Great Stuff by Dow is a wonderful product when used properly. I realized a savings of 15Kw per day off my electric bill with 6 cans. You can save money now, just read on and have fun!

In Louisiana, our construction quality is lack luster at best. A recent rush of illegal labor has forced all home builders to use them just to stay competitive. As a result homes here are missing the finishing touches that they deserve. One notable touch is proper insulation and sealing in the attic. My attic had gaps around light fixtures and huge air leaks in the duct work of the air conditioning system. To fill these cracks I used Great Foam and a few other lower cost products over the past few weeks.

Great Stuff comes out looking like whipped butter and rapidly expands in any space you place it. One day after application the foam has expanded to 5 times its original size and can be filed to shape. When used outdoors you can paint the foam as well, this is should be done because the foam will turn a deep orange color when exposed to sunlight.

Product Usage
These tips are for your benefit, if not used properly you will waste alot of this pricey product. For this discussion, let's assume you will be using Great Stuff to seal your home air conditioning duct work.

Preparation
First, turn on your home AC and go in the attic with a pen and paper to take notes. Check the ducts and junction boxes for any drafts. Then if you can see light from downstairs or feel any cold drafts below your feet elsewhere note these locations as well. Now knowing that one can will cover 1 sqft, use your notes to compile a mental image of how much foam you will need.

Application
Shake the can vigorously for at least a minute. If you do not, the foam will dispense very slowly making your work that much longer.

Precautions
Wear only clothing and shoes that you do not care about. My leather sandals now have foam all over them which is a fashion statement that makes a conversation starter at any hardware store! "Yeah, I caught that West Nile Virus last week."

The foam does not bond well to metal. Do not think you can apply it upside down either.

My recent shopping trips to the local hardware store have created a lot of stir amongst the clerks there. They keep asking me how the project is going because they want to use it in their attics as well. One particularulary concerned clerk told me a horror story about Great Stuff involving an elderly man and a gap in the brick wall behind his electric meter. The man filled the gap with the liquid foam by using an entire can and his fingers to manipulate the sticky material. Unfortunately the foam started expanding quickly and came pouring out of the wall. He started to scrape it off as quickly as he could but to his dismay a few minutes later the foam was hardening on his hands and arms! Rather than use mineral spirits to remove the slimy yellowish mass, he drove 15 minutes to the hardware store. The clerk said the foam had formed near perfect boxing gloves on his hands! The only way to remove the foam at this point was to pick each piece off.

Flammability
The pyromaniac in me insisted on burning the foam. I used a lighter on a piece the size of a fist. The foam burned briefly then died out. It appears the outer shell is flammable but the interior foam will not burn easily. The UL rating for this product is Flame Spread 20, Smoke Developed 20. The package says, "Cured foam is combustible and may present a fire hazard if exposed to flame or temperature above 240F." I believe the product is safe if you do not put it directly on any hot metal surfaces. To be cautious, I only used as much as I needed never going to excess.

Shelf Life
I was shocked to read that my can had an expiration date! Printed on the bottom of the can, the date was January 2009. You should check this as well when shopping.

Website
The product website is: http://greatstuff.dow.com/
Once on the website you will find several educational videos and tips for using Great Stuff. I encourage you to play the Handyman challenge on the site.

Summary
Great Stuff only gets a four star rating because of the price, high flammability and lower cost alternatives on the market. At the current retail price of $7.00 a 12oz can, Great Stuff is not cheap. However the benefits can truly save costly home repair and energy bills. You should pick up a can of Great Stuff and check the duct work in your attic before the summer heat claims more of your wallet. Just remember, to shake your can really good. The bottle that is...


Recommended: Yes