be sound, stable and free from dust, loose mortar, old foam, grease, oil and other contaminants that might interfere with adhesion. Reveals should be brushed or vacuumed clean and any loose material removed. Frames must be mechanically fixed, correctly packed and fully aligned before foaming, because the foam is not a substitute for mechanical fixings. Since the foam cures by reacting with moisture, slightly damp surfaces are beneficial, so lightly misting the sides of the joint with clean water just before application helps achieve a uniform cure. Avoid standing water or saturated substrates and protect nearby glass and finishes.

Q) What is the correct way to apply Soudal Soudafoam Window & Door Expanding Foam with a foam gun?

A) Bring the can to room temperature, then shake vigorously for at least twenty seconds to mix the contents thoroughly. Screw the can firmly onto a compatible foam gun with the trigger closed, and adjust the flow control to give a manageable bead size. With the can above the gun, insert the nozzle into the perimeter gap and apply foam steadily, generally filling about sixty to sixty five percent of the joint volume to allow for expansion. Work in continuous passes, starting at the bottom and moving up the sides, finishing at the head. For deeper cavities, apply in layers, lightly misting between passes.

Q) How much coverage does one can of Soudal Soudafoam Window & Door Expanding Foam provide?

A) Under standard test conditions, a 750ml can of Soudal Soudafoam Window & Door Expanding Foam provides a linear yield of around 22m of a typical joint bead, as measured by FEICA TM1002. The same can gives a free expansion volume of approximately 28L when measured to EN 17333-1. Actual coverage on site will depend on joint width, depth, gun settings, temperature and technique. Narrow gaps require less foam and therefore give a greater linear yield than wide or deep cavities. When estimating, it is sensible to allow a margin for trimming, deep voids and other variations between openings.

Q) How long does Soudal Soudafoam Window & Door Expanding Foam take to cure and when can it be trimmed?

A) In normal conditions of about 20°C and 60 percent relative humidity, Soudal Soudafoam Window & Door Expanding Foam forms a surface skin in approximately ten minutes. Cutting time, meaning when the foam can be cleanly trimmed with a sharp knife or saw, is typically around twenty five minutes under similar conditions. Lower temperatures or lower humidity slow curing, while higher humidity speeds it up. Although the surface may appear firm quite quickly, full cure through the entire section takes longer, especially in thick beads, so it is best to allow several hours before applying rigid finishes or significant mechanical load.

Q) What thermal and acoustic benefits does Soudal Soudafoam Window & Door Expanding Foam provide around frames?

A) Soudal Soudafoam Window & Door Expanding Foam provides excellent thermal and acoustic enhancements where it is used to seal perimeter joints. The cured foam has a low thermal conductivity of around 0.037W/mK, which helps to reduce heat loss and cold bridging around windows and doors. Its acoustic performance, with an airborne sound reduction of roughly 58dB to ISO 717-1, means it significantly reduces noise transfer through gaps and service openings. Together, these properties improve comfort, support energy efficient upgrades and help meet modern performance expectations for both new build and refurbishment fenestration projects.

Q) How does DuraValve technology benefit users of Soudal Soudafoam Window & Door Expanding Foam?

A) DuraValve is Soudal’s advanced valve system designed to maintain consistent foam output and quality throughout the product’s shelf life. In Soudal Soudafoam Window & Door Expanding Foam it helps ensure that each can delivers a predictable foam structure, expansion pattern and yield, even if the can has been stored or transported on its side. This reliability is particularly valuable for installers who carry cans in vans or store them on busy sites, as it reduces the risk of uneven expansion, poor bead quality or reduced yield from older cans. DuraValve supports efficient material usage and consistent professional results.

Q) Is Soudal Soudafoam Window & Door Expanding Foam safe to use and what protective equipment is recommended?

A) Soudal Soudafoam Window & Door Expanding Foam is a professional polyurethane foam and should be handled with appropriate care. Users should always wear protective gloves and safety goggles, and suitable work clothing, to prevent contact with skin and eyes. Work in well ventilated areas to avoid unnecessary exposure to vapours and aerosol mist, especially in confined rooms. Avoid smoking, eating or drinking while using the foam and wash hands thoroughly afterwards. In case of accidental contact with eyes, rinse immediately with plenty of clean water and seek medical advice. Uncured foam should be removed from skin promptly with suitable cleaner and soap and water.

