Type of flexible plastic pipe
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HDPE pipe is a type of flexible plastic pipe used for fluid and gas transfer and is often used to replace ageing concrete or steel mains pipelines. Made from the thermoplastic HDPE (high-density polyethylene), its high level of impermeability and strong molecular bond make it suitable for high pressure pipelines. HDPE pipe is used across the globe for applications such as water mains, gas mains,[1][self-published source?] sewer mains, slurry transfer lines, rural irrigation, fire system supply lines, electrical and communications conduit, and stormwater and drainage pipes. However, most United States municipal governments restrict its use on public works projects.
Benefits
The toughness and resistance to chemicals of polyethylene, as well as the corrosion resistance and low weight have contributed to its growing use in situations where cost-effective and durable fluid and gas piping systems are required. According to a press release from the Plastics Pipe Institute, "PE piping has been used for water and other fluids in Europe and America since the s due to its durability, leak free joints, resistance to corrosion, and long-term cost-effectiveness."[2][self-published source?]
HDPE pipe can be joined by butt welding, electrofusion welding, socket welding, or extrusion welding. These joints heat the pipe during the joining process, creating a completely homogeneous joint so the weld becomes as strong, or stronger than the existing pipe on either side of the weld. There is no need to use rubber seals or jointing chemicals, as is used for joining PVC pipe, which cause environmental health issues and increase the chance of failure over time. PE is less likely to have problems with root intrusion, and provides integrity for the pipeline, even when installed in unstable soils.
HDPE communications conduit pipe being installed by directional drilling in Perth, Western Australia
Due to the fusion welding system, the need for anchors or thrust restraint blocks are eliminated, as the joints become fully end load resistant, reducing costs for material and installation time. This also allows for safer excavation close to the pipeline in future, which is particularly important for high pressure gas pipelines. Coils of PE Pipe make trench-less installation safer and less intrusive on the surrounding environment.
HDPE pipe systems are available for many applications, providing for standard trenching of water mains, fire ring mains, sewer mains, and gas mains pipelines, as well as horizontal drilling for electrical and telecommunications conduits.[3] According to a company that manufactures HDPE, HDPE systems are cost-effective to install and have long-term maintenance cost savings, and also allow for cheaper installation methods, such as HDD (horizontal directional drilling), sliplining, pipe bursting, floating and submerged pipe.[4]
HDPE pipe is very durable and flexible and can be bent on site to a radius twenty-five times the nominal pipe diameter - for SDR11 and SDR17 pipe, at or below 20°C ambient temperature. This provides major cost savings, when compared to different pipe systems, some of which require glued fittings, restraints or thrust blocks for even minor changes in direction. Because of the high impact resistance and flexibility of HDPE pipe, it is well suited to installation in dynamic soils including in earthquake-prone areas. HDPE pipe has very high flow capacity, because of its smooth bore and end-to-end jointing methods. HDPE pipe does not corrode in the environment, and will maintain its flow capabilities over time, unlike ferrous piping systems, which will rust and build up internal resistance to fluid flowing through it.[5][self-published source?]
Because food-grade polyethylene virgin material is used to fabricate HDPE pipes, they are safe for the transfer of drinking water, provided that any initial debris has been flushed out. HDPE pipe is resistant to many chemicals, facilitating its use in process plants or around corrosive or acidic environments, without needing to use protective coatings or galvanising, as is required on steel pipes. As HDPE has a very low thermal conductivity, it can maintain more uniform temperatures compared to metal pipes when carrying fluids, which will greatly reduce any need for insulation to control condensation around the pipeline.[6][self-published source?]
Manufacture
To make pipe lengths, HDPE resin is heated and extruded through a die, which determines the diameter of the pipeline. The wall thickness of the pipe is determined by a combination of the size of the die, speed of the screw and the speed of the haul-off tractor. Polyethylene pipe is usually black in color due to the addition of 3-5% of carbon black being added to the clear polyethylene material. The addition of carbon black creates a product which is UV light resistant. Other colours are available but are less common. Coloured or striped HDPE pipe is usually 90-95% black material, with just a coloured skin or stripe on the outside 5%.
