H E AT F U S I O N

JOINING PROCEDURES
 TA B L E O F C O N T E N T S

INTRODUCTION.........................................................................................1

FEDERAL REGULATIONS..............................................................................1

HEAT FUSION...............................................................................................2

INCLEMENT WEATHER..................................................................................3

NOTES ON FUSION CONFIDENCE......................................................................3

FUSION CHECKLIST.......................................................................................4

BUTT FUSION...............................................................................................5
Procedure.....................................................................................6
Qualification.................................................................................10

SADDLE FUSION.........................................................................................15
Definitions...................................................................................15
Procedure....................................................................................17
Qualification.................................................................................18

SOCKET FUSION.........................................................................................22
Equipment Requirements...................................................................22
Heater Temperature.........................................................................22
Procedure....................................................................................23
Qualification.................................................................................25

APPENDIX A................................................................................................29
Hydraulic Fusion Machine Gauge Pressure.................................................29

REFERENCES.............................................................................................30

FIGURES
FIGURE I – Butt Fusion Bent Strap Test Specimen...........................................10
FIGURE II – Saddle Fusion Bent Strap Test Specimen........................................18
FIGURE III – Socket Fusion Bent Strap Test Specimen.......................................25
TABLES
TABLE I – Butt Fusion: Approximate Melt Bead Size.......................................7
TABLE II – Butt Fusion: Maximum Heater Plate Removal Time..............................8
TABLE III – Butt Fusion: Bead Widths Per Wall Thickness.....................................9
TABLE IV – Butt Fusion: Troubleshooting Guide..........................................14
TABLE V – Saddle Fusion: Maximum Heating/Minimum Cooling Times................16
TABLE VI – Saddle Fusion: Troubleshooting Guide........................................21
TABLE VII – Socket Fusion: Time Cycles......................................................24
TABLE VIII – Socket Fusion: Troubleshooting Guide......................................28

The statements and technical data given in this brochure were developed on the basis of conservative test measures and are believed to be accurate. The
information is meant to serve only as a general guide; and the operator and/or any individual user must verify the specific parameters of each application for their
intended use and specific system. Due to wide variations in service conditions, installation techniques, field conditions, weather conditions, and other factors, NO
WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, IS GIVEN IN CONJUNCTION WITH THE USE OF THESE PROCEDURES.

In addition, this procedure does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this procedure
to establish any and all appropriate safety and health practices and to determine the applicability of regulatory requirements prior to use.
INTRODUCTION

An integral part of any pipe system is the method procedures that follow, electrofusion is recognized as
used to join the system components. Proper an acceptable method of producing socket and saddle
engineering design of a system will take into fusions but is not addressed in this document. The user
consideration the type and effectiveness of the of electrofusion products should contact the provider of
techniques used to join the pipe and appurtenances, as those products for details on use in joining pipe.
well as the durability of the
resulting joints. The integrity and versatility of the joining The fusion procedures that follow have been
techniques used for polyethylene (PE) pipe allow the proven to consistently produce sound fusion joints
designer to take advantage of the performance in bench trials when used correctly and are
benefits of PE in a wide variety of applications. recommended for the joining of PolyPipe® products.
The recommended procedures for butt and saddle
There are three types of heat fusion joints currently fusions are consistent with the Plastics Pipe Institute
used in the industry: butt, saddle and socket fusion. (PPI) Technical Reports (TR) TR-33, Generic Butt
Additionally, there are two methods for producing the Fusion Procedures and TR- 41, Generic Saddle
socket and saddle fusion joints. In addition to the Fusion Procedures.
fusion

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PolyPipe® POLYTOUGH1TM PolyPipe® EHMW PLUS
PolyPipe® GDY20 PolyPipe® POLYPLUS
PolyPipe® GDB50/GB50 PolypipE® LIGHTVIEW PLUSTM
POLYPIPE® ENVIROPIPE TM

FEDERAL REGULATIONS

Federal regulations require that all operators qualify both of their fusion joining processes and procedures are in
their joining procedures and the personnel installing compliance with the requirements of 49 CFR, Part 192
pipe. The Pipeline Safety Regulations, issued by the and ASTM standards.
U.S. Department of Transportation (DOT) Pipeline and
Hazardous Materials Safety Administration, are found
at 49 CFR Part 192. Pursuant to 49 CFR
192.283(a),
an operator is required to qualify heat fusion joining
procedures before the procedure is used in the field.
Further, 49 CFR Part 192.285 requires that an operator
qualify the personnel who will be making heat fusion
joints in the field. Additional Federal regulations may
apply, and State regulations that are corollaries to the
Pipeline Safety Regulations also apply, as may additional,
more stringent, state regulations.
The operator is responsible for ensuring that all aspects
1
Federal regulations require that all operators qualify
both their joining procedures and the personnel
installing pipe. The Pipeline Safety Regulations,
issued by the
U.S. Department of Transportation (DOT) Pipeline
and Hazardous Materials Safety Administration,
are found at 49 CFR Part 192. Pursuant to 49
CFR 192.283(a),
an operator is required to qualify heat fusion
joining procedures before the procedure is used in
the field. Further, 49 CFR Part 192.285 requires
that an operator qualify the personnel who will
be making heat fusion joints in the field.
Additional Federal regulations may apply, and
State regulations that are corollaries to the
Pipeline Safety Regulations also apply, as may
additional, more stringent, state regulations.
The operator is responsible for ensuring that all
aspects of their fusion joining processes and
procedures are in compliance with the
requirements of 49 CFR, Part 192 and ASTM
standards.

