HDPE

HIGH DENSITY POLYETHYLENE

PRODUCT GUIDE
TABLE OF CONTENTS

Vision and Mission 5

1. Introduction 6

2. Leading the Polyethylene Market with High Technologies 7

3. Product Features and Benefits 8

4. Eco Friendly 9

5. Applicable Standards 9

6. Product Range – Technical Information 11

7. Manufacturing Process 12

8. HDPE Pipe Dimension 14

9. Joining Methods of PE-HD Pipes 16

10. Control Testing 18

11. Handling, Storage and Transportation 19

12. Installation 21
 IPF
A market leader
VISION
Leading the pipe industry by discovering the new, reinventing the old, while preserving the culture of
pipe technology and its tradition, guarantying our client around the world the ultimate experience by
upholding our commitments and maintain the highest standards in design, manufacturing, quality,
services and trust worthy business practices.

MISSION
Offer the highest quality products through monitoring every stage of the process leading to
complete customer satisfaction.
Commitment to uphold the strictest quality assurance standards on all product in all aspects of
production.
Optimize the researched techniques to continually improve the efficiency of the facility and the
productivity of the staff.
Maintain reasonable profitability to support the mission and to expand the experience to
customer around the globe.

5
 1. INTRODUCTION
High density polyethylene (HDPE) is today considered the most suited piping material. Looking at
the outstanding performance of pipes made from this versatile thermoplastic for most rigorous
applications, it is no wonder HDPE pipes attained the highest popularity worldwide.

Since polyethylene was discovered in 1933, and was first polymerized to be high density polyethylene
in 1954, the superior properties of HDPE material were discovered in use of many products around the
world. Discovery of HDPE raw material is the most fruitful development which laid a new milestone in
field of piping engineers. MRS (Minimum Required Strength) based on performance of the material @
20°C, for 50 years, will classify HDPE compound to its designation.

Inter Pipe Factory®(High Density Polyethylene Pipes)

Inter Pipe Factory® is accredited with ISO 9001:2008,ISO 14001:2004, OHSAS 18001:2007, WARS (Water Regulation Advisory Scheme), etc … and
also approvals from ministries and municipalities all over U.A.E.

Inter Pipe Factory® manufactures High Density Polyethylene (HDPE) pipes using the extrusion
technology guaranteeing a consistently homogeneous product meter to meter. A HDPE pipe system
manufactured by Inter Pipe Factory® is the ultimate pipe selection for water supply systems as it has
proven its resistance to galvanic and electrolytic corrosion.

Moreover, HDPE pipe systems are used in sewer and storm applications since it has verified its
resistance to the acidic environment and other corrosive fluids. HDPE pipes have been recognized
internationally as the safest, most practical and adaptable product for Gas and Water distribution.
HDPE is flexible, leak-tight and highly resistant to chemical attack.

6
2. LEADING THE POLYETHYLENE MARKET WITH HIGH
TECHNOLOGIES
Corrosion resistant, Lightweight and manufactured under stringent quality standards, Inter Pipe
Factory®. Based on the international standard HDPE pipes are available in all pressure classes, with
diameters range from 90mm up to 500mm and it is necessary for lengths of pipes to be supplied
by agreement between purchaser & manufacturer. The increasing knowledge of the operational
cost savings and superior corrosion resistance offered by polyethylene pipe by Inter Pipe Factory®
operations has resulted in its widespread application for the following:

Sewer pipelines both pumping & gravity

Storm water and drainage
Water Transmission and distribution (Potable & Raw Water)
Gas distribution piping
Chilled water pipelines & District cooling piping
Pipe line Rehabilitation
Crude oil flow lines
Power & Desalination
Irrigation & Fire Fighting
Dredging pipeline & Slurry pipelines
Industrial & Mining
Ducting pipelines & plumbing
Under water piping
Geothermal Heating & Cooling

Inter Pipe Factory®Polyethylene pipe material delivers long, effective service life with lower operating
and maintenance costs compared to other piping materials.

