Hello high density polyethylene (HDPE) fans, today our focus is on the topic of fabrication.

Understand that one obscure unwritten rule in the world of writing or presenting the spoken word, is that you are allowed to use the most frowned-upon cliché in the history of the universe – the dictionary definition – ONCE in your lifetime.

Trust me I’m a writer.

And everybody gets one. This is my one…

According to Merriam-Webster:

fabricate
verb
fab·​ri·​cate ˈfa-bri-ˌkāt
fabricated; fabricating

Synonyms of fabricate:
transitive verb

1 – a: INVENT, CREATE

• b: to make up for the purpose of deception
  accused of fabricating evidence (let’s exclude this aspect for our discussion)

2 – a: CONSTRUCT, MANUFACTURE
specifically: to construct from diverse and usually standardized parts

The most common outcome of fabrication in our world is the creation of HDPE fittings, falling into two main categories: molded and fabricated. While this distinction may seem redundant, it serves a practical purpose. Stick with me, here.

In both cases, we are talking about elbows, tees, reducers, and reducing tees, wyes, end caps, crosses, and wall anchors.

Molded fittings are just that – they are crafted through injection molding and cater to smaller diameter pipes, typically ranging from two to eight inches. These fittings adhere to ASTM D3261 standards, ensuring consistency and reliability. Molded fittings are typically more readily available and offer a high level of uniformity. If you seek a 45-degree HDPE elbow – it will be 45 degrees. If you need an HDPE tee – you get a tee.

Fabricated fittings, on the other hand, enter the picture when custom specifications are required, such as unique angles or when working with larger-diameter pipes. Crafted from heavier feedstocks, fabricated fittings follow ASTM F2206 and FM 1613 standards, ensuring top-notch quality and rigorous testing.

How are they made?

The equipment used in fabricating fittings is similar to what is used in the field, with slight adaptations for efficiency. For instance, butt fusion—the cornerstone of HDPE fabrication—employs specialized equipment in a controlled shop environment, ensuring precision and durability that cannot not be achieved on the job site.

Moving beyond fittings when it comes to fabrication, we nudge toward non-traditional applications of fabrication.

Perforated pipes, designed to capture gases or fluids like leachate and methane, find extensive use in landfills and mining operations. Similarly, dual-containment pipes serve as a safeguard against toxic or harmful fluid “contained” within the pipe to protect the environment and surroundings.

Think of dual-containment as a smaller pipe (carrier) inside of a larger pipe (container) that acts as an insurance policy against leaks.

It’s a much more complex and exponentially more important version of the McDonald’s McDLT packaging keeping the hot side hot and the cool side cool (look it up if you need to – a young Jason Alexander in an absolute banger of a song).

In the world of custom fabrication, imagination knows no bounds. From initial concepts scribbled on cocktail napkins to fully realized solutions, the journey is guided by experienced technical experts who turn vision into reality.

ISCO approaches the process, as do others, that “if you can draw it we can build it.”  It takes an exceptionally skilled team to create a viable, functioning, customized solution.

Techniques like butt fusion, sidewall fusion and electrofusion, and extrusion welding—performed up to ASTM standards—are employed to create complex structures ranging from manholes, tanks, and vaults to marine floats.

Speaking of marine applications, the benefits of HDPE fabrication extend to boat docks, aquaculture pens, and pump stations, where flexibility, durability, and buoyancy reign supreme.

Next up is spooling—a technique that streamlines assembly by bringing pipe and fittings together in a controlled factory setting. By circumventing weather-related delays, potential safety risks, and ensuring quality, spooling offers a compelling alternative to field pipe construction that saves time, improves quality, and lowers overall cost.

HDPE fabrication encompasses a diverse array of processes and applications. Armed with this knowledge, you are equipped with the who, what, where, when, and wyes (sorry – low-hanging fruit there).

For further insights, check out our fabrication guide or watch our on-demand webinar recording, “HDPE Fabrication: From Specification to Fit – Your Blueprint for Success.”