Generic Electrofusion User Guide

for Field Joining of

Polyethylene Gas Piping

TR-49

2020
 FOREWORD

This user guide was developed and published with the technical help of the members of the
PPI (Plastics Pipe Institute, Inc.). The members have shown their interest in quality
products by assisting independent standards-making and user organizations in the
development of standards, and also by developing reports on an industry-wide basis to
help engineers, code officials, specifying groups, and users.

The purpose of this user guide is to provide important information available to PPI on a
particular aspect of polyethylene pipe electrofusion to engineers, users, contractors, code
officials, and other interested parties. More detailed information on its purpose and use is
provided in the document itself.

This guide has been prepared by PPI as a service of the industry. The information in this
report is offered in good faith and believed to be accurate at the time of its preparation, but
is offered “as is” without any express or implied warranty, including WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Consult the
manufacturer for more detailed information about the particular joining procedures to be
used with its piping products. Any reference to or testing of a particular proprietary product
should not be construed as an endorsement by PPI, which does not endorse the
proprietary products or processes of any manufacturer. The information in this report is
offered for consideration by industry members in fulfilling their own compliance
responsibilities. PPI assumes no responsibility for compliance with applicable laws and
regulations.

PPI intends to revise this guide from time to time, in response to comments and
suggestions from users of the report. Please send suggestions of improvements to the
address below. Information on other publications can be obtained by contacting PPI directly
or visiting the web site.

The Plastics Pipe Institute, Inc.

www.plasticpipe.org

This Technical Report, TR-49, was first issued in September 2020.

© 2020 The Plastics Pipe Institute, Inc.

ii
 TABLE OF CONTENTS

Acknowledgments --------------------------------------------------------------------------------------------------V
1.0 History ----------------------------------------------------------------------------------------------------------- 1
2.0 Scope ------------------------------------------------------------------------------------------------------------ 1
3.0 Introduction ----------------------------------------------------------------------------------------------------- 2
3.1. Other Acceptable Fusion Procedures -------------------------------------------------------- 2
4.0 Safety Notes and Warning Symbols -------------------------------------------------------------------- 3
5.0 Jobsite Preparation ------------------------------------------------------------------------------------------ 4
6.0 Fitting Storage and Handling ------------------------------------------------------------------------------ 4
7.0 Required Tools ------------------------------------------------------------------------------------------------ 5
8.0 Measuring Pipe ----------------------------------------------------------------------------------------------- 7
8.1. Diameter ----------------------------------------------------------------------------------------------- 7
8.2. Pipe Toe-In ------------------------------------------------------------------------------------------- 8
8.3. Roundness-------------------------------------------------------------------------------------------- 8
9.0 Pipe Preparation -------------------------------------------------------------------------------------------- 10
9.1. Cleaning --------------------------------------------------------------------------------------------- 10
9.2. Scraping/Peeling ---------------------------------------------------------------------------------- 11
10.0 Fitting Clamping ----------------------------------------------------------------------------------------- 15
11.0 Control Box ----------------------------------------------------------------------------------------------- 16
12.0 Power Requirements ---------------------------------------------------------------------------------- 17
13.0 Fusion Parameters ------------------------------------------------------------------------------------- 18
14.0 Electrofusion Installation Training Procedures ------------------------------------------------- 19
14.1. Coupling Installation ----------------------------------------------------------------------------- 19
15.0 Saddle Installation -------------------------------------------------------------------------------------- 22
15.1. Clean the Pipe ------------------------------------------------------------------------------------- 22
16.0 Installation Inspection Checklist -------------------------------------------------------------------- 26
17.0 Joint Inspection/Acceptance Criteria -------------------------------------------------------------- 28
17.1. During Installation: -------------------------------------------------------------------------------- 28
17.2. After Installation: ---------------------------------------------------------------------------------- 28
18.0 Assembly Error Examples---------------------------------------------------------------------------- 29
Frequently Asked Questions ---------------------------------------------------------------------------------- 31
Operator Training and Qualification Guidelines --------------------------------------------------------- 35
Sample Written Review ----------------------------------------------------------------------------------------- 37

LIST OF TABLES

Table 1: Standard Pipe Dimensions - Iron Pipe Size (IPS) ASTM D2513 ............................. 7
Table 2: Standard Pipe Dimensions - Copper Tube Size (CTS) ASTM D2737 .................... 8
Table 3: Maximum Out-of-Roundness (IPS/DIPS) ................................................................. 9
Table 4: Input Power Requirements ...................................................................................... 17
Table 5: Maximum Pipe Square-ness Gap ........................................................................... 26

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 TABLE OF FIGURES

Figure 1: Submersible pump .................................................................................................... 4

Figure 2: Tape Measure and Pi Tape ...................................................................................... 5
Figure 3: Pipe Marking ............................................................................................................. 6
Figure 4: Pipe cutters (rotational, ratcheting, and guillotine style) .......................................... 6
Figure 5: Marking and cutting larger diameter pipes............................................................... 7
Figure 6: Roundness Measurement ........................................................................................ 9
Figure 7: Schematic of Cleaned Pipe Areas ......................................................................... 10
Figure 8: Scraping/Peeling measurement using a caliper .................................................... 12
Figure 9: Pipe Peelers ............................................................................................................ 13
Figure 10: Tubing Peelers (≥ 2 IPS) ...................................................................................... 13
Figure 11: Examples of serrated type blade scrapers .......................................................... 14
Figure 12: Hand Scrapers ...................................................................................................... 14
Figure 13: Pipe Alignment and Restraining Clamps ............................................................. 15
Figure 14: Integral saddle clamps that remain in place after fusion ..................................... 15
Figure 15: Reusable saddle clamps ...................................................................................... 16
Figure 16: 24-Digit Barcode ................................................................................................... 18
Figure 17: Identification Resistor Pins ................................................................................... 18
Figure 18: Fusion Time & Voltage Label ............................................................................... 19
Figure 19: Cut Pipe Ends ....................................................................................................... 19
Figure 20: Pipe Cleaning – Steps 2a and 2b ........................................................................ 20
Figure 21: Stab Depth Markings ............................................................................................ 20
Figure 22: Scrape pipe surface to remove oxidation ............................................................ 21
Figure 23: Remark Stab Depth .............................................................................................. 21
Figure 24: Install fitting to stab depth ..................................................................................... 21
Figure 25: Secure the pipe ..................................................................................................... 22
Figure 26: Connect to Control Box ........................................................................................ 22
Figure 27: Pipe Wash Areas .................................................................................................. 23
Figure 28: Marked Scraping Area .......................................................................................... 23
Figure 29: Pipe Scraped Area................................................................................................ 24
Figure 30: Saddle Placement................................................................................................. 24
Figure 31: Secure Saddle ...................................................................................................... 25
Figure 32: Control Box Connection........................................................................................ 25
Figure 33: Pipe Square-ness Measurement ......................................................................... 26
Figure 34: Correct................................................................................................................... 27
Figure 35: Incorrect ................................................................................................................ 27
Figure 36: Correct................................................................................................................... 27
Figure 37: Short Stab - Incorrect Assembly .......................................................................... 29
Figure 38: Mis-Stab - Incorrect Assembly ............................................................................. 29
Figure 39: Mis-Cut - Incorrect Assembly ............................................................................... 30

iv
 ACKNOWLEDGMENTS

Critical input and review was requested of and provided by gas utility operators, Gas
Technology Institute (GTI), Operations Technology Development (OTD) members, and
electrofusion fitting and equipment manufacturers.

