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Replacing foam rubber in a sofa with your own hands

You can replace outdated foam rubber yourself or invite a specialist to do this. The first option is cheaper. Moreover, this process is quite easy. Initially, you should decide: you just need to replace the material or reupholster the entire sofa. To do this, it is recommended to evaluate the furniture: wear, sagging, appearance.

If you have no experience replacing foam rubber on a sofa, then it is best to contact a specialist.

Replacement with a new one

Many people are interested in the question: how to replace foam rubber with your own hands simply and quickly in a sofa. This process consists of several stages. The first step is to remove the sides and preferably detach the back. Then you need to remove the transformation system.

When replacing foam rubber, you must first carefully remove the upholstery.

Note! It is recommended to take photos of each stage in order to eliminate the risk of errors during the assembly process. It is advisable to make notes on the parts, thanks to which in the future it will be possible to understand from which side they were removed.

It is worth examining all the details at the same time. Perhaps some also require replacement or repair. For example, if the furniture begins to creak or make unpleasant sounds, then you should check the plywood. It is quite possible that you will have to glue it and fix it with nails.

First you need to carefully examine all the parts and decide what else needs to be replaced.

The upholstery is removed using a flat screwdriver designed for removing staples or an anti-stapler. After this, it must be washed and ironed. Thus, it will be useful for a new pattern if you want to sew it yourself. Also, such processes will restore the appearance of the material if it is still quite normal and does not need to be replaced.

Now we proceed directly to replacing the foam rubber itself.

Foam rubber is chosen based on two indicators - density and thickness.

The cut filler should be placed on the wooden base of each element, firmly fixed and secured with special staples using a construction stapler. Due to the thicker layer, you can increase the volume of the armrests and backrest. But don’t get too carried away, because then you will need more fabric for upholstery and the removed one will no longer fit in size.

The foam rubber is carefully laid out on the surface and secured with staples using a stapler.

Additional Information! For the back and sides, you can use cheaper and softer foam. These areas receive minimal load.

For the next stage, you need to take any fabric similar to canvas in density. Then tighten each element separately. Thus, the filler will fit more evenly and tightly to the product. This will also help protect the foam from contamination.

Each element of the sofa is covered separately.

What else can you replace it with?

Instead of foam rubber, you can also use a spring block, polyurethane foam, synthetic winterizer, felt, latex, Periotek, Durafil, and lamellas as a filler for a sofa. Each has its own specific properties:

Polyurethane foam is a completely safe and environmentally friendly material, it has an excellent balance of hardness and softness. The disadvantages include the fact that over time it begins to deform and becomes too rigid.

Due to its light weight, this material does not weigh down the structure.
Synthetic winterizer - does not cause an allergic reaction, has a low price, is environmentally friendly, resilient and elastic. Its service life is not long; it is better to use it only for armrests, pillows and backrests, and not for the entire product; over time, it may begin to clump together.

Sintepon is most often used to stuff the backs and armrests of sofas.
Felt is highly wear-resistant, affordable, evenly distributes the load, does not cause allergies, has a smooth surface, and distributes heat well. Disadvantages: insects can grow in it, and it also becomes moldy over time, since it is not resistant to moisture.

Felt is rarely used in the furniture industry. Most often they cover spring blocks.
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Latex is capable of restoring its shape in a short time, is non-toxic, follows the contours of the body, has a service life of about twenty years, is breathable, and hypoallergenic. It has only one drawback - high cost.

Latex has excellent wear resistance. Very popular as stuffing for sofas and mattresses.

Important! Some sofas may have a combined filling. Therefore, when replacing it, this must be taken into account or, as an option, only one type must be used.

Foam rubber and its features

Foam rubber is a lightweight porous material of synthetic origin that is resilient and elastic.

PPU appeared in 1941. Scientists from Germany wanted to create hard polyurethane, but ended up with a soft mass. No one figured out how to use this material for the needs of the army, so the development was of no interest to anyone for several years. It was only in the post-war years that this inexpensive material began to be produced intentionally, and not as a by-product.

The main drawback of foam rubber is its high flammability. When the temperature rises, polyurethane foam releases flammable gases. They mix with the air in closed cells and ignite. To prevent this problem, special additives began to be used at the end of the 20th century. But the cost of the production process has increased significantly.

Another drawback is its low durability. Polyurethane foam loses its physical properties in about 15 years. After this time period, the molecular bonds break down. Foam rubber becomes brittle and crumbles and the foam rubber needs to be replaced.

90% of polyurethane foam consists of air molecules that are closed in cells. Pressure causes rupture, causing air to escape. If you place foam rubber in a liquid, the pores will fill with water. This material can absorb a volume of water almost equal to its own.

In the furniture industry, foam rubber is used due to its ability to restore its original shape. Polyurethane foam with a density of 20-40 kg/m³ is used as a filler.

