What is HDPE Pipe?
| Types and Design of HDPE Pipes
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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 1953, Karl Ziegler and Erhard Holzkamp discovered high-
density polyethylene (HDPE). HDPE pipes can work satisfactorily
in a wide temperature range of -2200 F to +1800 F. However, the use of HDPE Pipes is not
suggested when the fluid temperature exceeds 1220 F (500 C).
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Table of Contents
Properties of HDPE Pipes
Types of HDPE Pipes
Length of HDPE Pipes
Joining HDPE Pipes
Fittings for HDPE Pipes
Design Criteria for Aboveground HDPE Pipe
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Pressure Consideration for HDPE
Pipes Advantages of HDPE Pipes
Disadvantages of HDPE Pipes
HDPE Pipe Frequently=Asked Questions
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.
Properties of HDPE Pipes
The physical and mechanical properties of a typical HDPE Pipe are listed below:
Governing Codes: ISO 1183, ISO 4427, AS/ NZS 4130, BS EN 12201, EN
12056, AWWA C901, AWWA C906, etc
Available size range: DN 16 to 1600 (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 Properties HDPE Properties
Yield Strength 18-26 Mpa
Elongation 10%
Elastic Modulus 900 Mpa
Hardness 61 Rockwell (Shore)
Poisson’s Ratio 0.45
Linear Coefficient of thermal expansion 0.17mm/m-0C
Brittleness temperature <-700C
Table 1: Mechanical Properties of HDPE Pipe
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Types of HDPE Pipes
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 20 0 C for 50 years
life span corresponding to ISO-4427. 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 factor
0-20 1
>20-25 0.9
>25-30 0.8
>30-35 0.7
>35-40 0.6
>40-45 0.5
>45-50 0.4
Table 2: Temperature Derating Factor for HDPE Pipes
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Length of 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.
Joining HDPE Pipes
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
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
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Fig. 1: HDPE Pipe Joining Methods
Fittings for HDPE Pipes
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
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Fig. 2: Typical HDPE Pipe Fittings
Design Criteria for Aboveground HDPE Pipe
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.
Pressure Consideration for HDPE Pipes
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.
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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
p = 2 x t x σ /d or alternatively t = p x d/(2.σ + p)
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
4427:
PE 63: 5 MPa
PE 80: 6.3 MPa
PE100: 8 MPa
Advantages of HDPE Pipes
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
Amazing Durability (More than 50 years)
Resistant to most chemical solvents
Stiff material
Environment friendly
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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
Disadvantages of HDPE Pipes
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
HDPE Pipe Frequently Asked Questions
What is the full meaning of HDPE pipe?
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.
Is HDPE the same as PVC?
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.
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What is HDPE piping used for?
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.
How long will HDPE pipe last?
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.
Is HDPE pipe safe for drinking water?
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.
Which is stronger PVC or HDPE?
PVC is stronger and stiffer as compared to HDPE.
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