The following is a list of contributors that provided technical assistance, user input, editorial
review, and endorsement of this guide:

Atmos Energy Palermo Plastics Pipe (P3)

CenterPoint Energy Plastics Pipe Institute (PPI)
CenterPoint Vectren Friatec (IPEX)
ConEdison Georg Fischer Central Plastics LLC
Dominion Energy Plasson USA
Gas Technology Institute
Infrasource
National Grid
Northeast Gas Association
Northwest Natural
One Gas
Peoples Gas
Quanta Services
SoCal Gas

v
 Generic Electrofusion User Guide for
Field Joining of Polyethylene Gas Piping

1.0 HISTORY

Electrofusion joining of PE pressure pipe has been commonly used in North America
for over 30 years. ASTM standard specifications for materials (ASTM D3350),
performance (ASTM F1055), and installation practice (ASTM F1290) have been in
publication for many years. Since each fitting manufacturer may have slightly varying
geometrical designs, and each manufacturer is responsible for establishing safe
installation temperature limits, it is also common that installation instructions can vary
from one manufacturer to another. Although instructions can vary, all fitting designs
share some common requirements for installation and all manufacturer’s instructions
include these same requirements.

A PPI task group was formed in 2017 to examine the differences among the varying
joining procedures, to identify similarities in those procedures, and to determine
whether there were a sufficient number of common elements to provide a basis for a
more uniform, or “generic” joining procedure that could be implemented by pipeline
operators for regulated gas applications as required in §192.283 (Plastic pipe,
qualifying joining procedures) of C.F.R (Code of Federal Regulations) Title 49.

The result of the task group work, along with input from utility users and industry
expertise, is the following technical report, TR-49 - Generic Electrofusion User Guide
for Field Joining of Polyethylene Gas Piping.

2.0 SCOPE

The purpose of this document is to provide background and supporting information

related to the common installation practices for electrofusion fittings. This information
is intended to be used in support of the development of generic joining procedures
and practices. The procedures contained herein are in alignment with the
manufacturers procedures that have been qualified by subjecting specimen joints
made using this procedure to the tests described in C.F.R Title 49, Part 192,
§192.283 (1)(iii) and (2).

This document is applicable for electrofusion joining to modern commercially

available PE pipe grades of PE2406, PE2708, PE3408, and PE4710. Legacy
materials such as PE2306, PE3406, PE3306, Dupont® Aldyl A, Uponor® Aldyl A,
and Driscopipe® 7000 or 8000 pipe materials were not included in the development
of this document.

PPI hopes that the inherent value of greater uniformity will provide all the incentive
necessary for companies to evaluate this procedure as a first option for electrofusion
joining of its PE piping products. Use of this procedure is obviously not mandatory,
and every electrofusion fitting producer, pipe producer, and pipeline operator retains
the option of developing different procedures for its particular products and pipelines.
However, PPI believes that its work in developing this procedure as a candidate for
1
 widespread acceptance throughout the industry will lead to greater efficiency,
simplicity, and understanding in this area and promote the use of effective, qualified
procedures for electrofusion joining of PE gas pipe.

3.0 INTRODUCTION

Electrofusion is widely used in the installation of polyethylene (PE) piping for gas
pressure applications. Electrofusion fitting designs vary between manufacturers and
historically each manufacturer had developed and qualified its own installation
procedure. Slight differences in procedures between manufacturers made it difficult
for pipeline operators to qualify persons through appropriate training and experience.
Creating a more uniform electrofusion joining guideline for natural gas distribution
systems would bring greater consistency to this aspect of the gas pipeline
installation, facilitate the pipeline owner’s efforts to qualify the procedure, increase
efficiencies, and simplify DOT enforcement duties.

Pipe preparation is perhaps the most important and least understood aspect of
making a sound electrofusion joint. Improper pipe preparation is overwhelmingly the
leading cause of unsuccessful electrofusion joint attempts because the installer may
not completely understand the goal of pipe scraping, which is to remove a thin layer
of the outer pipe surface (see trouble-shooting section for more details) to expose
clean virgin material beneath. Additionally, contamination is the second leading
cause of failures. Installers must appreciate the vital need to keep all surfaces of
the pipe and the electrofusion absolutely clean and free of contamination or other
foreign matter.

Proper installation techniques, installer understanding of and training to these

techniques, and effective examination before installation are key to a successful
installation. This document provides detailed instructions for each key step to a
successful installation, why each step is important, and how to tell if the requirements
of each step have been accomplished.

3.1. Other Acceptable Fusion Procedures

It must be recognized that there are many different procedures used both
currently and historically throughout the world that have been proven to make
effective, reliable electrofusion joints. The pipeline operator and every fitting
producer retain the option of developing different fusion procedures for its
particular products and pipelines. In certain cases, due to operating conditions,
weather, or the characteristics of the joining equipment, it may be necessary or
even advisable to use another procedure.

2
4.0 SAFETY NOTES AND WARNING SYMBOLS

Safety notes are included in this manual where appropriate, however this manual
does not purport to address all of the safety concerns associated with its use. It is the
responsibility of the user of this manual to establish appropriate safety and health
practices and to determine the applicability of regulatory limitations prior to use.

Symbols are used throughout this manual to indicate the potential for danger, injury,
and/or material damage, and to alert the user of important information related to the
fusion process. Symbols indicate that particular attention should be given and that
an action is necessary.

Symbol Meaning
Attention! – Important Information! Possible danger, damage, risk of
unsuccessful fusion or poor fusion quality.
Best Practice – This symbol is used to indicate an instruction that is
considered to be a “best practice”. This practice is recommended and
potentially vital to success.
Prohibited! – This symbol is used to indicate a practice, material, tool, or
action that is specifically prohibited in conjunction with instructions in this
manual.

Follow company guidelines and safety procedures for grounding/static

discharge.
Electrofusion fittings and equipment are not to be considered “explosion proof”.
Caution should be exercised when working with generators and other electrical
power sources.
Scraping/peeling tools can have sharp edges. Use with care to avoid injury.
Tools should be in good working order and inspected before use for wear and/or
damage. Damaged or worn tools should not be used until repaired.
The electrofusion processor and generator should be located out of the
excavation, when in a gaseous atmosphere, during the electrofusion operation.

3
5.0 JOBSITE PREPARATION

All heat fusion joining methods require that there is no water or any other foreign
liquids flowing or standing in the pipe that can reach the fusion surfaces. De-
watering of the site or excavation may be required to prevent ground water or other
liquids from reaching the fusion and contaminating the surfaces to be joined.
Dewatering can be accomplished using portable pumps (Fig.1) in moderate
conditions.

Figure 1: Submersible pump

Electrofusion fittings can be installed in ambient temperatures as recommended by
the manufacturer. A typical qualified temperature range for installation is 14°F
minimum to 113°F maximum. Some manufacturers have lower and/or higher
temperature limits and will state their qualified range in their technical specifications,
contact the fitting manufacturer to verify.

