PolyPipe ®

R E C O M M E N D E D

Heat Fusion
Joining Procedures
TABLE OF CONTENTS

INTRODUCTION 1

FEDERAL REGULATIONS 1

QUALIFICATION PROCEDURE 2

HEAT FUSION 2

INCLEMENT WEATHER 3

NOTES ON FUSION CONFIDENCE 4

FUSION CHECKLIST 5

BUTT FUSION 6

PROCEDURE 6
QUALIFICATION 10

SADDLE FUSION 14

DEFINITIONS 14
PROCEDURE 15
QUALIFICATION 17

SOCKET FUSION 21

EQUIPMENT REQUIREMENTS 21
HEATER TEMPERATURE 21
PROCEDURE 21
QUALIFICATION 23

APPENDIX A 27

HYDRAULIC FUSION MACHINE GAUGE PRESSURE 27

REFERENCES 28
FIGURES NOTES:

FIGURE I – BUTT FUSION BENT STRAP TEST SPECIMEN 10

FIGURE II – SADDLE FUSION BENT STRAP TEST SPECIMEN 17

FIGURE III – SOCKET FUSION BENT STRAP TEST SPECIMEN 23

TABLES

TABLE I – BUTT FUSION: APPROXIMATE MELT BEAD SIZE 7

TABLE II – BUTT FUSION: BEAD WIDTHS PER WALL THICKNESS 9

TABLE III – BUTT FUSION: TROUBLESHOOTING GUIDE 13

TABLE IV – SADDLE FUSION: MAXIMUM HEATING/MINIMUM COOLING TIMES 15

TABLE V – SADDLE FUSION: TROUBLESHOOTING GUIDE 20

TABLE VI – SOCKET FUSION: TIME CYCLES 22

TABLE VII – SOCKET FUSION: TROUBLESHOOTING GUIDE 26

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; however, the individual user is encouraged to
verify the specific parameters of each application. Due to wide variations in service conditions, quality of installation, etc., no
warranty or guarantee, expressed or implied, is given in conjunction with the use of this material.

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 appropriate safety and health practices and to determine the applicability of
regulatory limitations prior to use.
INTRODUCTION
An integral part of any pipe system is the method used to join the system components. Proper
engineering design of a system will take into consideration the type and effectiveness of the
techniques used to join the piping components and appurtenances, as well as, the durability of
the resulting joints. The integrity and versatility of the joining techniques used for polyethylene
pipe allow the designer to take advantage of the performance benefits of polyethylene in a wide
variety of applications.

There are three types of heat fusion joints currently used in the industry: Butt, Saddle and
Socket Fusion. Additionally, there are two methods for producing the socket and saddle fusion
joints. In addition to the fusion procedures that follow, electrofusion is recognized as an
acceptable method of producing socket and saddle fusions but is not addressed in this
document.

The fusion procedures that follow have been proven to consistently produce sound fusion joints
when used correctly and are recommended for the joining of PolyPipe® products. The
recommended procedures for butt and saddle fusions are consistent with the Plastic Pipe
Institute (PPI) TR-33, Generic Butt Fusion Procedures and TR-41, Generic Saddle Fusion
Procedures.

POLYPIPE® PRODUCTS
GAS DISTRIBUTION M&I, WATER AND SPECIALTY
POLYPLUSTM
POLYPIPE® GDB50 (GB50) POLYPIPE® EHMW PLUS
POLYPIPE® GDB40 (GB40) POLYPIPE® EHMW
POLYPIPE® GDB30 (GB30) POLYPIPE® PW
POLYPIPE® GDY20 POLYPIPE® DUCT
POLYPIPE® LIGHTVIEW™

FEDERAL REGULATIONS
Individuals who are involved in joining gas piping systems must note certain qualification
requirements of the U.S. Department of Transportation Pipeline Safety Regulations. The U.S.
Department of Transportation, D.O.T., requires that all persons who make fusion joints in
polyethylene gas piping systems must be qualified under the operator’s written procedures (49
CFR, Part 192, §192.293(a)), and require that gas system operators ensure that all persons
who make fusion joints are qualified (49 CFR, Part 192, §192.285(d)).

These fusion joining procedures, when used to join PolyPipe® gas pipe and fittings, are qualified
in accordance with U.S. Department of Transportation Regulations.

8 D.O.T. regulations require that written procedures for butt fusion, saddle fusion and socket
fusion joining of polyethylene gas piping must be qualified before use by subjecting
specimen joints to required test procedures (CFR 49, Part 192, §192.283(a)).

8 D.O.T. regulations require that each joint in a gas piping system must be made in
accordance with written procedures that have been proved by testing to produce strong
gastight joints (CFR 49, Part 192, §192.273(b)).

1
8D.O.T. regulations require that all persons who make joints in polyethylene gas piping must APPENDIX A
be qualified under the operator’s written procedures (CFR 49, Part 192, §192.285(a)).

8D.O.T. regulations require that the gas system operator must ensure that all persons who HYDRAULIC FUSION MACHINE GAUGE PRESSURE
make or inspect joints are qualified (CFR 49, Part 192, §192.285(d) & §192.287).
The manufacturer of the fusion machine should be consulted for guidance in determining the
Where an operator is already using qualified procedures that are in compliance with the D.O.T., proper conversion of PolyPipe®’s recommended interfacial pressure to the gauge pressure. The
these recommended procedures do not constitute a requirement for that operator to change to effective hydraulic piston area must be available in order to calculate the required hydraulic
these fusion procedures. gauge pressure. The calculation for hydraulic gauge pressure is as follows:

0.785 u OD 2  ID 2 u PI
PG  DF
Qualification Procedure AP
Due to the requirements of the U.S. Department of Transportation, any person joining
Where PG = Hydraulic Gauge Pressure, psi
polyethylene gas pipe must receive training in each of the fusion procedures (49 CFR, Part
OD = Pipe outside diameter, inches
192). Each operator should make a sample joint for each procedure used. Each sample joint
ID = Pipe inside diameter, inches
must pass the following inspections and tests:
PI = Required interfacial pressure, psi
AP = Total hydraulic piston area, in2
1. Pressure and tensile testing as described in §192.283, CFR,
DF = Hydraulic fusion pressure required to move the carriage holding the
2. Ultrasonically inspected and found to contain no flaws, or
pipe (generally accepted minimum is 30 psi).
3. Cut into at least three (3) strips, each of which is:
*The drag factor is an important parameter easily overlooked. If two long pieces of pipe are
(a) Visually examined and found free of voids or discontinuity on the cut surface of the
being fused, the drag factor can easily reach several hundred pounds per square inch (psi).
joint.
(b) Deformed by bending, torque or impact, and if failure occurs, must not initiate in the
joint area.

A person must be re-qualified under an applicable procedure during a 12-month period for the
following conditions:

1. The individual does not make any joints under the procedure.
2. The individual has three (3) joints or 3% of the joints made, whichever is greater, that are
found to be unacceptable by §192.513, CFR.

Each operator shall establish a method to determine that each person making a joint in plastic
pipelines in his/her system is qualified in accordance with this section.

HEAT FUSION
The principle behind heat fusion is to heat two surfaces to a designated temperature, and then
fuse them together by application of a sufficient force. This applied force causes the melted
materials to flow and mix, resulting in a permanent, monolithic fusion joint. When fused
according to the recommended procedures, the fusion or joint becomes as strong as or stronger
than the pipe itself in both tensile and pressure properties. PolyPipe® fusion procedures require
specific tools and equipment for the fusion type and for the sizes of pipe and fittings to be
joined.

ƒ 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 the appropriate applied force.

