Our site uses cookies necessary for its proper functioning. To improve your experience, other cookies may be used: you can choose to disable them. This can be changed at any time via the Cookies link at the bottom of the page.


Variability and quality control for production of corrugated HDPE pipe manufactured with recycled content

 

Crista K. McNish, Joe Babcanec, Rachel M. Thurston, Zacharias Obermeyer

Papers # 2018 Las-Vegas

This paper presents findings from extensive testing performed on various recycled HDPE resins at different stages of processing to evaluate: (1) the variability expected from a source resin (e.g. post-consumer materials from bulk recycling, post-industrial waste stream), (2) variability when blending different types of HDPE (e.g. high molecular weight resin, wide spec resin), (3) variability through processing (e.g. pelletizing), and (4) variability within the final pipe product. By quantifying the variability of each phase in the handling and manufacturing process, manufacturers can implement best practices and inspectors/specifiers can set minimum test frequencies to ensure consistent, quality pipe is produced to meet performance requirements specified in ASTM and AASHTO recycled HDPE pipe product standards. 

The worldwide usage of high density polyethylene (HDPE) is estimated at 47,980 thousand metric tons this year with usage expected to continue to rise over the next several years (1). North America continues to have a significant share of HDPE volume with usage coming in various product forms, most commonly as consumer packaging and containers with relatively short-term use. With the number of short-term use products being disposed of by both consumers and industry, there is significant potential to recycle the HDPE material and repurpose the material for use as other products. One such use is production of gravity-flow drainage pipe. When repurposed for use as drainage pipe, the HDPE material that may otherwise have been disposed of in a landfill after short-term use, is used for applications that are generally designed with an installed service life of 50 and more years (2). 

A primary focus of ensuring high performance of recycled-content HDPE drainage pipe is development of test methods and minimum test requirements that accurately quantify the quality of the resin being used for pipe production. This initiative has been underway in both ASTM and AASHTO associations through many years of research leading up to today, where performance-based product standards are being evaluated and implemented that allow the use of recycled-content pipe products. The next logical step in the implementation of product specifications is the development of quality control measures that ensure an inherently variable stream of HDPE source materials and blends are tested at a frequency that adequately characterizes the performance of the material as a finished pipe product. 

This paper presents findings from extensive testing performed on various recycled HDPE resins at different stages of processing to evaluate: (1) the variability expected from a source resin (e.g. post-consumer materials from bulk recycling, post-industrial waste stream), (2) variability when blending different types of HDPE (e.g. high molecular weight resin, wide spec resin), (3) variability through processing (e.g. pelletizing), and (4) variability within the final pipe product. By quantifying the variability of each phase in the handling and manufacturing process, manufacturers can implement best practices and inspectors/specifiers can set minimum test frequencies to ensure consistent, quality pipe is produced to meet performance requirements specified in ASTM and AASHTO recycled HDPE pipe product standards. 

Related keywords : Recycled HDPE, variability, processing, blending.
Please note that the whole article content is available on PPCA website only


Related papers

2021 Amsterdam : A TRADE ASSOCIATION EXPLORED

Author(s) : Drew Mueller, Peter Dyke

HDPE Pipe holds a dominant position in several markets in North America: natural gas distribution, oil patch, mining, landfill and geothermal. So why are polyethylene’s municipal water and wastewater market shares so much lower than these other industries? How has the polyethylene industry been successful in growing...

2021 Amsterdam : APPLICATIONS OF HDPE PIPING TO SUPPLY WATER TO RURAL VILLAGES IN MOROCCO

Author(s) : Donald Swen, Leanne Pichay, Nicholas Vallin, Alice Wu, Jim Johnston

In the rural commune of Ait Bayoud, Morocco, two of the most remote villages in the area, Ilguiloda and Izgouaren, live with water scarcity. To meet their water needs, women and children walk several kilometers to the nearest spring each day, often multiple times a day. Consequently, children cannot attend school...

2021 Amsterdam : CHALLENGING THE 10% WALL THICKNESS RULE FOR HDPE MARINE PIPELINES

Author(s) : Ilija Radeljic, Ebbe Smith

HDPE pipe can be relatively easily scratched during the manipulation on the site, which is especially true for the marine pipelines. Installing the scratched marine pipe with the S bend method presents a risk and repair methods are usually performed. Currently, there is no standard defining the repair procedure, in...