Inter Pipe Factory® High Density Polyethylene (HDPE) pipes are produced by using the highest levels
of technology and quality in manufacturing by extrusion technology.

7
 3. PRODUCT FEATURES & BENEFITS
Inter Pipe Factory® brings a product to market that can provide low cost, long – term pipe solutions
to client around the globe. The multiple advantages of HDPE pipes systems and add up to provide
effective design life and cost effective system.

Features Benefits

Extensive, effective service life

No need for coatings, lining, cathodic protection, wraps or other forms
of corrosion protection
Corrosion resistant material
Hydraulic characteristics effectively constant over time
Low maintenance costs
Ideal pipe for the rehabilitation of corroded sewer lines

Design life time is more than 50 years Maximum economical optimization

Low Transportation Cost

Light weight
Eliminates need for expensive pipe handling equipment

Fewer joints reduce installation time

Long standard lengths
More Pipe per Transport Vehicle results in lower delivery cost

Low friction loss means less pumping energy needed and lower
Extremely smooth bore operating cost
Minimum slime build up helps in lowering cleaning costs

Tight efficient joints designed to eliminated infiltration and exfiltration.

Low cost of installation Ease of joining, reducing installation time
Leak - free joints and reduced maintenance costs

Flexible material; internal pressure design only.

Internal Pressure Rating: Stress due to working pressure cannot exceed
the HDB (1,600psi) ÷ 2.0 safety factor (Hydrostatic Design Stress =
High technology pipe design
800psi) for PE 100
Surge pressures are allowed to compromise the “design factor” which
results in a reduction in the safety factor below 2.0

Perfect material for drainage systems from an ecological point of view.

It is a simple compound of carbon & hydrogen atoms-harmless to man,
Environment friendly
animals & plants. It consumes less energy during manufacture and
transport than steel, cast iron or copper pipes.

High Technology pipe manufacturing system

producing pipe that strictly complies with High and consistent product quality worldwide which ensures reliable
stringent performance international standards product performance
(ISO, AWWA, BS, EN, etc……

Table 3.1

8
4. ECO FRIENDLY
HDPE compound contains molecules of carbon and hydrogen. HDPE is not considered hazardous
material. Material will burn if ignited. Result of HDPE combustion in an excess of O2 is CO2 and
H2O. Some CO is produced if insufficient O2. Inhalation of dust can cost irritation problem to the
respiratory system. HDPE pipe should not be installed in the ground polluted by hydrocarbon base
such as hydrogen sulfide or gasoline that may cause odor to water in the pipe.

HDPE pipe is considered environmental conservative product, being the best pipe material when being
designed with proper condition. Inter Pipe Factory® using granule form raw material it is not added
any additive for production of the pipes. Raw material is used absolutely in its original composition.
For long term development and research, HDPE pipe is superior to any other pipes in terms of:

Long life usage at least 50 years or more

Save erection and reinstallation cost
Save energy consumption to deliver the same volume of water from place to place.
Carry clean water inside for people
Can be used after earthquakes or change the location
No contamination to soil and earth
Keep and delivery sewage water inside to proper place
No harm to animal life in both above and under water
Economic sufficient in long term for next generation

5. APPLICABLE STANDARDS
High Density Polyethylene Pipes produced by Inter Pipe Factory® are manufactured and tested
according to International Organization of Standardization (ISO), American Standards (ASTM/AWWA)
and European Standards (EN).

5.1. ISO Standards

ISO 4427 is one of the most widespread product standards in existence for HDPE pipe. This standard
is for water supply piping systems, concentrating on quality control and prototype qualification
testing. In addition to being a water supply piping standard, ISO has also published one of the most
comprehensive design methods for supply of Gaseous fuels.

ISO 4437, HDPE Pipe Design, provides complete criteria for hydrostatic strengths, elongation at break,
longitudinal reversion, oxidation index time, melt flow index, carbon black content etc….

