While the technology of electrofusion welding is getting close to celebrating its 50th birthday, the process is still seen as a bit of a mystery and “new technology” by some.

Here we uncover what’s involved in electrofusion welding of PE piping, why it works so well and why installers may choose to make connections through electrofusion instead of other methods.

Electrofusion is a process employed for the connection of MDPE, HDPE, and various plastic pipes. It utilises specialist fittings equipped with integrated electric heating elements to effectively fuse the pipes at their junction.

The electrofusion welding technique involves positioning these fittings around the intended joint. Within these fittings, metal coils are embedded, and an electric current passes through them, generating heat that melts portions of the pipes. This molten material then solidifies, resulting in a strong joint.

Electrofusion couplings are fittings designed to facilitate the joining of polyethylene water and gas pipes. These fittings are constructed using high-density PE 100 to ensure a robust connection between the inner layer of the fitting and the outer layer of the pipe. The actual welding process occurs through the electrical resistance within the fitting, using a designated welding machine. The machine, combined with the app on your smartphone, helps the installer initiate the weld by scanning the barcode. The barcode scan automatically sets the parameters to begin the welding process, as well as recording all details against the barcode for future reference through the app.

One of the key advantages of electrofusion is its ability to create secure and dependable connections, thanks to its even distribution of heat. Additionally, the automatic retrieval of parameters by the welding machine minimises the tasks that the operator must carry out during the installation process. This level of safety and efficiency has made electrofusion the preferred method, especially within the gas sector.

The 2 most common approaches to connecting PE piping are electrofusion and metric compression.

As mentioned earlier, electrofusion welding uses electricity and heat to melt and form a permanent bond with the 2 pipes being connected.

On the other hand, metal compression relies on specially designed rubber gaskets (known as O rings) to form an internal watertight seal. Both are effective in creating a seal and connecting pipes.

Here are some of the reasons why electrofusion connections are preferred in many scenarios:

1. Emphasis on Safety and Consistency: Electrofusion welding is renowned for its commitment to safety and consistent results. It produces robust, leak-resistant joints, particularly crucial in sectors like water and gas distribution.

2. Versatility in Applications: Electrofusion welding finds utility across a broad spectrum of applications. It is employed to connect polyethylene (PE) and polypropylene (PP) pipes in water supply, gas distribution, industrial processes, and even geothermal energy systems.

3. Exceptional Joint Durability: Electrofusion joints frequently exhibit durability equivalent to the original pipe, withstanding both internal and external pressures. This exceptional strength contributes to their longevity.

4. Enhanced Data Recording: Contemporary electrofusion machines often incorporate data recording capabilities, enabling the preservation of welding parameters. This functionality proves valuable for quality assurance and traceability purposes.

5. Global Acceptance: Electrofusion welding has gained widespread acceptance in numerous countries globally and continues to grow in popularity as the preferred method for connecting plastic pipes.

6. Stringent Quality Assurance: Quality assurance stands as a pivotal component of the electrofusion welding process. Welds are subject to rigorous non-destructive assessments, such as visual inspection, ultrasound examination, or even X-ray analysis, to ensure their structural integrity.

Allmach technical staff have helped hundreds of installers make the most of electrofusion welding for PE piping.

Here are 2 of the most common questions we get asked:

What are hot and cold zones in electrofusion welding, and why are they important?

Hot and cold zones are also known as melt and freeze zones. This refers to the bond formed when elements are heated and cooled during the process. The length of these zones is crucial to forming a strong bond when melt pressure is optimal.

What is oxidization failure?

This is one of the most common failure points of electrofusion welding. Improper pipe preparation is the main cause. If the outer layer of the pipe is not properly prepared by pipe scraping, the oxidation that can form on the pipe creates a micro-barrier on the surface. While this is very thin (as thin as a piece of paper), it is enough to prevent the surfaces from fusing during the electrofusion process.

Roughing the surface is not enough – all pipes, even new, must be properly scraped before attempting to fuse the elements.

Allmach staff can help in determining how to remove this oxidation layer, plus recommend the proper tools to scrape off this layer. Wood rasps or metal files cannot be used as they produce inconsistent surface preparation. /

Electrofusion welding is a robust method for creating strong PE pipe joints. Through proper training, certification, and adherence to industry standards, the quality and integrity of the joints can be improved.

Also, by avoiding some of the common pitfalls during preparation, you can ensure a rigid and strong joint that will give you trouble-free distribution of water or other material being transported.

Speak with an Allmach technical representative on our range of electrofusion products, as well as tips and recommendations to suit your individual needs, at www.allmach.com.au

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