The following shows the process for HDPE Pipe Extrusion:
Freshly Extruded 800 mm (31.50 in) HDPE Pipe
Polyethylene raw material is pulled from a silo, into the hopper dryer, which removes any moisture from the pellets. Then it is pulled by a vacuum pump into the blender, where it is heated by a barrel heater. The PE material becomes molten at around 180 °C (356 °F), allowing it to be fed through a mould/die, which shapes the molten material into a circular shape. After coming through the die, the newly formed pipe quickly enters the cooling tanks, which submerge or spray water at the pipe exterior, each one reducing the temperature of the pipe by 10-20 degrees. Because polyethylene has a high specific heat capacity, the pipe must be cooled in stages, to avoid deforming the shape, and by the time it reaches the "haul-off tractor", it is hard enough to be gently pulled by the 2-3 belts. A laser or powder printer prints the size, type, date and manufacturers name on the side of the pipe. It is then cut by a saw cutter, either into lengths of 3 or 6 or 12 or 24 meters (9.8 or 19.7 or 39.4 or 78.7 ft), or it is coiled to 50 or 100 or 200 m (164 or 328 or 656 ft) lengths on a coiler.
HDPE Pipe with Blue stripes
A different die is used for striped HDPE pipe, which has small channels that the coloured material runs through, just before it is pushed through the die. This means the stripes are formed as an integral part of the pipe and are not likely to separate from the main pipe body. Co-extruded, or co-ex HDPE pipe, has a second extrusion screw which adds an extra skin of colour around the black HDPE pipe, this allows the pipe to be coloured on the outside, for identification or thermal cooling requirements.
Uses
An example of the durability of HDPE pipe is the 600 m (1,969 ft) long HDPE boom used for the Ocean Cleanup project. The HDPE pipeline is being released into the ocean to clean up the Great Pacific Garbage Patch.[7]
HDPE pipe has been used in rural and mining environments in Australia for over 50 years, proving to be a very durable and effective means of fluid and gas transfer.[8][self-published source?]
Life expectancy
HDPE yellow jacket Gas Pipe, white jacket communications conduit, and orange jacket electrical conduit
Although HDPE pipe is often estimated to last 50 years, they are in fact more likely to have life expectancies of 100 years. PIPA (Plastics Industry Pipe Association) and the Plastic Pipe Institute (PPI) have written technical white papers on HDPE design life. The PIPA paper is called "Life Expectancy for Plastics Pipes" which mentions that because of the fifty-year stress regression data, people[who?] falsely assume that plastic pipe systems' life expectancy is only fifty years. In fact, these pipe systems can be reasonably expected to last up to or more than 100 years.[5][self-published source?] In Australia, PE pipes and PE fittings were introduced during the mid-s, mainly for irrigation or water supply, but also for gas, fuel, and other industrial applications. The use of this 50-year time interval, leads to a misunderstanding that it represents a 50-year pipe life. For pipe systems that have been correctly manufactured and installed, the actual life cannot be predicted, but can be expected to be over 100 years until major rehabilitation is needed.[5][self-published source?]
Are you new to the HDPE piping world? No problem. Take a few minutes between projects to review the below collection of common HDPE pipe terminology and definitions. Once you have finished, please contact us for additional information and guidance or to discuss your company’s specific HDPE needs.
HDPE: High density polyethylene (HDPE) refers to the thermoplastic polymer produced from the monomer ethylene. HDPE piping has a high strength-to-density ratio and highly bendable, allowing for pipe to be coiled. HDPE is lightweight, flexible, inexpensive and corrosion resistant. In addition to piping, HDPE is used in the production of plastic bottles, geomembranes, grocery bags, toys, containers and plastic lumber.
IPS and DIPS: Iron Pipe Size or IPS represents the nominal diameter of the pipe. A 6-in. IPS pipe has an inside diameter of six inches. Ductile Iron Pipe Size or DIPS is used to specify the size of ductile iron pipe. Typically, IPS refers to black iron or carbon steel pipe while DIPS refers to cast/ductile iron pipe. IPS and DIPS are used in the HDPE market to replicate the familiar dimensions of these other IPS pipe is available in size ranging from ¾-in. to 65-in. diameters while DIPS is available from 4- in. to 36-in. diameters.
