1

Your Trusted Polyethylene

(PE) Pipes Manufacturer

Polyflow Pipes Sdn Bhd was incorporated in 1990.

lt manufactures Polyethylene (PE) pipes for use in :
• Potable water distribution
• Cable/communication protection pipe/conduit system
• Gas distribution
• Irrigation
• Sewerage and effluent disposal
• Chemicals pipes in factories

Currently, it is marketing under the brand name “POLYFLOW”.

It is used widely by all the Sarawak Water Authorities. It is
the pioneer in the manufacture of PE pipes in East Malaysia.
The pipe sizes range from 20 mm to 500 mm outer diameter
(OD). Customers can specify the pipes to have stripes of blue, red
or orange for water distribution and cable/communication system
protection respectively and yellow pipes for gas distribution.

“POLYFLOW” pipes conform to MS1058 (Malaysian Standard for

potable water HDPE pipes), ISO4427 (ISO Standard for potable
water HDPE pipes), MS1086 (Malaysian Standard for gas PE pipes)
& ISO4437 (ISO Standard for gas PE pipes). Polyflow Pipes Sdn
Bhd is committed to quality assurance and customer satisfaction
through our ISO9001 Certified Quality Management System.

Polyflow Pipes Sdn Bhd is a wholly owned subsidiary of Quality

Concrete Holdings Berhad which is a very diversified group of
companies listed in the Kuala Lumpur Stock Exchange (Bursa Malaysia).

2 POLYFLOW PIPES SDN BHD Company Profile

Our Products
WATER CABLE/COMMUNICATION GAS
PE PIPES PE PIPES PE PIPES

Blue Stripe Water Pipes Red/Orange Stripe Yellow Gas Pipes

(Straight lengths) Cable/Communication Pipes (Straight lengths)
(Straight lengths)

Blue Stripe Water Pipes Red/Orange Stripe Yellow Gas Pipes

(Coiled lengths) Cable/Communication Pipes (Coiled lengths)
(Coiled lengths)

FITTINGS

Push Fit Compression Fittings Tapping Saddles Fabricated Fittings

End Caps, Stub Ends and Flanges Electrofusion Fittings

1
 Properties of High Density
Polyethylene Pipes

• The weight of PE pipe is only about 1/5 of a steel pipe of a similar size.
• Easy handling.
• Significant savings in costs of handling and transportation.
Light
Weight
• Natural flexibility.
• Can be bent to conform to terrain contours and soil movements.
• Can be bent at a minimum radius of 25 to 40 times the pipe diameter.
• Long length without joints.
Flexibility

Ultra-
Violet
Resistance
• Physiologically harmless.
• Polyflow PE Pipes are protected • Free from toxicity and does not
against Ultra-Violet radiation affect taste of drinking water.
(sunlight). Non-toxic
and
Odorless

• Lower overall
Lower cost results from
Overall all the good
Project Cost properties of PE
Pipes.

• Good chemical resistance to Versatility

most common organic and • Superior physical and chemical-
inorganic chemicals, from pH resistant properties.
values of 0 to 14. • Can be used in a large number of
• Resistant to rotting or rusting. applications and industries.
Chemical
Resistance

Superior
Flowability
• PE Pipes have extremely smooth inner surface giving lowest
flow resistance.
• No scaling or corrosion encrustation.
Impact
Resistance
• High flexural and impact strength.
• Will not easily crack, break or fracture
when handled roughly.

2 POLYFLOW PIPES SDN BHD Company Profile

 Applications Back-Up
of PE Pipes Service from
1. Potable Water Distribution - On land or
underwater.
Manufacturer
2. Irrigation, Agriculture and Aquaculture.
3. Sewerage and Effluent Disposal. • Installation & Welding Services.
4. Pipes Relining. • Technical Advice Available.
5. Conveyance of Chemicals. • Training on Welding provided for
6. Gas Distribution. Pipe Installation.
7. Cable/Communication Protection Pipe/
Conduit System.

