HydroFoamer is a self-contained, portable automated spray platform engineered to rapidly apply a layer of closed-cell, rigid polyurethane (PU) foam—or other sprayable polymers—around pipeline systems.
This robotic system enables efficient, consistent, and large-scale polymer application in the field. Originally developed for high-pressure GRP pipelines in hydropower, the platform supports a broad range of use cases across sectors such as oil & gas, water infrastructure, and trenchless construction involving both polymer and metal pipes.
Functional Benefits
Applying PU foam or other polymers directly to the pipe enables backfilling with native soil—eliminating the need for imported or crushed granular material. The foam’s closed-cell structure forms a stiff, load-bearing shell around the pipe, distributing external forces evenly while resisting moisture and chemical ingress from surrounding soils.
This structural effect:
- Protects the pipe mechanically and chemically
- Reduces or removes the need for concrete thrust blocks
- Mitigates ovalisation in thin-walled pipes
- Enables the use of lower-strength materials like HDPE in demanding conditions
- Significantly cuts overall installation cost and complexity
The result is a highly stable system that accommodates axial and radial loads, improves geostatic performance, and enhances lifecycle durability across a range of soil types and climates.
Academic & Technical Validation
“The commissioning of Lille Måsevann penstock proves that the method with PU-foam as backfill works on a full-scale project, both for construction and operation.”
Prof. Leif Lia – NTNU Trondheim
HydroFoamer’s method has undergone rigorous independent academic validation through a collaboration between NTNU (Norwegian University of Science and Technology) and leading engineering consultants, including iVest & Multiconsult.
Three master’s theses have focused on the PU foam backfill method, confirming its structural suitability across a wide range of risk classes. Professor Lia—an internationally recognized authority on hydropower pipeline design—has declared the system fit-for-purpose based on field results.
The first full-scale installation was delivered for Statkraft in Northern Norway in 2016. Over three production seasons, the system demonstrated superior geotechnical and hydraulic performance, even beyond predicted models.
The method is suitable for all risk-classes.
Documentation
You can download Professor Leif Lia’s 2018 presentation to ICOLD in Vienna from here.