DIY sofa spring block repair

Repairing a spring block in a sofa with your own hands will not take much time and is not a labor-intensive process. The first step is to separate the sides of the product. To do this, it is recommended to use a wrench. The upholstery material is removed using pliers. Once the mattress is removed, the size of the problem can be assessed. The springs should first be wiped and then carefully inspected.

Before you move on to repairing a spring unit, you need to know what types of springs there are.

Broken parts are removed with pliers and replaced: the old part is cut with wire cutters, a new one is put in its place, and then tied with a rope to the remaining elements.

All types of springs have different service lives.

Main characteristics

Manufacturers produce dozens of varieties of foam rubber. When purchasing polyurethane foam, it is important to consider the type and purpose of the piece of furniture. For example, for sofas that are used as a permanent sleeping place, it is better to choose hard foam rubber. But for seats it is recommended to purchase soft filling with a high comfort factor. To choose the most suitable option, it is worth studying the characteristics of the material:

Foam rubber density (compactness). One of the most important indicators that determines characteristics such as softness, elasticity, and wear resistance. It is measured in kilograms per cubic meter.
Stiffness (compressive stress). Determines the force that must be applied to compress the filler by 40%, measured in kilopascals (kPa).
Fortress. The higher it is, the stronger the material. The parameter determines the ability of the filler to withstand tensile loads.
Elasticity. It can be measured using special testing, during which the canvas is crushed, released, and the rebound height is determined. The higher the elasticity index, the softer and more comfortable the furniture.
Residual deformation. Reveals the ability of foam rubber to maintain size and shape. To determine this indicator, the material is compressed by 50%, exposed to high humidity and temperature, and then the difference between the original shape, before and after external influence is analyzed.
Convenience. It is determined by two coefficients: support (uniformity of load distribution over the entire plane) and comfort (how soft the material is).

Polyurethane foam is available in different formats and sizes. There are quite a lot of types of material. For the manufacture of upholstered furniture, sheet foam rubber is most often used. The thickness of the canvas varies from 5 to 1000 mm. Roll and block polyurethane foam are less commonly used.

Step-by-step instructions for upholstering furniture with your own hands

Polyurethane foam has a cellular structure, so its processing entails certain difficulties. CNC laser machines are used to cut and obtain the workpiece of the desired shape and size. The technique is silent, effective, and affordable. Advantages: minimum waste, ability to cut products with complex geometric shapes.

Rigidity

Fortress

Elasticity

Permanent deformation

Convenience

DIY corner sofa repair

To repair a corner sofa, the first step is to completely disassemble its frame. In this case, it is advisable to number all the details. After this, you need to prepare the fabric for reupholstery.

Prepare the fabric for the reupholstery with a reserve. It will come in handy in case of a possible error.

Along the way (if such a need arises), you can replace some parts with new ones. When assembling the device, all elements are coated with glue. Fixation is performed using cross-shaped metal dowels.

According to old standards, parts are cut out of plywood. The frame is coated with glue, then plywood is applied to it and fixed with a stapler. The springs are secured with the same tool so that they remain in one place. In this way, the necessary parts are replaced. After this, everything should be collected in its original form.

A chipboard frame is very difficult to repair. But if the frame is intact, then the sofa can be restored.

DIY sofa frame repair

The frame carries the main load, so if damaged elements appear in it, it is better to replace them with new parts. To do this, you should take their measurements, and then make the necessary product in the carpentry shop. You can do this yourself or find a professional. The connection is made using wood glue, but for greater efficiency it is also recommended to use metal dowels.

If the frame is damaged, then you should not delay repairs and it is better to do it right away.

First, glue the connection and then clamp it in a vice. Plywood is used as a base, the thickness of which is approximately four millimeters. For better reliability, joints are made on jumpers. It is recommended to support the joints with a beam.

Typically the sofa frame is made of wood or chipboard.

How to replace a spring block in a sofa

Instead of a spring block, you can use types of fillers such as foam rubber, felt or padding polyester.

The first one is an elastic material, provides elasticity, can serve as both a softening and a supporting product, while it is highly breathable and has a fine-mesh structure.

Foam rubber is soft polyurethane foam. The name comes from the Porolon supplier company.

The second is environmentally friendly, durable and reliable. Due to the increased strength, its service life is significantly extended.

Felt is a dense non-woven material made from natural wool.

The third one is low priced, environmentally friendly, does not cause an allergic reaction, resilient and elastic. In this form, fungus or other harmful bacteria do not grow.

Sintepon is one of the most popular materials in the modern world. The leader among synthetic insulation materials.

Criterias of choice

The main criterion is density. The service life of the furniture depends on it. The denser the polyurethane foam, the better quality it is. This means that sofas and armchairs with such filling will last longer.

According to standards, the density of the material used in the production of upholstered furniture cannot be less than 30 kg/m³. At the same time, this standard is suitable for backrests and armrests, since the load on them is not very large. But for seats, it is advisable to choose polyurethane foam from 35 kg/m³.