2
HEAT FUSION

The principle behind heat fusion is to heat two surfaces

to a designated temperature, and then fuse them
together by application of the required force. This
applied force joins the melted surfaces resulting in a
permanent, monolithic fusion joint. PolyPipe® fusion
procedures require specific tools and equipment for
the fusion type and for the sizes of pipe and fittings
to be joined.

Butt Fusion – This technique consists of heating

the squared ends of two pipes, a pipe and fitting,
or two fittings by holding them against a heated
plate, removing the plate when the proper melt
is obtained, promptly bringing the ends together
and allowing the joint to cool while maintaining Butt Fusion
the appropriate applied force.

Saddle Fusion – This technique involves melting

the concave surface of the base of a saddle
fitting, while simultaneously melting a matching
pattern on the surface of the pipe, bringing the two
melted surfaces together and allowing the joint
to cool while maintaining the appropriate applied
force.

Socket Fusion – This technique involves

simultaneously heating the outside surface of a
pipe end and the inside surface of a fitting Saddle Fusion
socket, which is sized to be smaller than the
smallest outside diameter of the pipe. After the
proper melt has been generated at each face to
be mated, the two components are joined by
inserting the pipe into the fitting. The fusion is
formed at the interface resulting from the
interference fit. The melts from the two
components flow together and fuse as the joint
cools.

Properly fused PE joints do not leak. If a leak is detected

during pneumatic or hydrostatic testing, it is possible for
a system failure to occur. Caution should be Socket Fusion
exercised
in approaching a pressurized pipeline and any attempts
to correct the leak should not be made until the system
has been depressurized.

Note: PE cannot be joined by solvent bonding or threading.

Extrusion welding or hot air welding is not recommended for
pressure applications.
3
INCLEMENT WEATHER automated

PE has reduced impact resistance in sub-freezing

conditions. Additional care should be exercised while
handling in sub-freezing conditions. In addition, PE pipe
will be harder to bend and/or uncoil.
For recommended guidelines when fusing in inclement
weather, refer to the Plastics Pipe Institute, PPI, Technical
Note TN-42: Recommended Minimum Training
Guidelines for PE Pipe Butt Fusion Joining
Operators for Municipal and Industrial Projects.
http://plasticpipe.org/pdf/tn-42-min-training-
guide-pe-butt-fusion.pdf These guidelines apply
to all applications.
Additional information concerning cold weather
procedures is available in ASTM F2620, Standard Practice
for Heat Fusion Joining of Polyolefin Pipe and Fittings,
Annex A1.
The operator should ensure that its qualified fusion
procedures take into account and are adapted for all
potential inclement weather conditions in which the
operator may be fusing polyethylene pipe.

NOTES ON FUSION CONFIDENCE

Reliable fusion joints of PE piping systems can be

accomplished under reasonable latitude of conditions.
The operator should qualify its own procedures for
every condition under which it will be fusing
polyethylene pipe. Additionally, the operator should
qualify all personnel who will responsible for performing
fusions of polyethylene pipe.

The following is a listing of general notes to help ensure

proper equipment and techniques are utilized:

1.The fusion operator must have adequate training

and understanding of the equipment and tools and
the fusion procedure.

Improper understanding of the operation of the

equipment and tools can produce a fusion of poor
quality. The operator must understand thoroughly
how to use the equipment and tools, their function
and operation. The operator should adhere to the
equipment manufacturer’s instructions.

Fusion pressures and heating/cooling cycles may vary

dramatically according to pipe size and wall
thickness. Operators should not rely exclusively on
4
fusion equipment for joint qualification. In addition, equipment components should be replaced or
visual inspection and qualification should always be repaired prior to fusing pipe.
made. If necessary, test fusions should be made to
determine correct pressures and heat/cool cycle times.
Destructive test methods, such as bend back tests, may
be necessary to formulate correct pressures and
heat/ cool cycle times (refer to Qualification
Procedures).

2.Pipe and fitting surfaces must be clean

and properly prepared.

Any contaminants present on the surfaces or poor

preparation of the surfaces can produce a poor
quality fusion joint. Ensure that all pipe and fitting
surfaces are clean. If surfaces are reintroduced to
contaminants, they should be cleaned again.

3.Heater plates must be clean, undamaged and

the correct surface temperature.

Heater surfaces are usually coated with a non-

stick material. Cleaning techniques should be
used accordingly. If a solvent is deemed
necessary, do not use gasoline or other petroleum
products. Refer to the equipment manufacturer’s
instructions for
proper cleaning products. It is important to regularly
clean the heater surface to remove any buildup of
PE material that will degrade due to extended
contact with the heater.

Recommended heating tool temperatures are

specified for each procedure. This temperature is
indicative of the surface temperature, not the heating
tool thermometer. The surface temperature should be
verified daily by using a surface pyrometer. If a crayon
indicator (melt stick) is used, it should not be used
in an area that will be in contact with the pipe or
fitting.

If the heater plate is not in use, it is recommended

that it be stored in an insulated holder. This not
only protects the heater surfaces from contaminants,
but it can also prevent inadvertent contact, which can
result in serious injuries.

4.Proper equipment and condition of tools and

equipment for the job

Each type of fusion requires special tools and

equipment. Fusions performed with the incorrect
fusion equipment, materials or tools and/or with fusion
equipment that has not been properly maintained
can result in a poor fusion. Any non-working
5
FUSION CHECKLIST

Inspect pipe lengths and fittings for unacceptable cuts, gouges, deep scratches or other defects. Damaged
products should not be used. Refer to PolyPipe® InfoBrief No. 2 for allowable surface damage according to the
Plastics Pipe Institute (PPI) and the American Gas Association (AGA).

