What is Ethafoam? Its Grades and Uses | Ethafoam 220 for Pipeline Applications (PDF)

In today’s world, where packaging and product protection are paramount, Ethafoam has emerged as a versatile and indispensable material. This lightweight, durable, and resilient foam is used in various industries, from packaging delicate artifacts to providing cushioning in sports equipment. In this article, we will delve into the world of Ethafoam, its properties, grades, applications, and why it is important in the piping and pipeline industry.

What is Ethafoam?

Ethafoam is a resilient and flexible closed-cell, cross-linked polyethylene foam. It is manufactured by Sealed Air Corporation, a global leader in packaging solutions. It is a low-density plastic foam produced by expanding polyethylene by around 30 times in volume. Ethafoam has

  • excellent chemical resistance ability
  • excellent energy absorption capability under impact,
  • low water absorption and water-vapor transmission ability,
  • good insulation value,
  • no odor, and
  • easily fabricable.

Ethafoam is a true cushioning medium with the ability to sustain its resilience under repeated impacts. Its high load-bearing characteristics help it to be reused several times thus making it a very economical material.

Ethafoam is known for its exceptional strength-to-weight ratio, excellent shock absorption capabilities, and resistance to moisture, chemicals, and UV radiation. These properties make it an ideal choice for a wide range of applications, specifically packaging industries. But as we are dealing more with piping and pipeline applications in whatispiping, first we will learn the applications of Ethafoam in the oil and gas industries.

Applications of Ethafoam in the Oil and Gas Industries

In the Oil and Gas industries, Ethafoam is utilized in the following ways:

Pipeline Insulation:

Ethafoam is an excellent insulating material. In the oil and gas industry, pipelines often carry materials at extreme temperatures. Ethafoam can be used as an insulating layer to maintain the temperature of the transported fluids, preventing heat loss or gain, which is crucial for efficient operations.

Buoyancy Modules:

In offshore oil and gas operations, pipelines are sometimes laid on the seabed. Ethafoam is used to create buoyancy modules that help keep these pipelines afloat during installation and operation. These modules are designed to provide buoyancy while also offering protection against corrosion and mechanical damage.

Subsea Protection:

Subsea equipment and infrastructure in the oil and gas industry are exposed to harsh underwater conditions. Ethafoam is used to create protective covers and coatings that shield critical components from impacts, abrasion, and corrosion.

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Piping Supports:

Ethafoam is frequently used in the fabrication of pipe supports, especially in situations where vibration and thermal expansion need to be managed. The foam can be shaped to create custom pipe supports that provide cushioning and support while also dampening vibrations. This is particularly important for preventing damage to pipelines and ensuring their longevity.

Floatation for Cable Lines:

In underwater operations, cables are used for various purposes, including data transmission and power supply. Ethafoam can be employed to create buoyancy for these cable lines, ensuring they remain at the desired depth and minimizing the risk of damage.

Damping of Vibrations:

The oil and gas industry frequently deals with heavy machinery and equipment. Ethafoam can be employed to dampen vibrations in machinery, reducing noise and minimizing the risk of structural damage.

Sealing and Gasket Applications:

Ethafoam’s resistance to chemicals and moisture makes it suitable for sealing applications, including gaskets for flange connections. It can help maintain the integrity of the pipeline and prevent leaks in critical areas.

Cathodic Protection:

Ethafoam can be used in cathodic protection systems, which are essential for preventing corrosion on pipelines. It is often used as a dielectric insulator to separate metal components and protect them from galvanic corrosion.

Custom Packaging for Oilfield Equipment:

Ethafoam’s customizability makes it ideal for creating protective packaging for sensitive oilfield equipment. It can be molded to fit precisely around equipment, providing cushioning and protection during transportation.

Other Applications of Ethafoam

Art and Museum Conservation:

Ethafoam is a crucial material in the conservation of artworks and artifacts. Its ability to provide cushioning and protect delicate items from shocks, temperature fluctuations, and humidity changes is invaluable in this sector.

Electronics and Aerospace Packaging:

The lightweight yet sturdy nature of Ethafoam is highly advantageous in packaging electronic components and aerospace parts. It ensures that fragile equipment remains intact during transit.

Sports Equipment:

Ethafoam is used in the production of sports equipment such as helmets and padding. Its shock-absorbing qualities help reduce the risk of injury in various sports.