2021 Amsterdam : CONCEPT TO STANDARD – HOW RECYCLED MATERIAL WAS EFFECTIVELY ADDED TO U.S. STANDARDS FOR CORRUGATED HDPE PIPE

Author(s) : Daniel Currence, Michael Plumier

Over a ten-year period, the North American corrugated plastic pipe industry successfully demonstrated that post-consumer and post-industrial recycled materials could be responsibly incorporated into corrugated pipes used for drainage applications. Prior to this work, the material standards were established for ...

2021 Amsterdam : DESIGN BUILD OF A 54” REDUNDANT FORCE MAIN UTILIZING HORIZONTAL DIRECTIONAL DRILLING

Author(s) : Bruce Mowry, PhD, P.E., Brian Dorwart, P.G., P.E., David Mancini, Bryan Fletcher, Roger Williams, P.E., Rene Brito, EIT, Arnelio Alfonso, P.E .

The City of Miami Beach owns and operates a 54-inch sanitary sewage PCCP force main (FM) that was built in 1977. This FM is the only transmission pipeline for conveying about 22 million gallons per day (MGD) of raw sewage to the wastewater treatment plant. In 2012, the City identified structural deficiencies in the...

2021 Amsterdam : DEVELOPMENT OF A RAPID AND INNOVATIVE IN-FACTORY PROCEDURE FOR TESTING THE PERFORMANCES OF PE PIPES CONTAINING VARIOUS PROPORTIONS OF RECYCLED POLYMER MATERIAL

Author(s) : Dominique GUEUGNAUT, Pascal AUSSANT, Romuald BOUAFFRE, Myriam BECHROURI

Concerns regarding the environment and sustainable development have revived interest in the reprocessing and re-use of polymer materials from manufactured objects that have reached the end of their operating life. Within this framework, formal professional agreements have been put in place at global level under the...

2021 Amsterdam : DEVELOPMENTS IN NORTH AMERICAN CONDUIT PRACTICES

Author(s) : Tom Stewart, Richard Hicks, Patrick Vibien, Lance MacNevin

Arguably, broadband technologies have become as vital to society as water delivery, waste removal and energy distribution. However, the role of plastic conduit in broadband is often overlooked within the piping industry and society in general. HDPE conduit is an essential component to the build -out of 5G cell...

2021 Amsterdam : DRAINAGE HANDBOOK STRUCTURAL DESIGN PROCEDURE FOR CORRUGATED POLYOLEFIN PIPE

Author(s) : Joe Babcanec, P.E., Dan Currence, P.E.

The newly released Drainage Handbook provides complete guidance on corrugated polyolefin pipe. Perhaps the biggest contribution this new handbook makes to the advancement of both HDPE and PP corrugated plastic pipe is the design procedure presented. The design procedure reflects the industry’s recommended practice for...

2021 Amsterdam : HISTORY OF HDPE USE AT THE CITY OF PALO ALTO FOR POTABLE WATER DISTRIBUTION

Author(s) : Greg Scoby, PE

This paper will detail the steps taken during adoption of HDPE for potable water systems improvements including material justification, creation of related specifications, investigation of available piping components, qualification of contractors and the construction/inspection of related systems. The City of...

2021 Amsterdam : LARGE DIAMETER & THICK WALL HDPE PIPES PRODUCED AND DEVELOPED IN THE MIDDLE EAST – 3 CASE STORIES

Author(s) : Eng. Grigorios Vigellis, Eng. Mohamed Hageb

Continuous development and innovation in the production of plastic pipes made by high density polyethylene (HDPE) has enabled the industry to produce much larger diameter systems than ever believed possible. The enablers for production of such large plastic pipes are three main pillars: continuous innovation...

2021 Amsterdam : MULTILAYER POLYMER PIPES – THE INFLUENCE OF RESIDUAL STRESS ON FATIGUE LIFETIME

Author(s) : Lukas Travnicek, Pavel Hutar, Jan Poduska, Andreas Frank, Florian Arbeiter, Jaroslav Kucera, Jiri Sadilek, Gerald Pinter, Lubos Nahlik

The application of recycled material in pressure piping systems has been considered lately – it was suggested, that the recycled polyethylene could be used as a part of a multilayer pipe together with virgin material. This type of pressure pipes is not availableon the market yet, so their properties can be only...

