Before you can understand the benefits of a High-Density Polyethylene Pipe (HDPE), you need an understanding of what it is and how it differs from other piping on the market. HDPE is a thermoplastic pipe that isn’t really known compared to traditional options such as iron, PVC and concrete. Regardless, it has been used for over 50 years. The HDPE Pipe is built using materials that have been melted down and reshaped, resulting in a durable, flexible and rugged piping material.
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HDPE pipes are used for carrying potable water, wastewater, hazardous waste, chemicals and compressed gases. It has long been a favored material in the oil, gas and mining industries and continues to increase in popularity.
There are many benefits of using a high-density polyethylene pipe, in this article we present you with the top four!
Corrosion is one of the largest problems faced with metal piping and can be extremely costly to repair. Since HDPE pipes do not rust, rot or decompose, it is not as susceptible to corrosion and therefore significantly extends the pipe’s life.
HDPE pipes are connected through heat-fusion welding. This is essentially heating the two pipe surfaces together, when they cool they have formed a permanent, monolithic system. Bells, spigots and mechanical joints aren’t needed, thus reducing the cost of the system. In addition, one study found that states report an average of 16% water loss due to leaking joints. Since HDPE pipes are joined using heat fusion, they are permanently leak-free!
Traditional systems require a large ditch to be dug out in order to properly install the pipes. While HDPE pipes can be installed in this manner, they can also be installed using trenchless installation. This involves a horizontal direction machine digging a continuous hole into the ground, which the pipe is then pulled through. This method allows for much less land disruption, making it a popular choice near rivers, lakes and busy roads.
HDPE pipes have less of an environmental impact than other pipes. Some of the eco-friendly benefits include:
Less energy used to manufacture the pipes;
Lightweight and more cost effective to transport;
Heat fusion preventing any leakage;
Piping can be recycled into non-pressure pipe applications; and
Less ground disruption due to trenchless installations.
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HDPE pipe is a flexible plastic pipe made of thermoplastic high-density polyethylene widely used for low-temperature fluid and gas transfer. In recent times, HDPE pipes got their extensive uses for carrying potable water, hazardous wastes, various gases, slurry, firewater, stormwater, etc. The strong molecular bond of HDPE pipe materials helps it to use for high-pressure pipelines. Polyethylene pipes have a long and distinguished service history for gas, oil, mining, water, and other industries. Due to its low weight and high corrosion resistance, the HDPE pipe industry is growing tremendously. In the year , Karl Ziegler and Erhard Holzkamp discovered high-density polyethylene (HDPE). HDPE pipes can work satisfactorily in a wide temperature range of - F to + F. However, the use of HDPE Pipes is not suggested when the fluid temperature exceeds F (500 C).
HDPE pipes are made by the polymerization of ethylene, a by-product of oil. Various additives (stabilizers, fillers, plasticizers, softeners, lubricants, colorants, flame retardants, blowing agents, crosslinking agents, ultraviolet degradable additives, etc.) are added to produce the final HDPE pipe and components. HDPE pipe lengths are made by heating the HDPE resin. It is then extruded through a die, which determines the diameter of the pipeline. The Pipe wall thickness is determined by a combination of the die size, the speed of the screw, and the speed of the haul-off tractor. Usually, 3-5% carbon black is added to HDPE to make it UV resistant, which turns HDPE pipes black in color. Other color variants are available but usually not used frequently. Colored or striped HDPE pipe is usually 90-95% black material, where a colored stripe is provided on 5% of the outside surface.
The physical and mechanical properties of a typical HDPE Pipe are listed below:
Governing Codes: ISO , ISO , AS/ NZS , BS EN , EN , AWWA C901, AWWA C906, etc
Available size range: DN 16 to (However, other customized sizes can be manufactured)
The density of HDPE Pipe: 930-970 kg/m3
Typical Mechanical Properties of HDPE Pipe are given in Table 1 below. However, these values vary from one manufacturer to another. So, must be consulted with the manufacturer.