CTS: Copper Tube Size is specific to plumbing and potable water systems. In copper, the OD is always 1/8 inch larger that the nominal size of the pipe, and that has carried over to HPDE that is built to CTS sizes. As a replacement for traditional copper lines for water, a 2-in. HDPE pipe that follows CTS sizing standards would have an OD of 2 1/8 in. For water applications HDPE pipe can be sized as small as ¾ in OD.
Bend Radius: Bend radius, measured to the inside curvature, is the minimum radius one can bend a pipe, tube, sheet, cable or hose without kinking it, damaging it or shortening its life. The smaller the bend radius, the greater is the material flexibility. HDPE piping is more flexible than other competitive piping options, offering a smaller bend radius. However, exceeding minimum bend radiuses may result in mechanical failure and decreased longevity. And for HDPE-encased fiber-optic cabling, it is problematic, as exceeding minimum bend radius can cause light attenuation resulting in performance loss.
Dimension Ratio (DR): The Dimension Ratio (DR) is the ratio of the pipe outside diameter to the pipe minimum wall thickness. As diameters change, the pressure rating remains the same for the same material, dimension ratio and application.
Standard Dimension Ratio (SDR):
Certain Dimension Rations (DRs) that meet an ASTM International specified number series (32.5, 26, 21, 17, 13.5) are referred to as Standard Dimension Ratios (SDRs). There is approximately 25% difference in minimum wall thickness between each SDR.
Calculating SDR: SDR is defined as the ratio of the nominal outside diameter to the nominal wall thickness.
SDR = dn/en
Where dn is the nominal outside diameter of pipe and en is the nominal (minimum) wall thickness of the pipe.
Carbon Black (CB): Carbon Black products are additives used to improve the strength and performance of HDPE pipe. CBs are typically used to improve UV resistance and to reduce or lower moisture absorption in pipe
Coefficient of friction: Coefficient of friction measures the amount of friction existing between two surfaces. As this measurement relates to piping, a lower coefficient of friction typically means less friction damage in piping (example: outer layer wear). To find the coefficient of friction (fr) use this formula:
Fr/N = fr
Where Fr is the resistive friction force and N is the normal force pushing on objects.
Surge pressure - Recurring and occasional: American Water Works Association standard AWWA C901 defines two types of surge pressure, recurring and occasional. The safe peak pressure or allowed total pressure for HDPE pipe is 1.5 times the pipe’s pressure rating for recurring surge and 2.0 times the pipe’s pressure rating for occasional surge.
Temperature derating: Materials rated for operating pressures or tensions at a standard temperature, must be ‘derated’ when temperatures increase. Derating is usually expressed graphically or in terms of derating factors. HDPE piping loses its strength to pressure and tension as temperature is increased.
FM approved: FM Approvals is a third-party testing and certification service. FM Approved-HDPE pipe and fittings are subjected to more severe performance testing. The five-step certification process includes product review, testing, and manufacturing facility audits.
UL Rating: Underwriters Laboratories (UL) is a global safety science company and third-party certification company founded in . The company tests products and technologies for safety. Beginning in , UL published a series of standards for polymer raceway products, including rigid PVC conduit as well as HDPE conduit.
Seismic loading: Seismic loading is one of the basic concepts of earthquake engineering which includes application of a seismic oscillation to a structure. It happens at contact surfaces of a structure either with the ground or with adjacent structures.
According to an Electric Power Research Institute report Nondestructive Evaluation: Seismic Design Criteria for Polyethylene Pipe Replacement Code Case, there are two potential sources for seismic loads on the piping: loads from wave propagation in the soil and from seismic anchor motion of the buildings that form the boundary for the buried pipe.
Most of these definitions come from industry-recognized sources such as PPI. See below for a complete list of sources.
About United Poly Systems
United Poly Systems produces quality HDPE pipe in diameters from ¾-in. to 26-in. IPS, 4-in. to 24-in. DIPS, and ¾-in. to 2-in. CTS for use in many industries including telecommunications, power utility, water, electrical and oil and gas. The market for HDPE pipe continues to expand as initiatives to improve, repair and expand the country’s infrastructure are implemented.
