HDPE Polyfusion Services
Butt Fusion Welding is the process of two pipe-ends brought into contact with a heating element. After the removal of the element, the molten pipe-ends are pressed together – creating a monolithic entity. Heat fusion joining is a leak proof process and the most common joining method of HDPE. The internal bead of butt-fused HDPE piping systems does not influence the flow rate and pressure of the pipe system. This means that you can ignore HDPE fusion beads. However they can be removed if desired with our internal or external bead removal tooling. This is done during the fusion process.
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Electro-Fusion Welding (fusion welded) is another HDPE jointing method, where two pipe-ends are fitted and melted into an electro-socket. A heating coil integrated into the electro-socket melts the material surrounding the coils and becomes part of the pipes inserted into the ends of the socket. After cooling, a leak proof joint forms. Flange joints are also suitable for the transition to other pipe materials and for the integration of accessories into the piping system. We use Central Plastics and Friatec Electrofusion couplings and processors.
HDPE or High Density Polyethelyne.
High density polyethylene plastic pipe (HDPE) delivers exceptional value, unwavering reliability and remarkable advantages over conventional types of piping. It’s today’s right choice for water, sewer, drainage, fuel gas, conduit and plumbing & heating. Other reasons HDPE is a superior choice:
- Long-term service life
- Highly-resistant to corrosion, abrasion and chemicals
- Strong, durable, flexible and lightweight
- Longer-length pipe with leak-proof joints
- Lower labor requirements for installations
Sewer Introduction – from Plastic Pipe Institute.
After more than 30 years of use in Municipal and Industrial sewer applications, polyethylene (PE) pipe is a proven solution. Independent testing of PE in sewer service for 25 years showed no significant changes in the material’s physical or chemical properties. The inherent properties of HDPE accommodate all the desired performance characteristics needed for these demanding applications:
- Forced Sewer Mains
- Pipeline Rehabilitation or Trenchless Pipeline Replacement
- Combined Storm and Sanitary Sewer Lines
- Sludge Lines
- Intake and Outfall Lines
- Culvert Relining
- Laterals
- Complete Systems (Open and Closed)
- Vacuum
Distinct Advantages
PE pipe provides several important benefits when used in sewer applications. These benefits include:
- Inflow and Infiltration (I & I) is totally eliminated, therefore minimizing the I & I in wet weather conditions on gravity flow systems.
- Total corrosion resistance.
- Cost-effective installation.
Sewer and Wastewater Application
There are several distinct advantages of PE pipe that provide important benefits for sewer and wastewater applications. These benefits are:
Heat Fused Joints
- HDPE pipe’s fused joints do not leak, eliminating infiltration and inflow problems experienced with alternate pipe joints.
- HDPE pipe can be heat fused together to form a joint that is as strong or stronger than the pipe itself and is leak-free. This eliminates the potential leak points every 10-20 feet as found with PVC and Ductile Iron bell-and-spigot connections.
- The Life Cycle Cost of HDPE pipe differs from other pipe materials because the “allowable water leakage” is zero rather than typical leakage rates of 10 to 20% for PVC and Ductile Iron.
- HDPE pipe fused joints are self-restraining and do not require costly thrust restraints or thrust blocks.
Chemical Resistant
- PE is highly resistant to the wet, hydrogen sulfide gas and the low concentration acid found in a sanitary sewer.
- PE pipe will not corrode, tuberculate or support biological growth
- To review information on PE’s resistance to various chemicals. (TR-19/2000)
- Superior chemical resistance to aggressive soils.
Abrasion Resistant
- PE is abrasion resistant and is well suited for the solids environment in sewer applications.
Construction Advantages
- The combination of flexibility and leak-free joints allow for unique and cost-effective types of installation methods that the rigid PVC and Ductile Iron pipes can’t use with bell-and-spigot connections. These alternate installation methods (Horizontal Directional Drilling, Pipe Bursting, Sliplining, Plow and Plant, Submerged or Floating Pipe, etc.) can save considerable time and money in most applications.
- Polyethylene pipe is produced in straight lengths up to 50 feet long and coiled in diameters up through 6 inches. Coiled lengths over 1,000 feet are available (depending on size) providing low cost installations.
- Polyethylene is about one-eighth the density of steel and does not require the use of heavy lifting equipment for installation.
Flexible and Fatigue Resistant
- HDPE pipe can be bent to a radius 25 times the nominal pipe diameter (Example: 12 inches of HDPE can be cold formed in the field to a 25-foot radius). This can eliminate many fittings required for directional changes in a piping system where fittings and thrust blocks or restraints are required with alternate materials.
