Guide to HDPE Pipe | Updated 2023

Chapter 1: HDPE History and Background

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High-density polyethylene (HDPE) continues to grow in popularity and usage. This material is a significant component of daily life, appearing in both household products and industrial applications. Since its invention nearly 70 years ago, HDPE piping has become a preferred choice in power, communications, and energy sectors. Its flexibility and versatility make it suitable for various industrial environments, including conduits for telecommunications and fiber optic lines, flowlines for oil and gas operations, gas transmission, cross-country pipelines, and municipal water and sewer systems.

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HDPE was discovered at Phillips Petroleum, with polyethylene—its lower-density counterpart—first being invented by Imperial Chemical Industries. The process for creating polyethylene requires high pressures of 20,000 to 30,000 pounds per square inch (psi). Scientists J. Paul Hogan and Robert Banks from Phillips developed a method that used nickel oxide and chromium oxide catalysts, enabling the production of HDPE at much lower pressures. The resulting material possesses superior strength, durability, and heat resistance compared to any existing plastics at the time. These production methods are still in use today.

After securing a patent, Phillips marketed HDPE under the brand name Marlex. Initially, sales were slow until demand surged due to the popularity of hula hoops, which utilize smaller-scale plastic tubing. As production methods improved, Marlex found applications in baby bottles and other household items. Today, HDPE is one of the most widely used plastic materials in both industrial and consumer categories due to its durable and robust nature.

HDPE Definition

HDPE stands for high-density polyethylene, a plastic noted for its strength and flexibility. Unlike low-density polyethylene (LDPE), which has a branched molecular structure, HDPE boasts a linear molecular structure. This characteristic allows the polymer chains to align closely, creating a dense material. Though LDPE is cheaper and more flexible, HDPE's durability makes it better suited for a host of industrial and household applications. Products made from HDPE, including pipe, are manufactured from resin.

HDPE is considerably stronger and lighter than traditional piping materials, while also exhibiting greater flexibility than concrete and iron. Its heat-fused joints are as robust as or stronger than metal pipe joints and do not leak. Additionally, HDPE offers outstanding corrosion and chemical resistance, as it does not corrode, tuberculate, or support biological growth. With an expected service life ranging from 50 to 100 years, HDPE pipe is also fully recyclable.

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HDPE and Plastic Organizations

Three organizations significantly influence the adoption and usage of HDPE piping: the Plastics Pipe Institute (PPI), the American Society for Testing and Materials (ASTM), and the American Water Works Association (AWWA).

Founded in [Year], PPI is the primary trade association representing all segments of the plastic piping industry. Its mission is to promote the acceptance and utilization of plastic pipe systems through research, education, technical expertise, and advocacy. PPI provides extensive publications covering specific design, operational, and manufacturing areas, aiding engineers and officials in implementing plastic piping solutions.

ASTM, established in [Year], is a nonprofit organization that develops standards across industries in 140 participating countries, involving volunteer members in the standards-writing committees. The ASTM's plastics committee includes over 500 members, ensuring quality and safety in plastic materials, including pipe.

AWWA, an international nonprofit scientific and educational society founded in [Year], focuses on total water solutions for effective management. They offer manuals and standards regarding HDPE, assisting engineers in the design, specification, procurement, and installation of HDPE pipes and fittings.

Chapter 2: Benefits of HDPE

Pipes are essential for the modern world, facilitating the housing of electrical and telecommunications wiring, gas transport, and drinking water distribution. Many do not consider pipes until a failure results in a gas leak, flood, or power outage. Recent technological advancements have led to the replacement of older pipe materials—such as lead, clay, and cast iron—with more durable options.

Why Choose HDPE?

Plastics have become the favored material in telecommunications, energy, and power applications. HDPE's characteristics make it an optimal choice as it is lightweight, resistant to corrosion, and immune to bacteriological and chemical buildup.

