Electrofusion Jointing Procedure

Electrofusion Fittings contain electrical filament wires which, when correctly connected to an
appropriate power source for the specified period of time, will fuse the coupling onto the pipe.
The correct jointing procedures for the installation of electrofusion couplers are contained within WIS 3-
32-08.

Electrofusion fittings for water and sewerage applications in both PE80 and PE100 are manufactured in
accordance with WIS 4-32-14 and EN 12201-3

It is possible to join dissimilar polyethylene pipe and wall thickness by using electrofusion fittings. For
example PE80 fittings may be used to join to PE100 pipe.

1. Tooling required for the welding of an

electrofusion fitting is a suitable electrofusion
control box with power supply and a scraper
capable of removing 0.2-0.4mm from the
outside of the polyethylene pipe.
An alignment clamp should be used to ensure
that the joint’s movement is kept to a
minimum during the heating and cooling
cycle together, with cleaning cloths and an
indelible pen. A welding shelter should also
be used to provide protection of the welding
area against adverse weather conditions and
contamination.

2. Using cleaning cloths firstly clean the area of Do not touch the scraped surface.
the pipe to be welded of any surface debris.

4. Open one side of the sealed bag containing the

Without removing the sealed packaging mark electrofusion fitting and slide it on to the pipe.
on the pipe the area which is to be scraped,
ie approximately 15-20mm beyond the
insertion depth of the coupler.

3. Using a suitable pipe surface preparation tool

“scraper” remove the pipe surface in the
selected area to a depth of
0.2-0.4mm; it is imperative at this stage of
the operation that this is preformed correctly.
Wherever possible a mechanical end
preparation tool is the preferred method of
pipe surface preparation as it is capable of
removing a continuous, even layer from the
pipe surface.
 The electrofusion coupler is fitted with a
centre stop. Slide the fitting along the pipe
until it comes into contact with the centre
stop. Mark the insertion depth using an
indelible marker pen.

7. Having ensured the power supply is working

correctly connect the electrofusion control
box to the fitting and power supply.

Follow the instructions given on the

Leave the bag over the end of the coupler to fusion box’s display screen.
protect against contamination coming into
contact with the inside of the fitting.
Input the fusion time either by using the
Scrape the second pipe as demonstrated in information embossed on the coupler or by
3. using the bar code affixed to the fitting.
The method used will depend on the type of
control box being used.
5. Remove the bag covering the coupler and
insert the second pipe up to the centre stop.
Then mark the insertion depth using an
indelible marker pen.

6. Correctly position and fit the restraining

clamp to the assembly.
Clamps should always be used to secure an
electrofusion assembly during the fusion
cycle.
 Fusion Cooling
time time

Melt well Bar code

Once the coupler has completed the fusion C. Turn the tool 90º and hook the cutting tool
cycle check that the melt indicators/melt under the edge of the flared skin. Then cut
wells show a successful fusion cycle has along the pipe.
taken place. Melt wells, as shown above,
should fill with melt to a point
approximately flush to the surface of the
fitting. The melt indicators fitted to
predominantly smaller fittings will rise
beyond the body of the electrofusion fitting.

The coupler must be left in retaining clamps

for the full cooling time specified on the
fitting although the terminal leads may be
removed with care at the end of the fusion
time.

Installing Electrofusion Couplers when

using ProFuse Pipe

D. Hold the edge of the skin and steadily peel

Profuse pipe allows electrofusion couplers
the skin to expose the naturally coloured
to be installed without the pipe having to be
pipe beneath.
scraped in the area to be welded.

A. Firstly remove any surface debris and clean

the general area of pipe to be welded.

B. Score the ProFuse pipe skin beyond the

insertion depth of the coupler.

Guide the Pipe Exposure Tool in the

direction of the arrow on the cutter around
the pipe whilst depressing the cutter to lift
the skin, resulting in a flared edge.
 3. Scrape or in this case score the Profuse pipe
skin and peel beyond the full length of the
couplers. Remove the centre stops and
position the fittings onto the pipe.