6.0 FITTING STORAGE AND HANDLING

Electrofusion fittings are packaged in sealed plastic bags as protection against

accumulation of dust, dirt, and contamination. The bag should remain in place during
normal handling and should only be removed immediately prior to installation.
Fittings are typically boxed to protect against sources of degradation, such as
oxidation due to UV exposure over long periods of storage. Surface oxidation can
still occur, therefore electrofusion fittings should not be exposed for long periods to
direct sunlight. Fittings should always be stored indoors in their original packaging
until installation. For transportation until installation, enclosed utility truck storage
bins are suitable.

Fittings with an unknown storage history or that have been exposed to

questionable storage conditions should be evaluated through destructive testing
of sample fusions. If fusion quality is shown to be affected, the fittings in
question should not be installed.

4
 Fittings should be inspected for damage before installing to ensure that connection
points such as terminal pins have not been damaged from handling, that there is no
visible damage to fusion surfaces or heating wires, and that no foreign materials are
present on or near the fusion surfaces.

Fittings can be cleaned if incidental contact is made with the fusion surface. A
suitable cleaning agent that contains no additives to hinder the fusion process must
be used. A 90% or greater concentration of Isopropyl alcohol, with no additional
additives except water, is universally accepted as a good cleaning agent. Ensure
that wipes are clean before use and do not use wipes on multiple surfaces to avoid
picking up and spreading contaminants.

Other cleaning agents, such as acetone, have been evaluated 1 and may be
acceptable alternates to Isopropyl alcohol. The fitting manufacturer or local
regulations should be consulted in case of questions.

DO NOT USE DENATURED ALCOHOL – Denatured alcohols may contain

additives that can prevent fusion and should not be used.

7.0 REQUIRED TOOLS

Proper tools are essential to a successful electrofusion installation. Tools include

devices for measuring, marking, cutting, scraping, peeling, cleaning, clamping (which
includes aligning and securing), re-rounding, and power delivery. At minimum, the
following items should be accessible during installation

• Measuring: A tape measure, rule, or fitting can be used for measurement of

insertion (stab) depth of pipe ends inside a coupling. A circumferential wrap Pi
tape for measurement of pipe diameter is also recommended to determine that
the pipe diameter is within specified tolerance.

Figure 2: Tape Measure and Pi Tape

1GTI-OTD FINAL REPORT 5.16.a-Project Number 21948 Solvent Cleaning and PE

Joining Procedures.
5
 • Marking: A fast-drying permanent visible marker of contrasting color to the pipe
is used to mark the pipe surface. The marker must not contain oils or other
ingredients that could accidentally contaminate a prepared pipe surface. Marks
are needed to locate insertion depths and to use as a guide for pipe scraping
effectiveness.

Figure 3: Pipe Marking

Markers that are slow-drying or contain oils that could be spread onto fusion
surfaces should not be used.

• Cutting: Devices that deliver a relatively clean and square cut (±3 degrees) on
the pipe ends are recommended. Square cut pipe ends are important when
inserting into electrofusion couplings because a pipe end that is cut with a severe
enough angle may not completely extend into the center cold zone or may not
cover the heating wires.

Many suitable types of pipe cutters are commercially available that can be used
for diameters of 12 inch and smaller (see Figure 4).

Use only those devices that are allowed/approved by the pipeline operator in a
manner that complies with all safety requirements.
Use caution when cutting pipe that has carried natural gas. Follow company
safety guidance for proper tools, grounding, or anti-static discharge measures.

Figure 4: Pipe cutters (rotational, ratcheting, and guillotine style)

For larger diameter pipe, a suitable saw (without lubricants that can be detrimental to
the joint) and a guide or guide marks can be used; reciprocating saws, circular saws
with a coarse-tooth blade, hot saws, chop saws, and chain saws are commonly used for
larger pipes with appropriate safety precautions and personal protective equipment.
Cutting marks can be made around the pipe using a 2 inch or wider strap or

6
 encirclement clamp as a guide so that the pipe can then be cut along the line as shown
in Figure 5.

Figure 5: Marking and cutting larger diameter pipes

8.0 MEASURING PIPE

8.1. Diameter

Electrofusion fittings are designed for use on pipe made to standard diameters
in dimensions for Iron Pipe Size (IPS) and Copper Tube Size (CTS). Pipe that
is outside of the diameter tolerance band of the appropriate pipe standard
should not be used. The following tables include diameters and tolerances
from ASTM D2513 and ASTM D2737 and can be used for reference when
measuring gas distribution pipe diameter to ensure that is within tolerance.

Table 1: Standard Pipe Dimensions - Iron Pipe Size (IPS) ASTM D2513
IRON PIPE SIZE (IPS) ASTM D2513
Nominal Pipe Size Nominal Diameter (inches) Tolerance (+/-)
1/2 IPS 0.840 0.004
3/4 IPS 1.050 0.004
1 IPS 1.315 0.005
1 1/4 IPS 1.660 0.005
1 1/2 IPS 1.900 0.006
2 IPS 2.375 0.006
3 IPS 3.500 0.008
4 IPS 4.500 0.009
6 IPS 6.625 0.011
8 IPS 8.625 0.013
10 IPS 10.750 0.015
12 IPS 12.750 0.017

7
 Table 2: Standard Pipe Dimensions - Copper Tube Size (CTS) ASTM D2737
COPPER TUBE SIZE (CTS) ASTM D2737
Nominal Tubing Size Nominal Daimeter (inches) Tolerance (+/-)
1/2 CTS 0.625 0.004
3/4 CTS 0.875 0.004
1 CTS 1.125 0.005
1 1/4 CTS 1.375 0.005
1 1/2 CTS 1.625 0.006
2 CTS 2.125 0.006

8.2. Pipe Toe-in

A slight reduction in pipe diameter at the end of the pipe is referred to as toe-in.
Pipes that are freshly cut and molded fittings generally do not have toe-in. If
severe toe-in is present, trimming up to 2 inches off the pipe end will usually
remove it.

8.3. Roundness

Polyethylene is a flexible material. Although pipe may be round at the time of

manufacture, pipe roundness can be affected by a number of conditions to
include coiling, storage/stacking, bending, and soil load if buried. The following
information can be used to determine if a pipe is suitable for electrofusion
joining without the use of re-rounding devices.

The condition of pipe roundness can be expressed in two ways; “out-of-

roundness” and “ovality”. While both are referencing the same basic condition,
it can sometimes be confusing.

8.3.1. Out-of-roundness is the difference in the maximum measured

diameter minus the minimum measured diameter. The pipe can be
measured with a tape measure or calipers to find the maximum (d1)
and minimum (d2) diameter points. The out-of-roundness is
calculated as d1- d2 as measured in the field.

8
 8.3.2. Ovality is the difference between the maximum and minimum
measured outside diameters expressed as a percentage. Ovality is
calculated as (d1 – d2) / Daverage x 100.

Figure 6: Roundness Measurement

Pipe out-of-roundness can have a negative effect on electrofusion
joint quality. If the pipe is out-of-round and is not corrected, the
amount of gap between the pipe and fitting can be too large for the
melt expansion to close and for proper heat transfer to occur
between the fitting and the pipe. An out-of-round pipe can also
increase the difficulty of sliding (coupling) or clamping (saddle) the
fitting onto the pipe.