Mechanical PropertiesHDPE PropertiesYield Strength18-26 MpaElongation10%Elastic Modulus900 MpaHardness61 Rockwell (Shore)Poisson’s Ratio0.45Linear Coefficient of thermal expansion0.17 mm/m-0CBrittleness temperatureTable 1: Mechanical Properties of HDPE Pipe
Depending on maximum pressure withstanding capability, HDPE Pipes are classified into several pressure grades known as PN grades. They are
PN 2.5 – max pressure 2.5 bar
PN 4 – max pressure 4 bar
PN 6 – max pressure 6 bar
PN 10 – max pressure 10 bar
PN 16 – max pressure 16 bar
PN 20 – max pressure 20 bar
PN 25 – max pressure 25 bar
Again, based on the types of materials used HDPE pipes are grouped into the following types:
PE 63 – medium pressure piping systems
PE 80 – gas pipe for natural gas distribution network with pressure rate up to 4 bars or drinking water pipe with pressure rate up to 16 bar – sewers, outfall pipes, industrial pipes
PE 100 – high demands piping applications
The numbers following PE indicate the minimum required strength in Bar at 200 C for 50 years life span corresponding to ISO-. The rated working pressure of HDPE pipes is determined at 200 C. For higher temperatures, a derating factor (Table 2 Below) is used to determine the maximum pressure to which the HDPE Pipe can be subjected.
Fluid Temperature (0C)Temperature Derating factor0-201>20-250.9>25-300.8>30-350.7>35-400.6>40-450.5>45-500.4Table 2: Temperature Derating Factor for HDPE Pipes
As HDPE Pipe manufacturing is a continuous process, pipes of any length can be manufactured. However, due to transportation requirements and ease of handling at the site, the HDPE pipe length is limited and normally produced in standard lengths of 6, 10, 12, 15, 24, and 30 meters. HDPE Pipe lengths of 50 and 100 meters can be produced on request.
HDPE Pipes and fittings are joined to each other by Welding or by mechanical fittings. There are two types of welding methods used to join HDPE pipes. They are
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Electrofusion Welding: Electrofusion is a simple and quick method to permanently join individual pipes and HDPE fittings or prefabricated sections in tight places. This method is suitable for on-site joints.
Butt Welding: Butt-welding homogenously joins HDPE pipes and fittings into prefabricated sections using heat and pressure without using additional connection fittings.
Various types of mechanical joints can be used for joining HDPE pipes to HDPE or dissimilar pipes. They are
Plug-in joint
Snap joint
Screw-thread joint
Flanged joint
Contraction sleeve
Sleeve coupling
Metal coupling
Rubber collar joint
Fig. 1: HDPE Pipe Joining Methods
A complete range of HDPE Pipe fittings is available for any purpose. Typical HDPE pipe fittings include:
Bends
Elbows
Reducers
Branches
End caps
Electrofusion couplers
Mechanical connection fittings
Traps
Sanitary fittings
Spare parts
Fig. 2: Typical HDPE Pipe Fittings
Factors that can influence the behavior and thus, the design of above-ground HDPE Piping Systems are
Temperature: For pressure systems, the use of HDPE pipes is usually limited to -400C to 500 C. For non-pressure services, higher temperatures can be used. Consult with the manufacturer for getting information about their product. Note that, the coefficient of linear thermal expansion for HDPE pipes is approximately 10 times higher than that of metal pipes. So, the potential of thermal expansion due to temperature fluctuations is very high and must be considered in the design. A typical Thumb rule is HDPE pipes will expand or contract by 0.2mm Per Meter per °C increase or decrease in temperature.
Internal Pressure
Chemical exposure
Potential mechanical impact or loading: Extra protection must be given if the HDPE pipe is installed in a region of high traffic or mechanical abuse.
Ultraviolet radiation: To safeguard against ultraviolet radiation effects, black HDPE pipes containing a minimum of 2% carbon black are selected.