Coupler direction

E. Open one side of the bag containing the

coupler and slide it on to the pipe. Then
follow Electrofusion Procedure From stage 4.

Pipe ends

Using Electrofusion Couplers in the Slip

Mode
4. Slide the couplers back into position and
mark the pipe with an indelible pen, making
sure the pipe joint is central to the couplers.
The centre stops fitted in the Radius coupler
have been designed to be removable,
enabling the coupler to slip completely
along the pipe thereby allowing As with the electrofusion procedure the assembly
electrofusion to be used for pipe repairs and should be clamped prior to fusing.
connections.

1. In the first instance of a pipe repair, the

pipe ends must be cut square.

2. Cut a section of pipe to bridge the two

exposed pipe ends. Also position timbers to
support the gap section of pipe.
Electrofusion Tapping Tee Assembly Procedure.

Electrofusion Tapping Tees are available in a range of sizes with both 32 and 63mm
outlets. These fittings are suitable for joining to a range of pipe sizes and wall
thicknesses, the details of which are normally printed on each individual fitting.

1. Tooling required for the fitting of 5. Remove the fitting from its
the tee is a 40volt control box, a top packaging and then remove the cap,
loading clamp, scraper, a 12mm exposing the cutter, which should be
hexagon-tapping key, cleaning cloths flush. Do not touch the fitting base.
and an indelible pen. Begin by
checking that the pipe and fitting sizes
are compatible.

2. Using cleaning cloths firstly

clean the area of pipe, where you
intend to weld the fitting.

3. Without removing the fitting

from its packaging place the fitting
over the required position on the pipe.
With an indelible pen, mark on to the
pipe around the fitting the area to be 6. Ensure the loading screw on top
scraped. of the loading clamp is screwed out
fully, and then secure the fitting onto
the clamp.

4. Using a suitable scraping tool,

scrape the surface of the pipe to a
depth of 0.2 to 0.4mm over the whole
of the identified area.

DO NOT TOUCH SCRAPED SURFACE

7. Remove the filament protection apply the correct loading onto the
cover and position the fitting over the fitting.
prepared area of the pipe securing the
clamp to the manufactures instructions
at the same time. Check that there is sufficient fuel in
During this operation it is imperative the generator to fuse the service
that the scraped pipe surface and the connection and that the fusion box and
fusion pad are kept clean and free leads are in a good serviceable
from contamination. condition.

9. Start the generator and connect

the fusion box. Then connect the
leads from the fusion box to the
terminals of the tee. Follow the
instructions given on the fusion
boxes display screen and input the
fusion time either by using the fusion
time embossed on the fitting or by
using the bar code affixed to the
fitting, the method used will depend
on the type of control box being
employed.

8. Apply the correct loading by

winding down on the clamp until the
correct load is indicated. The preset
load indicator may vary slightly
between tools. The procedure
recommended by the clamp
manufactures should be followed to

Once fused the fitting must be left with

the clamp on for the full cooling
time, which is also embossed on the
fitting.
 and from the service pipe. A range of
Check that melt well has been filled mechanical scrapers are on the
with melt before proceeding. market, which best perform this
function.

Clamps are available for all

combinations of surface connection.

A number of industry specifications

advise that service connections are
10. During the cooling time it is the pressure tested before tapping into the
ideal time to assemble the service host main. Details of this operation
pipe, fittings and equipment needed to should be sourced from the relevant
connect the tapping tee outlet to the industry specifications.
surface pipe.
11. When the service pipe is in
place and has been successfully tested
The tee outlet is classified as pipe and then the host main may be tapped.
as such, follow the Radius Systems The pipeline may be tapped in or out
procedure for jointing couplers. of service. Firstly engage the hexagon
The service outlet requires scraping drive key into the cutter then wind the
and clamping cutter down in a continuous clockwise
direction until the cutter comes into
contact with the pipe.

