Soudafoam Gap Fill is a one component and moisture curing PU-foam. The product will expand up to 3x its original size during curing, therefore it is mostly being used for filling larger gaps and cracks, or cavities that are difficult to reach.
Available in 12 oz. (Straw) and 20 oz. (Genius Gun), and 24 oz. (Gun)

Technical Data:




Stable Foam

Curing System


Skin Formation (68°F/65% R.H)

7 – 8 minutes

Drying Time (68°F/65% R.H)

Dust-free after 20 – 25 minutes

Cure Rate – Straw Foam (68°F/65% R.H)

1 hour for a 1/8” bead

Cure Rate – Gun Foam (68°F/65% R.H)

30 minutes for a 1/8” bead

Cure Rate – Genius Gun (68°F/65% R.H)

1 hour for a 1/8” bead

Yield – Straw Foam

3.8 gallon cured foam

Yield – Gun Foam

11 gallon cured foam

Yield – Genius Gun Foam

5.8 gallon cured foam

Yield (ASTM C-1536) – Straw Foam

1500 linear feet for a 1/4″ bead

Yield (ASTM C-1536) – Gun Foam

4315 linear feet for a 1/4″ bead

Yield (ASTM C-1536) – Genius Gun Foam

2279 linear feet for a 1/4″ bead



Post Expansion


Cellular Structure

70 – 80% closed cell



Insulation Factor

3.9 – 4.1 for 1 inch

Water Absorption

1% Vol

Shelf Life

18 months

Application Temperature

41°F to 95°F

Service Temperature

-40°F to 194°F


SoudaFoam Gap Fill is a one-component, self- expanding, ready to use polyurethane foam with propellants, which are completely harmless to the ozone layer. SoudaFoam Gap Fill is available for use with a standard straw applicator, a foam applicator gun, and our patented Genius Gun Applicator.


  • Permanent color

  • Paintable

  • Mildew resistant

  • Very good adhesion on many materials

  • Very easy application

  • Low Expansion (Gun Foam)


    • Filling of cavities

    • Sealing of openings in roof construction

    • Creation of a soundproof screen

    • Connecting of insulating materials and roof construction

    • Application of a soundproofing layer on motors

    • Improving thermal isolation in cooling systems

    • Installation of air conditioners


Aerosol can 12 oz (Straw) Aerosol can 20 oz (Genius Gun) Aerosol can 24 oz (Gun Foam)

Shelf life:

  • 18 months in unopened packaging in a cool and dry storage place at temperatures between 41°F and 77°F

  • Always store can with the valve pointed upwards

Application Instructions:

Straw/Gun: Shake the aerosol can for at least 30 seconds. Fit the adapter on the valve.

Genius Gun: Shake the canister thoroughly for 30 seconds. Open the lid on the top and straighten the applicator.

All: Apply a fine water spray to the surface which needs to be clean and free of grease and dust. Turn around the canister and extrude the foam carefully by applying pressure on the trigger. Fill holes and cavities approximately 40-50% (Mega Straw and Genius Gun Max) or 65% (Gun Foam) as the foam will expand. Shake canister regularly during application. If foam is applied in several layers, moisten between each layer of foam.

Fresh foam can be removed using Soudal Foam cleaner or acetone. Cured Foam can only be removed mechanically. Application temperature 41°F to 95°F. (68°F to 77°F recommended)

Genius Gun: At the end of application, close the applicator tube screwing the sealing plug onto the Max adapter and click into the holder. Close the lid. The canister can be reactivated for up to 6 weeks if resealed correctly.


ASTM C-1620

UL 723

UL 1715



  • Always moisten surfaces in order to improve curing and cellular structure

  • Cured PU foam must be protected from UV- radiation by painting or applying a top layer of sealants (silicone, MS Polymer, etc.)

  • For the filing of large volumes apply product in layers and moisten between each layer

  • We recommend preliminary compatibility tests on surfaces on which PU foams have not been applied previously

  • Always store canister with the valve pointed upwards.

Health- and Safety Recommendation:

  • Apply the usual industrial hygiene

  • Wear gloves and safety goggles

  • Remove cured foam by mechanical means only, never burn away

Limited Warranty:

SOUDAL warrants product to be of good quality and will replace or, at our election, refund the purchase price of any products proved to be defective. Satisfactory results depend not only upon quality products, but also upon many factors beyond our control. Therefore, except for such replacement or refund, SOUDAL MAKES NO WARRANTY OR GUARANTEE, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, RESPECTING ITS PRODUCTS, and SOUDAL shall have no other liability with respect thereto. Any claim regarding product defect must be received in writing one (1) year from the date of shipment. No claim will be considered without such written notice or after the specified time interval. User shall determine the suitability of the products for the intended use and assume all risks and liability in connection therewith.

*For the most up to date version click to download the Technical Data Sheet