A number of variables determine the hydrostatic pressure capacity of HDPE pipes. Those are
Standard Dimension Ratio or SDR is defined as the ratio between the outside HDPE Pipe diameter and the wall thickness.
The hydrostatic design stress of the HDPE material being used (PE63, PE 80, PE100) for HDPE Pipe Manufacturing.
The maximum and minimum operating temperatures.
The duration and variability of the stress applied by the internal hydrostatic pressure during hydrostatic testing.
The chemical resistance of the HDPE pipe for the service chemical (the standard pressure rating is based on a pipe carrying water).
Usually, HDPE pipe can withstand short-term hydrostatic water pressures that are considerably higher than the pressure rating, or class. But the duty of the HDPE pipe should always be determined following the pipe’s long-term strength at 20°C to ensure a design life of at least 50 years.
Barlow’s Formula is also applicable for HDPE piping that is related to the internal pressure, pipe outer diameter, wall thickness, and circumferential hoop stress and is given by
Here:
p = internal pressure (MPa)
t = minimum wall thickness (mm)
d = mean outside diameter (mm)
σ = circumferential hoop stress (MPa)
The design hoop stresses for HDPE pipe materials are considered as follows as given in ISO :
PE 63: 5 MPa
PE 80: 6.3 MPa
PE100: 8 MPa
HDPE pipes provide various advantages with respect to other piping materials like
Cost-effective. Hence, easily affordable
High flow rate due to the smooth inner surface
Wide temperature range
Non-leaching
Easy transportation due to low-weight
UV-resistant
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Amazing Durability (More than 50 years)
Resistant to most chemical solvents
Stiff material
Environment friendly
Lower maintenance cost
High Quality
Reduced installation cost
Due to its flexible shape, simple to use on slopes.
Simple joining methods.
Not affected by underground movements (Seismic Resistant)
Bad conductor of electricity.
low-friction
Ability to dampen water-shock
Sun-resistant
Non-stick surface.
Leak-free due to its seamless nature.
Prefabricated HDPE pipe sections can be easily installed
The main disadvantage of HDPE pipes are
Poor weathering resistance
Highly Flammable
Sensitive to stress cracking
Difficult to bond
Poor High-Temperature capability
High thermal expansion
The full form of HDPE is High-Density Polyethylene. This hydrocarbon polymer is produced from petroleum by a catalytic process. Famous for its tensile strength in a similar product category, High-Density Poly Ethylene is a kind of thermoplastic.
Both HDPE and PVC are considered plastics. However, they are not the same. HDPE is a thermoplastic made from petroleum and PVC is a durable vinyl polymer. While comparing HDPE and PVC, HDPE due to its flexibility, high strength-to-density ratio, no corrosion, and chemical stability is a strong choice for low-pressure and low-temperature applications.
HDPE or High-density polyethylene pipe is widely used to carry potable water, slurries, wastewater, chemicals, hazardous wastes, and compressed gases. They have been used in various industries like gas, oil, mining, water, and other industries.
Properly designed HDPE piping systems provide a long-lasting performance as compared to other piping systems. As per the estimates of the Plastic Pipe Institute, they are supposed to last 50 to 100 years.
Yes, HDPE is totally safe for carrying drinking water. This is one of the main reasons that in the water industry and desalination plants, high-density polyethylene pipes are widely used. The application of HDPE pipes for potable water applications is certified by NSF. Various disinfectants like chlorine and chloramine are approved for use in HDPE pipes.
PVC is stronger and stiffer as compared to HDPE.
Piping made from polyethylene is a cost effective solution for a broad range of piping problems in municipal, industrial, marine, mining, landfill, duct and agricultural applications. It has been tested and proven effective for above ground, surface, buried, sliplined, floating, and sub-sur face marine applications.
