High Density Polyethylene (HDPE) pipe is one type of nonmetallic piping material used for a wide range of applications and services, such as fire water, oil and gas. HDPE pipes provide many advantages, including corrosion resistance, lightweight, flexible, and cost effective. Appropriate HDPE construction methods should be developed and followed to mitigate any risk of failure in the piping, fittings or joints. This paper illustrates the challenges faced during the construction of a new project. Furthermore, HDPE field fabricated joints — that failed hydrotesting due to air entrapment — will be showcased. Although the total number of failed joints was insignificant compared with the total joints completed; a thorough review was carried out to prevent any similar failures during operations. The review identified the root cause, the best practices and recommendations wherein the main is to ensure proper venting and to allow for more time to stabilize the pressure during hydrotesting. Sharing these real-life challenges will help avoid recurrence of these failures and their associated cost, and impact on safety and operations.