Most often, 2 IPS and smaller diameter tubing is flexible enough that
the coupling and alignment clamps will provide the necessary
rounding forces and no other re-rounding device is needed.

For sizes equal to or larger than 3” IPS, re-rounding clamps may be

needed on either side of an electrofusion fitting to ensure that the gap
between the pipe and fitting is not too large. The table below can be
used for guidance when re-rounding clamps are used.

Table 3: Maximum Out-of-Roundness (IPS/DIPS)

PIPE SIZE d1 - d2
3" .0625 or 1/16"
4" .0625 or 1/16"
6" .125 or 1/8"
8" .125 or 1/8"
10" .125 or 1/8"
12" .125 or 1/8"

8.3.3. Pipe scratches, gouges, and damage: Installation of pipe can

cause surface scratches or gouges. Smaller scratches from dragging
or normal handling are not problematic and will normally be removed
during the pipe preparation process by scraping.

Gouges that are deeper than the scrape depth may also require extra attention
when scraping the pipe to ensure that any debris or contaminants embedded in
the gouges are removed. If the gouge exceeds 10% of the pipe wall thickness

9
 (refer to Coupling Installation, Sec. 4, p. 17), that pipe section should be cut out
and replaced to maintain the maximum pressure rating of the pipe.
Hydrocarbon contamination of PE pipe can result in reduced heat fusion joint
strength. Do not attempt to electrofuse to pipe that has been permeated by
heavy hydrocarbons at the external surface of the pipe area being fused. Refer to
ASTM D2513 Appendix X.1 for guidance on joining PE pipe that is known to have
hydrocarbon permeation.

9.0 PIPE PREPARATION

9.1. Cleaning

Clean the pipe beyond the area to be scraped with clean water 2 without
soap to remove dirt, mud, or other debris. Soaps should not be used
because it may contain surfactants or wetting agents that could be
detrimental the fusion process.
Clean the pipe for a length far enough beyond the area to be fused to
ensure that remaining debris on the pipe surface will not be transferred to
the area to be prepared during handling.
Inspect the cleaned pipe surface for gouges or embedded debris such as
rocks that might damage scraping and peeling blades.
Next, clean an area approximately twice as long as the area to be scraped
with 90% or greater isopropyl alcohol.

Figure 7: Schematic of Cleaned Pipe Areas

NOTE 1: Other cleaning agents (such as acetone) may be suitable. Refer to local regulations for
environmental and health effects.

2 At installation temperatures at or below freezing, a solvent may be used in place of water

for the initial cleaning.
10
 9.2. Scraping/Peeling

Pipe preparation is perhaps the most important and least understood aspect of
making a sound electrofusion joint. Improper pipe preparation is
overwhelmingly the leading cause of unsuccessful electrofusion joint attempts
because the installer may not completely understand the goal of pipe scraping,
which is to remove a thin layer of the outer pipe surface (see trouble-shooting
section for more details) to expose clean virgin material beneath.

Pipe surfaces exhibit surface oxidation from the extrusion process,

transportation, and outdoor exposure. Surface oxidation is a normal chemical
reaction that results in a physical change to the molecular structure of the
polymer chains on the pipe surface. Oxidation acts as a physical barrier and
therefore those surfaces cannot be heat fused. Simply roughing the pipe
surface is not sufficient. In order to achieve fusion, this layer must be removed.
Even new pipe must be properly scraped and prepared before a fusion will be
successful.

NOTE 2: The pipe preparation method discussed in this guide and references to “peeling” or “peelers”
refers to methods of removing the outer surface of the PE pipes. It should not be confused
with commercial products designated as “peelable pipes” which contain a removable outer
layer. While peelable pipe is suitable for use with electrofusion, the pipe preparation methods
discussed in this guide and references to “peeling” or “peelers” are not related to the use of
peelable pipe.

The outer oxidation layer on a pipe surface is very thin. It does not increase in
depth of more than a few thousandths of an inch even over long periods of
outdoor exposure, so regardless of the amount of time the pipe has been
stored before scraping, the scraping depth requirement is the same. An
adequate minimum amount of material that must be removed is just seven
thousandths of an inch (.007” or 7 mils). That thickness is approximately the
same as two sheets of ordinary paper.

Pipe preparation tools should be inspected at each use to ensure that they are
performing as intended. Cutting blades can dull quickly as they peel pipe.
Measurement of material thickness of peeled ribbon can be helpful to
determine if tools are working properly. The figure below shows a caliper being
used to measure a plastic peel ribbon. The 0.008 inch thickness indicates that
the tool is working properly. Preparation tools should be cleaned before each
use to remove any dirt, oils, or other residues from parts that will contact the
pipe surface.

11
 Figure 8: Scraping/Peeling measurement using a caliper

Sand paper, emery cloth, or other abrasives should never be used to prepare a
pipe surface for electrofusion. Abrasives have been proven to be ineffective for
electrofusion because they don’t adequately remove material, they can
redistribute contaminants on the surfaces, and because they can leave behind a
grit residue that forms another barrier that will also prevent fusion.

There are many tools that can be used for pipe preparation, however there are
differences in operation that should be considered, differences in appearance of the
pipe surface after use, and care must be used depending on the type of tool selected.
The only tools suitable for use for pipe surface preparation are those that are specifically
designed and qualified for electrofusion scraping and peeling.

12
9.2.1. Peelers

Examples of acceptable tools that “peel” the pipe surface to a

controlled depth are most commonly referred to as “peelers” and are
shown below.

Figure 9: Pipe Peelers

Figure 10: Tubing Peelers (≥ 2 IPS)

13
 9.2.2. Scrapers

Tools with serrated blades are also available; these tools physically
scrape the pipe surface by pulling the serrated blade across the pipe
in a perpendicular position to the pipe. Although these tools can be
used satisfactorily for pipe preparation, it is important to know that
serrated blades sometimes mask the pipe surface by leaving behind
score marks that make it difficult to visually tell if all of the original
surface material has been removed. Additionally, if a pipe surface
with serrations becomes dirty or contaminated, it may not be reliably
cleaned with a solvent and wipe due to the serrations trapping and
retaining material.

Figure 11: Examples of serrated type blade scrapers

9.2.3. A third type of tool is referred to as a “hand scraper”. These

scrapers are generally not recommended when peelers and
scrapers are commercially available due to inconsistent surface
preparation and difficulty in mastering skills required for uniform
surface preparation, however they can be used effectively. As a best
practice, they should only be used in situations where confined
working space or pipe scratches or gouges require a hand tool.

Figure 12: Hand Scrapers

Wood rasps and metal files are not acceptable scraping tools.

It is strongly recommended that, no matter what type of tool is used, witness marks
should be made on the pipe surface with a permanent marker prior to scraping. Some
reviews have shown that markers can penetrate the pipe surface so any marking that
remains after scraping is clear evidence to the user that areas were missed or that more
scraping is required.

14
10.0 FITTING CLAMPING

Electrofusion fittings generate significant pressures from thermal expansion during

the melt phase of the fusion process. This melt pressure is an integral part of the
fusion process and a designed function of the fitting and fusion parameter.
Polyethylene is also a thermoplastic that softens when heated. As a result, it is
recommended that all electrofusion fittings should be installed with the use of
alignment and restraining clamps or devices.