High-density polyethylene pipe (HDPE) can carry potable water, wastewater, slurries, chemicals, hazardeous wastes, and compressed gases. In fact, polyethylene pipe has a long and distinguished history of service to the gas, oil, mining and other industries. It has the lowest repair frequency per mile of pipe per year compared with all other pressure pipe materials used for urban gas distribution. Polyethylene is strong, extremely tough and very durable. Whether you’re looking for long service, trouble-free installation, flexibility, resistance to chemicals or a myriad of other features, high-density polyethylene pipe will meet all your requirements.
• LEAK FREE
Polyethylene pipe is normally joined by heat fusion. Butt, socket, sidewall fusion and electrofusion create a joint that is as strong as the pipe itself, and is virtually leak free. This unique joining method produces significant cost reductions compared to other materials.
• CORROSION, ABRASION, AND CHEMICAL RESISTANT
Polyethylene piping’s performance in mining, dredging and similar applications proves it will outwear many more costly piping materials when conveying a variety of abrasive slurries. HDPE has excellent corrosion resistance and is virtually inert. It does not need expensive maintenance or cathodic protection. It offers better overall resistance to corrosive acids, bases and salts than most piping materials. In addition, polyethylene is unaffected by bacteria, fungi and the most “aggressive” naturally occurring soils. It has good resistance to many organic substances, such as solvents and fuels.
• EXCELLENT FLOW CHARACTERISTICS
Because polyethylene is smoother than steel, cast iron, ductile iron, or concrete, a smaller HDPE Pipe can carry an equivalent volumetric flow rate at the same pressure. It has less drag and a lower tendency for turbulence at high flow. Its superior chemical resistance and “non-stick” surface combine to almost eliminate scaling and pitting and preserve the excellent hydraulic characteristics throughout the pipe service life.
• LIGHTWEIGHT AND FLEXIBLE
Polyethylene pipe is produced in straight lengths or in coils. Made from materials about one-eighth the density of steel, it is lightweight and does not require the use of heavy lifting equipment for installation. It reduces the need for fittings, is excellent in shifting soils and performs well in earthquake-prone areas. HDPE resists. the effects of freezing and allows bending without the need for an excessive number of fittings. Since HDPE is not a brittle material, it can be installed with bends over uneven terrain easily in continuous lengths without additional welds or couplings.
• DUCTILITY AND TOUGHNESS
Polyethylene pipe and fittings are inherently tough, resilient and resistant to damage caused by external loads, vibrations, and from pressure surges such as water hammer. Even in cold weather polyethylene pipe is tolerant to handling and bending.
• MANUFACTURED UNDER AWWA, NSF, ASTM, AGA, EPA, DNR, DOT, API, FM, CSA AND OTHER NATIONALLY RECOGNIZED STANDARDS.
Polyethylene pipe is listed and approved by the standards or committees of the agencies listed above.
• AVAILABLE IN DIAMETERS FROM
½ INCH TO 63 INCH. Polyethylene pipe is available in a wide range of diameters and wall thickness, with flanges, elbows, tees, wyes, and valves, providing a total system solution. HDPE pipe is also available in Iron Pipe Size (IPS), Ductile Pipe Size (DIPS) as well as metric sizes. Plastic Pipe Institute members can provide pipe, fittings and other appurtenances.
• APWA COLOR CODING BYAPPLICATION
Polyethylene pipe is available with color coding by application as developed by the utility location and coordination council of the American Public Works Association (APWA).
High-density polyethylene (HDPE) pipes have become a cornerstone in the infrastructure and utilities sectors, largely due to their remarkable versatility, durability, and resistance to environmental factors. From water distribution networks to complex industrial systems, HDPE pipe installations are found in various applications, proving their value in diverse environments. Understanding HDPE pipe sizes and HDPE pipe fittings is essential to ensure that each installation performs optimally. This blog aims to provide an in-depth exploration of HDPE pipe sizes, fittings, and applications. By the end of this guide, you’ll have a thorough understanding of how to select the correct HDPE pipe size and fittings for your projects, ensuring that your systems run efficiently and reliably.
