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Pink fire-resisting, self-expanding polyurethane foam

Pink self-expanding polyurethane foam can offer application-specific fire resistance for certain gaps or penetrations in fire-rated assemblies. However, to ensure compliance with the required Fire Resistance Level (FRL), these products must be carefully evaluated for suitability, using the manufacturer's application guide and test data. Despite their fire-resisting properties, pink foam should be considered only after evaluating other proven methods—such as ablative coatings, fire-resistant mastics, fire pillows, or elastomeric intumescent foams—which often provide more reliable and well-documented performance.

Russ Porteous
CEO, Firewize
26 Mar, 2025
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Pink Foam

Fire-resisting foam also known as "pink foam" is a type of self-expanding polyurethane foam promoted by some manufacturers for its ability to resist ignition and reduce fire propagation, however, pink foam has very limited application and may not comply with the required fire resistance level and structural integrity in many circumstances. Pink foam has limited use and is not a substitute for other established fire-resisting products, methods and forms of construction.

Typically pink in colour, this foam is easily distinguished from standard expanding foams that lack fire-resistant properties, making it suitable for use in sealing gaps and joints in limited and very specific fire-rated building elements.

When applied correctly, these foams expand upon application, filling cavities and creating barriers that can contribute to the fire resistance of structures. In the real world, the fire-resisting performance of these foams varies depending on the specific product used and application.

In Australia, the fire resistance of building materials is evaluated according to AS 1530.4:2014, titled "Methods for fire tests on building materials, components and structures – Fire resistance tests for elements of construction." This standard specifies testing methods to determine the fire resistance levels (FRLs) of various building elements, including sealing systems like fire-resistant foams.

Limitations using fire-resisting, self-expanding polyurethane foam

Fire-resisting, self-expanding polyurethane foam may be used in a extremely limited applications consistent with the required fire resistance level (FRL) and Evidence of Suitability (A5G3) requirements of the National Construction Code ("NCC") and Australian Standard AS 1530.4:2014 and applied exactly as per the manufacturer's technical data and installation instructions.

Subject to manufacturers advice and application guidance, typical applications may include;

  • sealing of small (thin) vertical or horizontal linear gaps;
  • sealing of certain small openings and gaps around fittings, pipes and services.

Importantly, the fire resistance level (FRL) of the self-expanding polyurethane foam after it has been applied is related to the width and depth of the gap being filled, and under scrutiny may not comply with the required FRL of the surrounding structure.

The use of fire-resistant, self-expanding polyurethane foam should only be considered after consideration of other fire resisting products that serve similar purposes such as;

  • ablative coatings;
  • fire resisting mastic;
  • fire pillows;
  • elastomeric intumescent foam.

As a general rule, pink fire-resisting, self-expanding polyurethane foams have limited use compared to other well-established methods for maintaining the required Fire Resistance Level (FRL). Solutions such as ablative coatings, fire-resistant mastics, fire pillows, and elastomeric intumescent foams are often more reliable and better supported by tested application data.

In most cases, the use of  pink fire-resisting, self-expanding polyurethane foam is typically limited to small gaps of between 10mm to 40mm in vertical or horizontal structural elements, but application must always be done in a manner to satisfy the required fire resistance level of the surrounding structure.

Purchasing fire-resisting, self-expanding polyurethane foam

When purchasing fire-resisting, self-expanding polyurethane foam, users must consider the manufacturer application guidance for the product. This will typically include details of the fire resistance level performance given specific applications.

Most manufacturers of fire-resisting, self-expanding polyurethane foam will specify the performance of the foam making a statement like "can provide up to 3 hours fire resistance" but in most cases, this is under particular circumstances and installation conditions.

For example, according to the fire assessment report (FAS21003011) published by "HB Fuller Australia Ptr Ltd" for their "FulaFoam Fire Resistant PU Foam Filler" the assessment outcome varies according to the joint width and joint depth for "vertical linear joints" as shown in the the table below;

Table 1 - Fire Rated Foam Fulafoam FR in Vertical linear joints
  • 1

    Fire assessment report, Fire rated foam Fulafoam FR and Fulafoam Pro FR in vertical linear joints, FAS210301 R1.0, HB Fuller Australia Pty Ltd.

Typical application checklist for fire-resisting polyurethane foam

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Fire-resistant, self-expanding polyurethane foam may be a solution for certain (limited) passive fire protection, such as the protection of gaps, joints, and service penetrations in fire-rated building elements. 

The correct application of self-expanding polyurethane foam is essential to ensure the foam performs as tested and complies with relevant requirements such required fire resistance level of the surrounding structure, the National Construction Code and Australian Standard AS 1530.4:2014. The following checklist provides a step-by-step guide to ensure correct application and long-term fire performance.

