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Leak-Free Piping System
According to an article published in the July 1994 issue of Opflow, by American Water Works Association (AWWA), 10-15% water loss in typical municipal water systems is the accepted standard.

Average Daily Water Usage & Water Loss Statistics by Population Size

(Information based on AWWA Water Industry Data Base, Utility Profile Averages)

Population Average Daily Water Loss @ 10% Average Daily Water Loss @ 15%
20,000 604,110 U.S. gallons 906,164 U.S gallons
50,000 1,510,274 U.S gallons 2,265,411 U.S gallons
100,000  3,020,548 U.S gallons 4,530,822 U.S gallons

Leakage reduces flow rates, increases electricity costs for pumping, cuts profits, increases water treatment costs, creates back-siphon contamination risk, and requires continual maintenance and monitoring.  These industry- wide problems demand a LEAK-FREE SOLUTUION!

In the thermal-fusion process, two lengths of HDPE pipe are literally fused into one homogenous piece.  When the polyethylene pipe ends are heated, the molecular structure is transformed from a crystalline state into an amorphous state.  When specific fusion pressure is applied, the shapeless molecules from each pipe end mix.  As the joint cools, the molecules return to their crystalline state, the original interfaces are gone, and the two pipes have become one homogeneous pipe. The HDPE joint becomes stronger than the pipe itself in both tensile strength and pressure conditions, therefore producing one continuous, leak-free piping system.

Thermal fusion of HDPE eliminates all mechanical joints (and potential leaks) in pipes, fittings and service connections.  HDPE leak-free piping systems result in long-term lower life-cycle costs, increased profit with zero maintenance and zero leakage.  

All ductile iron and PVC piping systems are categorically engineered with certain leakage allowances taken into account (please reference charts below). As of January 1, 2001 the American Water Works Association has not released a standard for HDPE piping system design, installation, or hydrostatic pressure testing.  The Plastics Pipe Institute (www.plasticpipe.org) has established HDPE standards including those for piping system design, installation and hydrostatic pressure testing.

Example “A” HDPE:

12” Nominal Pipe Diameter

40’ sections

Thermal Fusion Joints

50 joints, 40’ sections (2000’)

100 psi (operating or test pressure)

Plastics Pipe Institute Hydrostatic testing recommendations:

Maximum Allowable Leakage:  0 gph per 50 joints

0 gph (24 hours) = 0 gallons maximum loss per day

0 (365 days) = 0 gallons maximum loss per year!


Example “B” Ductile Iron:

12” Nominal Pipe Diameter

20’ Sections

Push-On Joints

50 joints, 20’ sections (1000’)

100 psi (operating or test pressure)

AWWA C600-93 (page 21):

Maximum Allowable Leakage:  .90 gph per 50 joints

.90 gph (24 hrs) = 21.60 gallons maximum loss per day

21.60 (365) days = 7,884 gallons maximum loss per year!


Example “C” PVC:

12” Nominal Pipe Diameter

20’ Sections

Bell and Spigot Joints

50 joints, 20’ sections (1000’)

100 psi (operating or test pressure)

AWWA C605-94 (page 17):

Maximum Allowable Leakage:  .81 gph per 50 joints

.81 gph (24 hrs) = 19.44 gallons maximum loss per day

19.44 (365 days) = 7,095.6 gallons maximum loss per year!

For every 5 miles of water main there is a minimum of 1,320 joints (assuming a straight pipe run, 20’ sections, no elbows or service saddles).

“The Water supplier has the responsibility to prevent contamination of the public water system….  This responsibility begins at the source and includes the entire water distribution system and ends at the user connection." 1992 Manual of Water Supply Practices, AWWA M14.

“Even in systems with excellent treatment, leaking pipes can lead to a loss of pressure and cause back-siphonage of contaminated water….  Leaks also waste water and energy as treated water escapes from the distribution system.” Comments from EPA’s G-058 1997 Report.

“Washington DC- 1993- Four day boil notice costs the city and its residents an estimated $24 million dollars…” Comments from EPA’s G-058 1997 Report.

Are you willing to risk the environmental concerns related to contamination surrounding a leaky distribution system?  A leak-free piping system for treated and untreated media not only results in greater profit, but also reduces the environmental risks and liabilities associated with contamination and system failure.

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