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HDPE, or High-Density Polyethylene, is a thermoplastic polymer made from petroleum. Its molecular structure gives it a high strength-to-density ratio, making it both lightweight and incredibly durable. This unique material has made HDPE pipe systems a preferred choice in industries that require reliable and long-lasting piping solutions.
HDPE is produced through the polymerization of ethylene, which results in a chain of hydrocarbons that creates a strong, lightweight material. The production process involves heat and pressure, which align the molecules in a way that maximizes strength while maintaining flexibility in the HDPE pipe.
The benefits of HDPE pipe systems stem from their physical properties, which allow them to outperform traditional piping materials in many applications. Some of the most notable benefits include:
HDPE pipes are resistant to chemicals, abrasions, impacts, and environmental stressors like extreme weather conditions.
HDPE pipe systems’ flexibility makes them ideal for use in regions prone to seismic activity or shifting soil conditions, as they can bend without breaking.
Unlike metal pipes, HDPE pipe installations are non-corrosive, which is a significant advantage in water and wastewater systems where corrosion can lead to contamination and system failure.
While the initial cost of HDPE pipes may be higher than some alternatives, their longevity and low maintenance requirements make them more economical in the long run.
HDPE pipe is fully recyclable, contributing to its popularity as an environmentally friendly option. Recycled HDPE can be repurposed into new pipes or other products, reducing waste in landfills.
HDPE pipe systems are used in a wide range of industries, from residential water supply to industrial chemical transport. Their ability to resist wear and tear makes them suitable for transporting gases, slurries, and water, both potable and wastewater.
Choosing the appropriate HDPE pipe size is critical to ensuring the system functions effectively. There are a wide variety of sizes, each suited for specific applications.
The size of an HDPE pipe is determined by its nominal diameter (ND) or outside diameter (OD). The wall thickness also plays a critical role, as it determines the pipe’s pressure rating. The larger the HDPE pipe, the more fluid it can transport, but there are many factors to consider beyond just flow rate. HDPE pipe sizes are measured either in inches (imperial system) or millimeters (metric system). Each measurement standard offers pipes in various sizes to suit different needs.
HDPE pipe sizes are available in a range of standard dimensions, typically grouped by their nominal or outside diameter. The most commonly used HDPE pipe sizes include:
These HDPE pipe sizes are often used in household plumbing, irrigation systems, and small municipal water supply projects.
These HDPE pipe sizes are popular for sewer systems, drainage systems, and municipal water distribution networks.
These are typically used for stormwater management, industrial wastewater treatment, and other large-scale applications. For larger projects, HDPE pipe sizes can even exceed mm in diameter, though these are generally custom-made for specific industrial uses.
The measurement system you use for HDPE pipe sizes can depend on your geographic location or the industry standards for your project. In the United States and other countries that use the imperial system, HDPE pipe sizes are measured in inches. In countries that follow the metric system, HDPE pipe sizes are measured in millimeters.
The size of an HDPE pipe is selected based on the application and the required flow rate. Below are common HDPE pipe size categories and their uses:
Several factors influence the selection of the appropriate HDPE pipe size:
HDPE pipe fittings are essential for ensuring a secure and leak-free system. The types of HDPE pipe fittings used depend on the type of installation, the size of the pipes, and the specific demands of the application.
There are several types of HDPE pipe fittings available, each designed for a particular function. Some of the most common HDPE pipe fittings include:
Each type of HDPE pipe fitting is designed to be compatible with the pipe’s material and pressure rating, ensuring a long-lasting and secure connection.
The type of HDPE pipe fittings you choose depends on the specific needs of your piping system. For example:
HDPE pipe fittings can be installed using various methods, depending on the system’s requirements:
HDPE pipes are used in a wide range of industries due to their durability, flexibility, and chemical resistance.
One of the most common uses of HDPE pipes is in potable water distribution systems. Because HDPE is resistant to corrosion and scale build-up, it maintains water quality over time. Municipalities and water authorities often choose HDPE pipes for their long-term reliability and low maintenance costs.