Q) How can uncured and cured Soudal Soudafoam Window & Door Expanding Foam be cleaned or removed?

A) Uncured Soudal Soudafoam Window & Door Expanding Foam can be removed from tools, guns and compatible surfaces using a dedicated PU foam cleaner, such as Soudal’s Gun and Expanding Foam Cleaner. The cleaner is applied to soften the fresh foam, which is then wiped away with a cloth. Always test the cleaner first on sensitive substrates like painted or lacquered finishes. Once the foam has cured fully it cannot be dissolved and must be removed mechanically by cutting, scraping or sanding. For stubborn cured residues, a specialist polyurethane remover may be used where compatible, following the manufacturer’s instructions carefully.

Q) Can Soudal Soudafoam Window & Door Expanding Foam distort PVCu or aluminium frames during curing?

A) Soudal Soudafoam Window & Door Expanding Foam is specifically formulated for controlled linear expansion to reduce the risk of frame distortion when applied correctly. The key is to avoid overfilling joints and to apply foam in a controlled way using a gun, generally filling only around sixty to sixty five percent of the gap. Frames must be properly packed and mechanically fixed before foaming so they are structurally supported. When used within these guidelines, the foam’s expansion and excellent dimensional stability allow it to seal and insulate around frames without imposing excessive lateral pressure that might distort PVCu, aluminium or timber profiles.

Q) Can Soudal Soudafoam Window & Door Expanding Foam be plastered, sealed or painted over after curing?

A) Yes, once Soudal Soudafoam Window & Door Expanding Foam has fully cured and been trimmed flush, it can be covered with most common finishing systems. Internal reveals can be plasterboarded, plastered or finished with suitable fillers over adjacent solid surfaces, with the foam acting as a backing within the gap. Exposed foam should always be protected from sunlight and mechanical damage by a finish such as render, plaster, paint or trim. Perimeter sealants can be applied over the junction between frame and reveal after trimming, using compatible silicones, hybrid sealants or acrylics chosen to suit the specific substrates and exposure.

Q) Are there any important limitations when using Soudal Soudafoam Window & Door Expanding Foam?

A) Soudal Soudafoam Window & Door Expanding Foam is not UV resistant, so any exposed foam must be covered with a suitable finish to prevent discolouration and degradation. It is not suitable for polyethylene, polypropylene, PTFE or other very low surface energy plastics, and it is not a fire rated or intumescent foam, so it must not be used where a fire resisting seal is required. The foam is not a substitute for mechanical fixings; frames must be anchored in accordance with relevant standards. It should not be used in continuously wet or submerged conditions, or where substrates are saturated or visibly leaking.

Q) What are the recommended storage and application temperature conditions for Soudal Soudafoam Window & Door Expanding Foam?

A) Soudal Soudafoam Window & Door Expanding Foam should be stored in a cool, dry, well ventilated place, ideally upright, away from direct sunlight and sources of heat. Cans must not be exposed to temperatures above about 50°C and should be protected from frost. For application, can and ambient temperatures should generally be between about 5°C and 30°C, with substrate temperatures between 5°C and 35°C. Using the foam within this range ensures reliable expansion, curing and adhesion. Cold cans should be brought to room temperature before use for best yield, and the can should always be shaken thoroughly before and during application.

Q) Is Soudal Soudafoam Window & Door Expanding Foam environmentally responsible compared with older foams?

A) Soudal Soudafoam Window & Door Expanding Foam uses a modern propellant system that is Freon free and therefore does not harm the ozone layer. While it is still a polyurethane product that must be handled and disposed of responsibly, the formulation reflects current environmental expectations by avoiding CFC propellants used in older foams. Efficient use of each can is supported by DuraValve technology, which helps limit waste by ensuring predictable yield throughout the shelf life. Empty cans should be disposed of in accordance with local regulations for pressurised containers and should never be incinerated or punctured, even when apparently empty.

Technical Data Sheet

Safety Data Sheet