2 27
 Table VII ƒ Saddle Fusion – This technique involves melting the concave surface of the base of a
Socket Fusion Troubleshooting Guide 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
Observed Condition Possible Cause appropriate applied force.
ƒ Insufficient heating time
ƒ No evidence of cold-ring ƒ Socket Fusion – This technique involves simultaneously heating the outside surface of a
ƒ Depth gauge not used
impression in socket fitting pipe end and the inside of a fitting socket, which is sized to be smaller than the smallest
ƒ Cold ring not used
melt bead outside diameter of the pipe. After the proper melt has been generated at each face to be
ƒ Cold ring set at incorrect depth
mated, the two components are joined by inserting one component into the other. The
ƒ Pipe or fitting not removed straight from heater face fusion is formed at the interface resulting from the interference fit. The melts from the two
ƒ Gaps or voids around the
ƒ Components not joined together straight when fusing components flow together and fuse as the joint cools.
pipe at the socket fitting
ƒ Cold ring not used
edge
ƒ Cold ring set at incorrect depth
Properly fused polyethylene joints do not leak. If a leak is detected during hydrostatic testing, it
ƒ Cold ring not utilized
is possible for a system failure to occur. Caution should be exercised in approaching a
ƒ Wrinkled or collapsed pipe pressurized pipeline and any attempts to correct the leak should not be made until the system
ƒ Cold ring set at incorrect depth
end has been depressurized.
ƒ Incorrect heating sequence

ƒ Pipe or fitting not removed straight from heater face

Note: Polyethylene cannot be joined by solvent bonding or threading. Extrusion welding or hot
ƒ Components not joined together straight when fusing
ƒ Voids in fusion bond area air welding is not recommended for pressure applications.
ƒ Cold ring not used
ƒ Cold ring set at incorrect depth
ƒ Unbonded area on pipe at ƒ Cold ring not used
end of pipe ƒ Cold ring set too deep INCLEMENT WEATHER
ƒ Socket melt extends past
ƒ Cold ring set too shallow Polyethylene has reduced impact resistance in sub-freezing conditions. Additional care should
end of pipe
ƒ Rough, sandpaper-like, be exercised while handling in sub-freezing conditions. In addition, polyethylene pipe will be
ƒ Hydrocarbon (gasoline vapors, spray paint fumes, harder to bend or uncoil.
bubbly, or pockmarked
etc.) contamination
melt bead surface
In inclement weather and especially in windy conditions, the fusion operation should be shielded
to avoid precipitation or blowing snow and excessive heat loss from wind chill. The heating tool
should also be stored in an insulated container to prevent excessive heat loss. Remove all
frost, snow or ice from the OD and ID of the pipe; all surfaces must be clean and dry prior to
fusing.

The time required to obtain the proper melt may increase when fusing in cold weather. The
following recommendations should be followed:

1. Maintain the specified heating tool surface temperature. Do not increase the tool
surface temperature.
2. Do not apply pressure during zero pressure butt fusion heating steps.
3. Do not increase the butt fusion joining pressure.

In butt fusion, melt bead size determines heating time; therefore, the procedure automatically
compensates when cold pipe requires longer time to form the proper melt size.

The outside diameter of polyethylene pipe and fittings will contract in cold weather conditions.
This can result in loose or slipping cold rings. For best results, clamp one cold ring in its normal
position adjacent to the depth gage. Shim around the pipe behind the clamp with paper, tape,
etc., and place a second cold ring over this area. This cold ring will prevent slippage while the
inner cold ring will allow for the pipe to expand during the heating cycle of the fusion process.

26 3
The proper cycle time for any particular condition can be determined by making a melt pattern Socket Fusion
on a piece of scrap pipe using the recommended standard heating time. If the melt pattern is
incomplete, increase the heating time by three (3) second intervals until a complete melt pattern
is established. Each time the procedure is repeated, a new piece of scrap pipe should be used. UNACCEPTABLE FUSIONS
For additional information concerning cold weather procedures, refer to ASTM D2657, Standard
Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings, Annex A1.

NOTES ON FUSION CONFIDENCE

Reliable fusion joints of polyethylene piping systems can be accomplished under reasonable
latitude of conditions. 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.

Contact pressures and heating/cooling cycles may vary dramatically according to pipe size
and wall thickness. Operators should not rely exclusively on automated fusion equipment Short stab depth caused by failure to use Excessive stab depth caused by failure to
for joint qualification. In addition, visual inspection and qualification should always be made. a depth gauge. use a cold ring.
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 cannot
produce a 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.

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. Misalignment.
This not only protects the heater surfaces from contaminants, but it can also prevent
inadvertent contact, which can result in serious injuries.

4 25
Socket Fusion 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 can result in a poor fusion.
ACCEPTABLE FUSIONS
Fusion Checklist
ˆ 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. 17 for
allowable surface damage according to the Plastics Pipe Institute (PPI) and the American
Gas Association (AGA).

ˆ Any surface damage at pipe ends that could compromise the joining surfaces or interfere
with fusion tools and equipment should be removed.

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

ˆ 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.

ˆ Shield heated fusion equipment and surfaces from inclement weather and winds. A
temporary shelter over fusion equipment and the operation may be required.

Proper alignment and stab depth. Melt bead flattened due to cold ring. No gaps or voids. ˆ 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.

ˆ Pipes must be correctly aligned before making connections.

ˆ 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.

Bend back testing. No gaps or voids.

(See Figure III)

24 5
BUTT FUSION Qualification

ˆ Heater Surface Temperature: Minimum 400oF – Maximum 450oF (204 – 232oC) 1. Prepare a sample joint such as a coupling with pipe socket fused to both ends. The pipe
should be at least 6” or 15 times the wall thickness in length.
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 2. Observe the fusion process and verify the recommended procedure for socket fusion is
within the prescribed minimum and maximum temperatures and the maximum temperature being followed.
difference between any two points on the heating tool fusion surfaces must not exceed 20oF
(11oC) for equipment for pipe smaller than 18” diameter, or 35oF (19oC) for larger 3. Visually inspect the sample joints for quality.
equipment. Heating tool surfaces must be clean.
4. Allow the sample to cool completely (minimum of one hour).
ˆ Interface pressure :: Minimum
Minimum 60
60 psi
psi –– Maximum
Maximum 90
90 psi
psi (414
(414 –– 621
621 kPa;
kPa; 4.16
4.16 –– 6.21
6.21 bar)
bar)
5. Prepare test straps as shown in Figure III. Cut the joints lengthwise into at least three
Interface pressure is used to calculate a fusion joining pressure value for hydraulic butt longitudinal straps with a minimum of 1” or 1.5 times the wall thickness in width.
fusion machines or manual machines equipped with force reading capability. The interface
pressure is constant for all pipe sizes and all butt fusion machines. However, fusion joining
pressure settings are calculated for each butt fusion machine, which are dependent upon Figure III
the OD and DR (Dimension Ratio). Socket Fusion Bent Strap Test Specimen
(Reference ASTM D2657)
For hydraulic machines, the interface 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 interface 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 to the pipe surface during joining.

Procedure

1. Secure 6. Visually inspect the cut joint for any indications of voids, gaps, misalignment or surfaces that
Clean the inside and outside of the component, pipe or fitting ends by wiping with a clean, have not been fused.
dry, lint-free cloth or paper towel. Remove all foreign matter. Align the components of the
machine, place them in the clamps, and then close the clamps. Do not force pipes into 7. Bend each test strap 180o with the inside of the pipe facing out.
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 8. The fusion joint must be free of cracks, voids, gaps and separations. If failure does occur at
alignment. Adjust alignment as necessary by tightening the high side down. the weld in any of the samples, then the fusion procedure should be reviewed and
corrected. After correction, another sample weld should be made per the new procedure
2. Face and re-tested.
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.