The fusion contact area must be free of any defects or surface disruption.

Be sure all required tools and equipment are on site and in proper working order.

Pipe and fitting surfaces where tools and equipment are fitted must be clean and dry. Use clean, dry, non-
synthetic (cotton) cloths or paper towels to remove dirt, snow, water and other contaminants. If alcohol
is used, 99% reagent grade isopropyl alcohol is recommended. The standard “drug store variety” contains
impurities that can act as a contaminant to the fusion process.

Shield and/or cover fusion equipment and surfaces from inclement weather and winds. A temporary shelter
over fusion equipment and the fusion operation may be required.

Relieve tension in the line before making connections.

When joining coiled pipe, making an S-curve between pipe coils can relieve tension. In some cases, it may
be necessary to allow pipe to equalize to the temperature of its surroundings. Allow pulled-in pipes
to relax for several hours to recover from tensile stresses.

Pipes must be correctly aligned before making connections.

Trial fusions.
A trial fusion, preferably at the beginning of the day, can verify the fusion procedure and equipment
settings for the actual jobsite conditions. Refer to Qualification Procedures for detailed information on the
bend back test procedure.

6
BUTT FUSION

Heater Surface Temperature: Minimum 400oF – Maximum 450oF

Heating tool surfaces must be to temperature before you begin. All points on both heating tool
surfaces where the heating tool surfaces will contact the pipe or fitting ends must be within the prescribed
minimum and maximum temperatures and the maximum temperature difference between any two
points on the heating tool fusion surfaces must not exceed 20oF for equipment for pipe smaller than 18”
diameter, or
35oF for larger equipment. It is a good practice to set the heater plate to 425oF which can help keep normal
fluctuations between 400oF and 450oF. Heating tool surfaces must be clean.

Interfacial pressure: Minimum 60 psi – Maximum 90 psi

Interfacial pressure is used to calculate a fusion joining gauge pressure value for hydraulic butt fusion
machines or manual machines equipped with force reading capability. The interfacial pressure is constant
for all pipe sizes and all butt fusion machines. However, fusion joining gauge pressure settings are
calculated for each butt fusion machine, which are dependent upon the outside diameter (OD) and
dimension ratio (DR) and the piston area of the fusion machine.

For hydraulic machines, the interfacial pressure, the fusion surface area, the machine’s effective piston area
and frictional resistance, and if necessary, the pressure needed to overcome external drag resistance, are
used to calculate hydraulic fusion joining pressure gauge settings (refer to Appendix A). The
equipment manufacturer’s instructions are used to calculate this value. The proper amount of force should
be verified by visual inspection of the joint.

NOTE: The interfacial pressure and the hydraulic gauge pressure are not the same.

For manual machines without force reading capability, the correct fusion joining force is the force required to
roll the melt beads over until they contact the pipe surface as required by the joining procedure.

When joining pipes with different melt properties, such as bimodal MDPE to unimodal MDPE, apply sufficient
force to make the bimodal pipe fusion bead roll back and contact the pipe surface. Bimodal MDPE has a
lower melt flow ratio than unimodal pipe.

7
PROCEDURE

1.Secure
Clean the inside and outside of the pipe or fitting
(components) ends by wiping with a clean, dry,
lint- free cloth or paper towel. Remove all foreign
matter. Align the components in the machine,
place them in the clamps, and then close the
clamps. Do not force pipes into alignment
against open fusion clamps. Component ends
should protrude past the clamps enough so that
facing will be complete. Bring the ends together
and check high-low alignment. Adjust
alignment as necessary by tightening the high side down.
2.Face
Place the facing tool between the component ends,
and face them to establish smooth, clean, parallel
mating surfaces. Complete facing produces
continuous
circumferential shavings from both ends. Face until there
is minimal distance between the fixed and moveable
clamps. If the machine is equipped with facing stops,
face down to the stops. Stop the facer before moving
the pipe ends away from the facer. Remove the
facing tool, and clear all shavings and pipe chips
from the component ends. Do not touch the
component ends with your hands after facing.
3.Align
Bring the component ends together, check
alignment and check for slippage against fusion
pressure. Look for complete contact all around
both ends with no detectable gaps, and ODs in
high-low alignment. If necessary, adjust the high
side by tightening the high side clamp. Do not
loosen the low side clamp because
components may slip during fusion. Re-face if high-low
alignment is adjusted.
4.Melt
Verify that the contact surface of the heating tool is
maintaining the correct temperature. Place the
heating tool between the component ends, and move
the ends against the heating tool. Bring the
component ends together under pressure to ensure full
contact. The initial contact pressure should be held very
briefly and released without breaking contact.
Pressure should be reduced when evidence of melt
appears on the circumference of the pipe. Hold the
ends against the heating tool without force (drag force
8
may be necessary to ensure contact).
Beads of melted PE will form against the heating tool at
the component ends. When the proper melt bead
size is formed, quickly separate the ends and remove
the

9
heating tool. The proper bead size is dependent upon
the size of the component. Approximate values are
shown in Table I.

During heating, the melt bead will expand out flush

to the heating tool surface, or may curl slightly away
from the surface. If the melt bead curls significantly
away from the heating tool surface, unacceptable
pressure during heating may have occurred.

TABLE I
APPROXIMATE MELT BEAD SIZE

Approximate Wall Thickness, inches Melt Bead Size*

(Approximate)
≤ 0.15 1/32” – 1/16”
0.15 – 0.30 1/16”
Above 0.30 – 0.75 1/8” – 3/16”
Above 0.75 – 1.15 3/16” – 1/4”
Above 1.15 – 1.60 1/4” – 5/16”
Above 1.60 – 2.20 5/16” – 7/16”
Above 2.20 – 3.00 7/16” – 9/16”
*The appearance of the melt swell zone may vary depending on the pipe material. The melt bead width is to be
determined by measuring the distance from the heater plate to the melt swell origin.