However, many manufacturers ignore this recommendation. This happens because the higher the density, the more expensive the material. Owners of furniture factories save money, which is why the filler becomes unusable just a couple of years after purchase. The surface becomes lumpy, it is no longer comfortable to sleep and the sofa needs to be repaired.

Thickness is also important. Preferably it should be 4 cm, but in any case not less than 3 cm. Pay attention to elasticity.

It is almost impossible for an ordinary user to visually distinguish the type of foam rubber. When choosing, you need to focus on the markings:

ST is a standard option that is used for the manufacture of inexpensive furniture. Density ranges from 16 to 35 kg/m³. Wears out quickly.
EL - increased rigidity. The best option. Density varies from 22 to 35 kg/m³.
HL - hard (25-40 kg/m³).
HS - soft, density 20-45 kg/m³.
HR - highly elastic (30-50 kg/m³).
HR* - highly elastic with increased comfort (30-55 kg/m³).

If a sofa is purchased as a place to sleep, polyurethane foam should be of increased rigidity. It is not recommended to sleep on surfaces that are too soft. If this is a place to relax, where you will spend a couple of hours a day, then standard foam rubber will do.

How to replace the cover

Replacing the covering consists of several stages. The first step is to remove the pillows, backrest, decor and sides. Then the furniture is separated from the base, that is, the seat is disassembled. After this, the old fabric is separated, but do not rush to throw it away, because it will be convenient to make a new pattern using it. The next stage is removing dust and dirt, as well as replacing foam rubber.

First, remove the old upholstery, cushions, and sides.

Now the pattern is being made, be sure to leave some space for the seams. The parts are fastened with needles and stitched on a machine. The new upholstery is attached separately to each element. Everything should be done very carefully to avoid tension. It is recommended to use a stapler for this; there should be a distance of about four centimeters between the staples.

You should remove the old upholstery carefully; you can use it to make a new pattern.

Purpose and properties

Foam rubber is a soft foam with a cellular structure, excellent insulating properties, excellent breathability and elasticity, which is why it is popular. 90% of the material consists of air. To make polyurethane foam, special synthetic components are used, which, reacting with each other, foam and then harden. The production of polyurethane foam involves the use of high-performance equipment and requires strict adherence to all the features and nuances of the technological process.

The main function performed by foam rubber for furniture is to give sofas, chairs, and poufs softness and elasticity. Polyurethane foam is used as a filler for any upholstered furniture, headboards, mattresses, and decorative pillows. The minimum permissible material thickness is 100 mm for the backrest, for seats - 300 mm, density - from 25 kg/m3.

Positive properties of foam rubber for furniture:

environmental safety - does not contain, and therefore does not emit toxic components;
is not an allergen;
moisture-resistant, does not allow mold spores and fungi to multiply;
retains its characteristics over a wide temperature range (from -40 to +100 degrees);
has excellent sound insulation properties, effectively absorbs noise;
soft and elastic, makes furniture comfortable and convenient;
does not deform under the influence of weights, is able to withstand significant mechanical loads;
it collapses under the weight of a person, but quickly restores its shape;
has a large working resource.

The best fabrics, designs for oversized furniture covers, nuances of choice
As for the shortcomings, there are few of them. With daily, intensive use, furniture with this filler will last 7–8 years. When foam rubber burns, harmful substances are released, which complicates disposal.

The undeniable advantage of the material is its affordable cost. Furniture made using this filler is classified as budget.

Repairing the transformation mechanism

At home, you can repair the transformation mechanism.

For example:

Sofa book - the mechanism is attached to the table, the broken rivet is drilled out. To select the correct size, a special compass is used. If repairs cannot be made using a rivet, then use a nut or bolt.

This type of furniture unfolds like a book and has two positions - sitting and lying.
Accordion - the rollers are replaced, but to do this, the first step is to find wheels that are exactly the same size and height. To do this, drill out the mounting axis. It can be easily replaced with ordinary bolts so that the rollers are better fixed. You can also replace the lamellas: drill out the rivet, change the product, secure with bolts.

The accordion sofa is very compact and can easily fit even in a small room.
Click-clack - the spring is replaced, which over time begins to deform. Instead of old rivets, ordinary bolts are installed.

The click-klyak sofa is an improved version of the book sofa. Suitable for permanent or guest sleeping space.

As can be seen from all of the above, repairing a sofa with your own hands will not cause any difficulties, but it will save money. It's relatively easy to do. This process will not take much time.

Recommendations from professionals

Experts advise replacing the foam in the sofa yourself in the following situations:

This furniture has been in use for quite some time and it has become uncomfortable to sleep on.
The sofa turned out to be defective or low-quality foam rubber was used when filling it.
The sofa has become too soft.

You can replace the foam rubber in the sofa at home and on your own. But if you do not have the appropriate knowledge, it is better to use the services of a specialist.

Sofa Furniture