2021 Amsterdam : RECYCLING COMMITMENT OF THE EUROPEAN PLASTIC PIPE INDUSTRY

Author(s) : Ludo Debever, Peter Sejersen

The European Plastics Strategy is a priority for the European Union. Recycling more post- consumer plastics (PCRs) is paramount. That is why the Circular Plastics Alliance has been established. The alliance gathers public and private stakeholders in the plastics value chains to promote voluntary actions and...

2021 Amsterdam : Sustainability is achieved through less time for excavation, less handling of soil excavated from trench, less hauling of materials (both to and from construction sites), and reuse and recycling. This all means less energy consumption: In many cases, thes

Author(s) : Amster Howard

Deeper pipe burial, less expensive and environmentally friendly backfill, uniform language for contractors and inspectors, simplified installations for smaller pipe, and allowable construction in poor soil conditions are highlights in the latest edition of AWWA M55 and all benefit the users of HDPE pressure pipe. This...

2021 Amsterdam : TESTING SPOOLABLE REINFORCED FLEXIBLE PIPES AND LINER MATERIAL FOR HIGH-PRESSURE HYDROGEN TRANSPORT

Author(s) : Sjoerd Jansma, Peter Cloos, Ernst van der Stok

This paper describes two different test methods used to determine the permeation rate of hydrogen through a reinforced thermoplastic pipe (RTP) system with a HDPE liner pipe and a gas-tight layer at a pressure of 42 bar(g) hydrogen and ambient temperature. One method involThe results of the aforementioned tests...

2021 Amsterdam : THE ADVANTAGES OF PE 100 GLOBAL CASE STUDIES

Author(s) : Youssef Taha, Rainer Kloth

In the early fifties, the first Polyethylene for the use in pipes was produced. Since then, the use of Polyethylene piping systems has spread rapidly around the globe to serve in various applications. In order to demonstrate the versatility and benefits of PE100, several companies founded in 1999 an association...

2021 Amsterdam : UTILIZATION OF HDPE RECYCLED MATERIALS IN SANITARY SEWER APPLICATIONS

Author(s) : John M. Kurdziel

The use of recycled plastics in high density corrugated polyethylene pipe for storm sewers, highway culverts and general land drainage applications has now been widely accepted by municipalities and transportation agencies. This acceptance has made it possible to convert what was once considered a single use plastic...

2018 Las-Vegas : Chlorine dioxide resistant HDPE mechanism, analytical tools and solutions

Author(s) : M. Boerakker, S. van Mierloo, D. v. Beek, R. Schipper, P. Voets, M. Soliman, K. Jacobson, D. Lukes, B. Rabaud, F. Zraick

HDPE pipes are used for standard pressurized water pipes, offering an excellent solution for safe transport of (drinking) water. The HDPE pipe market is growing globally. Especially in countries that suffer from water scarcity, surface water and water from rivers have to be used for drinking water supply. To guarantee...

2018 Las-Vegas : Engineering and testing requirements for infrastructure pipeline applications utilizing HDPE recycled materials

Author(s) : John Kurdziel, Michael Pluimer

Corrugated HDPE pipes have been successfully used for decades for sewers, culverts and land drainage applications and are advantageous due to their durability and service life in a variety of installation conditions. Pipes used for highway and storm sewer applications typically require stricter material standards than...

2018 Las-Vegas : Guidelines for corrugated HDPE pipes manufactured with recycled materials for highway culvert and storm drain applications

Author(s) : Michael Pluimer, Richard Thomas

Over the past decade, there have been several key research projects to evaluate the performance of corrugated HDPE pipes manufactured with post-consumer and postindustrial recycled materials for highway and railroad drainage applications. Three of these projects were recently completed and published (NCHRP Project...

2018 Las-Vegas : HDPE Pipe as a Solution to Utilities Operating on a Manage to Fail Basis

Author(s) : Sarah Eisenstat, Peter Dyke

Many cities in the US are operating their water utility on a “manage to fail” basis, meaning they are replacing >100-year-old pipes at a cycle time of over 150 years. At this rate, most of the pipes will have failed before they can be replaced. Ft. Wayne, IN made the realization that PE pipe is the solution due to its...

Members of the Association

BOREALISBOROUGEFormosa Plastics CorporationINEOS O&PIRPCKazanorgsintez PJSCKorea Petrochemical IND. Co., LTD (KPIC)LyondellBasellPetroChina Dushanzi Petrochemical CompanyPRIME POLYMERSABICSCG Chemicals & Thai PolyethyleneSinopecTASNEE
TOP