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RLA Foam Filler is a professional-grade polyurethane sealant engineered to maintain building envelope integrity by creating airtight and moisture-resistant seals in irregular cavities and wall penetrations. This moisture-cure system expands up to 45 times its original volume, providing a high-performance thermal and acoustic barrier that prevents thermal bridging and acoustic leakage in complex assemblies.
The cured foam remains stable in extreme temperatures ranging from -40°C to 80°C and bonds tenaciously to timber, brick, concrete, and steel while remaining fully workable for cutting, sanding, and painting after eight hours of curing.
Frequently Asked Questions
Can I paint over the cured RLA Foam Filler?
Yes, once the foam has fully cured (approximately 8 hours), it can be cut, sanded, and painted to match the surrounding surface. For outdoor applications, it is highly recommended to paint or coat the cured foam to protect it from discolouration and degradation caused by UV light exposure.
How much of a gap should I actually fill with the foam?
Only fill the cavity to approximately one-third (33%) of the space. RLA Foam Filler is a high-yield product that expands up to 45 times its original size. Under-filling allows it to expand and create a tight, complete seal without exerting excessive pressure that could deform substrates like window frames.
Is there a way to speed up the curing time on site?
Absolutely. RLA Foam Filler uses a moisture-cure system. To accelerate the curing process, you can lightly dampen the surfaces with a water mist spray prior to application. You can also lightly mist the applied foam itself. This introduces the moisture needed for a faster, more efficient cure, especially in dry, low-humidity environments.
What is the best way to clean up uncured foam?
For non-porous surfaces, uncured foam can be cleaned off by wiping immediately with a solvent-moistened cloth. If foam gets on carpet or textiles, do not attempt to wipe it. Allow it to fully cure, then remove it mechanically by carefully cutting or scraping it away.
Applications & Benefits
| Application / Use Case | Key Benefit | Primary Trades |
|---|---|---|
| Fixing and insulating door and window frames | Provides stability while creating an airtight seal to eliminate draughts and noise. | Builders, Carpenters, Joiners |
| Filling and sealing gaps, joints, and cavities | Expands up to 45x to completely fill irregular voids, stopping dust and air movement. | All Trades |
| Sealing wall penetrations for services | Creates a fast, permanent seal around pipes and conduits to block pests and draughts. | Plumbers, Electricians |
| Insulating electrical outlets and water pipes | Offers excellent thermal insulation to improve energy efficiency and prevent condensation. | Electricians, Plumbers, Remedial Contractors |
Applying RLA Foam Filler: Enhanced Protocols & Best Practices
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Surface & Can Preparation
Proper preparation is key to achieving maximum yield and adhesion. Ensure all surfaces are correctly prepared before starting.
Surface Cleaning
Surfaces must be clean and free from all loose material, dust, oil, and grease. Cover and protect surrounding areas to prevent contact with the foam.
Can Activation
Ensure the can is at room temperature (at least 12 hours). Shake the can vigorously 15-20 times to thoroughly mix the contents before screwing on the application tube and trigger.
Pro Tip: Lightly mist the substrate with water just before applying the foam. This provides the necessary moisture to accelerate the cure and improve adhesion, especially in dry climates. -
Application Technique
Apply the foam in a controlled manner to achieve a complete fill without causing damage from over-expansion.
Applying the Foam
Invert the can and direct the tube into the cavity. Apply steady pressure to the trigger. Fill the cavity to approximately one-third (33%) of the space to allow for expansion.
Layering for Large Voids
For larger or deeper cavities, apply the foam in stages or layers. This allows each layer to cure properly and ensures a consistent fill throughout the void.
Timing: The foam will form a tack-free skin in 15-30 minutes under normal conditions (23°C and 50% RH). -
Curing & Finishing
Once the foam has cured, it can be finished to create a clean, professional appearance.
Finishing
After approximately 8 hours, excess foam can be trimmed with a sharp knife. The surface can then be sanded smooth and painted to match the surrounding area.
Timing: Allow 24 hours for the foam to achieve full cure and maximum expansion. Colder conditions will extend these times.Pro Tip: For outdoor applications, always coat or paint the cured foam. This protects it from UV light, preventing discolouration and ensuring long-term durability.
Limitations & Safety
Product Limitations
Do not apply when surface or ambient temperatures are below 5°C or above 30°C, as this will affect yield and cure time.
Not suitable for use in areas subject to foot or vehicular traffic.
Not designed as a load-bearing material. For structural applications, use an appropriate product.
Not suitable for continuous water immersion or applications below the waterline.
Cured foam will discolour and degrade if exposed to direct UV light. Always paint or coat for outdoor applications.
Safety & Handling Requirements
Personal Protective Equipment
Always wear protective gloves, overalls, and chemical goggles or a face shield. Due to isocyanate content, respiratory protection is mandatory in case of inadequate ventilation.
Ventilation Requirements
Use only outdoors or in a well-ventilated area. If working indoors, ensure local exhaust ventilation is adequate to maintain air concentrations below exposure standards.
Fire & Handling Precautions
Extremely flammable aerosol. Keep away from all ignition sources including heat, sparks, open flames, and hot surfaces. Do not smoke. Do not pierce or burn the can, even after use. Protect from sunlight and do not expose to temperatures exceeding 50°C.
Emergency First Aid
Eyes:
Rinse cautiously with water for several minutes. Remove contact lenses if present and easy to do. Continue rinsing for at least 15 minutes and seek immediate medical attention.
Skin:
If skin contact occurs, immediately remove all contaminated clothing. Wash skin thoroughly with plenty of soap and water. If irritation or a rash occurs, get medical advice.
Inhaled:
Remove victim to fresh air and keep at rest in a comfortable position. If experiencing respiratory symptoms (allergy, asthma, or breathing difficulties), call a POISON CENTRE or doctor immediately.
Swallowed:
Rinse mouth with water. Give a glass of water to drink. DO NOT induce vomiting. Seek immediate medical advice.
Seek medical attention immediately in all cases of serious exposure.
RLA Foam Filler Substrate Guide
Porous Substrates (Timber, Brick, Concrete)
Surface Preparation
Ensure surfaces are clean, structurally sound, and free from dust, oil, grease, and any loose material. Lightly dampen the substrate with a water mist immediately prior to foam application to improve adhesion and accelerate curing.
Primer Requirements
No primer typically required
For standard applications on sound surfaces, no primer is necessary. Proper surface cleaning and pre-dampening are sufficient for excellent adhesion.
Non-Porous Substrates (Metals, Glass, Cement Sheet)
Surface Preparation
Surfaces such as galvanised steel, aluminium, glass, and compressed cement-sheet must be clean and free from contaminants. Lightly dampen the surface with a fine water spray to promote the moisture-curing reaction.
Primer Requirements
No primer typically required
Adhesion to clean, non-porous surfaces is excellent without a primer. Ensure all oils or residues are thoroughly removed before pre-dampening and application.
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