6 23
 B. Insert the fitting onto the male heating face. The fitting should be held against the back 3. Align
surface of the male heater face. 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
C. Insert the pipe into the female heating face. The female socket heating face should be outside diameters in high-low alignment. If necessary, adjust the high side by tightening the
against the cold ring clamp. high side clamp. Do not loosen the low side clamp because components may slip during
fusion. Re-face if high-low alignment is adjusted.
D. Hold the pipe and fitting in place against the heater faces for the recommended heating
time as shown in Table VI. 4. Melt
Verify that the contact surface of the heating tool is maintaining the correct temperature.
Table VI Place the heating tool between the component ends, and move the ends against the heating
Socket Fusion Time Cycles 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.
PE2406 PE3408 Pressure should be reduced when evidence of melt appears on the circumference of the
Pipe Size pipe. Hold the ends against the heating tool without force (drag force may be necessary to
Heating Time, Cooling Time, Heating Time, Cooling Time, ensure contact). Beads of melted polyethylene will form against the heating tool at the
seconds seconds seconds seconds component ends. When the proper melt bead size is formed, quickly separate the ends,
1/2” CTS 5–6 30 8 – 10 30 and remove the heating tool. The proper bead size is dependent upon the size of the
3/4” CTS 7–8 30 10 – 12 30 component. Approximate values are shown in Table I.
1” CTS 9 – 10 30 12 – 14 30
1/2” IPS 5–6 30 8 –10 30 Table I
3/4” IPS 8 – 10 30 12 – 14 30 Approximate Melt Bead Size
1” IPS 10 – 12 30 14 – 16 30
1-1/4” IPS 12 – 14 45 18 – 20 60 Melt Bead Size*
Approximate Wall Thickness, inches
1-1/2” IPS 12 – 14 45 18 – 20 60 (Approximate)
2” IPS 16 – 20 45 22 – 26 60 ” 0.15 3.8 mm and smaller 1/32” – 1/16” 1 – 2 mm
3” IPS 20 – 25 60 25 – 30 75 0.15 – 0.30 3.8 mm – 7.6 mm 1/16” 2 mm
4” IPS 25 – 30 60 30 - 35 75 Above 0.30 – 0.75 Above 7.6 mm – 19 mm 1/8” – 3/16” 3 – 5 mm
Above 0.75 – 1.15 Above 19 mm – 29.2 mm 3/16” – 1/4” 5 – 6 mm
3. Fusion and Cooling Above 1.15 – 1.60 Above 29.2 mm – 40.6 mm 1/4” – 5/16” 6 – 8 mm
A. At the end of the heating time, simultaneously remove the pipe and fitting straight out Above 1.60 – 2.20 Above 40.6 mm – 55.9 mm 5/16” – 7/16” 8 – 11 mm
from the tool using a “snap” action. Do not torque or twist the pipe or fitting during Above 2.20 – 3.00 Above 55.9 mm – 76.2 mm 7/16” – 9/16” 11 mm
removal. *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
B. A QUICK inspection should be made of the melt pattern on the pipe end and fitting plate to the melt swell origin.
socket. If there is evidence of an incomplete melt pattern, do not continue with the
fusion procedure.
During heating, the melt bead will expand out flush to the heating tool surface, or may curl
C. Immediately insert the pipe straight into the socket of the fitting so that the cold ring is slightly away from the surface. If the melt bead curls significantly away from the heating tool
flush against the end of the fitting socket. While cooling, pressure should be maintained surface, unacceptable pressure during heating may have occurred.
on the fusion per the recommended cooling time shown in Table VI.
5. Join
D. Allow the joint to cool an additional five (5) minutes before removing the cold ring. An Immediately after the heating tool is removed, quickly inspect the melted ends, which
additional 10 minutes of cooling time is recommended before exposing the joint to any should be flat, smooth and completely melted. If the melt surfaces are acceptable,
type of stresses (ie., burial or testing). 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
4. Inspection rolled over to the surface on both ends.
Visually inspect the weld. A complete impression of the rounding clamp should be visible in
the melt pattern at the end of the socket. There should be no gaps, voids or unbonded A concave melt surface is unacceptable; it indicates pressure during heating. Do not
areas. continue. Allow the component ends to cool and start over with Step 1.

22 7
6. Hold SOCKET FUSION
Hold joining force against the ends until the joint is cool. The joint is cool enough for gentle
handling when the double bead is cool to the touch. Cool for about 30 – 90 seconds per Equipment Requirements
inch of pipe diameter. Do not try to decrease the cooling time by applying water, wet cloths
or the like. In order to produce a quality socket fusion, the following equipment is required for this
ˆ Avoid pulling, installation, pressure testing and rough handling for at least an additional
procedure:
30 minutes.
ˆ Apparatus – Socket fusion tools manufactured in accordance with ASTM F1056.
ˆ Heavier wall thickness pipes require longer cooling times.
ˆ Heating Tool Faces – Consisting of two parts, a male end for the interior socket surface and
7. Inspection a female end for the exterior pipe surface.
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. ˆ 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.
1. The gap (A) between the two single beads must not be below the fusion surface
throughout the entire circumference of the butt joint. ˆ Depth Gauge – Proper positioning of the rounding clamp.

ˆ Chamfering Tool – Device to bevel the end of the pipe. The depth gauge and chamfering
tool may be combined into a single tool.

ˆ Holding Tools – Recommended for socket fusion of 2”IPS

IPS and larger pipe and fittings.

Heater Temperature

ˆ Heater Surface Temperature: Minimum 490oF – Maximum 510oF (254 – 266oC)

2. The displacement (V) between the fused ends must not exceed 10% of the pipe/fitting
minimum wall thickness.
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 clean.

Procedure

1. Preparation
A. Verify heating temperature is within the specified temperature range (490oF – 510oF).
3. Refer to Table II for general guidelines for bead width, B, for each respective wall
thickness.
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.

8 21
 Table V Table II
Saddle Fusion Troubleshooting Guide Bead Widths per Wall Thickness

Observed Condition Possible Cause Minimum

Approximate Bead Approximate Bead
ƒ Misalignment Wall Minimum Wall
Width (B), in. Width (B), in.
ƒ Non-uniform bead size around ƒ Defective heating tool Thickness, Thickness, in.
fitting base ƒ Fitting not secured in heating tool in. Minimum Maximum Minimum Maximum
ƒ Heating temperature not within specified range .118 5/32 1/4 1.06 19/32 25/32
ƒ Misalignment .157 5/32 9/32 1.18 5/8 13/16
ƒ Heating temperature not within specified range .197 3/16 5/16 1.34 21/32 7/8
ƒ One bead larger than the other
ƒ Fitting slipped in clamp .246 1/4 11/32 1.57 11/16 29/32
ƒ Defective or worn equipment .315 9/32 3/8 1.77 25/32 1
ƒ Insufficient heating .354 5/16 7/16 1.97 7/8 1-1/16
ƒ Beads too small .433 11/32 1/2 2.16 15/16 1-3/16
ƒ Insufficient joining force
.512 3/8 9/16 2.36 1 1-1/4
ƒ Excessive heating time .630 7/16 19/32 2.56 1-1/8 1-7/16
ƒ Beads too large
ƒ Excessive joining force .710 1/2 5/8 2.76 1-3/16 1-1/2
ƒ Absence of third bead, or third .750 1/2 11/16 2.95 1-1/4 1-9/16
ƒ Incorrect pipe main heating tool
bead widely separated from center .870 1/2 11/16 3.15 1-5/16 1-11/16
ƒ Insufficient joining force
bead .940 9/16 3/4 3.35 1-3/8 1-3/4
ƒ Excessive heating 3.54 1-1/2 1-13/16
ƒ Heating temperature not within specified range Instructions:
ƒ Pressurized main blowout (beside Determine the wall thickness of the pipe/fitting. Find the wall thickness above. If the exact wall
ƒ Incorrect heating tool faces
base or through fitting base) thickness is not shown, use the next lowest wall thickness for determination of bead width.
ƒ Excessive time to start heating or in joining the
fitting to the main pipe after heating time cycle
ƒ Rough, sandpaper-like, bubbly, or ƒ Hydrocarbon (gasoline vapors, spray paint fumes, 4. The size differential (Smax – Smin) between two single beads shall not exceed X% of the
pockmarked melt bead surface etc.) contamination actual bead width (B).
S
X u 100
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 = Width of bead, inches

NOTE: When butt fusing to molded fittings, the fitting side bead may have an irregular
appearance. This is acceptable provided the pipe side bead is correct.

20 9
Qualification Saddle Fusion

1. Prepare a sample joint. Sample lengths should be at least 6” or 15 times the minimum wall
thickness (see Figure I). UNACCEPTABLE FUSIONS
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 (minimum of one hour).

5. Prepare the sample as shown in Figure I. The sample should be cut lengthwise into at least
three longitudinal straps with a minimum of 1” or 1.5 times the wall thickness in width.

Figure I
Butt Fusion Bent Strap Test Specimen
(Reference ASTM D2657)

Fitting misaligned on pipe. Excessive heating and/or over-pressuriz-

ing of joint.

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 the pipe facing out until the ends touch.
The inside bend radius should be less than the minimum wall thickness of the pipe. In order
to successfully complete the bend back, a vise may be needed. For thick wall pipe, a
hydraulic assist may be required.

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, then the fusion procedure should be reviewed and
corrected. After correction, another sample weld should be made per the new procedure
and re-tested.

Insufficient melt. Excessive force.

