PE PIPE

JOINTING
SYSTEMS
PLASCO
OVERVIEW

MWANZA SEMINAR
22nd July 2015

JOINTING TECHNIQUES FOR PE PIPES

There are a number of techniques for
jointing of PE pipes
Compression fittings
Stub & flange - mechanical
Butt fusion
Socket fusion requires special fittings
Electro fusion requires special fittings

Compression fittings
Mainly for small diameters

Socket fusion
For small diameters
Special fittings and tools required

Mechanical jointing - PE Stub & Flange

For large diameters
Especially useful when connecting to other piping systems

Mechanical jointing - PE Stub & Flange

For large diameters
Especially useful when
connecting to other piping
systems

Mechanical Jointing

Demanding conditions
or remote locations

End restraint type

fittings

Connecting to other
materials and flanges

Butt fusion
Butt fusion technology is the safe,
reliable and favorable method of
jointing for a wide dimension range.

Butt Fusion Jointing

The fusion areas of the pipes and

fittings are heated to fusion
temperature and joined by means of
mechanical pressure, without using
additional materials. A homogeneous
joint results.

No fittings required
Continuous fully

Mechanical, hydraulic and CNCguided fusion machines for on site

constructions and the workshop are
available.

Preferred option, joint is

as strong as the pipe

homogeneous pipe

Butt fusion
For large diameters
Straight joints
Custom-made angles for fittings possible

Butt fusion
For large diameters
Forming continuous pipelines with flexible and leak free joints

No fluid losses during transportation

Butt fusion video

Electro fusion
In the electro fusion process a heating wire
permanently mouled into the fitting gets
heated by current at a low voltage. The
surrounding material around the wire gets
melted and expands due to the warming. The
melt starts closing the gap between pipe and
fitting, leading to a heat transition to the pipe
which also gets heated and melts in the
welding zone.
The pipe material also expands.
The increasing material expansion between
pipe and fitting, which is hindered by the cold
zones outside the welding zone, leads to a
build up a welding pressure between pipe and
fitting and a homogeneous welding
connection emerges.

Electro fusion
For all diameters
Only for jointing PE to PE
To be used when pipes cannot be butt welded
Special fittings and equipment required

Electro fusion video

Electro fusion Branch Saddle

Branching-off without cutting
the pipeline is possible using
Electro fusion Branch Saddles

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Electro fusion Branch Saddle

System features
Outlet:
d160-500mm
free
positioning in
axial and radial
position
Main pipe:
d315-2000mm

Cross
dimensional,
modular
installation
system

Tapping
device
integrated
windows scraper

EF Branch Saddle Video

INSTALLATION CONSIDERATIONS

INSTALLATION CONSIDERATIONS
Deliveries and storage on site
Pipe handling
Handling of pipes and fittings on site
Site damage
Thermal effects pipe expansion and
contraction
Welding management on site

Deliveries and storage on site straight pipes

Ensure that pipes and fittings are
delivered to site with the correct
documentation and that pipes are
marked in accordance with ISO 4427
Generally pipes can be stacked in a
regular manner up to a height of 3 m
Pipes should be placed on soft ground
or sand. When stored on concrete,
rocky or uneven ground timber battens
should be used
Provided the pipes are produced using
a good quality pre-compounded
material the pipes do not need to be
covered or shaded

Deliveries and storage on site coiled pipes

Coils are to be delivered with the
correct documentation and
marking

Coiled pipe should be stored flat

and on firm level ground which
has protection for the bottom coil.
Where space is limited coils can
be stacked up to a height of 2m
Wooden battens placed below the
bottom coil and between coils

Where large diameter coils are to

be stored vertically, coils must be
secured in racking

Handling of pipes and fittings on site

Pipes should never be thrown or
dropped of vehicles or platforms
Always use wide nylon or
polypropylene slings rather than
metal slings, hooks or chains
when handling pipes
Place pipes or fittings in contact
with lubricating or hydraulic oils,
gasoline, solvents or other
aggressive materials
Do not remove protective covers,
bags or end caps until required

Management of site damage

It is not unusual for the pipe surface to be
lightly scratched, scuffed or scraped
during installation and this is acceptable
Individual scratches of up to 10% of the
pipe wall thickness will not effect the
performance of the pipe (guidelines issued
by the US Plastic Pipes Institute and
several pipe producers)

If there are individual scratches of greater

than 10% of the wall thickness or large
areas of very heavy scratching, these
should be cut out and that section of the
pipe discarded