Certification and Standards

Polyflow Pipes Sdn Bhd “Polyflow” Water
Quality Management System Pipes are certified
of PE pipes manufacturing is by SIRIM QAS
certified to ISO9001 by British International Sdn Bhd
Standards Institution (BSI)

Polyflow Pipes Product Standards

• MS 1058 • ISO 4427 For Water Supply
• MS 1086 • ISO 4437 For Gaseous Fuels
• MS 1058 • BS EN50086-2-4 • ASTM D3350 For Cable/Communication Protection Pipe/Conduit Systems

Polyflow Pipes factory conducts the following Quality Assurance Test :-

a) Dimensional : Outside Diameter, Wall Thickness, Length, Circular Cross-section
b) Visual : Surface Finish, Marking
c) Weight : According to Standards
d) Performance : Internal Pressure Creep Test
e) Thermal : Dimensional Changes after subjection to heat
f) Tensile Strength : Elongation Test
g) Thermal Stability : Oxidation Induction Time

Typical Properties of HDPE

PROPERTIES TESTING METHOD UNIT VALUE

Density ISO 1183 G/cc 0.954
Melt Index, Condition 190˚C/5kg ISO 1133 G/10min 0.2-1.4
Thermal Stability MS 1058 min >20
ESCR, Condition A & B, F50 ASTM DI693 h >1000
F20 >500
Tensile Yield Strength ISO R 527 MPa 22
Tensile Strength, break ISO R 527 MPa 32
Ultimate Elongation ISO R 527 % >500
Flexural Modulus ASTM D 3350 MPa 758

3
 Polyethylene (PE80) Pipes
for Water Supply
MS 1058 : PART 2 : 2005 • ISO 4427 : PART 2 : 2007

DIMENSIONS:
PE80
Nominal
OD NB PN 6 PN 8 PN 10 PN 12.5 PN 16
SDR21 SDR17 SDR13.6 SDR11 SDR9
(mm) (inches) t (min) id t (min) id t (min) id t (min) id t (min) id
16
20 2.0 15.6 2.3 15.0
25 2.0 20.6 2.3 20.0 3.0 18.6
32 1.0 2.0 27.6 2.4 26.8 3.0 25.6 3.6 24.2
40 2.4 34.8 3.0 33.4 3.7 32.0 4.5 30.4
50 1.5 2.4 44.8 3.0 43.6 3.7 42.0 4.6 40.2 5.6 38.0
63 2.0 3.0 56.6 3.8 54.8 4.7 53.0 5.8 50.6 7.1 47.8
75 2.5 3.6 67.2 4.5 65.4 5.6 63.0 6.8 60.6 8.4 57.2
90 3.0 4.3 80.8 5.4 78.4 6.7 75.8 8.2 72.6 10.1 68.6
110 4.0 5.3 98.6 6.6 96.0 8.1 92.8 10.0 88.8 12.3 84.0
125 5.0 6.0 112.2 7.4 109.2 9.2 105.4 11.4 100.8 14.0 95.4
160 6.0 7.7 143.6 9.5 139.8 11.8 135.0 14.6 129.2 17.9 122.2
180 6.5 8.6 161.8 10.7 157.4 13.3 151.8 16.4 145.4 20.1 137.6
200 9.6 179.6 11.9 174.8 14.7 169.0 18.2 161.6 22.4 152.8
225 8.0 10.8 202.2 13.4 196.6 16.6 190.0 20.5 181.8 25.2 171.8
250 9.0 11.9 224.8 14.8 218.8 18.4 211.2 22.7 202.2 27.9 191.2
280 10.0 13.4 251.6 16.6 245.0 20.6 236.6 25.4 226.4 31.3 214.0
315 11.0 15.0 283.4 18.7 275.6 23.2 266.0 28.6 254.8 35.2 240.8
355 13.0 16.9 319.4 21.2 310.4 26.1 300.0 32.2 287.2 39.7 271.4
400 14.0 19.1 359.6 23.7 350.0 29.4 338.0 36.3 323.6 44.7 306.0
450 16.0 21.5 404.6 26.7 393.8 33.1 380.2 40.9 364.0 50.3 344.2
500 18.0 23.9 449.6 27.7 439.4 36.8 422.6 45.4 404.4 55.8 382.6
560 20.0 26.7 503.8 33.2 490.0 41.2 473.2 50.8 453.2
630 22.0 30.0 566.8 37.4 551.2 46.3 532.6 57.2 509.6
710 33.9 638.6 42.1 621.4 52.2 600.2
800 38.1 719.8 47.4 700.2 58.8 676.4
900 42.9 809.8 53.3 787.8
1000 47.7 899.6 59.3 875.2