9
 Standard Application

ISO 4427 Plastic piping systems - Polyethylene (PE) pipes and fittings for water supply

Buried polyethylene (PE) pipes for the supply of gaseous fuels – Metric series –
ISO 4437
specifications

5.2. AWWA Standards

AWWA C 906 is another most widespread product standard in existence for HDPE pipe. This standard
is for water distribution and transmission application, concentrating on quality control and prototype
qualification testing. AWWA C906 is also considered to be a product performance standard.

This pipe design provides complete criteria for quick burst test, bend back test, elongation at break
test, melt index, density etc….

Standard Application

AWWA C – 906 Polyethylene (PE) pressure pipe and fittings, for water distribution and transmission

5.3. EN & British Standards

Inter Pipe Factory® manufacture HDPE pipes ensuring that the performance requirements
qualification and control testing, and design to meet the following European & British Standards:

Standard Application

EN 12201-2:2003 Plastics Piping Systems for water supply – Polyethylene (PE)

10
6. PRODUCT RANGE – TECHNICAL INFORMATION
6.1. Diameter Range
Inter Pipe Factory® are supplied in the following Nominal Diameters* ND (mm)

Nominal Diameter ND (mm)

90 250

110 280

125 315

140 355

160 400

180 450

200 500

225

*for other pipe diameter range, consult Inter Pipe Factory®

Table 7.1

6.2. Pressure Class

Inter Pipe Factory® offers the pressure classes (PN) as indicated in below table 6.2-1 & 6.2-2
SDR= Standard Dimension Ratio, S= Series

Nominal Pressure for Material Class

SDR S (Series)
PE 80 PE 100
17 8 8 10

13.6 6.3 10 12.5

11 5 12.5 16

9 4 16 -

Table 6.2-1 -Medium - Water

Nominal Pressure for Material Class

SDR S (Series)
PE 80 PE 100
17.6 8.3 2 6

11 5 4 10

Table 6.2-2 - Medium Gaseous Fuel

11
 6.3. Other Characteristics & Properties

PE 80 PE 100
Design Stress
6.3 N/mm2 8.0 N/mm2
Density Kg/m3 945 – 960 950 – 960
Melt Index (5kg) g/10 min 0.4 – 0.7 0.2 – 1.4
Tensile Strength at yield N/mm2 20 23
Elongation at break % >600 >600
Brittleness temperature °C <-70 <-70
Durometer hardness Shore D 60 – 65 59
Charpy impact strength kJ/m2 No Failure No Failure

Table 7.3.1

7. MANUFACTURING PROCESS
HDPE pipe is manufactured by Extrusion process. (The process of extrusion consists of converting a
suitable raw material into a product of specific cross section by forcing the material through an orifice
or die under controlled condition. There are certain requirements which must be satisfied concerning
both the Equipment and the Raw material. The equipment must be capable for providing sufficient
pressure continuously and uniformly on to the material.

The material must be such that, when suitably conditioned it will flow under pressure and will solidify
when these condition are removed.) Single screw extruder designs are used for extruding HDPE raw
material. The extruder mainly consists of a barrel and screw specialty designed to ensure proper
plasticization of the material. While the barrel is fixed, the screw rotate counter-clock wise direction
by use of variable DC drive motor through reduction and distribution gears.

Single Screw extruder parts

Depending on the size to be produced a suitable die head is selected and assembled with the die set
and then mounted on to the barrel through an adapter. The barrel, the die head and the die set are
heated by a set of heater bands and the temperature is controlled through pyrometers.

Once the required temperature is attained, the extruder hopper is fed with HDPE raw material and
the main motor is started. The plasticized material gradually comes out of the pipe opening and once
the flow is uniform the extrudate is cooled and sized into a pipe. The OD of the pipe is controlled by a
cooling jacket attached in the vacuum tank. The pipe is cooled by a haul-off machine at a set constant
speed to insure the wall thickness is uniform throughout the length of the pipe. As the pipe passes
through a saw machine, the pipe is cut to required length to the help of limit switches. The cut length
of the pipe is then transferred.

