Driven to Discover


Cool Under Pressure: Learn Best Practices for HDPE Fusion Welding

2.2 minute read

February 02, 2016

Sewage is leaking onto the highway from your sewer force main. The public’s up in arms about the hazard. It’s the third recent crack in this mile-long pipe, so you need to come up with a new solution for the repair. Now.

Do you know what to do next?

So as to minimize traffic disruption to the highway and get your encroachment permit, you will want to use trenchless technology if you can. Your trenchless options will likely involve HDPE (high density polyethylene) with butt-fused joints. Is that the right approach, or will it do more harm than good?  

You’re in luck. We faced this situation recently and learned some valuable lessons. To make your life easier, we decided to share our story in the soon-to-be-released whitepaper entitled The Art and Science of HDPE Fusion Welding in High Pressure Applications. We’ll be presenting our whitepaper for the first time on March 8th at the Northern California Pipe Users Group’s monthly meeting and again on March 22 in Dallas at the 2016 No-Dig Show held by the North American Society for Trenchless Technology.

Our whitepaper and presentation will share best practices for ensuring high-quality welds when you and the pipeline are both under pressure. Specifically, it spells out the steps for verifying joint integrity for HDPE butt-fusion welds, including data logs that track the time, temperature and pressure for each connection.

We used two recent high-pressure force main sliplining projects in California as case studies. You’ll learn:

  • What’s critical for good welded connections
  • What designers should know in specifying HDPE as a high pressure pipeline
  • How to read real-time data logger output
  • How to specify the testing and inspection of welded connections
  • Good sliplining techniques to ensure joints are not degraded in installation

The great thing about our HDPE approach is how it benefits all stakeholders: Owners get assets that perform optimally and meet their expected design life, and contractors demonstrate their high-quality work and leave a good impression for owners.    

Save yourself the pain of learning on the job when time is of the essence. Come to either our PUG presentation or the NASTT No-Dig Show and discover state-of-the-art HDPE fusion welding methods you can start using with your team right away. We will be posting a copy of our whitepaper for download in April after the presentations occur. Contact us to receive an advanced copy of the whitepaper. 

Have your own helpful story? We want to hear it. Tell us how you’ve addressed unexpected welding issues on your worksites.



Vern Phillips, PE

Vern Phillips, PE

Principal Engineer / Engineering


Vern Phillips, PE




Civil Design


Trenchless Technology