Before Installation

  • Consider other methods of protection necessary to maintain the fire resistance level of the area being protected, prior to using fire-resisting, self-expanding polyurethane foam.
  • Verify product conformance and confirm the foam is tested and compliant with AS 1530.4:2014 and/or AS 4072.1:2005 for the specific application;
  • Read the Manufacturer’s Application and Approvals Data Sheet: Understand joint width/depth limitations, approved substrates, and curing conditions;
  • Confirm Environmental Conditions: Ensure temperature and humidity are within the specified limits for application and curing.

Surface Preparation

  • Clean surfaces of dust, oil, loose debris, and moisture;
  • Ensure substrates (e.g., concrete, masonry) are compatible with the foam.

Application

  • Use an approved foam applicator gun or straw (per manufacturer);
  • Fill the joint from bottom up in vertical applications to ensure consistent expansion;
  • Apply symmetrically from both sides of the wall if required (per test configuration);
  • Allow proper expansion room—do not overfill or compress the foam.

After Application

  • Allow the foam to cure fully (often 1–24 hours, depending on brand and thickness);
  • Trim any excess only after the foam has completely cured;
  • If required, apply protective coatings, paints, or flashings (as per the tested system).

Documentation

  • Take photos of the installed foam for record-keeping;
  • Update the Penetration Register: Record each fire-rated foam installation in a register, including the location, reference number, penetration details, and the method used to preserve the fire resistance level (e.g. foam type, depth, backing materials, etc.);
  • Label Each Penetration: Clearly label all fire-rated foam installations with a unique reference number that corresponds to the penetration register. The label must also state the required Fire Resistance Level (FRL) for that specific penetration.

Maintenance of fire-resisting polyurethane foam systems

Maintenance of fire-rated polyurethane foam installations is a critical component of a building’s overall fire safety strategy and forms part of the performance solution according to the National Construction Code. According to AS 1851 – Routine Service of Fire Protection Systems and Equipment, passive fire protection elements, including fire stopping systems like pink self-expanding polyurethane foam, must be regularly inspected to ensure ongoing compliance with their required fire resistance level.

While section 12 of AS 1815 provides for specific guidance on the routine inspections applicable to passive fire and smoke systems, the following checklist may be considered for guidance on the inspection requirements of fire-resisting polyurethane foam systems;

  • Maintenance
    • Fire-stopping installations must be inspected periodically as part of the building’s routine fire safety maintenance schedule (typically annually or as required by state/territory regulations or AS 1851 if applicable);
    • An inspection shall be conducted to identify if any barriers or penetrations have been added, removed or modified and to determine whether there are any areas that may require repair;
    • Inspections should check for:
      • Physical damage (e.g., cracks, holes, deterioration);
      • Movement or settlement around the seal;
      • Evidence of water or chemical exposure;
      • Unauthorised alterations or new penetrations.
  • Repairs and Reinstatement
    • If damage or degradation is identified, the foam must be repaired or replaced using the same tested system and installation method;
    • Reinstatement must comply with the original FRL and the product's tested configuration;
    • Any repair work should be documented and logged in the penetration register.
  • Maintenance Records
    • Keep the penetration register up to date with inspection dates, findings, any repairs or modifications, and the names of personnel who performed the inspections or maintenance.

How Firewize can help with building fire integrity

Firewize offers four practical solutions to assist building owners, their agents, occupiers, and contractors with the compliant sealing of penetrations and gaps in fire-resisting structures:

  1. Fire-Stopping Products – A comprehensive range including fire mastic, fire pillows, ablative coatings, intumescent foam, and other tailored solutions.
  2. Technical Consulting – Expert advice and custom fire-stopping solutions based on your building’s specific requirements.
  3. Installation Services – Professional installation of tested and approved fire-stopping systems.
  4. Annual Inspections – Routine inspections in line with AS 1851 to ensure ongoing compliance and system integrity.

Firewize provides a complete fire-stopping solution—from supply and installation to expert advice and annual inspections—all designed to help you maintain compliance and protect your building. Whether you're sealing new penetrations or maintaining existing systems, we've got you covered. Contact us today to discuss your fire protection needs.

    Disclaimer

    Firewize policy is one of continuous improvement, details of products, procedures or methods described within this document are subject to change without notice. All information provided here is believed to be correct at the time of publication.

    Every effort has been made to ensure the accuracy of information which is provided in good faith nothing contained herein is intended to incorporate any representation or warranty, either express or implied or to form the basis of any legal relations between the parties hereto, additional to or in lieu of such as may be applicable to a contract of sale or purchase.

    This website is provided solely on the basis that users will be responsible for making their own assessment of the matters discussed herein and are advised to verify all relevant representations, statements and information. Firewize does not accept any liability for any injury, loss or damage incurred by use of or reliance on the information.

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