12
Process Flow Diagram

13
 8. HDPE PIPE DIMENSION
For Water
PE-HD pipe PE 100 is produced according to ISO 4427 & EN 12201-2

Wall Thickness

Pipe SDR 17 (S - 8) SDR 11 (S - 5)

Diameter Nominal Pressures
PN 10 (Bar) PN 16 (Bar)
90 5.4 8.2

110 6.6 10.0

125 7.4 11.4

140 8.3 12.7

160 9.5 14.6

180 10.7 16.4

200 11.9 18.2

225 13.4 20.5

250 14.8 22.7

280 16.6 25.4

315 18.7 28.6

355 21.1 32.2

400 23.7 36.3

450 26.7 40.9

500 29.7 45.4

Note: - Please contact Inter Pipe Factory® for other diameters which are not included in the above table

SDR – Diameter – Wall Thickness Relation

SDR – Diameter – Wall Thickness Relation

da – Outside diameter (mm)

e – Wall thickness

PN – Nominal Pressure Rating (bar)

da SDR - 1
SDR = S = Series S =
e 2

14
For Gaseous fuels
Generally the gas industry uses PE80 materials for low pressure gas distribution up to 4 bar because
of their superior flexibility and ease of jointing and installation. For higher pressures, PE100 with
higher strength are used.

PE-HD pipe PE 100 is produced according to ISO 4437 (Medium – Gaseous fuels)

Wall Thickness
Pipe SDR 17.6 (S – 8.3) SDR 11 (S - 5)
Diameter Nominal Pressures
PN 6 (Bar) PN 10 (Bar)
90 5.4 8.2
110 6.6 10.0
125 7.4 11.4
140 8.3 12.7
160 9.5 14.6
180 10.7 16.4
200 11.4 18.2
225 12.8 20.5
250 14.2 22.7
280 15.9 25.4
315 17.9 28.6
355 20.2 32.3
400 22.8 36.4
450 25.6 40.9
500 28.4 45.5

Note: Please contact Inter Pipe Factory for other Diameters which are not included in the above Table
*for PE 80 please refer the above table – only read the pressures PN 6 & PN 10 as PN 2 & PN 4

15
 9. CONTROL TESTING
Quality Control testing includes scrupulous checks for all incoming raw materials and finished pipe
products against Inter Pipe Factory® strict written standards.

9.1. Raw Materials

Raw materials are only delivered with vendor certification indicating their conformity with Inter
Pipe Factory® quality requirements. Prior to their use, all raw materials are sample tested so as to
guarantee that pipe materials do comply with the declared technical specifications

Raw Material Tests

1. Melt Mass-Flow Rate

2. Oxydation Induction Time

16
3. Carbon Black Content

9.2. Physical Properties

Elongation at Break and Longitudinal capacities is checked on a regular basis HDPE Pipes. Moreover,
pipe composition and construction are confirmed.The following control checks are carried out:

1. Hydrostatic Strength of HDPE Pipes

2. Elongation at Break of HDPE Pipes
3. Longitudinal Reversion of HDPE Pipes

Inter Pipe Factory® has demonstrated its products compliance with the performance requirements
of international standards. The performance requirements are divided in to two parts:
Short-term requirements

17
 Long-term requirements

Inter Pipe Factory® has been rigorously tested to verify conformance to ISO 4427, ISA 1167, ISO 6259,
ISO 2505, ISO 3126 and all other international standards.

