HDPE POLYFUSION SERVICES

The Ted Berry Company Team has the experience and equipment required to fuse all diameters of HDPE pipe as well as fabrication of HDPE piping systems utilized in landfill leachate collection systems, chemical and process piping, underground utility systems, sludge and waste lines from our Maine office located in the heart of the Maine Pulp and Paper Industry.

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.

Critical path HDPE Projects eliminating downtime of critical piping system.

November 2009
A large local pulp and paper mill had a serious leak in its 90-100 psi main water supply system only 5 days before Thanksgiving of 2009. Failure of the system would have shut down the main production areas of the plant leaving over 1,000 local employees without work and costing tens of thousands of dollars of downtime per hour. The Ted Berry Company Inc Industrial Services Team deployed its HDPE Fusion team with multiple fusion machines, operators, and pipe fitters to install over 600' of 12" HDPE SDR 11 temporary piping that extended vertical from two points over 40' in the air to the water supply system keeping the mill operational saving millions of dollars. The project was mobilized, fabricated, installed, flushed, tested, and ready for service both on time and on budget. 

Senior Project Manager Matt Timberlake says "Our team was ready when they were needed and worked through the weekend to both design and fabricate this very intricate pipeline within our customers timeframe. Amazing people and amazing results, I cannot be more proud of our crew today" November 25th, 2009