LENGTHS AVAILABLE:
OD 20/25/32 mm 100/200/300 m coiled lengths
OD 50/63 mm 100 m coiled lengths
OD 75/90/110 mm 50 m coiled & 6.1 m straight lengths
OD 160 mm above Available on request

KEY:
OD : Outer Diameter
t (min) : Minimum Wall Thickness
id : Internal Diameter
PN : Nominal Pressure (bar)
NB : Nominal Bore of Metal Pipes
SDR : Standard Dimension Ratio

4 POLYFLOW PIPES SDN BHD Company Profile

Polyethylene (PE100) Pipes
for Water Supply
MS 1058 : PART 2 : 2005 • ISO 4427 : PART 2 : 2007

DIMENSIONS:
PE100
Nominal
OD NB PN 6 PN 8 PN 10 PN 12.5 PN 16 PN 20
SDR26 SDR21 SDR17 SDR13.6 SDR11 SDR9
(mm) (inches) t (min) id t (min) id t (min) id t (min) id t (min) id t (min) id
16
20 2.0 15.6 2.3 15.0
25 2.0 20.6 2.3 20.0 3.0 18.6
32 1.0 2.0 27.6 2.4 26.8 3.0 25.6 3.6 24.2
40 2.0 35.6 2.4 34.8 3.0 33.4 3.7 32.0 4.5 30.4
50 1.5 2.0 45.6 2.4 44.8 3.0 43.6 3.7 42.0 4.6 40.2 5.6 38.0
63 2.0 2.5 57.6 3.0 56.6 3.8 54.8 4.7 53.0 5.8 50.6 7.1 47.8
75 2.5 2.9 68.8 3.6 67.2 4.5 65.4 5.6 63.0 6.8 60.6 8.4 57.2
90 3.0 3.5 82.4 4.3 80.8 5.4 78.4 6.7 75.8 8.2 72.6 10.1 68.6
110 4.0 4.2 101.0 5.3 98.6 6.6 96.0 8.1 92.8 10.0 88.8 12.3 84.0
125 5.0 4.8 114.8 6.0 112.2 7.4 109.2 9.2 105.4 11.4 100.8 14.0 95.4
160 6.0 6.2 146.8 7.7 143.6 9.5 139.8 11.8 135.0 14.6 129.2 17.9 122.2
180 6.5 6.9 165.4 8.6 161.8 10.7 157.4 13.3 151.8 16.4 145.4 20.1 137.6
200 7.7 183.6 9.6 179.6 11.9 174.8 14.7 169.0 18.2 161.6 22.4 152.8
225 8.0 8.6 206.6 10.8 202.2 13.4 196.6 16.6 190.0 20.5 181.8 25.2 171.8
250 9.0 9.6 229.6 11.9 224.8 14.8 218.8 18.4 211.2 22.7 202.2 27.9 191.2
280 10.0 10.7 257.4 13.4 251.6 16.6 245.0 20.6 236.6 25.4 226.4 31.3 214.0
315 11.0 12.1 289.4 15.0 283.4 18.7 275.6 23.2 266.0 28.6 254.8 35.2 240.8
355 13.0 13.6 326.2 16.9 319.4 21.2 310.4 26.1 300.0 32.2 287.2 39.7 271.4
400 14.0 15.3 367.6 19.1 359.6 23.7 350.0 29.4 338.0 36.3 323.6 44.7 306.0
450 16.0 17.2 413.6 21.5 404.6 26.7 393.8 33.1 380.2 40.9 364.0 50.3 344.2
500 18.0 19.1 459.6 23.9 449.6 27.7 439.4 36.8 422.6 45.4 404.4 55.8 382.6
560 20.0 21.4 514.8 26.7 503.8 33.2 490.0 41.2 473.2 50.8 453.2
630 22.0 24.1 579.2 30.0 566.8 37.4 551.2 46.3 532.6 57.2 509.6
710 27.2 652.8 33.9 638.6 42.1 621.4 52.2 600.2
800 30.6 735.6 38.1 719.8 47.4 700.2 58.8 676.4
900 34.4 827.2 42.9 809.8 53.3 787.8
1000 38.2 919.6 47.7 899.6 59.3 875.2

