3 Simple Steps for Successful Electrofusion

Electrofusion is a method of fusing two pipes together that could not be joined using traditional butt fusion. This usually occurs when the pipes require the addition of valves, tees or elbows to connect. Despite its fancy title, the procedure of electrofusion is quite a simple one, which can be characterised by the following three steps.

What You’ll Need for Electrofusion

Before you get hands-on with electrofusion, it is vital that you source all necessary parts and tools, as minimum contamination is imperative for the success of the welding.

Here are the required tools for the job:

• The two pieces of pipe you would like to fuse
• A heavy-duty clamp
• An electrofusion fitting/control unit
• A clean cloth
• A permanent marker pen
• A rotary-scraper

Step 1: Preparation

The key to a successful electrofusion procedure lies in its preparation stage. Any contaminants - ranging from sweat or body oil, to dust and debris – can impede the quality of the fusion and lead to a faulty pipe down the line.

Begin by wiping down the length of the pipes with a clean cloth with freshly-washed hands (rubbing alcohol optional). Once the pipes are free from mess, using a pipe-end preparation tool (the rotary-scraper), shave down the ends of each pipe in accordance with the diameter of the electrofusion fitting.

Top tips: try to get this in one continuous ribbon for a smoother finish and avoid hand-scraping to promote continuity.

Wipe down the ends of the pipes with the cloth and discard: you’re ready to fit the electrofusion unit.

Step 2: Attaching the Electrofusion Fitting

Now that your pipes are prepared, use a permanent marker to measure the depth of the fitting on each side. Once this is done, you can attach the three parts together, being sure to securely fix the trio with a heavy-duty clamp – any movement during the welding may result in a fault.

When the unit has been secured, insert the voltage cables from your ECU in the electrofusion fitting – no amount of force should be required. Using the barcode scanner on the ECU, scan the front code on the fitting to send the correct
configuration settings to the unit.

Step 3: The Electrofusion Process

Check the settings on the ECU’s display to ensure it matches up with that of the fitting, then you’re ready to activate the machine. Each fitting is configured differently, so the length of the procedure will vary from model to model. After the heating process, the fitting will allow itself to cool, notifying through the display when it has finished. Do not remove the clamp until the equipment has completely cooled, lest it knocks out of place before full fusion.

Now you know how to successfully attach an electrofusion fitting, it’s time to peruse the Total Pipeline Systems range and start incorporating the practice into your engineering work. With a variety of BS EN12201 products in many sizes - ranging from 20mm to 400mm diameters - there’s something for every electrofusion purpose, whether it’s reducers, couplers or duckfoot elbows you’re on the hunt for.