10 19
Saddle Fusion Butt Fusion

ACCEPTABLE FUSIONS ACCEPTABLE FUSIONS

Proper alignment, melt and force. Proper alignment and double roll-back bead.

Bend back testing. No gaps or voids. (See Figure II) Bend back testing. No gaps or voids. (See Figure I)

18 11
Butt Fusion Qualification

1. Prepare at least two sample joints. The main pipe length should be a minimum of 2’ or
UNACCEPTABLE FUSIONS 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
being followed.

3. Visually inspect the sample joint for quality.

4. Allow the joint to cool completely (minimum of one hour). The main should not be tapped for
this qualification process.

5. Prepare test straps as shown in Figure II. Cut the joint lengthwise along the main pipe and
through the saddle fitting.

Figure II
Saddle Fusion Bent Strap Test Specimen
(Reference ASTM D2657)

Melt bead too small due to insufficient Melt bead too large due to excessive heat-
heat time. ing and/or over-pressurizing of joint.

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, but is not a requirement for individual qualification.

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 weld should be made per the new
Misalignment. Incomplete facing. procedure and re-tested.

12 17
2. Heating Table III
The heating and fusing process must be performed with accuracy and efficiency, especially Butt Fusion Troubleshooting Guide
when fusing to a pressurized main pipe.
Observed Condition Possible Cause
WARNING: Overheating or excessive time between these two processes can have
detrimental effects, including pipeline rupture. ƒ Overheating
ƒ Excessive double bead width
ƒ Excessive joining force
ˆ The heater must be fitted with the correct heater adapters. ƒ Excessive joining force
ƒ Double bead v-groove too
ˆ The heater adapter fusion surface must be between 490oF to 510oF (254oC to 266oC). deep
ƒ Insufficient heating
ˆ Ensure the heating surfaces are clean. ƒ Pressure during heating
ˆ Determine the saddle fusion force from the fitting label or by calculation. ƒ Excessive joining force
ƒ Flat top on bead
ƒ Overheating
A. Place the heating tool on the main centered beneath the fitting base. Immediately move ƒ Misalignment
the fitting against the heater faces, apply the Initial Heat Force (see fitting label), and ƒ Non-uniform bead size ƒ Defective heating tool
start the heat time. Apply the Initial Heat Force until melt is first observed on the crown around pipe ƒ Worn equipment
of the pipe main (Initial Heat is the term used to describe the initial heating (bead-up) ƒ Incomplete facing
step to develop a melt bead on the main pipe and is usually 3-5 seconds) and then ƒ Misalignment
reduce the force to the Heat Soak Force (bead-up force) (see fitting label). Maintain the ƒ Component slipped in clamp
Heat Soak Force until the Total Heat Time is complete. ƒ One bead larger than the ƒ Worn equipment
other ƒ Heating iron does not move freely in the axial direction
B. At the end of the Total Heat Time, remove the fitting from the heater and the heater from ƒ Defective heating tool
the main with a quick, snapping action. Quickly check for an even melt pattern on the ƒ Incomplete facing
pipe main and heated fitting surfaces (no unheated areas). The Total Heat Time ends ƒ Insufficient heating
when one of the following conditions are met: ƒ Beads too small
ƒ Insufficient joining force
ƒ Shallow v-groove – Insufficient heating & insufficient
i. When the Total Heat Time expires for a pressurized 1-1/4” IPS or 2” IPS main, or ƒ Bead not rolled over to joining force
ii. When a melt bead of approximately 1/16” is visible around the fitting base for a 1 surface ƒ Deep v-groove – Insufficient heating & excessive joining
1/4” IPS or 2” IPS non-pressurized main, or a larger pressurized or non-pressurized force
main.
ƒ Beads too large ƒ Excessive heating time
3. Fusion and Cooling ƒ Square type outer bead edge ƒ Pressure during heating
Regardless of whether the melt patterns are satisfactory, quickly press the fitting onto the ƒ Rough, sandpaper-like,
main pipe (within 3 seconds) after removing the heater and apply the Fusion Force (see the ƒ Hydrocarbon (gasoline vapors, spray paint fumes, etc.)
bubbly, or pockmarked melt
contamination
fitting label). Maintain the Fusion Force on the assembly for 5 minutes on 1-1/4” IPS and for bead surface
10 minutes for larger sizes. When this initial cooling time has expired, the saddle fusion
equipment may be removed. Cool the assembly for an additional 30 minutes before rough
handling or tapping the main.

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 main 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 main pipe. The third
bead, or center bead, is the main 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.

16 13
SADDLE FUSION Table IV
Maximum Heating/Minimum Cooling Times
ˆ Heater Surface Temperature: Minimum 490oF - Maximum 510oF (254 – 266oC)
Minimum Cooling
Main Size Maximum Heating Time
Heater tool surfaces must be up to temperature before you begin. All points on both heating Time
tool surfaces where the heating tool surfaces will contact the pipe and fitting must be within 1/16” melt pattern visible around the base of the fitting.
the prescribed minimum and maximum temperatures. Heater tool surfaces must be clean. 1-1/4” IPS 5 min + 30 min
Do not exceed 15 seconds when hot tapping.
1/16” melt pattern visible around the base of the fitting.
ˆ Interface Pressure: Minimum 54 psi – Maximum 66 psi (372 – 455 kPa ; 3.72 – 4.55 bar) 2” IPS
Do not exceed 35 seconds when hot tapping.
10 min + 30 min

3” IPS &
1/16” melt pattern visible around the base of the fitting. 10 min + 30 min
larger
Definitions
Interfacial Area
Initial Heat (Bead-up) ˆ Rectangular base fittings
The heating step used to develop a melt bead on the main pipe. 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.
Initial Heat Force (Bead-up Force)
The force (pounds) applied to establish a melt pattern on the main pipe. The Initial Heat Force ˆ Round base fittings
is determined by multiplying the fitting base area (in2) by the initial heat interfacial pressure (psi). The radius of the saddle base squared times ʌ (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.
Heat Soak Force
The force (pounds) applied after an initial melt pattern is established on the main pipe. The Fitting Labels
Heat Soak Force is the minimum force (essentially zero) that ensures the fitting, heater and The Initial Heat Force, Heat Soak Force and Fusion Force will be listed in the lower right hand
main stay in contact with each other. 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,
Fusion Force Heat Soak Force and Fusion Force, respectively. If this information is not located on the fitting,
The force (pounds) applied to establish the fusion bond between the fitting and the pipe. The please contact the fitting manufacturer for the correct fusion parameters.
Fusion Force is determined by multiplying the fitting base area (in2) by the fusion interfacial
pressure (psi).
Procedure
Total Heat Time
A time that begins when the heater is placed on the main pipe and Initial Heat Force is applied 1. Preparation
and stops when the heater is removed. Maximum heating times are shown in Table IV for both This procedure requires the use of a saddle fusion tool. This tool must be capable of
pressure (hot tapping) and non-pressure fusion applications. holding and supporting the main, rounding the main for proper alignment between the pipe
and fitting, holding the fitting, and applying and indicating the proper force during the fusion
Cool Time process.
The time required to cool the joint to approximately 120oF (49oC). The Fusion Force must be
maintained for 5 minutes on 1-1/4” IPS or 10 minutes for all other main sizes, after which the A. Install the saddle fusion tool on the main according to the manufacturer’s instructions.
saddle fusion equipment can be removed. The joint must be allowed to cool for an additional 30 The tool should be centered over a clean, dry location where the fitting will be fused.
minutes before tapping the main or joining to the branch outlet. Recommended minimum Secure the tool to the main. A main bolster or support is recommended under the pipe
cooling times are shown in Table IV. on 6” IPS and smaller main pipe sizes.

B. Abrade the surface of the main, where the fitting will be joined, with a 50–60 grit utility
cloth until a thin layer of material is removed from the pipe surface. The abraded area
must be larger than the area covered by the fitting base. After abrading, clean the
residue away with a clean, dry cloth.

C. Abrade the fusion surface of the fitting with 50-60 grit utility cloth. Remove all dust and
residue with a clean, dry cloth. Insert the fitting in the saddle fusion tool loosely. Using
the saddle fusion tool, move the fitting base against the main pipe and apply about 100
pounds-force to seat the fitting. Secure the fitting in the saddle fusion tool.