An even layer 0.2 to 0.4mm should be

removed from the outside of the outlet

When you are ready to tap the main,

continue screwing the cutter in a
continuous clockwise direction
through the wall of the pipe. This
forces a coupon of polyethylene up
into the cutter body to form a seal. A. Firstly follow stages 1,2 and 3 of
The load needed to rotate the tapping the Tapping Tee assembly procedure
key will drop as soon as the main is but instead of a scraper, when using
tapped. Continue rotating the cutter ProFuse pipe, a peeling tool is
clockwise for another two revolutions required.
before retracting the cutter in an
anticlockwise direction.
B. With the ProFuse peeling tool
12. Retract the cutter until the score the marked area
cutter is nearly flush with the top of
the fitting, remove the tapping key
and then replace the cap.

C. Remove the peeled section of

ProFuse skin. Follow the Tapping Tee
assembly procedure from number 5.
Weld to the exposed section of pipe

Installing Tapping Tees using

ProFuse Pipe

ProFuse pipe allows electrofusion

fittings to be installed without having
to scrape the area of pipe to be

jointed.
Tapping thick wall Polyethylene B. Remove the thread follower ‘if
the follower is not removed it will
When tapping larger diameter and restrict the outlet’
thicker walled pipes with Radius
Systems tapping tees, the fittings are
fitted with a two-part cutter.

The operation to tap the main is the

same as already mentioned, until the
point of retraction of the cutter. At
this point the cutter and thread
follower ‘coloured red’ are retracted to
the point where the cutter is nearly
flush to the top of the fitting, at which
point the thread follower is removed.

A. Retract the cutter and thread

follower until the thread follower can C. Replace the cap
be removed.

Thread
Follower
Underclamp Service Connections Fitting Instructions

The electrofusion underclamp fittings are available in a range of outlet sizes 20mm, 25mm
and 32mm and are available in diameters from 40mm to 180mm.

1. Tooling required for installing of the With an indelible pen, mark the area to be
undercamp fitting is a 40volt control unit, scraped on the pipe.
a 13mm spanner or socket, a pipe scraper,
a 12mm hexagon-tapping key, cleaning
cloths and an indelible marker pen.
Begin by checking that the pipe and fitting
sizes are compatible.

2. Using cleaning cloths firstly clean the

area of pipe, where you intend to weld the
fitting.

3. Remove the fitting from its protective

bag and slacken the retaining nuts on one
side of the underclamp.

5. Using a suitable scraping tool, scrape

the surface of the pipe to a depth of 0.2 to
0.4mm over the whole of the identified
area.

4. Without removing the protective

cardboard matt cover, place the fitting
over the required position on the pipe.
6. Remove the cardboard matt cover and Follow the instructions given on the
place the fitting in position. fusion box display screen and input the
fusion time either by swiping the bar code
label affixed to the fitting with the LED pen
connected to the control box, or
alternatively the fusion time can be
inputted into the fusion box manually.
The manual fusion time is embossed onto
the fitting body.

Once the fitting has completed its fusion

time it must be left to cool. The cooling
time will be indicated by the fusion box or
is embossed on the body of the fitting.
7. Firmly clamp the fitting into position
by tightening the clamping straps up to a Before continuing to install the service
positive stop using a 13mm spanner or check that the melt well has filled
socket.

Melt Well

Check that there is sufficient fuel in the

generator to fuse the service connection
and that and that the fusion box leads are
in a good serviceable condition.

9. Start the generator and connect the

fusion box. Then connect the leads from
the fusion box to the terminals of the tee.
 When you are ready to tap the main,
continue screwing the cutter in a
continuous clockwise direction through
the wall of the pipe. This forces a coupon
of polyethylene up into the cutter body to
form a seal. The load needed to rotate the
tapping key will drop as soon as the main
is tapped. Continue rotating the cutter
clockwise for another two revolutions
before retracting the cutter in an
anticlockwise direction.

11. Retract the cutter until the cutter is

nearly flush with the top of the fitting,
remove the tapping key and then replace
the cap.

10. When the service pipe is in place and

has been successfully tested then the host
main may be tapped.
The pipeline may be tapped in or out of
service. Firstly engage the 12mm
hexagon drive key into the cutter then
wind the cutter down in a continuous
clockwise direction until the cutter comes
into contact with the pipe.