LENGTHS AVAILABLE:
OD 20/25/32 mm 100/200/300 m coiled lengths
OD 50/63 mm 100 m coiled lengths
OD 75/90/110 mm 50 m coiled & 6.1 m straight lengths
OD 160 mm above Available on request

KEY:
OD : Outer Diameter
t (min) : Minimum Wall Thickness
id : Internal Diameter
PN : Nominal Pressure (bar)
NB : Nominal Bore of Metal Pipes
SDR : Standard Dimension Ratio

5
 Testing Guidelines
for HDPE Water Pipelines

A. High Co-efficient of Expansion of HDPE Pipes

Since PE pipe has a relatively high co-efficient of expansion, the pressure test should not be carried out in a
hot afternoon. In high temperature surroundings, the volume of make up water required is relatively large.
If there is a sudden cooling of the pipeline during the test (due to cloudy skies or rain), then the pressure in
the pipeline could rise critically over 2 times the rated pressure. Therefore, test should preferably be carried
out in the cool hours (i.e. very early morning) to prevent excessive expansion of the pipeline.

B. Pressure Reduction Factor

An additional factor needed to be considered in the testing of PE pipes is the Pressure Reduction Factor.
Please see overleaf for the Reference Chart. The implications are as follows:-
a) The Recommended Maximum Working Pressure (in bars) is not the same figure as the Pipe Pressure
number. For example, at our normal Malaysian temperature of 30 °C, a PN 10 pipe is designed for a
recommended maximum working pressure of 8 bars only. Conversely, if the working pressure is 10 bars
at normal temperature, then the recommended pipe should be PN12.5 instead of PN10.
b) During testing of the pipes after pipes jointing has been done, the testing pressure should not be selected
based on the pressure rating of the pipe at 20 °C (i.e. the Pressure No.). For example, if the ambient
temperature is about 30 °C, then the recommended maximum working pressure for a PN6 pipe would be
4.8 bars. Then the appropriate testing pressure should be 1.5 times 4.8 bars or 7.2 bars or 106 psi.
c) Since temperature plays such as an important role in the pressure rating of the PE pipe, it also inevitably
means that pipe-testing needs to be done at the correct temperature. It is advisable that testing should
not be carried out in the middle of the day or even towards the late afternoon because heat accumulation
by the pipe and the water inside the PE pipe can cause the water temperatue to rise very high (heat
absorption is accelerated by the black colour of the pipe). The pipe and the water temperature can rise
so high at different positions of the pipe that the testing would be out of control and the pipe may even
fail unnecessarily. Hence, it is more proper to have the pipe-testing done in the early morning hours
when the pipe and the water in the pipe have not accumulated much heat yet and the temperature of
the pipe material is not high.