14 15
SADDLE FUSION Table IV
Maximum Heating/Minimum Cooling Times
ˆ Heater Surface Temperature: Minimum 490oF - Maximum 510oF (254 – 266oC)
Minimum Cooling
Main Size Maximum Heating Time
Heater tool surfaces must be up to temperature before you begin. All points on both heating Time
tool surfaces where the heating tool surfaces will contact the pipe and fitting must be within 1/16” melt pattern visible around the base of the fitting.
the prescribed minimum and maximum temperatures. Heater tool surfaces must be clean. 1-1/4” IPS 5 min + 30 min
Do not exceed 15 seconds when hot tapping.
1/16” melt pattern visible around the base of the fitting.
ˆ Interface Pressure: Minimum 54 psi – Maximum 66 psi (372 – 455 kPa ; 3.72 – 4.55 bar) 2” IPS
Do not exceed 35 seconds when hot tapping.
10 min + 30 min

3” IPS &
1/16” melt pattern visible around the base of the fitting. 10 min + 30 min
larger
Definitions
Interfacial Area
Initial Heat (Bead-up) ˆ Rectangular base fittings
The heating step used to develop a melt bead on the main pipe. 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.
Initial Heat Force (Bead-up Force)
The force (pounds) applied to establish a melt pattern on the main pipe. The Initial Heat Force ˆ Round base fittings
is determined by multiplying the fitting base area (in2) by the initial heat interfacial pressure (psi). The radius of the saddle base squared times ʌ (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.
Heat Soak Force
The force (pounds) applied after an initial melt pattern is established on the main pipe. The Fitting Labels
Heat Soak Force is the minimum force (essentially zero) that ensures the fitting, heater and The Initial Heat Force, Heat Soak Force and Fusion Force will be listed in the lower right hand
main stay in contact with each other. 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,
Fusion Force Heat Soak Force and Fusion Force, respectively. If this information is not located on the fitting,
The force (pounds) applied to establish the fusion bond between the fitting and the pipe. The please contact the fitting manufacturer for the correct fusion parameters.
Fusion Force is determined by multiplying the fitting base area (in2) by the fusion interfacial
pressure (psi).
Procedure
Total Heat Time
A time that begins when the heater is placed on the main pipe and Initial Heat Force is applied 1. Preparation
and stops when the heater is removed. Maximum heating times are shown in Table IV for both This procedure requires the use of a saddle fusion tool. This tool must be capable of
pressure (hot tapping) and non-pressure fusion applications. holding and supporting the main, rounding the main for proper alignment between the pipe
and fitting, holding the fitting, and applying and indicating the proper force during the fusion
Cool Time process.
The time required to cool the joint to approximately 120oF (49oC). The Fusion Force must be
maintained for 5 minutes on 1-1/4” IPS or 10 minutes for all other main sizes, after which the A. Install the saddle fusion tool on the main according to the manufacturer’s instructions.
saddle fusion equipment can be removed. The joint must be allowed to cool for an additional 30 The tool should be centered over a clean, dry location where the fitting will be fused.
minutes before tapping the main or joining to the branch outlet. Recommended minimum Secure the tool to the main. A main bolster or support is recommended under the pipe
cooling times are shown in Table IV. on 6” IPS and smaller main pipe sizes.

B. Abrade the surface of the main, where the fitting will be joined, with a 50–60 grit utility
cloth until a thin layer of material is removed from the pipe surface. The abraded area
must be larger than the area covered by the fitting base. After abrading, clean the
residue away with a clean, dry cloth.

C. Abrade the fusion surface of the fitting with 50-60 grit utility cloth. Remove all dust and
residue with a clean, dry cloth. Insert the fitting in the saddle fusion tool loosely. Using
the saddle fusion tool, move the fitting base against the main pipe and apply about 100
pounds-force to seat the fitting. Secure the fitting in the saddle fusion tool.

14 15
2. Heating Table III
The heating and fusing process must be performed with accuracy and efficiency, especially Butt Fusion Troubleshooting Guide
when fusing to a pressurized main pipe.
Observed Condition Possible Cause
WARNING: Overheating or excessive time between these two processes can have
detrimental effects, including pipeline rupture. ƒ Overheating
ƒ Excessive double bead width
ƒ Excessive joining force
ˆ The heater must be fitted with the correct heater adapters. ƒ Excessive joining force
ƒ Double bead v-groove too
ˆ The heater adapter fusion surface must be between 490oF to 510oF (254oC to 266oC). deep
ƒ Insufficient heating
ˆ Ensure the heating surfaces are clean. ƒ Pressure during heating
ˆ Determine the saddle fusion force from the fitting label or by calculation. ƒ Excessive joining force
ƒ Flat top on bead
ƒ Overheating
A. Place the heating tool on the main centered beneath the fitting base. Immediately move ƒ Misalignment
the fitting against the heater faces, apply the Initial Heat Force (see fitting label), and ƒ Non-uniform bead size ƒ Defective heating tool
start the heat time. Apply the Initial Heat Force until melt is first observed on the crown around pipe ƒ Worn equipment
of the pipe main (Initial Heat is the term used to describe the initial heating (bead-up) ƒ Incomplete facing
step to develop a melt bead on the main pipe and is usually 3-5 seconds) and then ƒ Misalignment
reduce the force to the Heat Soak Force (bead-up force) (see fitting label). Maintain the ƒ Component slipped in clamp
Heat Soak Force until the Total Heat Time is complete. ƒ One bead larger than the ƒ Worn equipment
other ƒ Heating iron does not move freely in the axial direction
B. At the end of the Total Heat Time, remove the fitting from the heater and the heater from ƒ Defective heating tool
the main with a quick, snapping action. Quickly check for an even melt pattern on the ƒ Incomplete facing
pipe main and heated fitting surfaces (no unheated areas). The Total Heat Time ends ƒ Insufficient heating
when one of the following conditions are met: ƒ Beads too small
ƒ Insufficient joining force
ƒ Shallow v-groove – Insufficient heating & insufficient
i. When the Total Heat Time expires for a pressurized 1-1/4” IPS or 2” IPS main, or ƒ Bead not rolled over to joining force
ii. When a melt bead of approximately 1/16” is visible around the fitting base for a 1 surface ƒ Deep v-groove – Insufficient heating & excessive joining
1/4” IPS or 2” IPS non-pressurized main, or a larger pressurized or non-pressurized force
main.
ƒ Beads too large ƒ Excessive heating time
3. Fusion and Cooling ƒ Square type outer bead edge ƒ Pressure during heating
Regardless of whether the melt patterns are satisfactory, quickly press the fitting onto the ƒ Rough, sandpaper-like,
main pipe (within 3 seconds) after removing the heater and apply the Fusion Force (see the ƒ Hydrocarbon (gasoline vapors, spray paint fumes, etc.)
bubbly, or pockmarked melt
contamination
fitting label). Maintain the Fusion Force on the assembly for 5 minutes on 1-1/4” IPS and for bead surface
10 minutes for larger sizes. When this initial cooling time has expired, the saddle fusion
equipment may be removed. Cool the assembly for an additional 30 minutes before rough
handling or tapping the main.

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 main 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 main pipe. The third
bead, or center bead, is the main 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.

16 13
Butt Fusion Qualification

1. Prepare at least two sample joints. The main pipe length should be a minimum of 2’ or
UNACCEPTABLE FUSIONS 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
being followed.

3. Visually inspect the sample joint for quality.

4. Allow the joint to cool completely (minimum of one hour). The main should not be tapped for
this qualification process.

5. Prepare test straps as shown in Figure II. Cut the joint lengthwise along the main pipe and
through the saddle fitting.

Figure II
Saddle Fusion Bent Strap Test Specimen
(Reference ASTM D2657)

Melt bead too small due to insufficient Melt bead too large due to excessive heat-
heat time. ing and/or over-pressurizing of joint.

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, but is not a requirement for individual qualification.

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 weld should be made per the new
Misalignment. Incomplete facing. procedure and re-tested.

12 17
Saddle Fusion Butt Fusion

ACCEPTABLE FUSIONS ACCEPTABLE FUSIONS

Proper alignment, melt and force. Proper alignment and double roll-back bead.

Bend back testing. No gaps or voids. (See Figure II) Bend back testing. No gaps or voids. (See Figure I)

18 11
Qualification Saddle Fusion

1. Prepare a sample joint. Sample lengths should be at least 6” or 15 times the minimum wall
thickness (see Figure I). UNACCEPTABLE FUSIONS
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 (minimum of one hour).