Our off-the-shelf HDPE conduit/pipe is available in a variety of sizes, colors, dimensions and lengths, with or without stripes. We also offer fully customizable HDPE conduit options. In addition, piping can be customized with a ribbed interior (to maximize the distance cable may be pulled or jetted), pull tape, or a lubricated interior (for easier installation).
Success at UPS can be attributed to our vast experience, extensive client relationships, state-of-the-art manufacturing and quality processes. Our agile business model that allows UPS to quickly meet customers’ needs without the overhead expenses that are incurred by many of the larger producers in the industry.
Conveniently located in Springfield, Missouri and Albuquerque, New Mexico, United Poly Systems can provide quick delivery to a majority of the U.S. market.
HDPE piping is one of the things we do best here at US FUSION — but if you’re not working with it every day like we are, you may have some questions about what it is and how it works.
Below, we’ll explore the answers to some of those questions, giving you an overview of everything you need to know about HDPE piping: what it is, what it’s used for, and how it can benefit your application.
First things first — HDPE stands for high-density polyethylene, which is a type of thermoplastic made from petroleum. It’s flexible, but that definitely doesn’t mean it lacks in strength or performance. Among other things, HDPE is known for its outstanding water, chemical, and impact resistance — all qualities that come together to make it a top material choice for a number of applications, including heavy-duty piping.
HDPE piping is corrosion and abrasion-resistant, making it a great material for transporting various solids, liquids, and gases safely and effectively. You can find HDPE piping being used for many industrial applications, some of the most common being:
Municipal and industrial water and waste
Potable water
Wastewater and sewer
Drainage
Contact us to discuss your requirements of 6 Inch HDPE Pipe. Our experienced sales team can help you identify the options that best suit your needs.
Firewater
Oil and gas gathering systems
Methane recovery systems
Landfills
Water supply lines for oil recovery
The bottom line is, from firewater to hazardous waste, there is no system more effective at safely containing and transporting material than HDPE piping.
In recent years, HDPE piping has grown in popularity in various industries — and for good reason. Many have come to realize the countless benefits it brings, including:
Arguably the greatest benefit of HDPE piping is its exceptional durability. It offers water, temperature, and corrosion resistance — three things that other types of piping (galvanized steel, PVC, copper) just can’t do. Depending on how it’s applied, designed, and installed, HDPE piping can last an astounding 50-100 years.
Since HDPE piping is made of plastic, it’s much more lightweight than other types of piping. This means that it usually costs less to manufacture, transport, and install. It can also help save money and resources in regards to reduced installation time and labor.
One of the biggest issues you may face with other piping systems is leaks. However, HDPE’s installation and fusion process lends itself to unparalleled leak-free performance. The fusions create a monolithic connection and are even capable of handling the frequent surges common in water distribution and oil transportation.
On the off chance that your HDPE piping does have performance issues, due to aging or normal wear and tear, repairs are simple. Electrofusion couplers and off carriage butt welds can be performed in tight conditions to repair HDPE pipe. With trenchless techniques and technologies, HDPE pipe can be used to repair failing steel, concrete, and ductile iron pipelines. If it’s time to replace or upsize your existing piping system, whether it’s an HDPE system or not, HDPE piping makes it easier than ever.
For multiple reasons, HDPE piping is a fairly sustainable option. It takes less energy to manufacture than non-plastic pipes, requires fewer fittings due to its flexibility, and prevents hazardous toxins from escaping into the environment. It’s also capable of being recycled into non-pressure piping applications.
HDPE pipes can be installed through two techniques: trenching and trenchless. Trenching involves digging deep trenches, then installing the pipe. It’s messier than the trenchless technique, but it works more effectively for certain applications.
Trenchless installation, as the name suggests, doesn’t require digging any trenches before the pipes can be installed. It makes use of many different techniques to get the job done, such as directional drilling, sliplining, and pull-in-place lining.
If you’d like to learn more about how HDPE piping may suit your application, contact US FUSION. We’re one of the only companies in the industry equipped with over 35 years of experience in complete installation, supply, and on-site fusion. All of that experience combines to deliver you some of the most specialized HDPE piping systems on the market.
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.
Click here to see our full line of HDPE Pipe.
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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