It performs well at various temperatures without becoming brittle and has a remarkably low failure rate of only 1 in 10,000,000 incidents. Its flexibility makes it suitable for underground installations in soils prone to shifting due to compaction, expansion, or seismic activity. HDPE's high ductility allows it to withstand the shocks and pressure that can damage rigid pipe systems.

Comparing HDPE to Other Materials

When assessing alternative materials for industrial applications, HDPE conduit stands out, particularly for electrical, oil and gas, and telecommunications. Options include PVC, iron, copper, and concrete.

PVC Pipe

PVC pipe is commonly used in electrical and telecommunications systems. While both PVC and HDPE are made from plastic, PVC is stronger and stiffer but has a higher failure rate. It does not perform as reliably in extreme weather or temperature situations, and mechanical joints can lead to leakage issues.

Iron Pipe

Iron pipe is extensively utilized for gas, water, and sewage applications due to its strength and resistance to internal pressure. However, it has reduced flexibility, high transportation costs, and is vulnerable to corrosion.

Copper Pipe

Copper pipes are more corrosion-resistant and flexible than iron pipes. Nonetheless, they tend to be pricier and less flexible than HDPE options, and they can fail when exposed to extreme temperature variations.

Concrete Pipe

Primarily used in sewage and drainage applications, concrete pipes are robust but heavy and inflexible. Their weight complicates shipping, handling, and installation in comparison to HDPE, which offers greater versatility.

HDPE Installation

In many instances, installing HDPE pipe is more affordable and straightforward than other materials. Being much lighter than concrete, iron, and steel pipes reduces transportation costs and the need for heavy machinery during installation. HDPE is frequently delivered in long coils, spools, or straight lengths, facilitating fewer shipments.

Moreover, HDPE installation necessitates fewer joints and fittings than traditional methods, saving time and money. Its flexibility allows it to bend without additional joints, enabling installation without trenches and over uneven areas. Heat-fused joints are robust and leak-proof, while the material itself promises a service life of 50 to 100 years, highlighting its recyclable nature.

Methods for installing HDPE include pipe bursting, horizontal directional drilling, trenching, and micro-trenching, all of which are detailed in Chapter 5.

Chapter 3: HDPE Manufacturing Process

HDPE pipe is created from resin produced from natural gas, arriving via rail and stored in tanks until manufacturing begins. Atkore - United Poly Systems adheres to industry-standard practices while ensuring rigorous quality control and testing throughout the process.

Receiving and Testing Raw Material

The first step involves receiving HDPE resin, which comes in small, colorless pellets and undergoes inspection upon delivery. Manufacturers provide certifications, production codes, and data for traceability. This record ensures that if questions arise regarding material quality or origin, manufacturers can account for how much pipe was produced from specific resin batches.

Batching, Heating, Blending, and Extrusion

The process begins with batching, where resin is drawn to the production line through pneumatic tubes. Color additives may also be introduced at this stage. The resin is then processed through a heating element with a tapered screw to create a uniform mixture. Once heated and blended, the resin is extruded through a die head based on specified dimensions.

Sizing and Cooling

Post-extrusion, the pipe enters a vacuum tank, ensuring it remains at the correct diameter, before being cooled and hardened in several water tanks and open areas.

Quality Control

Throughout the manufacturing process, pipes are subjected to inspection to ensure quality. Operators monitor wall thickness and dimensional accuracy, while sample pipe sections are tested for tensile strength, burst rating, and sizing before final shipping.

Printing

Upon exiting the extrusion machine, identification strips can be added, and essential information such as date, material codes, and manufacturer details are hot-indented onto the pipe surface.

Cutting, Packaging, and Shipping

Once complete, pipes are cut using rotary automated cutters, ensuring smooth and uniform cuts. Finished pipes are then packaged, ready for shipment via flatbed delivery or box trucks.

Chapter 4: HDPE Applications

HDPE pipe serves as the ideal material for diverse industrial, energy, and telecommunications applications due to its durability, flexibility, longevity, and ease of installation.

