Polyethylene potable water mains with an assumed minimum design life of 50 years have been in widespread use in the water industry for more than 30 years.

In the 1980s and 1990s Severn Trent Water in the UK buried two polyethylene pipe test beds in the Midlands. These two test beds near the pumping stations at Great Gates and Coopers Green, had all the pipe material analysed chemically and mechanically before installation. This was documented in several studies as well as the subsequent exhumations in the following years.

IRRIGATION FITTINGS

PLASSON’s range of poly pipe fittings can help you complete any irrigation project. PLASSON fittings are high quality, UV stablised and corrosion-free to deliver leak-free watering systems that last.

The metric compression fitting range offers reliable options for joining blue stripe poly pipe as well as lilac pipe for recycled water. PLASSON’s Rural range has been specially engineered to join ag green stripe pipe. The innovative red barbed ends allow PLASSON Rural poly pipe joiners to connect both metric and imperial dimension pipe.

IRRIGATION FITTINGS THAT ARE SIMPLE YET SMART

PLASSON’s Quick Coupling Valve delivers easy control of pressurized water with a simple valve and key system.

This system can be installed almost anywhere with no power needed and no software required to make it work.  Just plug in the key, the valve is activated and water flows. Unplug the key, the valve closes and flow is switched off.

PLASSON also offers a lilac cap QVC for grey water and recycled water systems.

Increadingly, recycled water is now supplied to homes and businesses through purple pipes. These pipes supply water for flushing toilets, washing clothes and outdoor uses such as watering gardens in homes and businesses. The lilac cap QCV is designed to connect to recycled water supply to provide safe and secure connections for garden watering equipment, like sprinklers and hoses, as well as other irrigation tools.

PLASSON has always been a leading innovator – it was our technology that helped give the world the dual flush toilet cistern!

We are committed to providing a world-leading range of poly pipe joiners that deliver reliable. long-lasting PE pipelines.

PLASSON has always been a leading innovator – it was our technology that gave the world the dual flush toilet cistern!

We are committed to providing a world-leading range of poly pipe joiners that deliver reliable. long-lasting PE pipelines.

PLASSON products can be found in municipal water distribution systems, gas conveyance systems, industrial fluids transfer and wastewater systems and mines in over 80 countries around the world.

HOW TO JOIN POLY PIPE

When it comes to water, wastewater and gas pipelines, poly pipe (or polyethyene/PE as it is also known) is hard to beat. The flexible nature of polyethylene pipe allows it to be used in colder climates – where it will not crack – and in situations where rigid pipe would require multiple elbows to make complex turns. Unlike other plastic piping, poly pipe connections do not use glue to solvent weld pieces together. Instead, specially designed fittings seal poly connections using compression – this is why they are sometimes known as compression fittings.

PLASSON has engineered a range of simple yet smart compression fittings to make joining poly pipe easy and reliable. All PLASSON poly pipe joiners feature a unique O-ring design that means the fitting will seal the moment it goes on the pipe – tightening the nuts on PLASSON compression fittings is only neccesary to hold the pipe in place and prevent blow outs.

This innovative design feature means PLASSON compression fittings go on and stay on… and on! They are easy to install with a minimum of tools. All PLASSON poly pipe joiners are corrosion-resistant and made of UV stablilised material for a long service life.

Here’s some step-by-step install guides to show you how easy it is to connect poly pipe with PLASSON:

STEP-BY-STEP INSTALLATION GUIDE FOR PLASSON PLUMBING FITTINGS:

Plasson compression fittings are reliable and leak-free

HOW TO JOIN POLY PIPE OF DIFFERENT SIZES

STEP-BY-STEP INSTALLATION GUIDE FOR PLASSON REDUCING FITTINGS TO CONNECT PIPE OF DIFFERENT DIAMETERS

metric compression reduing fittings for 20 mm 63mm 110mm

Metric compression reducing tees Plasson Australia 63mm
WHAT IS ELECTROFUSION?

So Electrofusion.. it’s a mix of electricity and fusion but what does that mean?


Electrofusion, or EF for short, is a method of joining PE pipe in situations where butt fusion is not practicable, like where valves, elbows and tees need to be added.

TIPS FOR ELECTROFUSION WELDING

Specialised electrofusion fittings have electrical heating coils imbedded into them. When current is applied to these EF fittings, heat is created which melts the plastic of both the fitting and the pipe.

The plastic from both are forced to mix together under pressure due to the design of the fitting. Once the mixed plastic cools, the pipe and fitting are fused together permanently.