Couplings use clamps that restrain the pipe ends from moving and keep the pipes in
alignment. Some coupling clamp designs when placed on either side of the fitting
also serve to round the pipe. The pipe and coupling must be properly aligned and
supported in a stress-free condition for fusion and cooling.

Figure 13: Pipe Alignment and Restraining Clamps

Saddle type fittings require clamps to secure the fitting to the main to prevent
movement, restrain against generated melt pressure, and in some cases to form the
fitting to the contour of the main. Saddles are designed to be used with a particular
clamping device. Clamping devices are typically not interchangeable from one fitting
design or main size to another. In some cases clamping devices may be a part of
the fitting in the form of nylon straps or plastic clamps that bolt to the fitting
(commonly referred to as under-parts). Straps and underparts are typically intended
to remain in place after fusion.

Figure 14: Integral saddle clamps that remain in place after fusion

15
 Some other designs include a clamp that is re-usable and is removed after the fitting
has cooled.

Alignment and restraining clamps need to be inspected for excessive wear or

defects.

Figure 15: Reusable saddle clamps

11.0 CONTROL BOX

Electrofusion control boxes, sometimes referred to as processors, perform vital

functions during the fusion process. The control box provides carefully regulated
voltage for the required fusion time to input the designed energy necessary for fusion.
The control box performs basic checks prior to the beginning the fusion to verify that
the fitting coil has continuity, that the coil resistance matches the barcode information,
and that the voltage being supplied is sufficient. During the fusion process, the
control box also monitors the power being supplied to the fitting and can detect
certain assembly or fitting errors such as shorted heating coils or short-stabbed pipe
ends.

When using the fitting barcode, the control box checks the ambient air temperature
and automatically adjusts the fusion time for ambient temperature effects if the fitting
barcode requires.

The control box will terminate a fusion process when any defined protocol is out of
range and will display an error message. Most control boxes have a list of error
message meanings affixed to the unit that can be referred to if an error occurs. A
record of each fusion, as well as the result of the fusion cycle, is stored in a
downloadable memory.

The control box manufacturer recommends regular calibration intervals, typically

every 2 years, to ensure that all monitored parameters are measured accurately and
the control box is functioning normally. Units that are past their calibration interval will
normally alert the operator at power-up, but will continue to function when
acknowledged.

It is not recommended that units continue to be used beyond their calibration

period.

16
12.0 POWER REQUIREMENTS

Control boxes are typically available in 110v or 220v versions. The control box
monitors the energy input from the power source to ensure that fluctuations from the
generator are within designed tolerances and alerts the installer when parameters fall
out of range. Control boxes are typically tolerant to small fluctuations in input voltage
or frequency, however not all generators or inverters are equal. Generators
frequently are the cause of intermittent errors, when the assembly is known to have
been completed correctly. It is important to ensure that the power supply is in good
working order and capable of supplying the required energy for the fitting being
fused.

Each electrofusion fitting has an integral heating coil that requires a defined amount
of energy input to achieve the designed results. Heating coils are engineered
specifically for a fitting size or configuration and power requirements will vary from
one manufacturer to another for the same size fitting. The fitting manufacturer can
provide specific requirements for its particular products, but the table below can be
used as a guide for most fittings that are commonly available.

Table 4: Input Power Requirements

INPUT POWER REQUIREMENTS
FITTING FITTING GENERATO BREAKER EXTENSION EXTENSION
TYPE SIZE R MINIMUM MINIMUM CORD GAGE CORD GAGE
110v / 220v (25 ft.) (50 ft.)
SOCKET 1/2" to 2" 2.5 kVA 15 / 15 AMP #10/3 #8/3
SOCKET 3" to 12" 5 kVA 30 / 20 AMP #10/3 #8/3
SADDLE ALL 2.5 kVa 15 / 15 AMP #10/3 #8/3

Extension cords can be used, however the wire gage should not be less than that
shown in the table above for the applicable maximum length.

Consult the control box manufacturer for further details on recommended extension
cords, pigtails, generators or inverter needs.

Load tests can be performed on power supply equipment to verify output and duty
cycle.

17
13.0 FUSION PARAMETERS

Fusion parameters such as fusion time, voltage, and cooling time, can be entered
into the control box by various means.

• All electrofusion fittings have a fusion barcode attached that contains all of the
information needed by the control box to perform the fusion process. Barcodes
contain additional information about the fitting manufacturer, fitting resistance,
and temperature correction values if required by the fitting manufacturer.

o Codes are displayed on the fitting label in an interleaved barcode format

that can be read by a barcode wand or hand-held scanner.
o The 24-digit numerical value is also printed on the label, either directly
above or below the barcode that can be entered into the control box in in
the event that the code cannot be scanned.

Figure 16: 24-Digit Barcode

• Identification resistors are supplied in some fitting designs that can be read by a
compatible control box to automatically set the fusion time, voltage, and cooling
time. The resistor pin is usually identified by a colored insert in the center of the
pin that can be matched to a colored end of the control box cable.

Figure 17: Identification Resistor Pins

18
 • Manual entry of fusion time and voltage entry may be possible if printed on the
fitting label. The fusion time is typically preceded by the word “WELD” or “FUSE”
and displayed in seconds. The voltage is displayed and followed by “V”.

Figure 18: Fusion Time & Voltage Label

14.0 ELECTROFUSION INSTALLATION TRAINING PROCEDURES

Preamble: It is important to note that the cleaning, scraping, assembly and fusion
steps should be performed promptly in succession, for any type of fitting being
installed. Prompt execution of these steps will minimize the chances of
contamination on the fusion surfaces of the pipe and fitting.

14.1. COUPLING INSTALLATION

Cut the pipe ends (after cleaning first if necessary) squarely and evenly to
remove any toe-in.

Figure 19: Cut Pipe Ends

Clean the pipe ends inside and out to remove dirt, mud, and other debris
prior to scraping.

a. Clean water (no soap) can be used for initial cleaning of pipe surfaces
prior to scraping. Clean the pipe for a length far enough beyond the
area to be fused to ensure that remaining debris on the pipe surface
will not be transferred to the area to be prepared during handling. Dry
with a single-use clean cotton towel or disposable paper towel.

b. Solvent-clean the pipe with 90% or greater isopropyl alcohol using a

one-time use pre-saturated wipe or single use clean cotton towel or
disposable paper towel (exceeding area to be scraped, but within the
water-washed area). See Figure below and the Pipe Preparation
section for more details.

19
 Figure 20: Pipe Cleaning – Steps 2a and 2b

Measure and mark the stab depth on the pipe ends. If stab depth marks
are not indicated on the outside of the coupling, measure the total length
of the coupling to be installed and make a mark on both pipe ends equal to
½ the length of the coupling. This mark is used as visual indication by the
installer of the minimum length that needs to be scraped and that the pipe
ends are correctly inserted to the center of the coupler. Check the pipe
surface for any embedded debris that may cause damage to scraping
tools, and once more make sure that the outer pipe surface is clean and
free of any dirt or mud that could re-contaminate the scraped pipe
surfaces. Mark the entire pipe surface to be scraped with longitudinal
and/or circumferential lines.