Medical Devices:

In the medical field, Ethafoam is used to protect and package sensitive medical devices during transportation, ensuring they reach their destination in perfect condition.

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Construction and Building:

Ethafoam also plays a role in the construction industry, where it is used as insulation and underlayment. Its moisture resistance and insulation properties are highly valued in this context.

Custom Packaging Solutions:

Many companies opt for custom Ethafoam packaging solutions to protect their products during shipping. This can range from simple cushioning inserts to intricate custom-fit cases.

Grades of Ethafoam

Ethafoam comes in a range of grades. They are mainly classified based on the density and each is designed with specific characteristics to suit various applications. The most common types of Ethafoam grades are:

Ethafoam 220:

Ethafoam 220 has a density of 2.2 pounds per cubic foot (pcf) and is widely known for its shock-absorbing properties. Used in various industries, including oil and gas, electronics, and aerospace.

Ethafoam 400:

It has a density of 4 pcf and is often used in packaging heavy or fragile items, including industrial equipment and machinery.

Ethafoam 600:

A moderate to high-density (6 pcf) foam with superior strength and rigidity. Ideal for applications where extreme weight support and structural integrity are necessary, such as load-bearing parts and structural components.

Ethafoam 900:

A high-density (9.5 pcf) foam and used where high strength and durability are required like in crash tests, and marine applications.

Ethafoam FR:

Flame-retardant Ethafoam that meets specific fire safety regulations. Commonly used in applications where fire resistance is essential, such as transportation and construction.

Ethafoam ECO:

An environmentally friendly version of Ethafoam made from recycled materials. Used in various applications where sustainability is a priority.

Among the above grades, Ethafoam 220 is widely used in oil and gas applications.

The Properties of Ethafoam

Lightweight yet Durable:

One of the standout characteristics of Ethafoam is its lightweight nature. Despite its low weight, it exhibits impressive durability. This makes it perfect for packaging applications where minimizing weight is crucial, such as aerospace and electronics.

Shock Absorption:

Ethafoam’s ability to absorb shocks and vibrations is second to none. It cushions fragile items during transportation, ensuring they arrive at their destination intact. This quality is highly valued in industries dealing with delicate goods, like the art and museum sector.

Chemical and Moisture Resistance:

Ethafoam is highly resistant to chemicals and moisture, protecting the items it encases from potential harm. It doesn’t degrade or lose its structural integrity when exposed to various environmental factors, making it an excellent choice for long-term storage and transportation.

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UV Stability:

Unlike some other materials that can degrade when exposed to sunlight, Ethafoam remains stable under UV radiation. This makes it suitable for outdoor applications, including protecting outdoor equipment and furniture.

The Environmental Aspect

In an era where environmental concerns are paramount, it’s important to note that Ethafoam, like many foam materials, poses certain environmental challenges. It is not biodegradable and can persist in the environment for extended periods. However, efforts are being made to recycle and repurpose Ethafoam, reducing its environmental impact.

Ethafoam 220 for Underground Pipelines

Ethafoam 220 is a soft foam material used to mitigate elevated forces and stress concentration. It is widely used to mitigate isolated areas of stress concentration due to thermal expansion of short sections of underground pipes and fittings.

For use in pipe stress analysis requirements as an expansion medium, Ethafoam 220 can be modeled by either of the following two methods:

  • By applying a stiffness coefficient for the expansion medium or
  • By removing the soil stiffness coefficient and leaving a void for the area where the expansion medium is planned


Ethafoam, with its remarkable properties and diverse applications, has become an essential material in modern packaging and beyond. Its lightweight yet durable nature, along with its excellent shock absorption and resistance to environmental factors, makes it an ideal choice for industries that prioritize the safety and protection of their products. As technology and recycling methods advance, we can expect Ethafoam to continue evolving, potentially becoming even more sustainable in the future. In the meantime, it remains a cornerstone material in the world of packaging and beyond.

Anup Kumar Dey

I am a Mechanical Engineer turned into a Piping Engineer. Currently, I work in a reputed MNC as a Senior Piping Stress Engineer. I am very much passionate about blogging and always tried to do unique things. This website is my first venture into the world of blogging with the aim of connecting with other piping engineers around the world.

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