Sealing and protecting infrastructure like outdoor electrical enclosures, industrial lighting and HVAC units is a key consideration for engineers and manufacturers. In environments where there is a constant battle against the elements, a seal failure doesn’t just mean a bit of water ingress, but can lead to huge system failures that generate major safety hazards, downtime, and high repair costs. For such critical sealing applications, BISCO® HT800 is an increasingly popular choice of silicone sponge.

At CB Frost, as a preferred converter of Rogers Corporation, we supply and convert vast quantities of Rogers’ full range of BISCO® cellular silicones. HT800 silicone foam is increasingly viewed as the industry standard, and we believe the reasons for its popularity come down to three core facets:

1. Enduring physical memory (compression set)
2. Relentless environmental resistance
3. Lasting assembly line efficiency

HT800 – Memory and Durability

The real test of any sealing material isn’t how it performs on day one, but how it performs on day one hundred or day one thousand.

Many elastomers have a high compression set. This means that when compressed between two surfaces, they require a high closure force to effectively seal, and when compressed for extended periods they can permanently deform. For example, when a seal or gasket fails to bounce back to its original shape, it leaves a gap where water, dust and other contaminants can enter.

HT800 is engineered to have exceptional compression set resistance. It has an excellent cellular memory, which means it continuously pushes back against the surfaces it is sandwiched between, ensuring a tight and reliable seal even after years of sustained compression.

If your application involves panels, doors or housings that will be repeatedly opened and closed over their lifespan, then a HT800 silicone foam gasket ensures that seals won’t need to be replaced at every maintenance check.

UV and Ozone Resistance

Silicone sealing materials for outdoor applications are subjected to sometimes brutal environmental conditions. Many traditional rubbers become brittle or ultimately disintegrate when exposed to UV light and ozone for prolonged periods, but HT800 is formulated to be highly resistant to both, making it an ideal choice for applications such as:

• Outdoor enclosures: HT800 protects sensitive electrical and telecommunications components from wind-driven rain and environmental contaminants.

• HVAC units: It handles the thermal cycling and outdoor exposure in large heating and ventilation systems without degrading.

• Industrial lighting: It withstands extreme temperature fluctuations, along with the environmental exposure experienced in outdoor lighting systems.

EN45545 Compliance

In modern manufacturing, particularly in production for the rail, mass transit and aerospace sectors, fire safety is a non-negotiable. HT800 silicone foam is not just a physical barrier against the weather, but a critical safety component. It is compliant with the stringent EN45545-2 standard for fire safety in railway vehicles. Whilst this standard is specifically for compliance within the rail industry, it gives design engineers in all sectors peace of mind when it comes to fire safety, and simplifies the safety auditing process.

The Benefits of Adhesive-Backed HT800 Foam Conversion

When it comes to assembly line efficiency, messy liquid adhesives or struggles with aligning rubber, foam or sponge gaskets can affect production costs. In addition to the versatile resistance qualities of HT800, it is also just as versatile when it comes to conversion. It can be supplied with adhesive backing and cut into strips, or intricately die-cut gaskets on a roll, contributing to a streamlined assembly process.

• Peel-and-stick: Adhesive-backed HT800 strips or gaskets can be quickly pressed into place to create an effective seal.

• Consistency: Pre-cut strips with a consistent thickness and width ensure consistency of sealing footprint.

Upgrading Your Sealing Strategy

If you are designing new outdoor enclosures or looking to increase efficiency on HVAC production lines, BISCO® HT800 is the industry standard for silicone sponge or foam, providing the perfect balance of long-term durability, practical application, and fire safety compliance.

For assistance with material selection for your next project, or for gasket or strip production with fast-lead times and the highest performing cellular silicone materials, talk to us today. Our experienced sales team is here to help you find the precise grade, thickness and manufacturing processes for your application.