HDPE Sheet Specifications — Sizes, Thicknesses & Standards
HDPE sheet specifications define the standard stock formats you will encounter from distributors: 4'×8' and 4'×10' sheet formats, thickness increments from 1/16" to 2", rod diameters from 1" to 6", and the ASTM D4976 resin standard that governs material quality. Marine HDPE (Starboard/KING StarBoard) adds an extended color palette and additional sheet format options. This page consolidates the dimensional, tolerance, and regulatory specifications an engineer or buyer needs to confirm before ordering.
At a glance:
- Standard sheet sizes: 4'×8' (most common) and 4'×10'
- Thickness range: 1/16" through 2" in standard increments
- Rod: 1" to 6" diameter, standard 4' lengths
- Resin standard: ASTM D4976
- Thickness tolerance: ±10% on most thicknesses
- Marine HDPE available in 10+ stocked colors
- Borated HDPE available to custom sizes on request
Standard Sheet Formats
Sheet Size Options
The 4'×8' format is the workhorse stocking unit for standard HDPE and most Marine HDPE (Starboard) colors. The 4'×10' format is common in marine boatbuilding where longer unbroken runs are needed for hull liners, cabin sides, and deck structures. Some specialty formats (KING StarBoard XL) are available in wider or longer panels at volume.
Cut-to-Size Availability
Most HDPE distributors offer saw-cut pieces from stock sheets at no or low charge for small orders. Waterjet and CNC routing to net shape is available as a value-add service. If ordering cut pieces, specify thickness, width, length, and grade (including color for Marine HDPE) on the purchase order.
Thickness Range — Standard HDPE and Marine HDPE
| Thickness (inches) | Thickness (mm) | Typical Use |
|---|---|---|
| 1/16" (0.063") | 1.6 mm | Light liners, gaskets, thin covers |
| 1/8" (0.125") | 3.2 mm | Cutting board inserts, light panels |
| 3/16" (0.188") | 4.8 mm | Bin liners, thin tank panels |
| 1/4" (0.250") | 6.4 mm | Cabinetry, cutting boards, general fabrication |
| 3/8" (0.375") | 9.5 mm | Marine cabinetry, structural panels |
| 1/2" (0.500") | 12.7 mm | Tank walls (small tanks), dock hardware |
| 3/4" (0.750") | 19.1 mm | Tank walls, structural marine panels |
| 1" (1.000") | 25.4 mm | Heavy dock bumpers, thick tank walls |
| 1-1/2" (1.500") | 38.1 mm | Wear blocks, structural components |
| 2" (2.000") | 50.8 mm | Heavy-duty tank walls, radiation shielding base |
Not all thicknesses are stocked in all grades. Standard HDPE (natural, black, white) typically has the broadest in-stock thickness range. Marine HDPE colors may be stocked in 1/4", 1/2", 3/4", and 1" as core thicknesses; other thicknesses are available on order.
Borated HDPE sheet is generally available in custom thicknesses from 1/2" to 4". Because of the specialized nature of radiation shielding applications, borated HDPE is rarely stocked in standard increments; plan for extended lead times.
Dimensional Tolerances
Sheet Thickness Tolerance
| Thickness Range | Tolerance |
|---|---|
| 1/16" – 1/4" | ±0.010" (±0.25 mm) |
| 3/8" – 1/2" | ±0.015" (±0.38 mm) |
| 3/4" – 1" | ±0.020" (±0.51 mm) |
| 1-1/2" – 2" | ±0.030" (±0.76 mm) |
These tolerances apply to extruded HDPE sheet. For applications requiring tighter thickness tolerances (precision machined parts, close-tolerance assemblies), plan for a machining allowance and mill/grind to final thickness.
Width and Length Tolerance
- Width: ±1/16" on saw-cut stock sheets
- Length: ±1/8" on saw-cut stock sheets
- Custom CNC-cut parts: tolerances depend on the fabricator's equipment; typically ±0.005" on routed edges
Rod Specifications
| Diameter (inches) | Length | Tolerance (OD) |
|---|---|---|
| 1" | 4' | ±0.015" |
| 1-1/2" | 4' | ±0.020" |
| 2" | 4' | ±0.025" |
| 3" | 4' | ±0.030" |
| 4" | 4' | ±0.040" |
| 6" | 4' | ±0.060" |
HDPE rod is used for turned parts, bushings, spacers, and machined components where sheet stock is not suitable. Larger diameters (4", 6") may be extruded or compression-molded, and the fabrication method can affect property uniformity; verify with the supplier for critical applications.
Applicable Standards
Resin Standard
- ASTM D4976: Standard specification for polyethylene plastics molding and extrusion materials. Classifies HDPE by density, melt index, and performance requirements. Standard HDPE sheet meets the Type III, Class C, Grade E or P classifications under this standard.
Test Methods Referenced for HDPE Properties
| Property | Test Method |
|---|---|
| Density | ASTM D792 |
| Tensile strength/elongation | ASTM D638 |
| Flexural modulus | ASTM D790 |
| Hardness (Shore D) | ASTM D2240 |
| Water absorption | ASTM D570 |
| Heat deflection temperature | ASTM D648 |
| Izod impact | ASTM D256 |
| Flammability | UL 94 |
| UV weathering | ASTM G154, ASTM G155 |
Food-Contact Regulatory Standards
| Standard | Scope |
|---|---|
| FDA 21 CFR 177.1520 | Direct food contact approval for polyolefin articles |
| USDA acceptance | Food-processing equipment contact surfaces |
| NSF/ANSI 51 | Food equipment materials (selected grades) |
Marine HDPE Color Codes (KING StarBoard / Starboard)
The Marine HDPE product line is available in an extended color palette. The following are representative stocked colors; availability varies by distributor:
| Color Name | Approximate Color | Common Use |
|---|---|---|
| White | Bright white | Interior cabinetry, boat interiors |
| Black | Solid black | Exterior panels, rub rails, UV-critical |
| Gray | Medium gray | Dock hardware, neutral interior |
| Teak | Warm tan | Boat cabinetry (teak replacement) |
| Navy | Dark blue | Accent panels, exterior accents |
| Seafoam | Light teal-green | Accent, coastal architecture |
| Yellow | Safety yellow | Safety markers, dock hardware |
| Red | Signal red | Safety applications |
| Blue | Medium blue | Recreational marine |
| Cream | Off-white/ivory | Interior joinery |
Specific color codes, part numbers, and stocking status vary by manufacturer and distributor. Confirm availability before specifying an uncommon color on drawings.
Weight and Handling Data
Sheet weight (lbs) for standard 4'×8' sheet at 0.95 g/cc density:
| Thickness | Sheet Weight (4'×8') |
|---|---|
| 1/4" | ~12.2 lbs |
| 1/2" | ~24.4 lbs |
| 3/4" | ~36.6 lbs |
| 1" | ~48.8 lbs |
| 1-1/2" | ~73.2 lbs |
| 2" | ~97.6 lbs |
Weights are approximate; actual weight varies slightly with grade and extruder conditions.
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