Expansion Management: Navigating HDPE Pipe Installations
Managing Expansion in Above-Ground HDPE Piping Installations
HDPE piping has become a go-to choice for engineers and project managers thanks to its flexibility, durability, and resistance to corrosion. It’s especially effective in demanding environments, such as regional mine sites or suspended pipe galleries, where adaptability and longevity are crucial.
One of the most important factors in successful HDPE installations is expansion management. Because HDPE expands and contracts with temperature changes, managing these expansions and contractions is essential to prevent system failure or misalignment. With the right design, installation practices, and ongoing maintenance, this expansion can be controlled effectively.
Nathan Craig, CEO at Advanced Piping Systems, brings decades of experience in large-scale HDPE piping solutions. He highlights expansion management as a cornerstone of any above-ground project and shares practical insights to ensure reliable performance over time.
HDPE Installations in Australia
The unique Australian environment presents various challenges for local piping projects, particularly in terms of effective expansion management for above-ground installations.
“We experience significant temperature fluctuations, particularly in remote areas where mining and milling operations are located,” Nathan explains.
“From freezing cold temperatures to scorching summer heat, our pipes need to withstand these extremes and expand and contract as necessary.”
HDPE expands at a rate of 2.4 millimetres per metre per 10 degrees, which makes it an excellent solution in our unique conditions.
However, this unique expansion factor necessitates careful planning to accommodate these changes.
“In full summer sun, black HDPE pipes can exceed 60 degrees, resulting in significant expansion. While it’s the perfect solution, its flexibility must be considered when planning your installation.”
Working in Open Spaces
Snaking HDPE pipe is a standard solution for open spaces, helping to prevent pipe deformation, buckling, or damage during temperature fluctuations.
This approach allows the pipe to expand or contract more easily without accumulating excessive stress, ultimately extending the pipe’s longevity and productivity.
However, measures to manage pipe movement need to be carefully selected to allow for natural expansion without damaging the pipe or affecting roads or other structures.
If the piping is embedded into a block of concrete at multiple fixed points, the pipe will pull and push against the fixed structures as it expands or contracts. As a result, the piping at these points will need to be engineered to withstand the force.
Thrust blocks also offer an effective solution for managing these pipes, allowing for movement between the fixed points.
“For temporary or permanent cross-country pipelines that you don’t want to bury, concrete thrust blocks are an excellent option for accommodating pipe movement within certain limits,” Nathan suggests.
“They can be cost-effective, easy to maintain, and adaptable to different situations and environments.”
When determining how many thrust blocks are needed, Nathan advises erring on the side of caution.
“Each installation is unique, so there’s no one-size-fits-all rule.
“Balancing space for pipe expansion and contraction while minimising friction loss and accommodating roads or other obstructions requires early planning with all involved parties to achieve the right result for your project.”
Working Within a Structure
While snaking is a great option for mines with ample space, a different solution is required when HDPE pipe is used within a pipe gallery, such as a processing plant or mill.
Using heavy-duty expansion joints or bellows as an inline compensating device is an ideal way to support the pipe and allow for expansion when needed.
Advanced Piping Systems can also engineer telescopic expansion joints that absorb expansion in line without the need for expansion loops and deflection legs.
“If the customer provides us with the pipeline length and the expected temperature range, we can engineer telescopic expansion joints tailored to their application,” Nathan explains.
“These are custom-engineered devices, so they have a higher upfront cost, but they enhance pipeline performance by reducing friction loss and turbulence, ultimately saving energy in the long run.”
HDPE Pipe Planning for Success
In complex environments such as mining and industrial sites, expansion management is a crucial component of any above-ground HDPE piping system. Without a proper strategy to manage thermal movement, even the best pipe materials can underperform, leading to unexpected downtime and costly repairs.
Based on decades of experience, Nathan Craig, CEO of Advanced Piping Systems, emphasises the importance of thorough planning and comprehensive implementation for reliable and high-performing installations.
“One of the main challenges we’ve seen with large above-ground installations is under-engineering, leading to an underestimation of what’s required for smooth operation. Time is money, especially in a 24/7 mine or mill operation, and you need reliable piping services,” Nathan says.
“It’s not just about repair costs—it’s also the cost of downtime. Doing it right the first time pays off. The best results come from early collaboration, where we can work closely with project engineers to determine precise project needs and plan accordingly. We deal with these types of projects every day and may have insights you haven’t considered. Our goal is to help you design a system that meets your needs from day one.”
At Advanced Piping Systems, we don’t just supply products – we help solve problems. Whether you’re facing complex thermal movement challenges or looking for guidance on expansion management in HDPE piping, our expert team is ready to support your success.
Contact one of our HDPE specialists today to future-proof your piping system and ensure your next project runs smoothly from start to finish.