- The flexibility of HDPE pressure pipe makes it well suited for dynamic soils including areas prone to earthquake.
- HDPE pressure pipe can accept repetitive pressure surges that significantly exceed the static pressure rating of the pipe.
Cost Effective, Long Term and Permanent
- Polyethylene pipe installations are cost effective and have long-term cost advantages due to the pipe’s physical properties, leak-free joints and reduced maintenance costs.
- The polyethylene pipe industry conservatively estimates the service life for HDPE pipe to be 50-100 years. This relates to savings in replacement costs for generations to come.
Handling
- It is much easier to handle and install HDPE pipe vs. the heavier, rigid metallic or concrete pipe segments, allowing for huge cost advantages in the construction process.
- Polyethylene pipe is better able to structurally withstand an impact than PVC pipe, especially in cold weather installations where other pipes are more prone to cracks and breaks.
- HDPE pipe has a smooth ID that does not corrode or tuberculate and maintains its flow capability over time.
- The C Factor of Ductile Iron pipe is dramatically reduced over time due to corrosion and/or tuberculation.
Potable Water Applications
High Density Polyethylene (HDPE) Solid Wall Pipe has been used in Potable Water applications since the ’60’s, and has been gaining approval and growth in municipalities ever since. HDPE Pipe is specified and/or approved in AWWA C901, AWWA C906, NSF 14, NSF 61 and ASTM D3035.
Durability
Heat Fused Joints
- HDPE pipe can be heat fused together to form a joint that is as strong or stronger than the pipe itself and is leak free.
- This eliminates the potential leak points every 10-20 feet as found with PVC and Ductile Iron bell and spigot connections.
- The Life Cycle Cost of HDPE pipe differs from other pipe materials because the “allowable water leakage” is zero rather than typical leakage rates of 10 to 20% for PVC and Ductile Iron.
- HDPE pipe fused joints are self restraining and costly thrust restraints or thrust blocks are not required.
- HDPE pipe’s fused joints simply do not leak, eliminating infiltration and exfiltration problems experienced with alternate pipe joints.
Flexible and Fatigue Resistant
- HDPE pipe can be bent to a radius 25 times the nominal pipe diameter (Example: 12” HDPE can be cold formed in the field to a 25ft radius). This can eliminate many fittings required for directional changes in a piping system where fittings and thrust blocks or restraints are required with alternate materials.
- The flexibility of HDPE pressure pipe makes it well suited for dynamic soils including areas prone to earthquake.
- HDPE pressure pipe can accept repetitive pressure surges that significantly exceed the static pressure rating of the pipe.
Construction Advantages
- The combination of flexibility and leak free joints allow for unique and cost effective types of installation methods that the rigid PVC and Ductile Iron pipes can’t use with bell and spigot connections. These alternate installation methods (Horizontal Directional Drilling, Pipe Bursting, Sliplining, Plow and Plant, Submerged or Floating Pipe, etc.) can save considerable time and money in most potable water applications.
- Polyethylene pipe is produced in straight lengths up to 50 foot long and coiled in diameters up through 6”. Coiled lengths over 1000ft are available depending on size providing low cost installations.
- Polyethylene is about one-eighth the density of steel, it does not require the use of heavy lifting equipment for installation.
Cost Effective, Long Term and Permanent
- Polyethylene pipe installations are cost effective and have long term cost advantages due to its physical properties, leak free joints and reduced maintenance costs.
- The polyethylene pipe industry estimates a service life for HDPE pipe to conservatively be 50-100 years. This relates to savings in replacement costs for generations to come.
Corrosion and Chemical Resistant
- HDPE pipe will not corrode, tuberculate or support biological growth.
- HDPE pipe has superb chemical resistance and is the material of choice in harsh chemical environments
- The advantages of corrosion and chemical resistance over traditional metal pipes are shared by many plastic pipes, but HDPE pipe uniquely combines these attributes with the aforementioned advantages of heat fused joints, flexibility and fatigue resistance.
Handling
- It is much easier to handle and install HDPE pipe vs. the heavier, rigid metallic or concrete pipe segments, allowing for huge cost advantages in the construction process.
- Polyethylene pipe is better able to structurally withstand an impact than PVC pipe, especially in cold weather installations when other pipes are more prone to cracks and breaks.
Hazen Williams C Factor is 150 and doesn’t change over time
- HDPE pipe has a smooth ID that does not corrode or tuberculate and maintains its flow capability over time.
- The C Factor of Ductile Iron pipe is dramatically reduced over time due to corrosion and/or tuberculation.
from – Plastic Pipe Institute Municipal & Industrial Division