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Everflex Fire-Fill: A Technical Overview
Everflex Fire-Fill is a premium-grade, waterborne co-polymer intumescent acrylic sealant designed to expand under fire exposure, forming an insulating plug that prevents fire transmission through walls, floors, and service penetrations. It offers excellent UV resistance, superior adhesion to common substrates (including concrete, brick, Hebel, plasterboard, and metals), and +/–20% movement capability. It is paintable, mould-resistant, and provides long-term durability under Australian climate conditions.
Core Features & Specifications
- Tested to AS1530.4 & AS4072.1 – up to 4 hours fire rating
- Accommodates ±20% joint movement – ideal for expansion joints
- Excellent adhesion to concrete, masonry, plasterboard, metals & more
- UV & weather resistant – suitable for internal and external applications
- Paintable with acrylic, oil & rubber-based paints for seamless finish
- Water cleanup & low VOC (7g/L) – Green Star compliant
- Supplied in ready-to-use 600ml sausage
The Everflex Fire-Fill Advantage
- Trusted performance – proven on Australian projects, backed by Adheseal technical support
- Saves time on site – single-pack, easy to gun and tool with smooth finish
- Peace of mind – compliant with Australian Standards, delivering reliable FRL compliance
- Versatile – seals penetrations, wall/wall and wall/floor joints up to 50mm
Proactive Troubleshooting
Scenario: Applying to a wet substrate
Potential Outcome: Poor adhesion and possible delamination, leading to compromised fire rating.
Adheseal Best Practice: Ensure substrate is clean, dry, and structurally sound. Allow concrete to cure 28 days before application.
Scenario: Omitting backer rod in deep joints
Potential Outcome: Three-sided adhesion causing joint failure during movement.
Adheseal Best Practice: Always use Adhefoam open-cell backer rod or bond breaker tape to control joint depth and allow proper movement.
Applications in Practice: Trade Scenarios
For Builders (On-Site Applicators): Expansion Joint Fire Sealing
The Professional's Challenge
Meeting FRL compliance in tilt-up panel joints while ensuring a flexible, durable finish that can be painted over.
The Adheseal Solution
Everflex Fire-Fill accommodates ±20% movement, adheres strongly to concrete, and tools off easily, giving a smooth, paintable joint that passes compliance inspections.
Best Practice Note
Use masking tape for clean edges, tool within 10 minutes, and remove tape before skinning for a crisp finish.
For Fire Stopping Contractors (Specifier/Engineer): Service Penetrations
The Professional's Challenge
Sealing mixed-service penetrations to achieve FRL while managing differential movement between materials.
The Adheseal Solution
Fire-Fill forms an intumescent plug under fire conditions, has excellent adhesion to metal and masonry, and allows for single- or double-sided applications as tested.
Best Practice Note
Apply sealant cone and backer wrap as per test report to maintain compliance. Contact Adheseal for project-specific guidance.
Frequently Asked Questions
Can Everflex Fire-Fill be applied to damp surfaces?
Yes – it can tolerate slightly damp surfaces, but not free water or pooling moisture. For best results, ensure substrates are clean, structurally sound, and surface moisture is minimal. Avoid application if rain exposure is likely within 24 hours.
Is priming required before using Fire-Fill?
Priming is not normally required for most substrates. For critical joints, multi-storey buildings, or highly stressed applications, use Adheseal 50A Surface Prep (non-porous) or Adheseal 2001 / Supaprime (porous).
Can Fire-Fill be painted over?
Yes – it is paintable with acrylic, oil, and rubber-based paints. Check adhesion and flexibility of paint first, as rigid paints may crack with joint movement.
Applications & Benefits
| Application / Use Case | Key Benefit | Primary Trades |
|---|---|---|
| Wall / Floor Joints | Provides tested FRL up to 4 hrs with ±20% movement | Builders, Fire Contractors |
| Service Penetrations | Forms intumescent plug to stop fire spread through penetrations | Fire Stopping Installers |
| Precast & Tilt-Up Panels | Flexible, weather-resistant seal for external expansion joints | Concrete Contractors |
Applying Everflex Fire-Fill: Enhanced Protocols & Best Practices
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Surface Preparation
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.
Timing: Allow concrete to cure 28 days before application.Pro Tip: Use masking tape for clean joint edges and remove immediately after tooling before skin forms. -
Sealant Application
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.
Timing: Skin time 30–45 minutes @ 25°C, full cure 7 days (20mm x 10mm joint).Pro Tip: Avoid trapping air during application – this can cause bubbling and compromise FRL rating.
Limitations & Safety
Product Limitations
Not suitable for trafficable joints or long-term water immersion.
Do not use in totally confined spaces without atmospheric humidity (curing will not occur).
Avoid application when rain exposure is expected within 24 hours.
Safety & Handling Requirements
Personal Protective Equipment
Wear nitrile gloves, safety glasses, and protective clothing to avoid skin/eye contact.
Ventilation Requirements
Ensure adequate ventilation during application. Use in well-ventilated areas to avoid inhaling vapours.
Fire & Handling Precautions
Keep away from ignition sources. Store in a cool, dry place below 25°C.
Emergency First Aid
Eyes:
Flush with water for 15 minutes. Seek medical advice.
Skin:
Wash with soap and water. Remove contaminated clothing.
Inhaled:
Move to fresh air. Seek medical attention if symptoms persist.
Swallowed:
Rinse mouth. Do NOT induce vomiting. Seek immediate medical assistance.
Seek medical attention immediately in all cases of serious exposure.
Everflex Fire-Fill Application Guide
Concrete, Masonry, Brick
Surface Preparation
Ensure surfaces are fully cured (28 days for concrete), clean, and free from laitance, dust, oils, curing compounds, and contaminants. Mask edges for neat joints.
Primer Requirements
Primer recommended for critical joints
For optimal performance, apply Adheseal 2001 or Supaprime primer, allowing 30 min to 2 hrs before sealant application.
Metals & Non-Porous Surfaces
Surface Preparation
Lightly abrade surface with fine abrasive pad, then clean with solvent wipe. Remove all oxidation and contaminants.
Primer Requirements
Primer recommended for optimal adhesion
Pre-treat with Adheseal 50A Surface Prep. Apply sealant within 30 mins – 2 hrs of priming.
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