May. 13, 2024
PVC (polyvinyl chloride) and HDPE (high-density polyethylene) are both versatile thermoplastics used in a wide variety of applications, most notably in plastic piping systems. Though they share some similar characteristics and applications, there are several key differences between PVC and HDPE when it comes to their properties, manufacturing, performance, and uses.
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The most fundamental difference between PVC and HDPE is their chemical makeup. PVC is made by polymerizing vinyl chloride monomers into long chains. HDPE is made by polymerizing ethylene gas molecules into long chains under pressure.
This variation in chemistry lends different material properties to each plastic:
- PVC has moderate strength, chemical and weather resistance, and thermoplastic properties. It also has inherently high flame and smoke characteristics.
- HDPE is known for high impact strength, low moisture absorption, chemical resistance, weather resistance, and a relatively low thermal expansion coefficient. It has better stress-cracking resistance than PVC.
As their names indicate, PVC is less dense than HDPE. The density of rigid PVC ranges from 1.3-1.45 g/cm3 while HDPE has a density ranging from 0.93-0.97 g/cm3. The higher density of PVC allows it to be stiff and rigid, which is advantageous for certain piping applications. HDPE's lighter weight has advantages for transportation, installation, and seismic applications.
PVC can withstand temperatures up to 140°F continuously, while HDPE can handle temperatures up to 250°F continuously. Above these temperatures, material properties start to deteriorate. HDPE remains flexible and usable in cold temperatures down to -220°F. Its lack of plasticizers prevents it from becoming brittle. PVC becomes glass-like and breakable below -10°F.
PVC resins and compounds are manufactured by several processes, including suspension, bulk, emulsion, and dispersion. Different manufacturing techniques produce different grades of PVC. HDPE is manufactured by both slurry loop polymerization and gas-phase polymerization of ethylene, using catalysts like Ziegler-Natta or metallocenes.
PVC often requires the use of plasticizers, stabilizers, lubricants, and fillers to be formulated into different types and grades of material. HDPE does not require the use of plasticizers or stabilizers in either resin or pipe production. This makes the HDPE manufacturing process simpler overall, with fewer additives required.
Both PVC and HDPE pipes can have long lifespans of 50 years or more. High-quality pipes of either material can last over 100 years if properly manufactured, installed, and maintained.
HDPE is considered to have better long-term durability and chemical resistance properties overall. In particular, its resistance to environmental stress cracking gives it better longevity than PVC. However, PVC can also offer excellent longevity when properly formulated and reinforced for the intended application and environment.
Maintenance needs differ between the materials. PVC may require the use of plasticizers to retain its flexibility over its service life. HDPE is more resistant to aging and chemical attack and has fewer issues with environmental stress cracking. Good initial installation practices and periodic inspection and maintenance are recommended for either material.
Both PVC and HDPE are used extensively in piping systems, though HDPE dominates water and gas distribution piping while PVC dominates sewer collection networks.
PVC piping is widely used in the municipal wastewater industry for sewers, being suitable up to 18-inch diameter gravity sewers. It is also popular for residential drain, waste, and vent (DWV) systems. Specialty grades of PVC can handle chemical transport applications.
HDPE is the preferred piping material for natural gas and drinking water systems, including mains and service lines up to 60-inch diameter pipes. It is also popular for geothermal piping systems. HDPE is not suitable for waste or vent piping applications.
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PVC piping is generally joined using solvent cements while HDPE piping utilizes heat fusion welding to connect pipe sections and fittings. Overall installation and maintenance costs can differ between materials depending on the technique.
Both PVC and HDPE are recyclable materials; however, rates of recycling vastly differ. HDPE has an extensive recycling stream while PVC recycling is limited.
HDPE is one of the most recycled plastic materials. Recycling rates reached 33% in 2020 as infrastructure, technology, and markets continue to develop. Recycled HDPE is in demand for manufacturing new products and piping systems.
While technically recyclable, PVC recycling is economically and logistically challenging. In 2020, less than 1% of PVC was recycled in the United States. The primary strategy has focused on reuse rather than mechanical recycling of PVC. Developing larger-scale recycling has been hindered by the lack of profitable markets for recycled PVC resin.
In general, PVC piping costs are lower than HDPE piping costs. PVC resins are cheaper and easier to manufacture using less complex processes. PVC also uses less energy in the production process relative to production output when compared to HDPE. In large diameter piping suitable for both materials, installed PVC piping has historically cost 10-30% less than HDPE.
However, looking past initial costs, there are cases where HDPE provides longer-term value thanks to superior durability and lower maintenance costs over its lifespan. Installed costs also depend heavily on project particulars. In smaller diameter tubing, HDPE can be more affordable while still providing longevity. As sustainable infrastructure goals drive changes in the piping industry, cost profiles may shift between these materials over time.
In summary, while PVC and HDPE share similarities as versatile thermoplastic piping materials, they have distinct differences when it comes to chemical makeup, mechanical properties, manufacturing methods, lifecycle attributes, and product applications. These differences make each material suitable for distinct uses in piping markets as well as sustainability considerations. Understanding their unique strengths and limitations allows infrastructure designers to select the optimal material solution for piping system needs. Ongoing advances in both materials offer choices to improve piping system performance across public works and industrial and residential projects.
There are continuous debates as to which pipe is the best to work with for what type of project. The following is an effort to compare the advantages and disadvantages of using HDPE versus PVC pipe. Every effort will be made to be impartial on the pros and cons. That said, we are a manufacturer of HDPE pipe. HDPE pipe has been the material of choice for trenchless installation practices almost since the technology first appeared in the mid-to late 1960s.
PVC is a fairly durable vinyl polymer while HDPE is a thermoplastic made from petroleum. They are both considered plastics. When comparing failure ratings, PVC has shown to be higher than HDPE. PVC has a rating of one in 48,650 events compared to HDPE with one in 10,000,000. These failure events included rain stress, wind, heat, or cold. HDPE is known to be more durable in these events. PVC is shown to be more useful in one-time projects.
When joining PVC, a gasket or gluing sealant must be used. It can also be joined underwater while HDPE cannot. HDPE is joined by heat fusion (see our Push/Lock Couplings). However, HDPE is able to withstand and dampen more shock waves than PVC.
When covering fiber builds, HDPE works best for many reasons.
HDPE can be installed in the following ways:
PVC can be installed in the following ways:
When looking for a more suitable pipe for lower pressure, HDPE is more efficient. HDPE is softer and more bendable and has a tight bending radius. However, HDPE is a strong choice for both pressure and non-pressure piping applications. HDPE is known for its flexibility, chemical stability, and high strength-to-density ratio. HDPE offers a leak-free system via heat fusion joints. While PVC is stronger and stiffer material, it makes it suitable for direct burial and trenchless installation. The stiffness of PVC pipe allows their direct connection to mechanical valves, non-plastic fittings and various other water and wastewater connections. One of the biggest issues with mechanically joined traditional pipes (PVC) is the high incidence of background leakage. This is water that leaks out of the pipe through pipe joints. It is estimated that in the United States, about 14% of drinking water is lost each day due to background leakage! This represents more than 12 million gallons of water a year in a city of 100,000. HDPE pipes, and their fittings and connections, offer a distinct advantage in that they can be used to create leak-free joints that can prevent this issue.
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