Thermal expansion of PE100 in comparison

to other pipe materials

HDPE

1.8m
0.8m

PVC

0.1m

Steel

Change in the length of a 1 km

pipeline with a 10 oC rise
0.5

1
Expansion

1.5

Thermal effects pipe expansion and contraction

The coefficient of thermal expansion for PE100 is 0.18 mm/m/OC
Thermal movement on unrestrained pipes in hot weather will be
obvious snaking of the pipeline
Experienced pipe fitters can easily cope with this.
One method is to cut and fix the lengths of pipe at either end when
the pipe is relatively cool. If connections are made with a straight pipe
under hot conditions there will be a stress on the joint when the pipe
cools and shrinks
Once buried there is very little thermal movement due to constriction
by the backfill, pipe skin friction and a much smaller variation in
temperatures, but still use restrained joints

Welding management - the butt weld process

After positioning of the pipes
end in the welding machine
and planing of the pipe ends

Pipe
Heating element
Pipe

Heating of the pipe ends

until then are semi-molten

220C
Double roll back welded
joint after removal of the
heating element and
cooling under pressure

Welding management on site

- training, certification and good practice
Only welders that trained, tested
and certified in accordance with
an international standard (e.g.
Certified HDPE Pipe Welder - GW
330) should operate machines 5
day course

Site staff should be trained and

certified as supervisors - 2 or 3
day course
Care and clean site conditions are
essential for good welding
Record sheets and/or a welding
machine to record every joint

Welding management on site

- training, certification and good practice

Welding management on site

- training, certification and good practice
Plasco Limited

Form 07.03.01
Rev: 0

Field Job Card

Job Card No
Customer Details

Customer Name

IOR/Contract No

Contact Name
After Hours / Cell No
Physical Address

Tel No
Fax No
Date

Safety Considerations
Lockouts
Mechanical
Electrical

Height work

Safety Personal Protective Equipment (PPE)

Ladders

Cranes

S/Shoes

Earplugs

Slings

Fire

Gloves

S/Glasses

Reflective Jacket

Hard Hat

Masks

Customer Requirements

Names of Welding Team

Team Leader

Welder 1

Welder 2

Equipment Requirements
Equipment, Machine and Tools

Machine No

Qty

Work Times
Date

Location

Weld
Numbers

Welds
Completed

Start Time

Finish Time

Additional Comments

Team Leaders Signature

Technical Services Manager

Total Hours

Customers
Signature

Remarks

Welding management on site examination

and testing of welds in the jointing section
Random welds are to the cut
out immediately after being
welded and tested in a
laboratory. Some specifications
call for 1% of all welds to be
tested
Initially every joint should be
inspected. Once welding
process is up to speed
inspections need only be made
on a regular basis
Visual inspection & bend back
testing of the weld beads on a
regular basis gives a good
initial indication of weld quality

Send the welders and supervisor off site!

On site hydrostatic testing of the pipeline

PE is visco-elastic and creeps under stress. The pressure gauge
falls back as the pipe expands under pressure.
Therefore with a single phase test it is not possible to tell whether
falling pressures are due to leakage or creep of the material
The three phase test eliminates the material response. Therefore
any loss of pressure should therefore be from leakage.
Steel pipes are tested primarily for integrity ie. no explosions whilst
PE pipes are primarily tested for leak tightness of welded joints.
PE tests must be done in one working day. If any stoppage then
depressurise the pipeline and start again.
In hot climates its best to test when temperatures are either stable
or falling in order to minimise problems due to thermal pipeline
expansion.

Pipelines are like a chain. They are only as

strong as their weakest link

PE100 pipeline projects must be designed

by engineers who are familiar with the
material and whom have been trained in
its proper system design

When comparing pipeline material options

designers should consider the entire
construction cost, not just the cost of the
pipes alone. If possible take in to account
the whole life cost of the pipeline utilities
need to collect the data!

The pipes must be manufactured from a

high quality material (PE100+) in a high
quality facility and in accordance with
national and international standards

Pipelines are like a chain. They are only as

strong as their weakest link
They must be joined by trained
and certified welding technicians
using equipped that is tested
and certified in accordance with
international standards

The pipelines must be correctly

installed in accordance with the
standards and engineering
specification by an experienced
contractor employing trained
staff
The supervision of the works
should be undertaken by a
suitably trained and experienced
site team

Conclusion
PE100 pipeline projects must be designed by engineers who are familiar
with the material and whom have been trained in its proper system design
When comparing pipeline material options, designers should consider the
entire construction cost, not just the cost of the pipes alone. If possible take
into account the whole life cost of the pipeline utilities need to collect the
data!
The pipes must be manufactured from a high quality material (PE100+) in a
high quality facility and in accordance with national and international
standards
They must be joined by trained and certified welding technicians using
equipment that is tested and certified in accordance with international
standards

The pipelines must be correctly installed in accordance with the standards

and engineering specification by an experienced contractor employing
trained staff
The supervision of the works should be undertaken by a suitably trained
and experienced site team
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THANK YOU

PLASCO LTD.
www.plasco.co.tz
plascosales@plasco.co.tz

Your one-stop-shop for

piping solutions

Sales Hotlines :
+255 717 752 726 / +255 686 350 543 / +255 769 756 495
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