5.Join
Immediately after the heating tool is removed, quickly
inspect the melted ends, which should be flat, smooth and
completely melted. If the melt surfaces are acceptable,
immediately and in a continuous motion, bring the ends
together and apply the correct joining force (or fusion
pressure). The correct fusion pressure will form a double
bead that is rolled over and contacts the pipe surface.the
surface on both ends.

A concave melt surface is unacceptable; it indicates pressure

during heating. Do not continue. Allow the component ends to
cool and start over with Step 1.

The maximum recommended time allowed for heater

plate removal is indicated in Table II.

10
 TABLE II
MAXIMUM HEATER PLATE REMOVAL TIMES

Pipe Wall Thickness, in Max. Heater Removal Time, sec

0.20 to 0.36 8
>0.36 to 0.55 10
>0.55 to 1.18 15
>1.18 to 2.5 20
>2.5 to 4.5 25

6.Hold
Maintain fusion gauge pressure until the joint is cool. The
joint is cool enough for gentle handling when the double
bead is cool to the touch. Cool for a minimum of 11
minutes per inch of pipe wall. Do not try to decrease the
cooling time by applying water, ice, wet cloths or the like.

Avoid pulling, installation, pressure testing and rough

handling for at least an additional 30 minutes.

For ambient temperatures above 100oF, longer cooling

times may be required.

7.Inspection
On both sides, the double bead should be rolled over to
the surface, and be uniformly rounded and consistent in
size all around the joint.

1.The gap (A) between the two single beads must

not be below the fusion surface throughout the
entire circumference of the butt joint.

2.The displacement (V) between the fused ends must

not exceed 10% of the pipe/fitting minimum wall
thickness.

3.Refer to Table III for general guidelines for

bead width, B, for each respective wall
thickness.

11
 TABLE III
BEAD WIDTHS PER WALL THICKNESS

Minimum Approximate Bead Width Minimum Wall Approximate Bead Width

Wall (B), in. Thickness, in. (B), in.
Thickness, in.
Minimum Maximum Minimum Maximum
.118 5/32 1/4 1.06 19/32 25/32
.157 5/32 9/32 1.18 5/8 13/16
.197 3/16 5/16 1.34 21/32 7/8
.246 1/4 11/32 1.57 11/16 29/32
.315 9/32 3/8 1.77 25/32 1
.354 5/16 7/16 1.97 7/8 1-1/16
.433 11/32 1/2 2.16 15/16 1-3/16
.512 3/8 9/16 2.36 1 1-1/4
.630 7/16 19/32 2.56 1-1/8 1-7/16
.710 1/2 5/8 2.76 1-3/16 1-1/2
.750 1/2 11/16 2.95 1-1/4 1-9/16
.870 1/2 11/16 3.15 1-5/16 1-11/16
.940 9/16 3/4 3.35 1-3/8 1-3/4
3.54 1-1/2 1-13/16

Instructions: Determine the wall thickness of the pipe/fitting. Find the wall thickness above. If the exact wall thickness is not
shown, use the next lowest wall thickness for determination of bead width.

4.The size differential (Smax – Smin) between

two single beads shall not exceed X% of the
combined bead width (B).

Where:
X = Percent difference of bead width, %
Pipe to pipe, maximum X =
10% Pipe to fitting, maximum X
= 20%
Fitting to fitting, maximum X = 20%
∆S = Smax - Smin, inches
B = Combined width of both fusion beads, inches

NOTE:
1. When butt fusing pipe to molded fittings, the fitting side bead may have an irregular appearance.
The different manufacturing processes used (extrusion vs molding) will cause the bead appearance to be
different when it rolls back. This is acceptable, provided the pipe side bead is correct. (See Images 1 & 2.)
2. When fusing unimodal MDPE pipe to bimodal MDPE pipe or HDPE pipe, the unimodal MDPE pipe bead
may be slightly larger than the bimodal MDPE or HDPE pipe bead. This occurs because of the
different melt properties of the resins. (See Images 3 & 4)
3. PolyPipe POLYTOUGH1™ has been successfully fused to a variety of pipes that may be in use in existing gas pipe
12
systems. Photos of these fusions are provided for visual reference. (See Images 5 thru 16)

13
QUALIFICATION

The following summarizes the ASTM methods to

which the operator and/or user should refer for
specific qualification requirements

1.Prepare a sample joint. Sample lengths should

be at least 6” or 15 times the minimum wall
thickness (see Figure I).
2.Observe the fusion process and verify
the recommended procedure for butt
fusion is being followed.
3. Visually inspect the sample joint for quality.
4.Allow the joint to cool completely.
5.Prepare the sample as shown in Figure I. The BEND BACK TESTING - NO GAPS OR
sample should be cut lengthwise into at least VOIDS
three longitudinal straps with a minimum of 1” or 1.5 (See Figure 1)
times the wall thickness in width. It is
recommended that four equally spaced strips be
cut, one from each quadrant of the pipe.
6. Visually inspect the cut joint for any
indications of voids, gaps, misalignment or surfaces
that have not been properly bonded.
7.Bend each sample at the weld with the inside of Figure I
the pipe facing out until the ends touch. The inside Butt Fusion Bent Strap Test Specimen
bend radius should be less than the minimum wall (Reference ASTM F2620)
thickness of the pipe. In order to successfully
complete the bend back, a vise may be needed.
For thick (>1”) wall pipe, contact PolyPipe®
Engineering for recommended procedures and test
apparatus.
8. The sample must be free of cracks and
separations within the weld location. If failure
does occur at
the weld in any of the samples, cut another sample
adjacent to the position the failed sample came
from and retest. If the second sample fails, then
the fusion procedure should be reviewed and
corrected. After correction, another sample fusion
should be made per the new procedure and re-
tested.