5. Prepare the sample as shown in Figure I. The sample should be cut lengthwise into at least
three longitudinal straps with a minimum of 1” or 1.5 times the wall thickness in width.

Figure I
Butt Fusion Bent Strap Test Specimen
(Reference ASTM D2657)

Fitting misaligned on pipe. Excessive heating and/or over-pressuriz-

ing of joint.

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 the pipe facing out until the ends touch.
The inside bend radius should be less than the minimum wall thickness of the pipe. In order
to successfully complete the bend back, a vise may be needed. For thick wall pipe, a
hydraulic assist may be required.

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, then the fusion procedure should be reviewed and
corrected. After correction, another sample weld should be made per the new procedure
and re-tested.

Insufficient melt. Excessive force.

10 19
 Table V Table II
Saddle Fusion Troubleshooting Guide Bead Widths per Wall Thickness

Observed Condition Possible Cause Minimum

Approximate Bead Approximate Bead
ƒ Misalignment Wall Minimum Wall
Width (B), in. Width (B), in.
ƒ Non-uniform bead size around ƒ Defective heating tool Thickness, Thickness, in.
fitting base ƒ Fitting not secured in heating tool in. Minimum Maximum Minimum Maximum
ƒ Heating temperature not within specified range .118 5/32 1/4 1.06 19/32 25/32
ƒ Misalignment .157 5/32 9/32 1.18 5/8 13/16
ƒ Heating temperature not within specified range .197 3/16 5/16 1.34 21/32 7/8
ƒ One bead larger than the other
ƒ Fitting slipped in clamp .246 1/4 11/32 1.57 11/16 29/32
ƒ Defective or worn equipment .315 9/32 3/8 1.77 25/32 1
ƒ Insufficient heating .354 5/16 7/16 1.97 7/8 1-1/16
ƒ Beads too small .433 11/32 1/2 2.16 15/16 1-3/16
ƒ Insufficient joining force
.512 3/8 9/16 2.36 1 1-1/4
ƒ Excessive heating time .630 7/16 19/32 2.56 1-1/8 1-7/16
ƒ Beads too large
ƒ Excessive joining force .710 1/2 5/8 2.76 1-3/16 1-1/2
ƒ Absence of third bead, or third .750 1/2 11/16 2.95 1-1/4 1-9/16
ƒ Incorrect pipe main heating tool
bead widely separated from center .870 1/2 11/16 3.15 1-5/16 1-11/16
ƒ Insufficient joining force
bead .940 9/16 3/4 3.35 1-3/8 1-3/4
ƒ Excessive heating 3.54 1-1/2 1-13/16
ƒ Heating temperature not within specified range Instructions:
ƒ Pressurized main blowout (beside Determine the wall thickness of the pipe/fitting. Find the wall thickness above. If the exact wall
ƒ Incorrect heating tool faces
base or through fitting base) thickness is not shown, use the next lowest wall thickness for determination of bead width.
ƒ Excessive time to start heating or in joining the
fitting to the main pipe after heating time cycle
ƒ Rough, sandpaper-like, bubbly, or ƒ Hydrocarbon (gasoline vapors, spray paint fumes, 4. The size differential (Smax – Smin) between two single beads shall not exceed X% of the
pockmarked melt bead surface etc.) contamination actual bead width (B).
S
X u 100
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 = Width of bead, inches

NOTE: When butt fusing to molded fittings, the fitting side bead may have an irregular
appearance. This is acceptable provided the pipe side bead is correct.

20 9
6. Hold SOCKET FUSION
Hold joining force against the ends until the joint is cool. The joint is cool enough for gentle
handling when the double bead is cool to the touch. Cool for about 30 – 90 seconds per Equipment Requirements
inch of pipe diameter. Do not try to decrease the cooling time by applying water, wet cloths
or the like. In order to produce a quality socket fusion, the following equipment is required for this
ˆ Avoid pulling, installation, pressure testing and rough handling for at least an additional
procedure:
30 minutes.
ˆ Apparatus – Socket fusion tools manufactured in accordance with ASTM F1056.
ˆ Heavier wall thickness pipes require longer cooling times.
ˆ Heating Tool Faces – Consisting of two parts, a male end for the interior socket surface and
7. Inspection a female end for the exterior pipe surface.
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. ˆ 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.
1. The gap (A) between the two single beads must not be below the fusion surface
throughout the entire circumference of the butt joint. ˆ Depth Gauge – Proper positioning of the rounding clamp.

ˆ Chamfering Tool – Device to bevel the end of the pipe. The depth gauge and chamfering
tool may be combined into a single tool.

ˆ Holding Tools – Recommended for socket fusion of 2”IPS

IPS and larger pipe and fittings.

Heater Temperature

ˆ Heater Surface Temperature: Minimum 490oF – Maximum 510oF (254 – 266oC)

2. The displacement (V) between the fused ends must not exceed 10% of the pipe/fitting
minimum wall thickness.
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 clean.

Procedure

1. Preparation
A. Verify heating temperature is within the specified temperature range (490oF – 510oF).
3. Refer to Table II for general guidelines for bead width, B, for each respective wall
thickness.
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.

8 21
 B. Insert the fitting onto the male heating face. The fitting should be held against the back 3. Align
surface of the male heater face. 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
C. Insert the pipe into the female heating face. The female socket heating face should be outside diameters in high-low alignment. If necessary, adjust the high side by tightening the
against the cold ring clamp. high side clamp. Do not loosen the low side clamp because components may slip during
fusion. Re-face if high-low alignment is adjusted.
D. Hold the pipe and fitting in place against the heater faces for the recommended heating
time as shown in Table VI. 4. Melt
Verify that the contact surface of the heating tool is maintaining the correct temperature.
Table VI Place the heating tool between the component ends, and move the ends against the heating
Socket Fusion Time Cycles 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.
PE2406 PE3408 Pressure should be reduced when evidence of melt appears on the circumference of the
Pipe Size pipe. Hold the ends against the heating tool without force (drag force may be necessary to
Heating Time, Cooling Time, Heating Time, Cooling Time, ensure contact). Beads of melted polyethylene will form against the heating tool at the
seconds seconds seconds seconds component ends. When the proper melt bead size is formed, quickly separate the ends,
1/2” CTS 5–6 30 8 – 10 30 and remove the heating tool. The proper bead size is dependent upon the size of the
3/4” CTS 7–8 30 10 – 12 30 component. Approximate values are shown in Table I.
1” CTS 9 – 10 30 12 – 14 30
1/2” IPS 5–6 30 8 –10 30 Table I
3/4” IPS 8 – 10 30 12 – 14 30 Approximate Melt Bead Size
1” IPS 10 – 12 30 14 – 16 30
1-1/4” IPS 12 – 14 45 18 – 20 60 Melt Bead Size*
Approximate Wall Thickness, inches
1-1/2” IPS 12 – 14 45 18 – 20 60 (Approximate)
2” IPS 16 – 20 45 22 – 26 60 ” 0.15 3.8 mm and smaller 1/32” – 1/16” 1 – 2 mm
3” IPS 20 – 25 60 25 – 30 75 0.15 – 0.30 3.8 mm – 7.6 mm 1/16” 2 mm
4” IPS 25 – 30 60 30 - 35 75 Above 0.30 – 0.75 Above 7.6 mm – 19 mm 1/8” – 3/16” 3 – 5 mm
Above 0.75 – 1.15 Above 19 mm – 29.2 mm 3/16” – 1/4” 5 – 6 mm
3. Fusion and Cooling Above 1.15 – 1.60 Above 29.2 mm – 40.6 mm 1/4” – 5/16” 6 – 8 mm
A. At the end of the heating time, simultaneously remove the pipe and fitting straight out Above 1.60 – 2.20 Above 40.6 mm – 55.9 mm 5/16” – 7/16” 8 – 11 mm
from the tool using a “snap” action. Do not torque or twist the pipe or fitting during Above 2.20 – 3.00 Above 55.9 mm – 76.2 mm 7/16” – 9/16” 11 mm
removal. *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
B. A QUICK inspection should be made of the melt pattern on the pipe end and fitting plate to the melt swell origin.
socket. If there is evidence of an incomplete melt pattern, do not continue with the
fusion procedure.
During heating, the melt bead will expand out flush to the heating tool surface, or may curl
C. Immediately insert the pipe straight into the socket of the fitting so that the cold ring is slightly away from the surface. If the melt bead curls significantly away from the heating tool
flush against the end of the fitting socket. While cooling, pressure should be maintained surface, unacceptable pressure during heating may have occurred.
on the fusion per the recommended cooling time shown in Table VI.
5. Join
D. Allow the joint to cool an additional five (5) minutes before removing the cold ring. An Immediately after the heating tool is removed, quickly inspect the melted ends, which
additional 10 minutes of cooling time is recommended before exposing the joint to any should be flat, smooth and completely melted. If the melt surfaces are acceptable,
type of stresses (ie., burial or testing). 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
4. Inspection rolled over to the surface on both ends.
Visually inspect the weld. A complete impression of the rounding clamp should be visible in
the melt pattern at the end of the socket. There should be no gaps, voids or unbonded A concave melt surface is unacceptable; it indicates pressure during heating. Do not
areas. continue. Allow the component ends to cool and start over with Step 1.

