These guidelines are applicable to pipes and fittings complying with Australian/New Zealand Standards AS/NZS 4130 and AS/NZS 4129†.

1 GENERAL

Electrofusion fittings are currently available in the size range DN16 to DN1200. Larger sizes are under development.

The key to consistently making satisfactory joints is to follow the jointing procedure with particular emphasis on pipe surface preparation, avoidance of contamination, machine calibration, as well as temperature monitoring and control.

Pipes and fittings of different SDR can be joined together by the electrofusion process, eg DN250 SDR11 and SDR17 pipe can be successfully electrofused using a DN250 SDR17 fitting.

Some manufacturers supply electrofusion fittings for thinner pipes, down to SDR33 whereas others limit the use of some saddle type fittings to SDR11 or thicker. These limitations are usually detailed on the fitting body or on the packaging. If in doubt, check with the supplier or manufacturer, as unsatisfactory joints are likely to occur if the fitting/pipe combination is incorrect.

Pipes manufactured from different grades of PE materials- (for example PE80 and PE100) can be jointed successfully using electrofusion. Before welding it is important to confirm that all components have adequate nominal pressure rating for the operating conditions and the PE materials comply with AS/NZS 4131.

IMPORTANT: IN ALL CASES THE PN RATING OF THE FINAL ASSEMBLY IS THAT OF THE LOWEST RATED PIPE OR FITTING COMPONENT.

CAUTION: FIRE RISK – USING INCOMPATIBLE SDR PIPE WITH FITTINGS WILL RESULT IN A POOR WELD AND MAY CAUSE IGNITION OF THE ASSEMBLY

It is recommended to refer to the supplier or manufacturer of the electrofusion fittings for the installation instructions, as the method may be specific to the fitting.

Accurate record keeping and manual or automatic electrofusion equipment that provides good control of jointing conditions are essential.

SDR Pipe to Fitting Fusion Compatibility

It is advised to consult the fitting supplier or manufacturer for confirmation of fusion compatibility when using fittings suitable for different SDRs.

Operator Training

All welding operators shall be qualified to PMBWELD302B – Electrofusion weld Polyethylene Pipelines with a current license. Operators should be experienced with the equipment and pipe sizes relevant to the work being undertaken.

Training should be provided by Registered Training Organisations (RTO’s) that are accredited by State/Territory Training Authorities under the Australian National Training Authority (ANTA) guidelines and complying with PMB 07 Competency Standards prepared by Manufacturing Learning Australia, Qualification Framework for the plastics, rubber and cable making industry.

The RTO’s providing training in all forms of welding plastics pipeline systems must have staff qualified in presenting courses that meet competency standards covered by sections PMBWELD301A through PMBWELD311A in PMB 01.

The RTO’s normally issue an accreditation certificate to successful candidates completing the training course and maintain a register of accredited welders.

1.3 Required Equipment

The following is a list of the minimum equipment that should be available at each electrofusion welding site.

Diameter tape (i.e. Pi tape) – to measure average diameter in the weld zone
Metal Ruler – to measure insertion depth
Calliper or metal rule to measure Pipe ovality
Pipe preparation and alignment equipment
Pipe cutting – appropriate pipe cutting device to ensure pipe squareness
Rotational Peeling tool – Capable of removing a continuous minimum of 0.2mm of material per pass
Deburring tool – tool to remove sharp edge of pipe
Rerounding clamps – clamps must ensure area in weld zone remains within roundness specification during the weld
Alcohol cleaning wipes – EF fitting manufacturer approved cleaning wipes for final surface cleaning
White ink permanent marker
Alignment clamps – clamps must be able to align the pipe and fitting to ensure there are no bending stresses on the assembly during the welding
Environment protection enclosures (e.g. tent or shade apparatus for protection against direct sunlight exposure and adverse weather conditions )
Power supply (generator calibrated and rated as per fitting supplierspecification)

Electrofusion control unit in accordance with ISO 12176-2
Saddle fitting mounting tool (if using “top loading” saddles).