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For penetration pathways and expansion joints requiring a fire-resistant barrier, Everflex Fire-Fill Acrylic Sealant is tested in accordance with AS1530.4 and assessed to AS4072.1. This waterborne co-polymer-based intumescent sealant expands when exposed to fire, forming an inorganic plug that helps prevent fire transmission through partitions.
Everflex Fire-Fill functions by chemical expansion under heat. When exposed to fire, the intumescent material swells to block gaps around physical penetrations and linear joints. It accommodates up to ±20% joint movement while maintaining a flexible, waterproof joint. The formula is non-slump, water-cleanable while wet, and contains no isocyanates or asbestos. It has a low volatile organic compound content of 7g/L, meeting Green Star environmental criteria, and provides STC acoustic properties when installed in appropriate systems.
This sealant adheres to most common construction substrates including concrete, aerated concrete (Hebel block), speed panel, masonry, brick, stone, plasterboard, timber, glass, aluminium, and plastics. It is suitable for:
Joints should ideally maintain a 2:1 width-to-depth ratio. Internal joints require a minimum width and depth of 5mm; external joints require a minimum of 12mm. For joints deeper than 10mm, use an open-cell foam backer rod (such as Adhefoam) sized 25% larger than the joint width. Where space prevents a backer rod, apply a polyethylene bond-breaker tape to prevent three-sided adhesion.
Apply when substrate and air temperatures are between 5°C and 40°C (physical property application range is +5°C to +35°C). Fill the joint completely to avoid air entrapment. Tool dry with a moistened spatula within 5 to 10 minutes, before the surface skins. Masking tape should be removed immediately after tooling while the sealant is still wet.
New concrete must be allowed to cure for at least 28 days prior to application. While porous substrates do not normally require priming, optimal adhesion on highly stressed joints or under extreme weather exposure can be achieved by priming porous surfaces with Adheseal 2001 or Everflex Supaprime. For non-porous surfaces, slightly roughen the face and pre-treat with Adheseal 50A surface prep, allowing 30 minutes to 2 hours open time before applying the sealant.
Everflex Fire-Fill is not recommended for Colourbond panels. For natural stone, a stain testing program is always recommended before application to avoid discolouration or compatibility issues.
It provides up to a 4-hour fire rating, tested to AS1530.4 and assessed to AS4072.1. This rating applies to gaps up to 50mm, depending on the joint configuration and panel thickness.
Yes, Everflex Fire-Fill is paintable after 6-8 hours with acrylic, oil, and rubber-based paints. Always confirm adhesion with your chosen paint type, as non-flexible paints may crack due to the sealant's inherent movement capability.
No, Everflex Fire-Fill is not suitable for long-term water immersion or internal swimming pool applications. Avoid exposure to high levels of chlorine exceeding 5 ppm.
| Application | Key benefit | Primary trades |
|---|---|---|
| Fire-rated penetrations for cables, pipes, ducts through walls and floors | Forms an intumescent, inorganic plug to prevent fire and smoke transmission, tested to AS1530.4 and AS4072.1. | Fire protection installers, electricians, plumbers, commercial builders |
| Expansion joints in concrete, plasterboard, blockwork, and precast panels | Maintains fire integrity for up to 4 hours in joints up to 50mm, with ±20% movement capability. | Commercial builders, plasterers, concrete contractors |
| Acoustic sealing in wall and floor systems | Contributes to specified STC acoustic properties in appropriate systems, reducing sound transfer. | Plasterers, acoustic installers, commercial builders |
| Internal and external fire-rated sealing where weather exposure is a factor | Offers excellent UV and weather resistance, maintaining a flexible, waterproof joint. | Commercial builders, façade installers, fire protection contractors |
| Gap sealing around building services in fire-rated environments | Easy to apply and tool, ensuring efficient and compliant installation for critical fire zones. | Electricians, plumbers, HVAC technicians |
Ensure substrates are sound, dry, and free of dust, grease, or contaminants. For deep joints, install open-cell backer rod 25% larger than joint width.
Cut nozzle at 45° angle and gun sealant ahead of nozzle, ensuring full contact with both sides of joint. Tool off within 10 minutes for smooth finish.
Wear gloves and safety glasses. Nitrile Rubber gloves are suitable for intermittent contact. Always wash hands before eating, drinking, or using the toilet.
Ensure adequate ventilation to maintain air concentrations below exposure standards. Use in well-ventilated areas or with local exhaust ventilation. Avoid generating and inhaling dusts.
Store in a cool, dry area. Keep away from food, drink, and animal feeding stuffs. Dispose of product as prescribed waste in accordance with state and local regulations.
Proper surface preparation is crucial for reliable long-term performance and adhesion for fire-rated installations.
Surface prep: Ensure surfaces are structurally sound, dry, clean, and free from dust, loose material, oils, and other contaminants. Concrete must cure for at least 28 days. Avoid application if surface water or continuous dampness is present.
Primer: Optional, but recommended for optimal adhesion in high-performance or exposed applications. Use Adheseal 2001 or Everflex Supaprime primer applied by brush. Allow 30 minutes to 2 hours cure time before sealant application.
Surface prep: Ensure surfaces are stable, dry, clean, and free of dust or loose material. Mask joint edges for a neat finish.
Primer: Not normally required. Adhesion testing is always advised.
Surface prep: Slightly roughen the surface with a fine abrasive pad. Clean and pre-treat using Adheseal 50A surface prep with a clean cloth. Use the two-wipe process to ensure cleanliness.
Primer: Optional. Use Adheseal 50A surface prep. Allow 30 minutes to 2 hours before sealant application. For copper, brass, titanium-zinc, and other plastics, an adhesion test is advised.
Surface prep: Ensure surfaces are sound, dry, clean, and free from loose paint, dust, oils, or other contaminants. Perform compatibility tests for painted surfaces.
Primer: Not normally required. Test adhesion and compatibility, especially for painted surfaces.
| Property | Value |
|---|---|
| Type of Product | Acrylic paste |
| Curing System | Evaporation of water |
| Density | 1.53 g/cm3 |
| Application Temperature | 5°C to 35°C |
| Service Temperature | -10°C to 80°C |
| VOC Content | 7 g/L |
| Shelf Life | 12 months in original packaging |
| Working Time | 15 min |
| Max Joint Dimensions | 50 x 25mm |
| Movement Capability | ±20% |
| Fire Rating | Up to 4 hours (AS1530.4, AS4072.1) |
| Paintable After | 6-8 hours |
| Skin Time | 30-45 minutes |
| Cure Rate | 2mm per 24 hours (25°C, 50% humidity) |
| Full Cure | 7 days (20mm wide, 10mm deep joint at 20°C, 70% humidity) |
| Clean Up | Water (wet), Mechanical (cured) |
| Packaging | 600ml Sausage |
| Colour | Grey |
Here are some common examples on where Everflex Fire-Fill Acrylic Sealant used by our customers.
