Advancements in butt fusion jointing of HDPE pipes

We are happy to announce that Borouge, a PE100+ Association member company, has co-authored a comprehensive review recently published in Polymer Testing. The paper, written by Ahmed I. Alhatti, Imad Barsoum and Abdelrahman I. Hosny from Khalifa University, and Suleyman Deveci from Borouge.

Why is this important?

Butt fusion jointing (BFJ) is the backbone of reliable HDPE piping systems, critical for drinking water, natural gas, and industrial applications, such as desalination plants, thermal power plants, and nuclear power plants. This review distills best practices for fusion-condition optimization and evaluates the latest joint integrity assessment techniques—a great reference work for all the members of value chain for PE100 pipe systems.

Key highlights:

The paper explains how fusion temperature, interfacial pressure, and heating/cooling durations govern joint strength and reliability, while comparing international standards such as ISO 21307, ASTM F2620, and DVS 2207. It reviews both traditional and emerging mechanical testing methods—including tensile, impact, creep, and slow crack growth (SCG) tests—and discusses new approaches like tapered-waist tensile (TWT) and hydro-axial tension (HAT) for improved accuracy. The review also identifies critical research needs, such as real-time joint monitoring, adaptive pressure protocols, and qualification methods for large-diameter, thick-wall pipes, emphasizing the importance of robust jointing and testing standards.

🔗 Read the full open-access article: doi.org/10.1016/j.polymertesting.2025.108909