Pressure Applications

Resistant to fatigue and high flow velocities, HDPE is essential in industries such as oil and gas, mining, and others requiring pressure applications.

Energy and Industrial

HDPE performs exceptionally in rugged, harsh environments essential for oil, gas, and mining operations. Its resilience against extreme weather conditions, coupled with easy installation, makes it ideal for these sectors. Furthermore, HDPE's ability to resist corrosion and abrasion is crucial in transporting chemicals and waste materials.

Conduit

As a conduit, HDPE pipes protect electrical and telecommunications lines underground. Its resilience against seismic activities and extreme temperatures, alongside its corrosion resistance, adds to its effectiveness in infrastructure upgrades.

Power and Telecommunications

HDPE piping offers reliable protection for critical lines against harsh soils and seismic events, reinforcing its role in underground electric and communication systems.

Microduct

Microduct HDPE pipe serves as a modern alternative to traditional cabling, with Atkore - United Poly's MicroPath featuring multiple built-in micro ducts for fiber cabling. This innovation is particularly beneficial in confined areas and is expanding as a replacement option for outdated infrastructure.

Chapter 5: HDPE Pipe Installation Methods

Various installation methods exist for HDPE piping, tailored to numerous applications, sizes, and colors. Some of the most common methods are detailed below. More in-depth descriptions can be found in the Plastics Pipe Institute (PPI) Handbook of PE Pipe.

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Pipe Bursting

HDPE pipe bursting is a method that facilitates the replacement of outdated infrastructure without excavating traditional trenches. This trenchless technique pulls new HDPE into existing pipes, bursting them in the process while leaving the remnants in place, thus significantly reducing overall costs.

Horizontal Directional Drilling (HDD)

HDD is utilized when obstacles hinder traditional installation methods. A small borehole is drilled under the obstruction, allowing HDPE pipe to be pulled through. This method minimizes material damage and joint counts.

Micro-Trenching

Micro-trenching is ideal for smaller conduit installations. A narrow slot is cut next to streets or sidewalks, allowing for quick line placement and minimal disruption to traffic.

Plow

The plow method creates a furrow for conduit installation without removing soil. This method reduces acreage covered and the excavation process's environmental footprint.

Direct Burial

HDPE pipes can be directly buried, with depth specifications varying based on the presence of traffic. This method requires careful consideration of several parameters to ensure successful installation.

Slip Lining

Slip lining involves inserting new HDPE pipes into existing deteriorated lines, making it suitable for rehabilitating utilities while maintaining minimal disruption.

Installation Considerations for Microduct

Microduct installations may involve direct burial, micro-trenching, or traditional cable-pulling techniques. Air blowing methods can further enhance installation efficiency while minimizing the risk of fiber damage.

Chapter 6: Why Choose Atkore - United Poly Systems

At Atkore - United Poly Systems, quality products and customer service are our utmost priorities. Our extensive experience, solid client relationships, industry certifications, and advanced manufacturing processes guarantee our success.

Extensive Product Lines

We provide HDPE piping for both pressure and conduit applications across a wide diameter range. Our products are customizable and cater to various specifications.

Manufacturing and Quality Control

Through a rigorous manufacturing process, we ensure that our HDPE products meet or exceed requisite quality standards. Detailed records of material batches enhance traceability for future inquiries.

Packaging, Shipping, and Logistics

Our shipping methods—coils, reels, or straight-line packaging—are determined by application requirements to optimize delivery efficiency.

Customer Service

We prioritize effective communication and satisfaction, maintaining strong relationships with reliable carriers to ensure timely deliveries while promptly addressing any concerns.

Distribution Network

Manufacturing occurs across facilities in Springfield, MO, and Albuquerque, NM, supporting customers nationwide with direct shipping to expedite project timelines.

Compliant with the Buy American Act

Atkore - United Poly Systems complies with the American Recovery and Reinvestment Act, sourcing materials domestically for all finished goods.

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