Sounds like you're pretty familiar with HDPE as you hit on almost all of the points that I would have. We originally started building our racks out of it before moving to the EPVC, here are my thoughts:
- The stuff is indestructible. You can take a full piece or even just a sliver and bang it with a sledgehammer until your hand turns blue. The stuff doesn't break.
- It welds very easily. HDPE welding rods are readily available and are pretty cheap. A welded joint was very strong.
- It is very heavy. Not melamine heavy, but not that far off.
- Because it is soft (which is why it doesn't break), it scratches VERY easily. You can take your fingernail and just lightly knick the plastic and it's a permanent scratch. I also found that the plastic used in Sterilite tubs was harder than the plastic in the rack so it would show wear from pulling tubs in and out.
- You also mentioned the sagging. If I went over 18", it would start to sag. I couldn't even make my 'sideways' rack that holds a 32 quart box sideways because it would start to sag. It got worse over time as well.
- Don't understand the physics of it and it's not a big deal, but it also took a long time to warm up. It held temps fine when it did but the EPVC will warm up in 15 minutes where that stuff took 40 minutes.
Just my 2 cents...good luck,
Jason