9.3. Finished Pipe

HDPE pipe products produced by Inter Pipe Factory® are subject to the following control checks:

1. Wall Thickness
2. Diameter
3. Section length
4. Visual Inspection

10. JOINING METHODS OF PE-HD PIPES

10.1. Butt Welding
Butt Welding (or buff fusion) is a simple and quick jointing method to connect pipes and fittings of
PE-HD or PE-MD. The process starts by cutting the pipe ends straight and cleaning them carefully.
Heated plate is then placed in between, and the ends are heated under pressure and temperatures.
The polyethylene becomes soft and a so called beaded is formed between the pipe ends. The heater
plate is then removed and the pipe ends are pressed unto each other and allowed to cool under
pressure. This will form a welded joint that is water tight and homogeneous.

Process Description

18
10.2. Electro Fusion Jointing
This is an easy system were preinstalled
resistance wires on the inside of the fittings are
slightly coated with PE. When these wires are
connected to welding unit, they become warm and
the polyethylene consequently melts.

Having the ends of the pipes in the connection of

fitting (Socket), bend etc, the polyethylene then
melt into each other and form a rigid and durable Preparation and Installation

joint. The joining method is very common for gas

pipes & potable water pipes

10.3. Flange Joints

To be able to make a flange joint, a stub-end has
to be weld on each pipe. These are then connects
to each other by loose flanges, nuts & bolts.
Energy Input
Usually, flanges are used in connections which
are to be disassembled at a later stage, or, in
submarine pipe systems. The environment is very
important for the choice of loose flange material,
which could be made of steel, aluminum or plastic.

11. HANDLING, STORAGE Joint is stress able cooling time

AND TRANSPORTATION
Handling

High Density Polyethylene Pipe being tough

resilient material, light weight and easy to handle.
However, because it is softer than metals it is
more prone damage by abrasion and by objects
with a cutting edge.

HDPE pipe contains pigment to provide excellent

protection against degradation due to UV-
radiation. If due to unsatisfactory storage or
handling, a pipe is damaged or ‘kinked’, the
damaged portion should be cut out completely.

The material is not affected low temperature as

much as are some other plastics material and
there is no need for more cautions handling
during cold weather. Inter Pipe Factory® supplies
the pipes in standard lengths for easy handing. We
also supply bigger length however, the care should
be taken by the customer while handling.

19
 Storage
Black Polyethylene Pipe may be stored either under cover or in the open. It is suitably protected
from ageing due to sunlight by the addition of the appropriate quantity and type of Carbon
Black. Natural Polyethylene Pipe, however, should be stored under cover and protected from
direct sunlight.
Store pipes on flat/firm ground.
Keep pipes away from sharp edges.
Use wide non – metallic slings for lifting.
Keep pipes away from intense heat.
Allow for some bending deflection while lifting.
Pipes should not be stored alongside fertilizers, pesticides, insecticides and chemical
compositions such as these, as otherwise, those pipes are liable to develop cracks.
The ends of the pipes shall be plugged or covered.
Never throw, drag and drop from heavy vehicles.

Transportation

HDPE Pipes are ‘LIGHT WEIGHT AND TRANSPORTABILITY’. High Density Polyethylene Pipes are light
in weight (Density 0.955 gms/cm2), so they are easy to handle. Inter Pipe Factory® supplies the pipes
in length – packed with wooden bundles for easy to carry and handling. Whenever loading & unloading
is carried out, it is recommended to use cotton or nylon (synthetic) belts to avoid damage to the pipes.
If at all metal slings are used, the pipe should be protected against scratches.

It is preferable to cover the pipes while transporting them over long distance involving exposure to the
sun especially in the Arabian Gulf Cooperation Countries. Because irregular heat distribution on the
pipe circumference may result in kinking or distortion.

20
12. INSTALLATION
HDPE Pipes can be installed using the same methods, the same equipments as for any other rigid
plastic pipes. But HDPE, though rigid, is flexible enough to facilitate laying of the pipelines easily and
economically.