Figure 21: Stab Depth Markings

Scrape the outside of the pipe surface to remove oxidation and other
contaminants. Scrape for a distance slightly longer than the stab depth so
that the scraped area is visible beyond the coupling after assembly. Use
an appropriate scraping/peeling tool as described in the PIPE
PREPARATION section of this guide. Scrape the pipe surface until the
outer layer or “skin”, at least .007” thick, of the pipe has been removed to
expose a clean, virgin pipe material. If using a peeling tool, periodically
break the ribbon to prevent it from wrapping around the pipe. Continue
scraping/peeling to remove longitudinal or circumferential markings made
in step 3. Inspect the entire scraped area to ensure total scraping
coverage.

20
 Figure 22: Scrape pipe surface to remove oxidation

Remark the stab depth. Avoid touching the scraped pipe surface or the
inside of the coupling as body oils and other contaminants can affect
fusion joint performance. Optionally, clean thoroughly with 90% or greater
isopropyl alcohol using a one-time use pre-saturated wipe or single use
clean cotton towel or disposable paper towel. Allow to dry before
assembling. Do not use alcohol with any additives other than water.

CAUTION: Avoid all possible recontamination of the prepared surface.

Do not use Denatured Alcohol.

Figure 23: Remark Stab Depth

Remove coupling from plastic bag and immediately slide the coupling over
the scraped pipe ends to the stab depth markings. Fitting fusion surfaces
can be cleaned with 90% or greater isopropyl alcohol using a single-use
pre-saturated wipe or single-use low lint clean towel. Allow to dry before
assembling.

Figure 24: Install fitting to stab depth

21
 Clamp the pipe ends to align and secure the assembly. Verify alignment
and that no stress is exerted on the assembly. Make adjustments if
necessary and re-secure.

Figure 25: Secure the pipe

Connect the fitting to the control box, enter the fusion parameters, and
fuse the joint. See “Fusion Parameter” section for details.

Figure 26: Connect to Control Box

Allow the fused fitting and pipe assembly to remain undisturbed for the
minimum recommended cooling time.

Cooling is a vital part of the fusion process. Proper cooling and rough handling
times must be observed. See “clamping” section of this guide for further details.

15.0 SADDLE INSTALLATION

15.1. Clean the pipe

Clean the pipe to remove dirt, mud, and other debris.

a. Clean water (no soap) can be used for initial cleaning of pipe surfaces
prior to scraping. Clean the pipe for a length far enough beyond the
area to be fused to ensure that remaining debris on the pipe surface
will not be transferred to the area to be prepared during handling. Dry
with a single-use clean cotton towel or disposable paper towel.

22
b. Next, solvent clean a smaller area of the pipe with 90% or greater
isopropyl alcohol using a single-use pre-saturated wipe or single-use
clean cotton towel or disposable paper towel (exceeding the area to
be scraped, but within the water-washed area). See Figure below and
the Pipe Preparation section for more details.

Figure 27: Pipe Wash Areas

Mark the area on the pipe where the saddle is to be installed. This mark is
used by the installer to indicate the approximate size of the area to be
prepared. Check the pipe surface for any embedded debris that may
cause damage to scraping tools, and once more make sure that the outer
pipe surface is clean and free of any dirt or mud that could contaminate
the scraped pipe surface. Mark the entire pipe surface to be scraped with
longitudinal and/or circumferential lines.

Figure 28: Marked Scraping Area

Scrape the outside of the pipe surface to remove oxidation and other
contaminants. Use an appropriate scraping tool as described in the PIPE
PREPARATION section of this guide. Scrape the pipe surface until the
outer layer or “skin”, at least .007” thick, of the pipe has been removed to
expose a clean, virgin pipe material. . If using a peeling tool, periodically
break the ribbon to prevent it from wrapping around the pipe. Remove
longitudinal or circumferential markings made in step 3. Inspect the entire
scraped area to ensure total scraping coverage.

23
 Figure 29: Pipe Scraped Area
Avoid touching the scraped pipe surface or the fusion surface of the
saddle as body oils and other contaminants can affect fusion joint
performance. Optionally, clean thoroughly with 90% or greater isopropyl
alcohol using a one-time use pre-saturated wipe or single use clean cotton
towel or disposable paper towel. Allow to dry before assembling. Do not
use alcohol with any additives other than water.

CAUTION: Avoid all possible recontamination of the prepared surface.

Do not use Denatured Alcohol.

Remove saddle from bag and immediately place the saddle over the
scraped pipe surface. Ensure that the fitting fusion surface is only in
contact with the scraped pipe surface. Fitting fusion surfaces can be
cleaned with 90% or greater isopropyl alcohol using a single-use pre-
saturated wipe or single-use low lint clean towel. Allow to dry before
assembling.

Figure 30: Saddle Placement

Secure the saddle-to-pipe assembly with the appropriate clamping

mechanism required by the fitting manufacturer. If bolts are used in the
clamping device, make sure they are tightened in the proper sequence
and the required amount. See “clamping” section of this guide for further
details.

24
 Figure 31: Secure Saddle

Use only the clamps provided or required by the fitting manufacturer. Clamps
from one manufacturer’s fitting are not interchangeable with another’s.

Connect the fitting to the control box, enter the fusion parameters, and
fuse the joint. See “Fusion Parameter” section for details.

Figure 32: Control Box Connection

Allow the fused fitting and pipe assembly to remain undisturbed for the
minimum recommended cooling time.

Cooling is a vital part of the fusion process. Proper cooling and rough handling
times must be observed.

25
16.0 INSTALLATION INSPECTION CHECKLIST

• SQUARE CUT (±3 Degrees)

The square-ness of the cut can be checked if needed by placing a square at

the end of the pipe at its longest point and measuring the resulting gap
between the square and shortest point of the cut. The table below indicates the
resulting maximum measured gap when the cut angle is approximately 3
degrees from square.

Figure 33: Pipe Square-ness Measurement

Table 5: Maximum Pipe Square-ness Gap

Pipe or tubing size Maximum gap between square and pipe end to
result in approximately 3 degree angled cut
6"
1 1/2 & 2 IPS 1/8"
3 IPS 3/16"
4 IPS 1/4"
6 IPS 3/8"
8 IPS 1/2"
10 IPS 9/16"
12 IPS 5/8"

26
• SCRAPING

A properly scraped pipe has a thin outer layer of the pipe surface removed to
expose clean virgin PE material for fusion. Visual indicators can be very helpful
to ensure that all of the surface has been scraped, and that an adequate amount
has been removed.

Marking the pipe surface with a permanent marker is a simple and effective step.
Using the pipe print line as a depth indicator is also useful.

Figure 34: Correct

Figure 35: Incorrect

• ASSEMBLY/ALIGNMENT/RESTRAINT

Figure 36: Correct

27
 • FUSION
o Ensure that the generator or power source is adequately sized for the
fitting being fused.
o Ensure that the power source has an adequate supply of fuel to complete
the fusion cycle.
o Ensure that any extension cords are appropriately sized for the fitting
being fused.

• COOLING
o At minimum, mark the time on or near the fitting to indicate when the
minimum cooling time has elapsed. This will prevent inadvertent
movement or removal of the assembly and/or clamps.
o Additional information to be marked may include operator identification,
control box and fusion record number, or other installer or inspector
information.