Pressure Reduction Factor

Diagram 1 shows the pressure reduction factors for use in Diagram 1 : Working pressure reduction
temperatures above 20 °C and up to 40 °C. This is applicable factor versus temperature.
1.0
for water and other fluids which do not adversely affect the
0.9
long term properties of the PE material up to 40 °C. For use
0.8
at 30 °C, the maximum recommended working pressure are
Reduction Factor

0.7
tabulated in Table A. 0.6
0.5
Table A. Recommended Maximum Working pressure at 30°C 0.4
0.3
PIPE MATERIAL / NOMINAL RECOMMENDED MAXIMUM 0.2
TYPE PRESSURE WORKING PRESSURE (BAR) 0.1

16.0 12.8 0
20 25 30 35 40
PE80 12.5 10.0
Temperature °C
& 10.0 8.0
PE100 8.0 6.4
6.0 4.8

6 POLYFLOW PIPES SDN BHD Company Profile

Compression Fittings
Dimension Specifications
(Conform to Standards: BS 5114, AS 4129, ISO 3458, ISO 3459, ISO 3501, ISO 3503 & ISO 14236)

MALE THREADED ADAPTOR

1. 20mm x ½” 6. 32mm x ¾” 11. 63mm x 2”
2. 20mm x ¾” 7. 32mm x 1” 12. 75mm x 2”
3. 25mm x ½” 8. 50mm x 1 ½” 13. 75mm x 2 ½”
4. 25mm x ¾” 9. 50mm x 2” 14. 90mm x 3”
5. 25mm x 1” 10. 63mm x 1 ½” 15. 110mm x 4”

FEMALE THREADED ADAPTOR

1. 20mm x ½” 6. 32mm x ¾” 11. 75mm x 2 ½”
2. 20mm x ¾” 7. 32mm x 1” 12. 90mm x 3”
3. 25mm x ½” 8. 50mm x 1 ½” 13. 110mm x 4”
4. 25mm x ¾” 9. 63mm x 2”
5. 25mm x 1” 10. 75mm x 2”

STRAIGHT COUPLER
1. 20mm x 20mm 5. 63mm x 63mm
2. 25mm x 25mm 6. 75mm x 75mm
3. 32mm x 32mm 7. 90mm x 90mm
4. 50mm x 50mm 8. 110mm x 110mm

REDUCING COUPLER
1. 25mm x 20mm 6. 50mm x 32mm 11. 75mm x 63mm
2. 32mm x 20mm 7. 63mm x 25mm 12. 90mm x 63mm
3. 32mm x 25mm 8. 63mm x 32mm 13. 90mm x 75mm
4. 50mm x 20mm 9. 63mm x 50mm 14. 110mm x 90mm
5. 50mm x 25mm 10. 75mm x 50mm

MALE THREADED TEE

1. 20mm x ½” 5. 25mm x 1” 9. 63mm x 2”
2. 20mm x ¾” 6. 32mm x ¾” 10. 75mm x 2 ½”
3. 25mm x ½” 7. 32mm x 1” 11. 90mm x 3”
4. 25mm x ¾” 8. 50mm x 1 ½” 12. 110mm x 4”

FEMALE THREADED TEE

1. 20mm x ½” 5. 25mm x 1” 9. 63mm x 2”
2. 20mm x ¾” 6. 32mm x ¾” 10. 75mm x 2 ½”
3. 25mm x ½” 7. 32mm x 1” 11. 90mm x 3”
4. 25mm x ¾” 8. 50mm x 1 ½” 12. 110mm x 4”

7
 Compression Fittings
Dimension Specifications
(Conform to Standards: BS 5114, AS 4129, ISO 3458, ISO 3459, ISO 3501, ISO 3503 & ISO 14236)

EQUAL BEND
1. 20mm x 20mm 5. 63mm x 63mm
2. 25mm x 25mm 6. 75mm x 75mm
3. 32mm x 32mm 7. 90mm x 90mm
4. 50mm x 50mm 8. 110mm x 110mm

FEMALE THREADED BEND

1. 20mm x ½" 6. 32mm x ½" 11. 75mm x 2 ½"
2. 20mm x ¾" 7. 32mm x ¾" 12. 90mm x 3"
3. 25mm x ½" 8. 32mm x 1" 13. 110mm x 4"
4. 25mm x ¾" 9. 50mm x 1 ½"
5. 25mm x 1" 10. 63mm x 2"