Trench Preparation

The width of the trench at the crown of the pipe shall be as narrow as possible but not less than
the outside diameter of the pipe plus 300mm to allow proper compaction of the side fills material.
Provided that the excavated trench bottom is reasonably even and free from sharp stones etc., which
could cause abrasion to the pipe surface, on special bedding material is necessary for the laying
of HDPE pipes. If due to sunlight the temperature of the pipe is significantly higher than the trench
temperature, the pipe must be lightly covered before backfilling.

Pipe Coverage

erage

Gas (h=0.6 - 1 m) Water (h = 1.0 - 1.8 m

Pipe Laying
HDPE pipes can be welded or joined by compression fittings on the ground and then can be snaked in
to the trench easily. While on anchoring for buried HDPE pipelines, it is advisable to anchor at valves,
Blank ends etc. All temporary pipe supports leveling pegs etc., must be removed from beneath the
pipe prior to back filling.

Distance to underground systems

with parallel laying or at crossings with conductors or cables that emit heat, the HDPE pipes must be
protected by a sufficient distance, suitable heat protection or other appropriate measures.

Distance to conductors & cables up to 1KV

When laying pipes in open ditches without special protective measures, a distance of at least 0.10m
must be kept at crossings. With parallel laying, the minimum distance corresponds to half of the
nominal width of the pipe with larger diameter and may not be less than 0.20m without special
protective measures.

Distance to cable above 1KV

At crossings, a minimum distance of at least 0.20m must be observed. With parallel laying, the
minimum distance required is 0.40m. At bottle necks the distance may not be less than 0.20m without
special protective measures. If this distance cannot be observed appropriate measures such as
interleaving heat-regulating jackets or plates must be implemented to protect the gas pipes.

21
 Before Laying :
Check delivered pipes
Check the manufactures details
Transport and storage damage
Dimensional accuracy
Assemble pipe joints stress-free
Gas pipe network parts with operating pressures of more than 100m bar must be block able
within certain areas.

Side Filling
In order to develop reaction from the side-fill, which is necessary for, a flexible pipe to sustain top load,
some deformation of the pipes cross section must occur. It is generally considered that the maximum
vertical deflection of the pipe should be within 5% of the pipes outside diameter, but considering the
flexibility and toughness of HDPE pipe a higher deflection will not affect the long-term performance
of the pipeline.

Back Filling
The material used in the back filling of trenches for HDPE pipes need not be a special grade and
selected excavated material may be used, which is suitable for normal compaction. Fill up to 30cm
above the top of pipe with suitable materials, e.g. sand-gravel mixture with maximum 20mm grit size.

Depth of Cover
It is generally considered that the minimum depths of cover for HDPE pipes are:

500mm for location with no wheel load.

600mm for location with light vehicle load.
800mm for location with heavy vehicle load.

DISCLAIMER :
All information was accurate at the time of going to press. However, we reserve the right to alter, amend and update any product, information and service described in this
catalog. No part of this catalog may be reproduced in any form, by printing, photo print, microfilm, photocopies or any other means without the written authorization of
Inter Pipe Factory®. ©2009 by Inter Pipe Factory®.

OUTLINE :
Inter Pipe Factory®, branch of Nael & Bin Harmal Hydro Export Est. Inter Pipe Factory® was established in 2009 and look forward to be a leading supplier of composite
thermosetting pipe systems and technologies in GCC, Middle East, Africa, Asia and Europe.

ACCREDITATIONS :
Inter Pipe Factory® is accredited for the Quality Management Systems ISO 9001:2008, Environmental Management Systems ISO 14001:2004 & OHSAS 18001:2007.
In addition, certificates of the suitability to convey potable water from the Water Regulation Advisory Scheme (WARS) from UK, Kitemark from UK and the National Sanitation
Foundation (NSF International) from USA.

22
 INTER PIPE FACTORY®
PHONE +971 3 784 7444
FAX +971 3 784 7447
P.O. BOX 68932
AL AIN - UNITED ARAB EMIRATES
EMAIL : [email protected]
WWW.INTER-PIPE.AE