HDPE POLYFUSION SERVICES

Fusion of 10" gravity sewer main	Large diameter fusion
Storm drain liner fusion 18"	One of our McElroy #412 Tracstar Machine

Electro-Fusion Welding

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.

McElroy Polyhorse System

The PolyHorse is a new pipe handling system that consists of a series of adjustable racks to store and help install the pipe on the jobsite. For use with PE pipe sizes 3” through 20”, the PolyHorse can reduce manpower expense, provide an efficient, less hazardous environment for handling pipe bundles, and enhance productivity by 150%. PE pipe is off-loaded from the delivery truck directly onto the PolyHorse, off the ground and out of the way, until needed. In use, the operator rolls the pipe down the rack and onto the integral pipe rollers where it is easily loaded into a McElroy fusion machine. This eliminates the costs for additional lifting equipment and manpower. 

• Reduces manpower & additional equipment 
• Handles pipe sizes 3” through 24” 
• Enhance productivity by up to 150% 

Ted Berry Company HDPE Fusion Technicians utilize the McElroy PolyHorse System.

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 www.plasticpipe.org / Plastic Pipe Institute
After more than 30 years of use in Municipal and Idustrial 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:

1. Inflow and Infiltration (I & I) is totally eliminated, therefore minimizing the I & I in wet weather conditions on gravity flow systems.
2. Total corrosion resistance.
3. Cost-effective installation.
    

Steps for Proper Fusions

1. Secure. Clean the inside and outside of the component (pipe or fitting) ends by wiping with a clean, dry, lint-free cloth or paper towel. Align the component ends in the machine. Do not force pipes into alignment against open fusion machine clamps. Component ends should protrude past the clamps enough so that facing will be complete. Bring the ends together and check high-low alignment. Adjust alignment as necessary by tightening the high side down. Make sure clamps are properly secured to prevent slippage of the component ends.
    
2. Face. Place the facing tool between the component ends, and face them to establish smooth, clean, parallel mating surfaces. If stops are present, face down to the stops. Remove all shavings from pipe ends after facing. Do not touch the component ends with your hands after facing.
    
3. Align. Bring the component ends together, check alignment and check for slippage against fusion pressure. Look for complete contact all around both ends with no detectable gaps, and outside diameters in high-low alignment.
   
   

   Approximate Melt Bead Size
   Pipe Size	Approximate Melt Bead Size
   2” –4”	1/8” – 3/16”
   4” –12”	3/16” – 1/4”
   12” -24”	1/4” – 7/16”
   24” –54”	7/16”- 9/16”

4. Melt. Verify that the heating tool is maintaining the correct temperature. Place the heating tool between the component ends, and move the ends against the heating tool. The initial contact should be under moderate pressure to ensure full contact. Hold the ends against the heating tool without force.Beads of melted polyethylene will form against the heating tool at the component ends. When the proper melt bead size is formed, quickly separate the ends, and remove the heating tool.
5. Join. Immediately after heating tool removal, QUICKLY inspect the melted ends, then bring the ends together applying the correct joining force, using 60-90psi interfacial pressure. Do not slam. The correct joining force will form a double bead that is rolled over to the surface on both ends.
6. Hold. Hold joining force against the ends until the joint is cool. The joint is cool enough for GENTLE handling when the double bead is cool to the touch. Cool for about 30-90 seconds per inch of pipe diameter.• Heavier wall thickness pipes may require longer cooling times.
7. Inspect. On both sides, the double bead should be rolled over to the surface, and be uniformly rounded and consistent in size all around the joint.

Sewer and Wastewater Application

There are several distinct advantages of PE pipe that provide important benefits for sewer and wastewater applications. These benefits are listed below.

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

1. Heat Fused Joints -- Benefits
   • 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.
2. Flexible and Fatigue Resistant -- Benefits
   • 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.
3. Construction Advantages -- Benefits
   • 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.
4. Cost Effective, Long Term and Permanent -- Benefits
   • 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.
5. Corrosion and Chemical Resistant -- Benefit
   • 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.
6. Handling -- Benefits
   • 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.
7. Hazen Williams C Factor is 150 and doesn’t change over time - Benefit
   • 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 - http://plasticpipe.org/municipal_pipe/potable_water.html