14
 ACCEPTABLE FUSIONS

BUTT FUSION

Unimodal HDPE fused to molded POLYTOUGH1TM fused to molded fitting

fitting

Unimodal MDPE fused to Unimodal MDPE fused to HDPE

POLYTOUGH1TM bimodal MDPE

PROPER ALIGNMENT AND DOUBLE ROLL-BACK BEAD

15
POLYTOUGH1TM BIMODAL MDPE JOINED TO VINTAGE AND CURRENT MATERIALS

Unimodal MDPE fused to POLYTOUGH1TM POLYTOUGH1TM fused to POLYTOUGH1TM

POLYTOUGH1TM fused to PLEXCO PE2306 POLYTOUGH1TM fused to PE3408

PE4710 fused to POLYTOUGH1TM DRISCO M8000 fused to POLYTOUGH1TM

DUPONT ALDYL A PE2306 fused to POLYTOUGH1TM

16
 UNACCEPTABLE FUSIONS

BUTT FUSION

Melt bead too small due to insufficient heat time Melt bead too large due to excessive heating and/or over
pressurization of joint

Misalignment Incomplete Facing

Pressure fluctuation, misalignment over pressurization

17
 TABLE IV
BUTT FUSION TROUBLESHOOTING GUIDE

Observed Condition Possible Cause

• Excessive double bead • Overheating

width
• Excessive joining force

• Double bead v-groove too • Excessive joining force

deep
• Insufficient heating
• Pressure during heating

• Flat top on • Excessive joining force

bead
• Overheating

• Non-uniform bead size around • Misalignment

pipe
• Defective heating tool
• Worn equipment
• Incomplete facing

• One bead larger than the • Misalignment

other
• Component slipped in clamp
• Worn equipment
• Heating iron does not move freely in
the axial direction
• Defective heating tool
• Incomplete facing
• Also possible when fusing bimodal pipes
to unimodal pipes

• Beads too • Insufficient heating

small
• Insufficient joining force

• Bead not rolled over to • Shallow v-groove – Insufficient heating

surface
& insufficient joining force
• Deep v-groove – Insufficient heating
& excessive joining force
• Bead on bimodal pipe may have slight
gap to the pipe surface

• Beads too large • Excessive heating time

• Square type outer bead edge • Pressure during

heating

• Rough, sandpaper-like, bubbly, or pockmarked melt bead surface

• Hydrocarbon spray paint fumes, etc.)
(gasoline vapors, contamination

14
SADDLE FUSION

Heater Surface Temperature: 500oF ± 10oF Interface Pressure: Minimum 54 psi – Maximum
(Minimum 490oF - Maximum 510oF) 66 psi

Heater tool surfaces must be up to temperature

before you begin. All points on both heating
tool surfaces where the heating tool surfaces
will contact the pipe and fitting must be
within the prescribed minimum and maximum
temperatures. Heater tool surfaces must be
clean.

DEFINITIONS

Initial Heat (Bead-up) Total Heat Time

The heating step used to develop a melt bead on the A time that begins when the heater is placed on
pipe. the pipe and initial heat force is applied and stops
when the
Initial Heat Force (Bead-up Force) heater is removed. Maximum heating times are shown
The force (pounds) applied to establish a melt pattern in Table IV for both pressure (hot tapping) and non-
on the pipe. The Initial heat force is determined by pressure fusion applications.
multiplying the fitting base area (in2) by the initial heat
interfacial pressure (psi). Cool Time
The time required to cool the joint to approximately
Heat Soak Force 120oF ± 10oF. The Fusion Force must be maintained
The force (pounds) applied after an initial melt pattern for 5 minutes on 1-1/4” IPS or 10 minutes for all other
is established on the pipe. The heat soak force is pipe sizes, after which the saddle fusion equipment
the can be removed. The joint must be allowed to cool
minimum force (essentially zero) that ensures the fitting, for an additional 30 minutes before tapping the pipe
heater and pipe stay in contact with each other. or joining to the branch outlet. Recommended
minimum cooling times are shown in Table IV.
Fusion Force
The force (pounds) applied to establish the fusion
bond between the fitting and the pipe. The fusion
force is determined by multiplying the fitting base area
(in2) by the fusion interfacial pressure (psi).

15
 TABLE V
MAXIMUM HEATING/MINIMUM COOLING TIMES

Pipe Size Maximum Heating Time Minimum Cooling Time

1-1/4” IPS 1/16” melt pattern visible around the base of the fitting. 5 min + 30 min
Do not exceed 15 seconds when hot tapping.

2” IPS 1/16” melt pattern visible around the base of the fitting. 10 min + 30 min
Do not exceed 35 seconds when hot tapping.

3” IPS & larger 1/16” melt pattern visible around the base of the fitting. 10 min + 30 min

INTERFACIAL AREA

Rectangular base fittings

The major width times the major length of the saddle base, without taking into account the curvature of the
base or sides, minus the area of hole in the center of the base.

Round base fittings

The radius of the saddle base squared times π (3.1416), without taking into account the curvature of the base
or sides, minus the area of the hole in the center of the base.