MALE THREADED BEND

1. 20mm x ½" 6. 32mm x ¾" 11. 75mm x 2 ½"
2. 20mm x ¾" 7. 32mm x 1" 12. 90mm x 3"
3. 25mm x ½" 8. 50mm x 1 ½" 13. 110mm x 4"
4. 25mm x ¾" 9. 50mm x 2"
5. 25mm x 1" 10. 63mm x 2"

EQUAL TEE
1. 20mm x 20mm 5. 63mm x 63mm
2. 25mm x 25mm 6. 75mm x 75mm
3. 32mm x 32mm 7. 90mm x 90mm
4. 50mm x 50mm 8. 110mm x 110mm

REDUCING TEE
1. 25mm x 20mm 7. 63mm x 50mm
2. 32mm x 20mm 8. 75mm x 50mm
3. 32mm x 25mm 9. 75mm x 63mm
4. 50mm x 25mm 10. 90mm x 63mm
5. 50mm x 32mm 11. 90mm x 75mm
6. 63mm x 32mm 12. 110mm x 90mm

END CAP
1. 20mm x 20mm 5. 63mm x 63mm
2. 25mm x 25mm 6. 75mm x 75mm
3. 32mm x 32mm 7. 90mm x 90mm
4. 50mm x 50mm 8. 110mm x 110mm

8 POLYFLOW PIPES SDN BHD Company Profile

Mechanical Clamp/
Tapping Saddles
(Conform to Standards: ISO 3607, ISO 3609, UNI EN12201, DIN 8072-8074 & DIN 8077)

Name of Part: Name of Part:

Body Top Reinforced Ring
Material: Material:
Reinforce Polypropylene Stainless Steel - Grade 304

Name of Part:
Hexagon Nut
Material:
Mild Steel - Zinc Plated

Name of Part: Name of Part:

Gasket Round Washer
Material: Material:
Nitrile Butadiene Rubber Mild Steel - Zinc Plated

Name of Part:
Body - Bottom
Material: Name of Part:
Reinforce Polypropylene Hexagon Bolt
Material:
Mild Steel - Zinc Plated

TAPPING SADDLE Double Outlet

1. 32mm x ½" 15. 90mm x ½" 29. 160mm x ½"
2. 32mm x ¾" 16. 90mm x ¾" 30. 160mm x ¾"
3. 32mm x 1" 17. 90mm x 1" 31. 160mm x 1"
4. 50mm x ½" 18. 90mm x 1 ½" 32. 160mm x 1 ½"
5. 50mm x ¾" 19. 90mm x 2" 33. 160mm x 2"
6. 50mm x 1" 20. 110mm x ½" 34. 180mm x 3/4"
7. 63mm x ½" 21. 110mm x ¾" 35. 180mm x 1"
8. 63mm x ¾" 22. 110mm x1" 36. 180mm x 1 ½"
9. 63mm x 1" 23. 110mm x 1 ½" 37. 180mm x 2"
10. 75mm x ½" 24. 110mm x 2" 38. 225mm x ¾"
11. 75mm x ¾" 25. 125mm x ½" 39. 225mm x 1"
12. 75mm x 1" 26. 125mm x ¾" 40. 225mm x 1 ½" Single Outlet
13. 75mm x 1 ½" 27. 125mm x 1" 41. 225mm x 2"
14. 75mm x 2" 28. 125mm x 2"

9
 Fabricated Fittings
(Conform to Standards: MS 1058, ISO 4427, ASTM D3261, BS7291 & IS0 13953)

Z
Z
D

Z
r r
Z
Z D

Z Z
D D

Bends
D r Z (TEE)
Z (90o) Z (60o) Z (45o)

