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Our process
From recovered pipeto a product that lasts a lifetime.
We reprocess heavy-wall PE 3408 pipe pulled from oil and gas fields into finished HDPE sheet and welded assemblies. Engineered and built in-house, under one roof in Wyoming.
Watch
The full process, start to finish
Every step below is pulled straight from this walkthrough.
Recovered from the field
It starts in the field. We pull decommissioned heavy-wall PE 3408 HDPE pipe out of oil and gas sites and bring it back to the shop as our raw material.
Cleaned, dried, inspected
Every length is thoroughly cleaned, dried and inspected for dirt, debris and foreign material, so only sound material moves into production.
Shredded and granulated to chip
The pipe is reduced in two stages. A shredder breaks it down, then a granulator refines it into a clean, consistent 3/8 inch chip.
Chip becomes pure PE sheet
The chip is heated and extruded into sheet from 1/16 inch up to 1 inch thick, 48 inches wide, cut to any length. Pure PE 3408 with no post-consumer blends, so we build without lateral joints or seams.
We extrude matching welding wire at the same time, a perfect polyethylene match to the sheet for weld strength that is second to none.
Machined to spec
Our engineering team turns the design into a detailed CAD file that drives a CNC router, precisely machining every piece from sheet stock.
Fitted and tacked
Parts are clamped and secured in place, then tack welded to lock each assembly into precise position before final welding.
Prepped for a clean bond
Ambient air oxidizes the surface of polyethylene, so before welding we strip that layer back with a rotary bur or wire wheel, leaving clean material ready to bond.
Welded and finished
Handheld extrusion welders preheat the sheet and lay in matching filler under pressure, bonding every part. Welds and corners are cleaned and smoothed. The result is durable, watertight, maintenance free and built to last a lifetime.
American Made
Our HDPE barges and boats are designed, engineered, and manufactured under one roof. That gives us the ability to ensure everything is built to the highest standards and quality possible.
Every hull starts on a CAD station in our own engineering office, gets reviewed by the same team that will build it, and rolls out the door of the facility it was specified in. No outsourced naval architecture, no overseas fabrication, no handoffs between vendors who have never met. The crew welding your barge knows the engineer who drew it, and the engineer knows the operators who will run it.
That vertical integration is the difference between a barge that meets a spec sheet and a boats that solves the actual job in front of you. When you need a deck modification, a custom crane base, or a non-standard hull thickness for a specific operating environment, you are talking to the people who can answer in the same week, not the same quarter.
Built to last, backed by numbers
2,000,000+ lbs. of HDPE sheets shipped
225,000+ lbs. of plastic recycled into boat hulls
500+ miles of abandoned pipe recovered
37 custom
HDPE boats
built
2.5+ miles of welding completed
Putting our environment first by extracting and reusing HDPE pipe to make indestructible boats.
Command your HDPE boat on the waters today. Talk to our expert team of engineers ready to professionally advise you and help find the right boat for your needs.