22 7
BUTT FUSION Qualification

ˆ Heater Surface Temperature: Minimum 400oF – Maximum 450oF (204 – 232oC) 1. Prepare a sample joint such as a coupling with pipe socket fused to both ends. The pipe
should be at least 6” or 15 times the wall thickness in length.
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 2. Observe the fusion process and verify the recommended procedure for socket fusion is
within the prescribed minimum and maximum temperatures and the maximum temperature being followed.
difference between any two points on the heating tool fusion surfaces must not exceed 20oF
(11oC) for equipment for pipe smaller than 18” diameter, or 35oF (19oC) for larger 3. Visually inspect the sample joints for quality.
equipment. Heating tool surfaces must be clean.
4. Allow the sample to cool completely (minimum of one hour).
ˆ Interface pressure :: Minimum
Minimum 60
60 psi
psi –– Maximum
Maximum 90
90 psi
psi (414
(414 –– 621
621 kPa;
kPa; 4.16
4.16 –– 6.21
6.21 bar)
bar)
5. Prepare test straps as shown in Figure III. Cut the joints lengthwise into at least three
Interface pressure is used to calculate a fusion joining pressure value for hydraulic butt longitudinal straps with a minimum of 1” or 1.5 times the wall thickness in width.
fusion machines or manual machines equipped with force reading capability. The interface
pressure is constant for all pipe sizes and all butt fusion machines. However, fusion joining
pressure settings are calculated for each butt fusion machine, which are dependent upon Figure III
the OD and DR (Dimension Ratio). Socket Fusion Bent Strap Test Specimen
(Reference ASTM D2657)
For hydraulic machines, the interface 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 interface 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 to the pipe surface during joining.

Procedure

1. Secure 6. Visually inspect the cut joint for any indications of voids, gaps, misalignment or surfaces that
Clean the inside and outside of the component, pipe or fitting ends by wiping with a clean, have not been fused.
dry, lint-free cloth or paper towel. Remove all foreign matter. Align the components of the
machine, place them in the clamps, and then close the clamps. Do not force pipes into 7. Bend each test strap 180o with the inside of the pipe facing out.
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 8. The fusion joint must be free of cracks, voids, gaps and separations. If failure does occur at
alignment. Adjust alignment as necessary by tightening the high side down. the weld in any of the samples, then the fusion procedure should be reviewed and
corrected. After correction, another sample weld should be made per the new procedure
2. Face and re-tested.
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.

6 23
Socket Fusion 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 can result in a poor fusion.
ACCEPTABLE FUSIONS
Fusion Checklist
ˆ 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. 17 for
allowable surface damage according to the Plastics Pipe Institute (PPI) and the American
Gas Association (AGA).

ˆ Any surface damage at pipe ends that could compromise the joining surfaces or interfere
with fusion tools and equipment should be removed.

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

ˆ 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.

ˆ Shield heated fusion equipment and surfaces from inclement weather and winds. A
temporary shelter over fusion equipment and the operation may be required.

Proper alignment and stab depth. Melt bead flattened due to cold ring. No gaps or voids. ˆ 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.

ˆ Pipes must be correctly aligned before making connections.

ˆ 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.

Bend back testing. No gaps or voids.

(See Figure III)

24 5
The proper cycle time for any particular condition can be determined by making a melt pattern Socket Fusion
on a piece of scrap pipe using the recommended standard heating time. If the melt pattern is
incomplete, increase the heating time by three (3) second intervals until a complete melt pattern
is established. Each time the procedure is repeated, a new piece of scrap pipe should be used. UNACCEPTABLE FUSIONS
For additional information concerning cold weather procedures, refer to ASTM D2657, Standard
Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings, Annex A1.

NOTES ON FUSION CONFIDENCE

Reliable fusion joints of polyethylene piping systems can be accomplished under reasonable
latitude of conditions. 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.

Contact pressures and heating/cooling cycles may vary dramatically according to pipe size
and wall thickness. Operators should not rely exclusively on automated fusion equipment Short stab depth caused by failure to use Excessive stab depth caused by failure to
for joint qualification. In addition, visual inspection and qualification should always be made. a depth gauge. use a cold ring.
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 cannot
produce a 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.

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. Misalignment.
This not only protects the heater surfaces from contaminants, but it can also prevent
inadvertent contact, which can result in serious injuries.

4 25
 Table VII ƒ Saddle Fusion – This technique involves melting the concave surface of the base of a
Socket Fusion Troubleshooting Guide 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
Observed Condition Possible Cause appropriate applied force.
ƒ Insufficient heating time
ƒ No evidence of cold-ring ƒ Socket Fusion – This technique involves simultaneously heating the outside surface of a
ƒ Depth gauge not used
impression in socket fitting pipe end and the inside of a fitting socket, which is sized to be smaller than the smallest
ƒ Cold ring not used
melt bead outside diameter of the pipe. After the proper melt has been generated at each face to be
ƒ Cold ring set at incorrect depth
mated, the two components are joined by inserting one component into the other. The
ƒ Pipe or fitting not removed straight from heater face fusion is formed at the interface resulting from the interference fit. The melts from the two
ƒ Gaps or voids around the
ƒ Components not joined together straight when fusing components flow together and fuse as the joint cools.
pipe at the socket fitting
ƒ Cold ring not used
edge
ƒ Cold ring set at incorrect depth
Properly fused polyethylene joints do not leak. If a leak is detected during hydrostatic testing, it
ƒ Cold ring not utilized
is possible for a system failure to occur. Caution should be exercised in approaching a
ƒ Wrinkled or collapsed pipe pressurized pipeline and any attempts to correct the leak should not be made until the system
ƒ Cold ring set at incorrect depth
end has been depressurized.
ƒ Incorrect heating sequence

ƒ Pipe or fitting not removed straight from heater face

Note: Polyethylene cannot be joined by solvent bonding or threading. Extrusion welding or hot
ƒ Components not joined together straight when fusing
ƒ Voids in fusion bond area air welding is not recommended for pressure applications.
ƒ Cold ring not used
ƒ Cold ring set at incorrect depth
ƒ Unbonded area on pipe at ƒ Cold ring not used
end of pipe ƒ Cold ring set too deep INCLEMENT WEATHER
ƒ Socket melt extends past
ƒ Cold ring set too shallow Polyethylene has reduced impact resistance in sub-freezing conditions. Additional care should
end of pipe
ƒ Rough, sandpaper-like, be exercised while handling in sub-freezing conditions. In addition, polyethylene pipe will be
ƒ Hydrocarbon (gasoline vapors, spray paint fumes, harder to bend or uncoil.
bubbly, or pockmarked
etc.) contamination
melt bead surface
In inclement weather and especially in windy conditions, the fusion operation should be shielded
to avoid precipitation or blowing snow and excessive heat loss from wind chill. The heating tool
should also be stored in an insulated container to prevent excessive heat loss. Remove all
frost, snow or ice from the OD and ID of the pipe; all surfaces must be clean and dry prior to
fusing.

The time required to obtain the proper melt may increase when fusing in cold weather. The
following recommendations should be followed:

1. Maintain the specified heating tool surface temperature. Do not increase the tool
surface temperature.
2. Do not apply pressure during zero pressure butt fusion heating steps.
3. Do not increase the butt fusion joining pressure.