17.0 JOINT INSPECTION/ACCEPTANCE CRITERIA

Inspection of electrofusion joints can only determine what is visible externally after
the fusion has taken place. Quality assurance of the fusion joint before placing into
service is accomplished during installation by several methods.

17.1. During installation:

o A trained and qualified installer performed the installation.
o Adherence to installation instructions ensured proper pipe preparation was
accomplished.
o Avoidance of the introduction of contamination on the prepared pipe and
fitting surfaces was ensured by pre-washing and solvent cleaning.
o Scraping/peeling tools were inspected, cleaned, and in good working
order.
o Peeling ribbons were measured and inspected for adequate peeling depth.
o Witness marks on the pipe surface were completely removed by
scraping/peeling.
o Cleaning, scraping/peeling, fitting assembly, and fusion steps were
performed in a sequence without interruption.
o The fitting was properly clamped and aligned during the fusion and cooling
cycle.
o The correct energy was supplied to the fitting and recorded by the
calibrated control box.
o Extension cords are correct gage and length, if applicable.

17.2. After installation:

o The fitting remained clamped and free of external stresses until the entire
cooling time elapsed.
o No error messages were displayed/stored by the control box.
o No abnormal events were observed during the fusion or cooling cycles.
o Pressure test at 1.5 times the operating pressure was completed and
passed.

28
18.0 ASSEMBLY ERROR EXAMPLES

• Short Stab – Incorrect Assembly: Assembly errors that can occur include
“short-stab” conditions where the one or both of the pipe ends are not centered
in the coupling. This condition is avoidable by measuring and marking the stab
depth on the pipe ends before inserting them into the coupling. If the pipe ends
are not properly inserted, the melt generated during the fusion cycle will expand
and flow over the end of the exposed pipe inside the fusion zone. Heating coil
wires are carried by the uncontained melt flow, causing shorting and rapid
overheating of the fusion zones.

Figure 37: Short Stab - Incorrect Assembly

• Mis-Stab – Incorrect Assembly: A mis-stab is another avoidable assembly error

where the pipes are not located in the center cold zone of the coupling. In this
case, one pipe end is over-inserted into the coupling, while the other is under-
inserted. Melt again is allowed to escape between the pipe ends and the
potential for heating coil shorting is likely.

Figure 38: Mis-Stab - Incorrect Assembly

29
• Mis-cut - Another potential error that can cause loss of melt containment is the
lack of a square cut on the pipe ends. While it is not necessary, nor practical, that
the pipe ends must be cut to exactly 90 degrees, care should be taken to keep
the cut as square as possible. Cold zone lengths are designed to accommodate
some degree of mis-cut on the pipe ends and still ensure full coverage of the
heating wires and sufficient cold zone contact to contain melt flow. A condition
where the pipe end is cut at too great an angle to allow the pipe end to cover the
heating coil and cold zone is referred to as a “mis-cut” assembly.

Figure 39: Mis-Cut - Incorrect Assembly

30
 FREQUENTLY ASKED QUESTIONS

1. What pipes can be fused with electrofusion fittings?

• Electrofusion fittings are compatible with pipe dimensions conforming to ASTM
D2513, F714 and D3035.
• Fittings are typically compatible with pipes with an SDR or DR range of 9 to 17.
Other wall thickness ranges and pressure ratings may also apply. Consult the
specific fitting manufacturer for details.
• Electrofusion fittings are fusible to PE 2406/2708 and
PE3408/3608/3708/3710/4710 pipes.

2. What are the power requirements?

A reliable source of AC power is necessary for a successful fusion.

• Generator – well maintained generator meeting the capacity requirements

shown in the Table under “POWER REQUIREMENTS”.
o Generator should have enough fuel to complete the electrofusion cycle.
o The governor/economy switch should be off so that the throttle is opened all
the way in anticipation of the power draw at the start of the fusion cycle.
o Provide output voltage in the range that meets the specifications of the
applicable processor model.
o Operate within a frequency range of 50 to 60 Hertz.
o A matching outlet is needed to mate with the plug equipped on the
electrofusion processor.

3. Can I use an extension cord with my processor?

The use of extension cords should be avoided; in the event an extension cord must
be used a 25-foot cord should have a wire gage of #10/3 and a 50-foot cord should
have a wire gage of #8/3.

4. Can I use a pigtail with my electrofusion processor?

No for field installations

31
5. What are the most common electrofusion failures?
Electrofusion has proven to be an extremely reliable joining system. The most
common reasons for failure account for more than 95% of all fusion failures:

• Contamination – poor pipe preparation

o Poor, over, or under scraping

• Dirt, mud, dust

o Grease, oils
o Moisture
o Hands (body oil, sunscreen, etc.)
o Solvents, unsuitable wiping fluids
o Unclean or unsuitable wiping rags

• Geometry – pipe out of round or not cut square

o Alignment Errors
 Pipe Mis-Stab – pipe not cut square and pipe ends not being centered in
the cold zone of the fitting.
 Short Stab – can result from improper insertion of the pipe or movement
during weld due to incorrect restraint
 Excessive Gap – excessive gap between pipe and fitting due to pipe out
of roundness, undersized pipe or over scraping of pipe surface.
 Pipe Movement during Fusion Cycle – due to external forces or forces
induced by the welding process, when the pipes are not clamped
properly.

• Movement – pipe not properly restrained during fusion process

o Removal of clamping equipment before observance of minimum cooling
times.

• Unusual conditions - Contact EF manufacturers if smoke or melt flow outside the

fitting are observed.

6. Can I use sandpaper, dragon skin or emery cloth to clean the PE pipe?
No, it is very important to note that abrasive materials such as sand paper, dragon
skin or emery cloth should never be used in place of an approved scraping tool.
Abrasive materials have been proven to be ineffective in the removal of sufficient
amounts to surface material needed to achieve an electrofusion bond and in fact
have been shown to impede the electrofusion process.

See “SCRAPER” section of this document.

Note the use of wood rasps, metal files or paint scrapers are not considered acceptable.

32
7. Why does the fitting need to observe the entire cooling time prior to pressure test or
backfill?
• One of the most misunderstood and often ignored components of the entire
electrofusion process is the cooling phase. It is often assumed that if the fitting is
cool enough to touch it must be cool enough to remove the restraint device or
even pressure test the connections. The cooling phase is critical to the success
of the electrofusion process and careful attention should be given to ensure that
the stated cooling times are properly adhered to (refer to fitting manufacturer for
specific fitting cooling times).

• When current is applied to the fitting the plastic in the fitting and on the pipe
surface begins to melt and form a melt pool. With continued application of
current the melt pool deepens at the pipe and fitting interface which in turn forces
internal pressure to build up. After the heating phase, the melt pool re-solidifies.
This process is known as co-crystallization between the melted pipe and fitting
material. The cooling phase provides a controlled environment between the pipe
and fitting where solidification can effectively take place. This cooling phase
begins immediately following the termination of current being supplied to the
fitting and continues for a period of time beyond the point where the PE polymer
re-solidifies (also known as clamping time). This allows ample time for the fusion
area to regain the strength and flexibility it exhibited prior to fusion. Any
movement or external stresses applied to the fused are during this cooling phase
may result in a compromised fusion joint.

