Plastics trends: New developments in plastic pipes

Particularly noteworthy is the drastic reduction in gas permeation compared to conventional solid-wall polyethylene pipes. While these still show significant permeability to hydrogen and methane, multilayer pipes reduce permeation to a minimum. „They thus make a decisive contribution to reducing climate-relevant gas losses“, emphasises Dr. Mirko Wenzel, Expert Scientist at SKZ. 

Multilayer plastic pipes thus open up the possibility of quickly and efficiently converting existing gas networks to hydrogen transport without costly modifications or safety risks. They are an example of a technology that secures the energy transition at the infrastructure level. 

Welding technology – new processes increase quality and efficiency 

In addition to the materials themselves, joining technology is also of central importance for the performance of plastic pipes. Two technological innovations have emerged that are redefining the state of the art: SIMOClearWeld technology and the snapfuse method. 

With SIMOClearWeld technology, Simona AG, a manufacturer and development partner for thermoplastic products, has developed a welding technique that solves the problem of disruptive weld beads inside pipes for the first time. Conventional butt welding produces beads that impede flow and, in the case of cable protection pipes, have to be laboriously removed. The new technology shifts the weld bead into the pipe wall, eliminating the need for reworking. This is based on a combination of high-precision manufactured cable protection pipes, CNC-controlled welding preparation and automated process documentation. In practice, this has led to a doubling of welding output on the construction site and a reduction in construction time of up to 45 % in the current large-scale BBPIG 6 by transmission system operator Amprion. This means that the expansion of the underground high-voltage infrastructure in Germany can now be significantly accelerated. 

The snapfuse technology, developed by Star Engineering Systems (a provider of technologies in the field of welding and heating coil technology as well as mechanical engineering) and used for the first time in a major project by Stadtentwässerungsbetriebe Köln (StEB), takes a different approach. There, DN 1200 pressure pipes had to be laid in parallel under very cramped conditions – a scenario in which classic welding methods such as butt welding or socket welding reach their limits. The new technology integrates the heating coil directly into the pipe wall and enables pipe-to-pipe connections without sockets or large-volume machines. There are no internal or external bulges, ovalities are reliably compensated for, and installation can be carried out quickly and safely even on confined construction sites. The technology has proven its long-term durability in tests according to EN ISO 1167 and opens up new possibilities, especially for large-dimension pressure pipe systems. 

Both technologies – SIMOClearWeld and snapfuse – demonstrate that joining technology has long been a field of highly innovative developments. Not only do they increase efficiency and cost-effectiveness in the construction process, they also improve the quality and operational safety of pipe systems. 

Recycling and recycled materials – focus on the circular economy 

According to the KRV Kunststoffrohrverband e.V. (German Association of Plastic Pipe Manufacturers), the circular economy is becoming increasingly important alongside technological advances in materials and processing. The plastic pipe industry sees itself as responsible for contributing to resource conservation and climate protection. 

The greatest sustainability advantage of plastic pipes is probably their extraordinary durability. Products that function reliably for many decades, in some cases more than 100 years, do not need to be replaced, thus avoiding emissions and resource consumption throughout their entire life cycle. In addition, companies have been investing for years in energy-efficient production processes, the use of renewable energies and waste prevention. 

The use of recycled materials is also on the rise. According to recent analyses, polyethylene, polypropylene and PVC pipes with recycled content are increasingly being manufactured in Europe. In Germany, more than 57,000 tonnes of post-consumer recycled materials were used in pipe production in 2021. The following examples illustrate the sustainability efforts of the plastic pipe industry: 

• Amiblu Germany GmbH, in turn, is promoting the recycling of glass fibre-reinforced plastics through international research projects and its own closed-loop solutions – a challenge that has remained unsolved to date, for example with regard to waste from wind turbines. 

It is encouraging to note that the aspect of „sustainability“ is now at least partially taken into account in public tenders for construction projects. This strengthens the position of those companies that are leading the way with investments in the circular economy and climate-neutral products. 

Conclusion 

The latest developments in plastic pipe technology demonstrate the industry's high level of innovation. Multilayer pipes make existing gas networks suitable for hydrogen and significantly reduce climate-damaging gas losses. New welding technologies increase productivity and quality and open up new opportunities for large-scale projects in the energy transition and wastewater management. Finally, the growing use of recycled materials underlines the industry's commitment to actively shaping the circular economy without compromising the safety and quality of its products. Plastic pipe technology is thus positioning itself as an indispensable component of a sustainable infrastructure for energy, water and wastewater – and proving that technological innovation and environmental responsibility can go hand in hand.