FITTING LABELS

The initial heat force, heat soak force and fusion force will be listed in the lower right-hand corner of the fitting
label for the majority of saddle fusion fittings. This eliminates the need to calculate the information in the field.
For
example, 80/0/40 represents the initial heat force, heat soak force and fusion force, respectively. If this information is
not located on the fitting, please contact the fitting manufacturer for the correct fusion parameters.

16
PROCEDURE 2.Heating

1.Preparation The heating and fusing process must be performed with

accuracy and efficiency, especially when fusing to a
This procedure requires the use of a saddle fusion pressurized main pipe.
tool. This tool must be capable of holding and
supporting the pipe, rounding the pipe for proper WARNING: Overheating or excessive time between these
alignment between the pipe and fitting, holding the two processes can have detrimental effects, including
fitting, and applying and indicating the proper force pipeline rupture.
during the fusion process.
The heater must be fitted with the correct heater
A.Install the saddle fusion tool on the pipe adapters.
according to the manufacturer’s instructions. The
tool should be centered over a clean, dry location The heater adapter fusion surface must be
where the fitting will be fused. Secure the tool to between 490oF to 510oF.
the pipe. A support is recommended under the Ensure the heating surfaces are clean.
pipe on 6” IPS and smaller pipe sizes.
Determine the saddle fusion force from the fitting
label or by calculation.
B.Abrade the surface of the pipe, where the fitting
will be joined, with a 50–60 grit utility cloth
A.Place the heating tool on the pipe centered
until
beneath the fitting base. Immediately move the
a thin layer of material is removed from the pipe
fitting against the heater faces, apply the initial heat
surface. The abraded area must be larger than the
force (see fitting label) and start the heat time.
area covered by the fitting base. After abrading,
Apply the initial heat force until melt is first
clean the residue away with a clean, dry cloth.
observed on the crown of the pipe main. “Initial
heat” is the term used to describe the initial
C.Abrade the fusion surface of the fitting with 50-
heating (bead-up) step to develop a melt bead on
60 grit utility cloth. Remove all dust and residue
the pipe and is usually 3-5 seconds, and then
with a clean, dry cloth. Insert the fitting in the
reduce the force to the heat soak force (bead-up
saddle fusion tool loosely. Using the saddle fusion
force) (see fitting label). Maintain the heat soak
tool, move the fitting base against the pipe and
force until the total heat time is complete.
apply about 100 pounds-force to seat the fitting.
Secure the fitting in the saddle fusion tool.
B.At the end of the total heat time, remove the
fitting from the heater and the heater from the
pipe with
a quick, snapping action. Quickly check for an
even melt pattern on the pipe and heated fitting
surfaces (no unheated areas). The total heat time
ends when one of the following conditions are
met:

i. Total heat time expires for a

pressurized 1-1/4” IPS or 2” IPS pipe,
or

ii. A melt bead of approximately 1/16” is

visible around the fitting base for a 1 1/4” IPS
or 2” IPS non-pressurized pipe, or a larger

17
pressurized or non-pressurized pipe.

18
3.Fusion and Cooling being followed.

Press the fitting onto the pipe (within 3 seconds) 3.Visually inspect the sample joint for quality.
after removing the heater and apply the Fusion Force
(see the fitting label). Maintain the fusion force on the
assembly for 5 minutes on 1-1/4” IPS and for 10
minutes for larger sizes. When this initial cooling time
has expired, the saddle fusion equipment may be
removed. Allow the assembly to cool for an
additional 30 minutes before handling or Tapping.

If the melt pattern was not satisfactory or if the

fusion bead is unacceptable, cut off the saddle fitting
above the base to prevent use, relocate to a new
section of main, and make a new saddle fusion using
a new fitting.

NOTE: The fusion force may need to be adjusted during the

initial cooling period; however, the fusion force should never be
reduced.

4.Inspection

Visually inspect the fusion bead around the entire base

of the fitting at the pipe. The fusion bead should
be
of uniform size. The fusion should have a “three-
bead” shape, which is characteristic of this type of
fusion. The first bead is the fitting base melt bead.
The second or outermost bead is the result of the
heater tool face on the pipe. The third bead, or center
bead, is the pipe melt bead. All beads should be of
uniform size with the first and third beads
approximately 1/8” and the second bead being generally
smaller.

QUALIFICATION

The following summarizes the ASTM methods to

which the operator and/or user should refer for
specific qualification requirements

1.Prepare at least two sample joints. The pipe

length should be a minimum of 2’ or seven times
the
maximum saddle fitting base dimension, whichever
is greater.

2.Observe the fusion process and verify the

recommended procedure for saddle fusion is
19
4.Allow the joint to cool completely (minimum
of one hour). The pipe sample should not be
tapped for this qualification process.

Figure II
Saddle Fusion Bent Strap Test
Specimen

5.Prepare test straps as shown in Figure II. Cut

the joint lengthwise along the main pipe and
through the saddle fitting.

6. Visually inspect the joint for any voids, gaps,

misalignment or surfaces that have not been properly
bonded.

7.Bend each test strap 180o with the inside

facing out.

8. The fusion joint must be free of cracks, voids,

gaps and separations.

9. Test the other sample joint by impact against

the saddle fitting. The failure must occur by either
tearing the fitting, bending the fitting at least 45o
or by removing a section of the pipe. Failure at the
fusion is not acceptable. This test is a Federal
requirement for qualification of fusion
procedures.

10.If failure does occur at the weld in any of

the samples, then the fusion procedure
should be reviewed and corrected. After
correction, another sample fusion should be
made per the new procedure and retested.

