Understanding Blue60 Fire-Rated Foam & How Blue60 Changed Everything

Why There Was Scepticism About Fire Foams

Before the development of verified, independently tested products like Blue60 fire-rated foam, the market was flooded with general-purpose expanding foams that claimed “fire resistance” with little or no credible evidence. Many products were sold as “fire foams” based on minimal testing or on testing carried out under non-representative conditions.

1. Mis-selling And Vague Claims

In the early 2000s and 2010s, some foams were marketed as “fire-resistant” simply because they did not ignite easily. That’s a far cry from genuine fire-stopping performance. True fire-rated foams must maintain a barrier against flames and smoke for a defined period (generally 30, 60 or even 120 minutes) when tested to recognised standards. However, not all fire-rated foams are tested for use within fire door assemblies. For fire door applications, the foam must be assessed as part of a complete doorset under standards such as BS 476-22 or BS EN 1634-1. Without application-specific test evidence, claims can be misleading.

2. Misuse On Site

Even where fire foams were correctly tested, they were often used improperly. Installers sometimes applied them in large cavities or unsupported voids. As a result, products that might have been effective in small, sealed gaps failed when stretched beyond their design limits.

3. Inconsistent Testing And Unclear Documentation

For years, the industry struggled with inconsistent product data. Test certificates were incomplete, expired or not relevant to real-world applications. Specifiers couldn’t be sure what they were approving, and installers often lacked clear guidance. The result was a general perception that fire foams were unreliable.

The Turning Point: Introducing Blue60

The team behind Blue60 recognised these challenges and set out to prove that expanding foam could be both simple to use and truly dependable. The objective was not to simplify compliance, but to support it with clear, test-backed evidence.

Rather than relying on generic test results or broad marketing promises, Blue60 fire foam was developed through a detailed programme of independent testing, carried out by accredited laboratories under rigorous, full-scale fire conditions. These tests measured not only fire integrity but also insulation performance, gap width and compatibility with door frames and other building components.

Test evidence and supporting documentation are made available through Blue60’s technical resources, an open record designed to give specifiers and contractors confidence in what they’re using.

How Blue60 Rebuilt Trust

Blue60 didn’t just meet expectations, it redefined them. Here’s how it restored confidence among specifiers and installers:

1. Evidence-Based Performance

Blue60 backed every claim with independently verified test data. Each product was assessed against recognised standards, ensuring that fire resistance claims were accurate, not theoretical. This transparency helped eliminate the guesswork that had undermined trust in other foams.

2. Clear, Honest Documentation

Blue60 simplified documentation for specifiers. Every data sheet, test certificate and installation guide is clear, consistent and easy to access. There’s no ambiguity about where and how the foam can be used, only practical, compliant information backed by evidence.

3. Trusted By The Industry

Through consistent testing, honest communication and visible proof of performance, Blue60 has become a commonly specified solution on projects where compliance and traceability are critical.

Changing Perception Across the Industry

What started as a mission to prove one product’s worth has helped shift industry perception of fire foams altogether. Today, Blue60 is frequently referenced in best-practice discussions and compliance checklists as an example of how fire-stopping products should be designed, tested and documented.

By demonstrating that expanding foam can deliver reliable, independently verified fire performance when specified and installed correctly, Blue60 has contributed to a more informed, evidence-led approach to fire-stopping. Specifiers now have a clear, proven alternative to generic products, supported by transparent evidence and backed by consistent results.

Through rigorous testing, openness, and consistent real-world performance, Blue60 fire foam has shown that expanding foam can be both practical and fully compliant. If you’d like to learn more about how Blue60 fire-rated foam can support your next project, contact us today.