Proper Use of Fabricated Fittings
&
Fusion Methods for Transition Connections
John Murphy
Blair Supply Agenda
 Butt Fusion vs. Electrofusion
 Proper Use of Fittings
 Types Of Transition Fittings
 Restraining Fittings & Pipe Movement
 Hands on Fusion Demo
HDPE MARKET - WATER
 EUROPE

70 – 75% HDPE MARKET PENETRATION
 RUSSIA 
90% HDPE MARKET PENETRATION
U.S.
3% HDPE MARKET PENETRATION
GROWING STEADILY
ELECTROFUSION vs. BUTT
FUSION
EUROPEAN MARKET
85% ELECTROFUSION FITTINGS
15% BUTT FUSION FITTINGS
UP TO 18” IN MOLDED BUTT FITTINGS
UP TO 12” IN EF TEES, ELBOWS, CAPS
US MARKET
15% ELECTROFUSION
85% BUTT FUSION
UP TO 12” IN MOLDED BUTT FITTINGS
STILL DEVELOPING EF TEES, ELBOWS, CAPS(LIMITED SIZES CURRENTLY OFFERED)
What is Butt Fusion?  The Joining of two ends of HDPE pipe or fittings
 Pipe Ends are Heated to 395 – 420 degrees
 Pipe Ends are joined together to mold into one and allowed to cool
 Beads are same inside and outside of pipe
Butt Fusion Procedures
•Pipe Cutting, Square Ends
•Proper Alignment Into Machine •Fusion Temperature •Fusion Pressure
•Cooling Time Butt Fusion Machine
CF14 , 1” – 4” Size
City of Courtland WWTP Up‐Grades
CF‐28 Machine 2”IPS – 8” DIPS
Village of Sodus, Water Intake Extension
CF620 Machine 6” IPS‐ 20DIPS Village of Sodus, Water Intake Extension Transition Fittings MJ Adapters IPS & DIPS With & W/O Stiffeners
Accessory Kits C110 HD Gland, Gaskets, & Long Tee Botls
NPT Threads Up to 4”  Male & Female  Carbon & Stainless
Butt Fuse Fittings
What is Electrofusion ??
 This technique involves preparing the outside surface of a pipe end, and inserting the Electrofusion fittings onto the pipe. The inside of the fitting has a copper coil that will heat to specific temperature when connected to EF processor . The melts from the two components flow together and fuse as the joint cools IntegriFuse EF Fittings
 Couplers
 1/2” - 48” IPS
 4” – 30” DIPS
 SDR 6 to SDR 32.5 Available
 Specialty Fittings
 90’s, 45’s & Tees
 Reducers & Flex Restraints
 Branch Saddles
 2” x 2” – 48” x 36”
 SDR 9 to SDR 32.5 Fusions Available
 NEW: Saddles with Electrofusion Outlets
IntegriFuse Electrofusion Fittings
Cutting Pipe Ends
Cut pipe at right angles Marking the Fusion Zone
Measure the fusion zone
Scraping the fusion zone
 This operation ensures removal of oxide layer, which will increase melt flow during the fusion process. It is critical that the oxide layer be removed completely; otherwise it may cause cold welding resulting in leakage. Mechanical Scraper Manual Scraper Deburring/Beveling Ends
Debur or Bevel pipe ends Cleaning the Fusion Zone
Insert the Pipe into the Coupler
 An assembly, which is stressed, may result in defective joint.  Ensure that both pipes are inserted into the fitting and the two ends are meeting each other in the center of the coupler (the cold zone). The maximum allowable gap between the two pipes is to be less than > ½”. If there are stops, push all the way to the stops.
Mis-Alignment- Unacceptable Fusion
Possible Causes: Inadequate Clamping or
Restraint during fusion.
Mis-Stab- Unacceptable Fusion
Possible Causes: Failure to mark and monitor
stab depth.
Short Stab- Unacceptable Fusion
Possible Causes: Failure to mark and monitor
stab depth.
Exposed Wire- Unacceptable Fusion
Possible Causes: Pipe Ovality, Flat Spots,
Undersized Pipe, Binding
Melt Out- Unacceptable Fusion
Possible Causes: Pipe Ovality, Flat Spots,
Undersized Pipe, Binding
Good Fusion- Acceptable.
Cool Time
The Cooling time is a critical step in determining the successful fusion of the EF Coupler to the pipe.
The Cooling Time is indicated by “Cool” on the coupler and is the amount of time required prior to examination, movement, and pressurization of the coupler.
After the Cooling time is finished, you are required to perform a flashlight test, in which the installer views the coupler/pipe interface to check for remaining gaps or wires that can be seen.
Utilize a metal hose clamp or plastic electrical tie to check the coupler/pipe interface to make sure that the tie or claps stops at the first wire.
The EF Fitting can be fused a maximum of 3 times if necessary, after the cooling time. FLEX RESTRAINT
ELECTROFUSION
 Designed for use on HDPE pipe 6" IPS/DIPS - 63" IPS
 Used to Create Thrust Restraints
 To minimize Pipe Expansion & Contraction
Water Park – Discovery Cove (Disney)
Village of Macedon WWTP Improvements 2013
Fusion Demo & Questions
Resources Blair Supply , www.blairsupplyusa.com Integrity Fusion Products, www.integrityfusion.com