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Blue60 vs Traditional Methods: Which Is Best To Reduce Costs

Written by Blue60 | Sep 24, 2025 9:00:01 AM

In order for fire doors to work properly and meet the required standards, all gaps around the door frame need to be tightly filled using fire-rated products. These insulated materials help prevent the spread of smoke and flames, compartmentalise fires and provide crucial extra time for building occupants to evacuate.

Traditionally, installers used materials like Rockwool and mastic. Though effective, these methods are labour-intensive and can add to the cost and timescale of the installation. Here, we take a look at how Blue60 compares to Rockwool fire mastic and what benefits the foam offers over traditional methods.

Blue60 Foam

Blue60 Fire Foam is a specially formulated product that’s designed to fill and seal the gaps around fire door frames in order to prevent the spread of smoke and flames. Once dry, Blue60 fire-rated expanding foam forms a robust seal that contributes to the overall fire resistance of the door installation. The foam is engineered to be a quick and efficient solution for passive fire protection in building applications.

Traditional Methods

Traditionally, installers have sealed fire doors using materials like Rockwool and mastic. These are applied manually to fill gaps between the door frame and the wall in order to create an effective seal. Very labour-intensive, these methods can add to the overall duration of the installation.

Cost Comparison

When it comes to cost, Blue60 is the clear winner. When installing 10 fire doors, Blue60 is estimated to be around £96.51 cheaper than using Rockwool and fire mastic. A single can of Blue60 and associated packers costs around £13.07 per door and has an associated labour cost of around £10 (based on 20 minutes of labour at £30 per hour). In contrast, the traditional Rockwool and mastic method costs £15.25 for materials and £17.49 for labour per door.

Application And Efficacy

Blue60 Fire Foam is far quicker to apply than traditional Rockwool fire sealant and mastic. The foam expands to form a fire and smoke seal that helps to block the passage of flames and hot gases. This intumescent action provides an effective barrier for passive fire protection, allowing installers to complete a safe and effective installation without compromising on safety or compliance.

Installation Procedures

Installing Blue60 Fire Foam is faster and more streamlined than traditional methods. It’s estimated that it takes just 15 minutes to seal a door with Blue60 and around 30 minutes to complete the job using traditional methods. This means that, over the course of installing 10 fire doors, installers will save an average of 2.5 hours.

Recommendations

When you take cost, efficiency and safety into account, Blue60 Fire Foam is the recommended choice for fire door installations. Able to create a safe, secure seal quickly and effectively, it offers installers a reliable, high-quality tool they can rely on.

Contact us today to find out more.