63 94 244 204 190 180

90 135 285 228 206 195

110 165 315 245 218 205

125 188 338 258 228 215

160 240 390 288 249 230

225 338 488 345 290 265

250 375 625 466 412 375

280 420 670 492 424 390

345 518 818 599 515 475

400 600 900 646 548 500

450 675 975 689 580 525

500 750 1100 783 665 600

560 840 1190 835 698 630

630 945 1295 896 741 665

10 POLYFLOW PIPES SDN BHD Company Profile

Backing Flanges
and Stub Ends

(Conform to Standards: (Conform to Standards:

ISO 9624 & ISO 7005-1) DIN 16963, GB/T 13663, ISO 4427,
ISO 4437, EN 1555 & EN 12201)

D
k
H1
d2
H2

Pipe Flange Flange Bolt Bolt No. Stub Stub

Size For Stub Outer Circle Hold of Bolt End End Rim
End Use Diameter Diameter Diameter Bolts Size OD Height Thickness
(mm) D (mm) k (mm) d2 (mm) No. (mm) A (mm) H1 (mm) H2 (mm)

63 50 165 125 18 4 M16 103 50 15

90 80 200 160 18 8 M16 140 80 20

110 100 220 180 18 8 M16 158 80 20

125 100 220 180 18 8 M16 158 80 25

160 150 285 240 22 8 M20 212 80 25

180 175 315 270 22 8 M20 242 80 30

225 200 340 295 22 12 M20 268 80 40

250 250 405 355 26 12 M24 320 80 40

280 250 405 355 26 12 M24 324 100 40

315 300 460 410 26 12 M24 378 100 50

345 300 460 410 26 12 M24 382 100 50

355 300 515 460 26 12 M24 430 120 50

400 350 520 470 26 16 M24 440 120 50

450 400 580 525 30 16 M27 492 120 50

500 450 640 585 30 20 M27 550 120 50

560 500 715 650 33 20 M30 614 120 50

630 600 840 770 36 20 M33 720 120 50

11
 Electrofusion Fittings
for Gas and Water Pipes

Terminal Electrofusion Coupling

Fusion Coil

Pipe Wall

Fusion Coil
Cold zone | Fusion zone | Cold zone

ELECTROFUSION FITTING SYSTEM

Electrofusion fittings feature a unique resistance The effectiveness of electrofusion depends on:
element design, in the form of heating wire embedded a) Preparation of the jointing surfaces.
on/within the outer layer in the inner wall of the
b) Ensuring that the surfaces to be welded have
fittings. The fusion is achieved in the following way:
satisfactory contact during the welding and
cooling cycles.
The fittings are fixed with barcode labels which
contain specification including pipe size, fusion
pressure, heating temperature, SDR, heating/fusion/ The pipe surfaces to be fused need to be scraped to
cooling times etc. A controller with processor unit remove the surface oxidation layer prior to fusion.
and barcode reader will scan the barcode labels,
start the fusion cycle and automatically monitor the To prepare the jointing surfaces, the pipe surface
electrofusion jointing process. When electric current must be scraped with an appropriate pipe scraper, as
is applied via an Automatic Controller equipped with recommended by the pipe or fitting manufacturer, to
power cord leads to the fittings, the plastic around the remove the entire surface of the pipe over the area
heating elements in the fitting and on the pipe surface indicated for the fitting, to a depth of approximately
begins to melt and form a melt pool. With continued 0.3mm. Metal files, rasps, emery paper & etc. are
application of current, the melt pool deepens at the not suitable preparation tools. The scraped surface
pipe and fitting interface which in turn forces internal must be wiped with the recommended isopropanol
pressures to build up. impregnated pipe wipe, as recommended by the pipe
or fitting manufacturer, to remove any dust residue.
The increasing material expansion between pipe and The prepared surfaces must be completely dry before
fitting, which is hindered by the cold zones outside proceeding.
the Fusion (Hot) zone, leads to a buildup of a welding
pressure between pipe and fitting and a homogeneous All electrofusion fittings/couplings (regardless of
welding connection emerges. manufacturer) require the pipe to be restrained or
sufficiently supported on each side of the pipe to:
This process is known as co-crystallization between a) Restrict movement during the fusion and cooling
the melted pipe and fitting material. Re-solidification process.
during cooling phase forms a fusion joint which is as b) Alleviate or eliminate sources of stress and/or
strong as the pipe itself. strain until both the fusion cycle and the cooling
cycle are completed.
As a result of this electro-fusion process, every joint
will be sealed precisely to specification, automatically,
every time, minimizing the risk of human error.