20
 ACCEPTABLE FUSIONS

Proper Alignment,
Melt and Force

Area where likely

gaps and voids
might occur Area where likely
gaps and voids
might occur

Bend Back Testing - No Gaps or

Voids (See Figure II)

21
 UNACCEPTABLE FUSIONS

Fitting Misalignment on Excessive Heating

pipe and/or Overpressurization
of joint

Insufficient Melt Excessive Force

22
 TABLE VI
SADDLE FUSION TROUBLESHOOTING GUIDE

Observed Condition Possible Cause

• Non-uniform bead size around fitting base • Misalignment

• Defective heating tool
• Fitting not secured in heating tool
• Heating temperature not within specified
range
• One bead larger than the other • Misalignment
• Heating temperature not within specified
range
• Fitting slipped in clamp
• Defective or worn equipment
• Beads too small • Insufficient heating
• Insufficient joining force

• Beads too large • Excessive heating time

• Excessive joining force

• Absence of third bead, or third • Incorrect pipe main

bead widely separated from center heating tool Insufficient joining
bead force
• Pressurized main blowout • Excessive heating
(beside base or through fitting base) • Heating temperature not within specified
range
• Incorrect heating tool faces
• Excessive time to start heating or in joining
the fitting to the main pipe after heating time
cycle
• Rough, sandpaper-like, • Hydrocarbon (gasoline vapors, spray
bubbly, or pockmarked melt bead paint fumes, etc.) contamination
surface

23
SOCKET FUSION

Equipment Requirements

In order to produce a quality socket fusion, the following

equipment is required for this procedure:

Apparatus – Socket fusion tools manufactured

in accordance with ASTM F1056.

Heating tool faces – Consisting of two parts, a

male end for the interior socket surface and a
female end for the exterior pipe surface.

Rounding clamps (cold ring) - Device to maintain

the roundness of the pipe and control the
depth of pipe insertion into the socket during
the joining operation.

Depth gauge – Proper positioning of the rounding

clamp.

Chamfering tool – Device to bevel the end of

the pipe. The depth gauge and chamfering tool
may be combined into a single tool.

Holding tools – Recommended for socket fusion of

2”IPS and larger pipe and fittings.

Heater Temperature

Heater Surface Temperature: Minimum 490oF –

Maximum 510oF

In order to obtain a proper melt, a uniform

temperature must be maintained across the
heating surface. All points on both heating
surfaces where the heating surfaces will
contact the pipe and fitting must be within the
prescribed minimum and maximum
temperatures. Heating tool surfaces must be
24
clean.

25
Procedure

1.Preparation

A.Verify heating temperature is within

the specified temperature range (490oF –
510oF).

B.Cut the pipe end squarely, and clean the

pipe end and fitting, both inside and out with a
clean, dry, lint-free cloth. Do not touch cleaned
surfaces with your hands.

C.Chamfer the outside edge of the pipe

end slightly. The pipe should be free of
debris and burrs.

D.Place the cold ring on the pipe as

determined by the depth gauge – Place the
depth gauge over the chamfered end of the
pipe. Clamp the cold ring immediately behind
the depth gauge.

2.Heating

A.Review the recommended heating times in

Table VI. The heating time begins after Step C
has been completed.

B.Insert the fitting onto the male heating face.

The fitting should be held against the back
surface of the male heater face.

C.Insert the pipe into the female heating

face. The female socket heating face should be
against the cold ring clamp.

D.Hold the pipe and fitting in place against

the heater faces for the recommended heating
time as shown in Table VI.

26
 TABLE VII
SOCKET FUSION TIME CYCLES

PE2708 PE4710
PolyPipe® GDY20 & POLYTOUGH1™ & PolyPipe®
Pipe Size fused to unimodal MDPE fittings POLYTOUGH1™ PE27081
fused to HDPE fittings

Heating Time Cooling Time Heating Time Cooling Time

seconds seconds seconds seconds

1/2” CTS 5–6 30 8 – 10 30

3/4” CTS 7–8 30 10 – 12 30
1” CTS 9 – 10 30 12 – 14 30
1/2” IPS 5–6 30 8 –10 30
3/4” IPS 8 – 10 30 12 – 14 30
1” IPS 10 – 12 30 14 – 16 30
1-1/4” IPS 12 – 14 45 18 – 20 60
1-1/2” IPS 12 – 14 45 18 – 20 60
2” IPS 16 – 20 45 22 – 26 60
3” IPS 20 – 25 60 25 – 30 75
4” IPS 25 – 30 60 30 - 35 75

Notes: If an incomplete bead rollout is noticed when joining PolyTough1 to unimodal socket fittings, PolyPipe® recommends the use
of bimodal MDPE fittings HDPE fittings or other means of joining the pipe.

3.Fusion and Cooling D.Allow the joint to cool an additional five (5)
minutes before removing the cold ring. An
A.At the end of the heating time, simultaneously additional 10 minutes of cooling time is
remove the pipe and fitting straight out from the tool recommended before exposing the joint to any
using a “snap” action. Do not torque or twist the type of stresses (i.e., burial or testing).
pipe or fitting during removal.
4.Inspection
B.A QUICK inspection should be made of the
melt pattern on the pipe end and fitting socket. If Visually inspect the weld. A complete impression of
there is evidence of an incomplete melt pattern, the rounding clamp should be visible in the melt
do not continue with the fusion procedure. pattern at the end of the socket. There should be no
gaps, voids or unbonded areas.
C.Immediately insert the pipe straight into the
socket of the fitting so that the cold ring is flush
against the end of the fitting socket. While
cooling, pressure should be maintained on the
fusion per the recommended cooling time shown
in Table VI.

