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Many sectors have historically relied on concrete, metal, and clay for pipe products. However, because of the pressing need to keep production costs down and maintain quality, performance, and efficiency, HDPE pipes have become the preferred material of choice for nearly any project.
Today, HDPE pipes are a necessity as they are built to address modern-day challenges in contemporary development. As demand for water, gas and many more industries continue to soar, the use of HDPE is on the rise and is expected to keep growing.
Technical innovation and development are continually propelling HDPE as a superior material of choice in various applications.
Are Hdpe Pipes Worth It or Are We Biased to Their Use Due to Their Cost Effectiveness?
It wouldn&#;t be much of an article if the answer was yes. The costs are undoubtedly a significant plus, but what good would HDPE products be if they couldn&#;t stand the test of time?
HDPE pipes are a favourite for their &#;green&#; attributes as they can safely convey potable water, wastewater, hazardous waste, chemicals and even compressed gases. We&#;ll look at the how the pipes are manufactured later in the article, but you can read more about HDPE material in its entirety:
To put it all in perspective let&#;s have a look at everything you need to know about HDPE pipes starting with a brief history.
1. Historic Development of HDPE Pipe
The first ever polyethylene (PE) pipe was produced in . But, the manufacturing costs were extraordinarily high, and chemists had to find new and innovative ways of reducing costs while achieving better yields. After a staggering 20 years, they finally had a breakthrough.
In the &#;s, the first HDPE pipe was created by chemists working at the Phillips Petroleum Co.
HDPE materials were first used to manufacture baby bottles since it was safe and didn&#;t break like glass bottles used at the time.
Here&#;s a short timeline of HDPE&#;s rise to fame:
In the late &#;s, hard-wall HDPE pipe began taking over the functions of metal pipes in gas and oil gathering systems.
In the &#;s PE started replacing iron pipes in nearly all distribution systems. Soon enough, HDPE took over the functions of clay pipes in agricultural drainage frameworks.
In the &#;s, HDPE pipe made headway with advanced diameter width and was corrugated to become a better replacement for metal and concretes in the construction of stormwater culverts.
Today, HDPE is a thermoplastic resin that has continued to evolve throughout the centuries with constant developments in its performance capabilities. They are currently in the fourth generation stage of development. Its uses have diversified to replace glass in bottling and metal making of bails, gas tanks, and drums.
20 years into the future, HDPE pipes are expected to replace cast iron, concrete, and steel in all piping and conduit systems. Which promises a great future in a variety of sectors, including:
Natural gas distribution
Potable (drinking) water
Plumbing
Industrial chemicals conveyance
Oil and gas production
Underfloor heating
Mining (slurry and leachates)
Road heating and cooling
A fairly quick rise to fame and it&#;s not slowing down anytime soon.
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2. How Are HDPE Pipes Manufactured
HDPE, like many other thermoplastic materials, does not possess cross-linked molecular chains and therefore can be melted after application of the right amount of heat. Manufacturing an HDPE Pipe relies heavily on the melting point of PE &#; the temperature at which the plastic gets to an entirely amorphous state (between 120 to 180 °C (248 to 356 °F).
What Form is HDPE Before it&#;s Melted?
HDPE starts out as pellets, also known as thermoplastic resins. At this point, the first stage of quality control should take place. The raw material quality to be used to manufacture the pipes is the first essential (and necessary) step towards compliance with the specified requirements of a quality finished product.
Most companies use three different types of HDPE pellets which are well mixed before adding it to the hopper &#; plain, recycled and pellets with colorants for UV protection. The mix ratio depends on the specific application of the pipes. If the pipes are going to be buried or used as culverts the need for UV protection is limited, but not excluded as the pipes will still be exposed to UV during installation.
&#;Depending on the application of the pipe
the quality testing could be very in-depth,
or at least should be if the manufacturer
is worth their salt.&#;
Which means it would use less coloured pellets for productions. Typically, the process starts by feeding the thermoplastic resins into the extrusion machine using a hopper that feeds the pellets onto a rotating screw using gravity. The rotation of the screw moves the plastic along the heated barrel.
As the plastic runs along the channel depth decreases, forcing the plastic through a smaller area. The combination of compression and screw rotation causes friction and rotation, called sheer heating. This heat, with the heat of the barrel, melts the HDPE (at a temperature of about 230 degrees Celcius.) By the time it reaches the end of the line, the material is melted down and hot enough to go through the die.
The hot and melted HDPE is then forced through a die which then causes the solid particles to align in an extruding cavity. After which it can be molded, shaped, and extruded to be formed into a pipe. The hot liquid HDPE is then injected into the pipe mold while applying vacuum pressure for even distribution. An even flow is essential to maintaining the overall integrity of the final product. Any variations in the flow can produce weak areas.
The molten plastic then flows evenly around the mold to form and results in the diameter of the pipe being produced. A built-in cooling system hardens the plastic just enough to set the shape, enabling the pipe to be extracted from the mold. The pipe then passes through a cold shower to completely harden the plastic.
Random pipe samples are then selected for quality inspection. Depending on the application of the pipe the quality testing could be very in-depth, or at least should be if the manufacturer is worth their salt.
3. HDPE Pipe Quality Control