8. Do I need to use clamps?

• Electrofusion couplings:

Electrofusion couplings (regardless of manufacturer) require the pipe to be

restrained or sufficiently supported on each side of the pipe to restrict movement
during the fusion and cooling process and alleviate or eliminate sources of stress
and/or strain until both the fusion cycle and the cooling cycle are completed.

To achieve this we recommend the use of some form of pipe restraint and/or
support for the primary purpose of controlling and eliminating any movement of
the fitting due to fusion pressures generated during the fusion process and/or
any external forces exerted on the pipe or fitting. The basis for using pipe
restraint and/or support when joining two pieces of PE pipe with an electrofusion
coupling is to:

o Minimize potential short stab, mis-stab or binding situations

o Ensure proper cold zone contact with the prepared fusion area so that
sufficient interfacial pressure is achieved.
o Eliminate unwanted loss of molten material from the fusion zone

33
 • Electrofusion saddles

Electrofusion saddles fittings include tapping tees, branch saddles, corp saddles
and others. Installation of an electrofusion saddle requires the use of
recommended restraint systems for the purpose of:

o Holding the fitting in place during the fusion process

o Eliminating fitting movement due to material expansion
o Ensuring proper cold zone contact with the prepared fusion area so that
sufficient interfacial pressure is built up.

A properly prepared and assembled joint that is kept stationary and free from stresses
and strains during the fusion process and recommended cooling time should have good
joint integrity that will last for the lifetime of the pipeline.

9. Can electrofusion fittings be re-fused if I have a power related failure?

• Electrofusion fittings can be re-fused only in the event of an input power
interruption.

o Fusion leads were detached during fusion

o Generator runs out of gas
o Processor malfunction
o Other circumstances that results in processor input power interruption

• Recommended procedure for re-fusing fittings:

1. Fitting should remain in restrained position

2. Fittings should be allowed to cool to ambient temperature
3. Fitting should be reconnected to the processor
4. Fitting should be completely refused for the entire fitting fusion time

This re-fusion procedure should be used for fusions that terminated due to input
power reasons only. Fittings that fault for any other reason should be removed
or abandoned

34
 OPERATOR TRAINING AND QUALIFICATION GUIDELINES

This guide provides a general introduction to the tools and steps required for making a
sound electrofusion joint. It does not take the place of operator training, experience, and
qualification through destructive testing. Installers shall complete these requirements prior
to installation of electrofusion fittings in a gas distribution system.

The instructions contained in this manual have been qualified to the requirements of Title
49 Code of Federal Regulations, Part 192.283.

Electrofusion fittings shall be installed only by persons that have received training from an
authorized instructor, that have a strong working knowledge of polyethylene and heat
fusion, and that have demonstrated their understanding of these requirements by making
electrofusion joints that have been qualified by destructive testing. Persons responsible for
the joining of polyethylene pipe for regulated gas applications must qualify according to the
requirements of Title 49 Code of Federal Regulations, Part 192.285. Other regulations may
also apply depending on the application, local codes, and/or jurisdictional oversight of state
and local regulating agencies.

35
49 CFR §192.285 Plastic pipe: Qualifying persons to make joints.
(a) No person may make a plastic pipe joint unless that person has been qualified
under the applicable joining procedure by:
(1) Appropriate training or experience in the use of the procedure; and
(2) Making a specimen joint from pipe sections joined according to the procedure
that passes the inspection and test set forth in paragraph (b) of this section.
(b) The specimen joint must be:
(1) Visually examined during and after assembly or joining and found to have the
same appearance as a joint or photographs of a joint that is acceptable under the
procedure; and
(2) In the case of a heat fusion, solvent cement, or adhesive joint:
(i) Tested under any one of the test methods listed under §192.283(a), or for PE
heat fusion joints (except for electrofusion joints) visually inspected and tested in
accordance with ASTM F2620-12 (incorporated by reference, see §192.7) applicable to
the type of joint and material being tested;
(ii) Examined by ultrasonic inspection and found not to contain flaws that would
cause failure; or
(iii) Cut into at least 3 longitudinal straps, each of which is:
(A) Visually examined and found not to contain voids or discontinuities on the cut
surfaces of the joint area; and
(B) Deformed by bending, torque, or impact, and if failure occurs, it must not initiate
in the joint area.
(c) A person must be re-qualified under an applicable procedure once each
calendar year at intervals not exceeding 15 months, or after any production joint is
found unacceptable by testing under §192.513.
(d) Each operator shall establish a method to determine that each person making
joints in plastic pipelines in the operator's system is qualified in accordance with this
section.
(e) For transmission pipe installed after July 1, 2021, records demonstrating each
person's plastic pipe joining qualifications at the time of construction in accordance with
this section must be retained for a minimum of 5 years following construction.

36
 SAMPLE WRITTEN REVIEW

The following is a sample written qualification test. Users should modify this test to address
their unique operating environment.
Generic Electrofusion Operator Training & Qualification Section

Operator Name: ____________________ Date: _______________________

Location: ________________

All Questions should be answered with either T for True or F for False.

1. The purpose of scraping is to remove the oxidized layer of PE pipe from the pipe
surface prior to electrofusion.
a. True
b. False

2. For out of round pipe it is acceptable to scrape the high points until the pipe fits
into the electrofusion coupling.
a. True
b. False

3. Sand paper, dragon skin, emery cloth, and other abrasives are acceptable for
scraping.
a. True
b. False

4. If the pipe becomes re-contaminated after scraping it is acceptable to use a

suitable solvent for cleaning purposes.
a. True
b. False

5. It is acceptable to perform an electrofusion with a slight trickle of water running

across the fusion area.
a. True
b. False

37
6. In case of an input power interruption only, an electrofusion fitting can be refused
for the entire fusion time after it has been allowed to cool completely.
a. True
b. False

7. Pressurizing, testing, and backfill can be performed immediately after the

electrofusion has been completed.
a. True
b. False

8. Pipe ends can be cut to within 10° of being completely square.

a. True
b. False

9. A 2500 watt generator is recommended for fusing electrofusion couplings (12" and
smaller).
a. True
b. False

10. Slow drying markers that contain oils should not be used when marking the pipe
for scraping.
a. True
b. False

11. If the electrofusion coupling is to be pushed completely over one pipe, it is

necessary to scrape the entire length of the coupling onto one of the pipes.

a. True
b. False

12. A standard metal file is acceptable for scraping the pipe surface.
a. True
b. False

13. There is no need to support hanging pipe ends during fusion.

a. True
b. False

14. Operators must re-qualify annually or if they make any bad joint
a. True
b. False

38
 15. Observance of pipe print line under saddle fitting fusion area after scraping is
acceptable.
a. True
b. False

16. A gouge or scratch in the pipe of more than 15% of the wall thickness is
acceptable.
a. True
b. False

17. An electrofusion joint should not be started if the processor incorrectly identifies
the fitting fusion parameters.
a. True
b. False

18. Alignment clamps should be used only if the pipes do not line up.
a. True
b. False

19. The generator should be checked prior to electrofusion to make sure it is

sufficiently fueled .
a. True
b. False

20. Electrofusion fittings should be kept in original packaging until installed

a. True
b. False

Number Correct: _______

Authorized Trainer: ________________________ Date: ________________

39