In butt fusion, melt bead size determines heating time; therefore, the procedure automatically
compensates when cold pipe requires longer time to form the proper melt size.

The outside diameter of polyethylene pipe and fittings will contract in cold weather conditions.
This can result in loose or slipping cold rings. For best results, clamp one cold ring in its normal
position adjacent to the depth gage. Shim around the pipe behind the clamp with paper, tape,
etc., and place a second cold ring over this area. This cold ring will prevent slippage while the
inner cold ring will allow for the pipe to expand during the heating cycle of the fusion process.

26 3
8D.O.T. regulations require that all persons who make joints in polyethylene gas piping must APPENDIX A
be qualified under the operator’s written procedures (CFR 49, Part 192, §192.285(a)).

8D.O.T. regulations require that the gas system operator must ensure that all persons who HYDRAULIC FUSION MACHINE GAUGE PRESSURE
make or inspect joints are qualified (CFR 49, Part 192, §192.285(d) & §192.287).
The manufacturer of the fusion machine should be consulted for guidance in determining the
Where an operator is already using qualified procedures that are in compliance with the D.O.T., proper conversion of PolyPipe®’s recommended interfacial pressure to the gauge pressure. The
these recommended procedures do not constitute a requirement for that operator to change to effective hydraulic piston area must be available in order to calculate the required hydraulic
these fusion procedures. gauge pressure. The calculation for hydraulic gauge pressure is as follows:

0.785 u OD 2  ID 2 u PI
PG  DF
Qualification Procedure AP
Due to the requirements of the U.S. Department of Transportation, any person joining
Where PG = Hydraulic Gauge Pressure, psi
polyethylene gas pipe must receive training in each of the fusion procedures (49 CFR, Part
OD = Pipe outside diameter, inches
192). Each operator should make a sample joint for each procedure used. Each sample joint
ID = Pipe inside diameter, inches
must pass the following inspections and tests:
PI = Required interfacial pressure, psi
AP = Total hydraulic piston area, in2
1. Pressure and tensile testing as described in §192.283, CFR,
DF = Hydraulic fusion pressure required to move the carriage holding the
2. Ultrasonically inspected and found to contain no flaws, or
pipe (generally accepted minimum is 30 psi).
3. Cut into at least three (3) strips, each of which is:
*The drag factor is an important parameter easily overlooked. If two long pieces of pipe are
(a) Visually examined and found free of voids or discontinuity on the cut surface of the
being fused, the drag factor can easily reach several hundred pounds per square inch (psi).
joint.
(b) Deformed by bending, torque or impact, and if failure occurs, must not initiate in the
joint area.

A person must be re-qualified under an applicable procedure during a 12-month period for the
following conditions:

1. The individual does not make any joints under the procedure.
2. The individual has three (3) joints or 3% of the joints made, whichever is greater, that are
found to be unacceptable by §192.513, CFR.

Each operator shall establish a method to determine that each person making a joint in plastic
pipelines in his/her system is qualified in accordance with this section.

HEAT FUSION
The principle behind heat fusion is to heat two surfaces to a designated temperature, and then
fuse them together by application of a sufficient force. This applied force causes the melted
materials to flow and mix, resulting in a permanent, monolithic fusion joint. When fused
according to the recommended procedures, the fusion or joint becomes as strong as or stronger
than the pipe itself in both tensile and pressure properties. PolyPipe® fusion procedures require
specific tools and equipment for the fusion type and for the sizes of pipe and fittings to be
joined.

ƒ 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 the appropriate applied force.

2 27
REFERENCES INTRODUCTION
1. Plastics Pipe Institute Technical Report-33. Generic Butt Fusion Joining Procedure for An integral part of any pipe system is the method used to join the system components. Proper
Polyethylene Gas Pipe, 2001. engineering design of a system will take into consideration the type and effectiveness of the
techniques used to join the piping components and appurtenances, as well as, the durability of
the resulting joints. The integrity and versatility of the joining techniques used for polyethylene
2. Plastics Pipe Institute Technical Report-41. Generic Saddle Fusion Joining Procedure for pipe allow the designer to take advantage of the performance benefits of polyethylene in a wide
Polyethylene Gas Pipe, 2002. variety of applications.

There are three types of heat fusion joints currently used in the industry: Butt, Saddle and
3. Plastics Pipe Institute.Polyethylene Joining Procedures, March 1998. Socket Fusion. Additionally, there are two methods for producing the socket and saddle fusion
joints. In addition to the fusion procedures that follow, electrofusion is recognized as an
acceptable method of producing socket and saddle fusions but is not addressed in this
4. ASTM D2657-97. Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings. document.
Volume 8.04. American Society of Testing and Materials. Baltimore, 2002.
The fusion procedures that follow have been proven to consistently produce sound fusion joints
when used correctly and are recommended for the joining of PolyPipe® products. The
5. ASTM F1056-97. Standard Specification for Socket Fusion Tools for Use in Socket Fusion recommended procedures for butt and saddle fusions are consistent with the Plastic Pipe
Joining Polyethylene Pipe or Tubing and Fittings. Volume 8.04. American Society of Institute (PPI) TR-33, Generic Butt Fusion Procedures and TR-41, Generic Saddle Fusion
Testing and Materials. Baltimore, 2002. Procedures.

POLYPIPE® PRODUCTS
6. Pipeline Safety Regulations. U.S. Department of Transportation. CFR 49. Washington,
2002. GAS DISTRIBUTION M&I, WATER AND SPECIALTY
POLYPLUSTM PE100
POLYPIPE® 7810 POLYPIPE® EHMW
POLYPIPE® 6810 POLYPIPE® PERFORATED
POLYPIPE® 4810 POLYSTRIPE®
POLYPIPE® 3810 POLYPIPE® DUCT
POLYPIPE® LIGHTVIEW

FEDERAL REGULATIONS
Individuals who are involved in joining gas piping systems must note certain qualification
requirements of the U.S. Department of Transportation Pipeline Safety Regulations. The U.S.
Department of Transportation, D.O.T., requires that all persons who make fusion joints in
polyethylene gas piping systems must be qualified under the operator’s written procedures (49
CFR, Part 192, §192.293(a)), and require that gas system operators ensure that all persons
who make fusion joints are qualified (49 CFR, Part 192, §192.285(d)).

These fusion joining procedures, when used to join PolyPipe® gas pipe and fittings, are qualified
in accordance with U.S. Department of Transportation Regulations.

8D.O.T. regulations require that written procedures for butt fusion, saddle fusion and socket
fusion joining of polyethylene gas piping must be qualified before use by subjecting
specimen joints to required test procedures (CFR 49, Part 192, §192.283(a)).

8D.O.T. regulations require that each joint in a gas piping system must be made in
accordance with written procedures that have been proved by testing to produce strong
gastight joints (CFR 49, Part 192, §192.273(b)).

28 1
 ★
★
★

★
★ ★

GAINESVILLE PLANT ERWIN PLANT ROARING SPRINGS PLANT

P.O. Box 390 P.O. Box 199 P.O. Box 298
2406 N. I-35 1050 Industrial Drive South 11000 Hwy. 70 South
Gainesville, TX 76241-0390 Erwin, TN 37650 Roaring Springs, TX 79256
(940) 665-1721 (423) 743-9116 (806) 348-7551
(800) 433-5632 Fax: (423) 743-8419 (877) 771-8330
Fax: (940) 668-8612 Fax: (806) 348-7905
Sales Fax: (940) 668-2704

FERNLEY PLANT SANDERSVILLE PLANT KIMBALL PLANT

230 Lyon Drive P.O. Box 784 3405 PolyPipe Road
Fernley, NV 89408 995 Waco Mill Road Kimball, NE 69145
(775) 575-5454 Sandersville, GA 31082 (308) 235-4828
Fax: (775) 575-6960 (478) 553-0576 Fax: (308) 235-2938

PolyPipe® is an active member of the Plastics Pipe Institute,

AWWA, AGA and ASTM.
ISO 9001:2000
PolyPipe, Inc.
2406 N. I-35 I P.O. Box 390 I Gainesville, TX 76241
Phone 940.665.1721 I 800.433.5632 I Facsimile 940.668.8612
Sales Facsimile 940.668.2704 I www.polypipeinc.com
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