12 POLYFLOW PIPES SDN BHD Company Profile

Electrofusion Fittings
(Conform to Standards: BS EN12201-3, EN1555-3, ISO 4427-3 & ISO 4437-3)

ELECTROFUSION COUPLER
1. 20mm 6. 75mm 11. 180mm 16. 355mm
2. 25mm 7. 90mm 12. 225mm 17. 400mm
3. 32mm 8. 110mm 13. 250mm
4. 50mm 9. 125mm 14. 280mm
5. 63mm 10. 160mm 15. 315mm

ELECTROFUSION ELBOW
1. 20mm 5. 63mm 9. 125mm
2. 25mm 6. 75mm 10. 160mm
3. 32mm 7. 90mm 11. 180mm
4. 50mm 8. 110mm
45° ELBOW 90° ELBOW

ELECTROFUSION REDUCER
1. 32mm x 25mm 7. 63mm x 32mm 13. 110mm x 90mm 19. 125mm x 75mm
2. 32mm x 20mm 8. 63mm x 25mm 14. 110mm x 75mm 20. 125mm x 63mm
3. 50mm x 32mm 9. 63mm x 20mm 15. 110mm x 63mm 21. 160mm x 110mm
4. 50mm x 25mm 10. 90mm x 75mm 16. 110mm x 50mm 22. 160mm x 90mm
5. 50mm x 20mm 11. 90mm x 63mm 17. 125mm x 110mm 23. 180mm x 160mm
6. 63mm x 50mm 12. 90mm x 32mm 18. 125mm x 90mm

ELECTROFUSION EQUAL AND UNEQUAL TEE

1. 25mm x 25mm 9. 63mm x 32mm 17. 90mm x 32mm 25. 160mm x 160mm
2. 25mm x 20mm 10. 63mm x 25mm 18. 110mm x 110mm 26. 160mm x 125mm
3. 32mm x 32mm 11. 63mm x 20mm 19. 110mm x 90mm 27. 160mm x 110mm
4. 50mm x 25mm 12. 75mm x 75mm 20. 110mm x 75mm 28. 160mm x 90mm
5. 50mm x 20mm 13. 90mm x 90mm 21. 110mm x 63mm 29. 180mm x 180mm
6. 50mm x 75mm 14. 90mm x 75mm 22. 110mm x 50mm
7. 63mm x 63mm 15. 90mm x 63mm 23. 125mm x 125mm
8. 63mm x 50mm 16. 90mm x 50mm 24. 125mm x 63 mm

ELECTROFUSION SERVICE TAPPING TEE

1. 63mm x 32mm 6. 90mm x 32mm 11. 110mm x 20mm 16. 225mm x 50mm
2. 63mm x 25mm 7. 110mm x 63mm 12. 160mm x 63mm 17. 250mm x 63mm
3. 63mm x 20mm 8. 110mm x 50mm 13. 160mm x 50mm 18. 315mm x 63mm
4. 90mm x 63mm 9. 110mm x 32mm 14. 160mm x 32mm
5. 90mm x 50mm 10. 110mm x 25mm 15. 225mm x 63mm

ELECTROFUSION END CAP

1. 20mm 5. 63mm 9. 125mm
2. 25mm 6. 75mm 10. 160mm
3. 32mm 7. 90mm 11. 180mm
4. 50mm 8. 110mm

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14 POLYFLOW PIPES SDN BHD Company Profile