27
Qualification

The following summarizes the ASTM methods to

which the operator and/or user should refer for 6. Visually inspect the cut joint for any
specific qualification requirements indications of voids, gaps, misalignment or surfaces
that have not been fused.
1.Prepare a sample joint such as a coupling with
pipe socket fused to both ends. The pipe should 7.Bend each test strap 180o with the inside of
be at least 6” or 15 times the wall thickness in the pipe facing out.
length.
8. The fusion joint must be free of cracks,
2.Observe the fusion process and verify the voids, gaps and separations. If failure does occur
recommended procedure for socket fusion is at the weld in any of the samples, then the fusion
being followed. procedure should be reviewed and corrected. After
correction, another sample weld should be made
3.Visually inspect the sample joints for quality. per the new procedure and retested.

4.Allow the sample to cool completely (minimum

of one hour).

Figure III
Socket Fusion Bent Strap Test
Specimen

5.Prepare test straps as shown in Figure III. Cut the

joints lengthwise into at least three longitudinal
straps with a minimum of 1” or 1.5 times the
wall thickness in width.

28
 ACCEPTABLE FUSIONS

SOCKET FUSION

Proper Alignment and Stab Depth

Melt Bead Flattened Due to Cold Ring - No gaps or voids

Area where likely Area where likely

gaps and voids gaps and voids
might occur might occur

Bend Back Testing - No Gaps or

Voids (See Figure III)

29
 UNACCEPTABLE FUSIONS

SOCKET FUSION

Short Stab Depth Excessive Stab Depth

Caused by Failure to Use a Depth Gauge Caused by Failure to Use a Cold
Ring

Socket Fusion

30
 TABLE VIII
SOCKET FUSION TROUBLESHOOTING GUIDE

Observed Condition Possible Cause

• No evidence of cold-ring • Insufficient heating time

impression in socket fitting melt •Depth gauge not used
bead • Cold ring not used
• Cold ring set at incorrect depth

• Gaps or voids around • Pipe or fitting not

the pipe at the socket fitting removed straight from heater face
edge • Components not joined together
straight when fusing
• Cold ring not used
• Cold ring set at incorrect depth

• Wrinkled or collapsed pipe end • Cold ring not utilized

• Cold ring set at incorrect depth
• Incorrect heating sequence

• Voids in fusion bond area • Pipe or fitting not removed straight from
heater face
• Components not joined together
straight when fusing
• Cold ring not used
• Cold ring set at incorrect depth
• Unbonded area on pipe at end of pipe • Cold ring not used
• Cold ring set too deep

• Socket melt extends past end of pipe • Cold ring set too shallow

• Rough, sandpaper-like, bubbly, or • Hydrocarbon (gasoline vapors, spray

pockmarked melt bead surface paint fumes, etc.) contamination

31
APPENDIX A

HYDRAULIC FUSION MACHINE GAUGE PRESSURE

The manufacturer of the fusion machine should be consulted for guidance in determining the proper conversion of
PolyPipe®’s recommended interfacial pressure to the gauge pressure. The effective hydraulic piston area must be
available in order to calculate the required hydraulic gauge pressure. The calculation for hydraulic gauge pressure is as
follows:

Where PG = Hydraulic gauge pressure, psi

OD = Pipe outside diameter, inches
ID = Pipe inside diameter, inches
PI = Required interfacial pressure, psi
AP = Total hydraulic piston area, in2
DF = Hydraulic fusion pressure required to move the carriage holding the pipe
(generally accepted minimum is 30 psi).

* The drag factor is an important parameter easily overlooked. If two long pieces of pipe are being fused, the drag
factor can easily reach several hundred pounds per square inch (psi).

Example Calculations

Fusion Machine: McElroy Manufacturing 28 High Force Machine

Hydraulic piston area is provided by the fusion equipment manufacturer.
Total hydraulic piston area for this machine is 4.71 in2

Desired Interfacial Pressure: 75psi

For 2” IPS SDR 11:

32
REFERENCES

1. Plastics Pipe Institute Technical Report-33. Generic Butt Fusion Joining Procedure for Polyethylene Gas Pipe, 2006.
www.plasticpipe.org

2. Plastics Pipe Institute Technical Report-41. Generic Saddle Fusion Joining Procedure for Polyethylene Gas Piping,
2002. www.plasticpipe.org

3. Plastics Pipe Institute Technical Note – 42. Recommended Minimum Training Guidelines for PE Pipe Butt Fusion J
oining Operators for Municipal and Industrial Projects, 2009. www.plasticpipe.org

4. ASTM F2620-11. Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings. www.astm.org

5. ASTM F1056-11. Standard Specification for Socket Fusion Tools for Use in Socket Fusion Joining Polyethylene
Pipe or Tubing and Fittings. www.astm.org

6. Pipeline Safety Regulations. U.S. Department of Transportation. CFR 49. Washington, June 2011.
http://ecfr. gpoaccess.gov/cgi/t/text/text-idx?c=ecfr&tpl=/ecfrbrowse/Title49/49cfr192_main_02.tpl

33
NOTES
NOTES
Corporate Headquarters, Gainesville, Tx Gainesville, Tx
Plant Sandersville, GA Plant

2406 N. 1-35 995 Waco Mill Road

Gainesville, TX 76240 Tennille, GA 31089

Physical: 2406 N. 1-35

Gainesville, TX 76240 Midland, Tx Erwin, TN Plant
Plant
1-800.433.5632
940.665.1721
Fax: 940.668.8612
Evansville, WY Plant

polypipeinc.com • polytough1.com

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