HDPE pipes are well-suited for sewerage and drainage systems due to their flexibility and resistance to chemical degradation. These pipes can handle large volumes of wastewater and stormwater while minimizing the risk of blockages and leaks. HDPE pipes are also resistant to root intrusion, a common issue with older systems made from concrete or clay.
HDPE pipes transport chemicals, slurries, and gases in industrial environments. Their chemical resistance makes HDPE ideal for handling hazardous materials, while their high tensile strength allows them to withstand the pressures and impacts associated with industrial use.
HDPE pipes are frequently used in agricultural irrigation systems due to their flexibility and durability. They can be installed in challenging terrain, allowing for the efficient distribution of water across large fields.
HDPE pipes are also used in marine applications, such as aquaculture and underwater pipelines, due to their resistance to corrosion in salty and brackish environments.
HDPE pipes are popular in various sectors because they offer many advantages over traditional piping materials like PVC, concrete, and steel.
One of the standout features of HDPE pipes is their ability to withstand harsh conditions without succumbing to corrosion. This makes HDPE pipes ideal for use in environments where metal pipes would typically rust or degrade, such as in underground installations or in systems that transport chemicals.
HDPE pipes are highly flexible, allowing them to be easily installed in locations where traditional rigid pipes would be impractical. They can be bent to follow the contours of the land or routed around obstacles, reducing the need for additional HDPE pipe fittings and lowering installation costs. This flexibility also makes HDPE pipes less likely to crack under pressure or when exposed to freeze-thaw cycles.
Although the initial cost of HDPE pipes may be higher than other options, they provide substantial cost savings over time. Their long lifespan, minimal maintenance requirements, and resistance to environmental factors mean that HDPE pipes require fewer replacements, repairs, and operational downtime.
HDPE pipes are 100% recyclable. As sustainability becomes a key concern across industries, the ability to recycle HDPE pipes into new products is an attractive feature for companies looking to reduce their environmental impact.
HDPE pipes benefit drainage systems immensely due to their ability to handle large volumes of water while resisting chemical and physical wear. These pipes offer specific features that make them highly efficient for both residential and industrial drainage solutions.
HDPE drainage pipes have smooth interior surfaces, which allow water to flow freely with minimal friction. This feature makes HDPE drainage pipes less prone to blockages, as debris can pass through more easily compared to pipes made from other materials.
Traditional drainage systems made from materials like clay, concrete, or cast iron are more susceptible to cracking, corrosion, and blockages. HDPE drainage pipes, in contrast, provide a lightweight, corrosion-resistant alternative that is easier to install and maintain over time. The flexibility of HDPE drainage pipes also allows them to withstand ground movement without breaking, a common issue with more rigid materials.
Proper installation of HDPE drainage pipes is key to ensuring their long-term performance. Adequate support with the right bedding material is important to prevent pipe deformation. Additionally, regular inspections should be carried out to check for any blockages or damage, ensuring that the HDPE drainage pipe system continues to function effectively.
As industries evolve, HDPE pipe technology is also advancing, with new materials and manufacturing processes emerging to meet the growing demand for more efficient and sustainable piping solutions.
Technological advancements have led to the development of reinforced HDPE pipes, which offer enhanced strength without compromising flexibility. These innovations are particularly useful in applications requiring high-pressure handling, such as gas distribution or industrial fluid transport. Additionally, improvements in jointing techniques, such as electrofusion and butt fusion, have made it easier to install HDPE pipes with precision and durability. These methods result in leak-proof joints that are stronger than the pipe itself, reducing the risk of system failures.
As environmental sustainability becomes increasingly important, HDPE pipes are being recognized for their role in reducing environmental impact. Producing HDPE pipes requires less energy than metal pipes, and because HDPE is recyclable, old pipes can be repurposed into new products. The future of HDPE pipes will likely focus on improving these sustainability measures, as well as developing pipes that can withstand even higher pressures and more extreme environmental conditions.
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