How does EF welding work?

The parameters of each fitting, like the fusion time, are recorded in the barcode on each fitting. These details are entered into the welding control box via a barcode scanner or some control boxes automatically detect a fitting’s settings when it is connected to the machine’s leads.

An electrofusion control box sends electrical current through metal coils inside the fitting. The current causes the metal to heat up. The plastic around the coils begins to melt and forms an expanding pool of hot, molten plastic. The melt pool from the fitting comes into contact with the surface of the pipe. The continued application of current causes the pipe surface to also melt.

The pipe melt and fitting melt is forced to mix as pressure builds up in the coupler area, due to the design of the fitting, forcing the two plastics together. This is key to producing a good weld. Following the end of the weld cycle, the fitting and the pipe are left to cool and the melted material solidifies to form a permanent joint.

Hot and cold zones, sometimes called melt and freeze zones, are formed when the wire coils heat up. The length of these zones is key to achieving melt pressure. The precise positioning of the coils in the fitting is also important to ensure uniform heat distribution.

Fusion parameters: temperature, pressure and time, are controlled by the electrofusion control box and it is fed parameters from the barcode on each fitting, or from the fitting itself. The electrofusion control box also records a report of the procedure with all the settings and data from the weld.

PLASSON has developed the SmartFuse system, which includes specialist fittings, a range of EF weld control boxes and an mobile phone app which guides installation, to help simplify the whole electrofusion process. Using the SmartFuse system makes welding quicker and easier. The automated process helps reduce errors and prompts installers to complete and double check all steps. You can read more about SmartFuse and watch our demonstration videos here…

HOW PLASSON ADAPTORS CONNECT POLY, COPPER, STEEL AND PVC PIPE

PLASSON’s unique design delivers maximum flexibility including offering reliable, leak-free way to connect a number of pipe materials.

Any standard PLASSON fitting can easily adapt to connect several different pipe materials, pipe sizes and also be used as a threaded connection with the help of our handy range of conversion kits.

EF TIPS TO SAVE TIME, MONEY AND HASSLES ON ANY JOB

No-one wants to re-do welds so the best way to save time, money and hassles is to ensure each and every weld is done according to best practice.  The key to good electrofusion welding is contained in the POP001 guidelines for electrofusion installation.

POP001 was put together by PIPA, the Plastics Industry Pipe Association of Australia to detail the best practice processes and parameters for electrofusion welding. Following these steps will help ensure quality, long-lasting and reliable pipe connections, helping you be a better installer and achieve more reliable, leak-free EF welds.

This quick install video shows how the steps outlined in POP001 apply in the field.

see the best practice method to install a 125mm electrofusion coupler

PLASSON has developed the SmartFuse system to help make electrofusion welding simplier. All SmartFuse fittings have built-in resistors that automatically load the correct weld parameters for the fitting into PLASSON SmartFuse electrofusion weld machines.

Welding is made even easier thanks to the SmartFuse app.  It not only guides and prompts installers to complete all of the best practice steps in POP001, the SmartFuse app records this information and the weld record either on USB or in the cloud.

It is important to know and understand all the steps outlined in POP 001 as omitting steps or failing to complete processes adequately can undermine weld quality and lead to failed pipelines.

The processes outlined in POP001 are known as best-practice.  It is crucial to always follow best-practice as failure to do so can open operators up to claims of negligence and compromise insurance cover.

For a full copy of POP001, click here…

SMARTFUSE FOR RELIABLE, LONG-LASTING PIPELINES

SmartFuse might just look like a product name etched into PLASSON fittings but it represents our commitment to high quality, reliable electrofusion welding – for installers, asset owners and those who rely on what comes down the pipes.


Over the last 50 years, metallic pipelines have been increasingly replaced by thermoplastic systems such as polyethylene, or PE. This is due to the significant advantages of PE like environmental resistance, especially corrosion, low maintenance demands and ease of installation; PE pipelines can even endure earthquakes.


Most newly installed water, sewage and gas distribution pipelines will be PE pipelines and they are increasingly being joined by electrofusion or EF.  Electrofusion is considered the most reliable method of joining gas-carrying pipes.  In fact, the gas industry was where EF was first used since gases can be hazardous if not secured properly.

Plasson EF couplers for welding poly pipe


SMARTFUSE: THE KEY TO RELIABLE LONG-LASTING INFRASTRUCTURE

Given the obvious need for reliable, long-lasting infrastructure, developing high quality electrofusion fittings and systems for installation has been a PLASSON priority.
 

With specialized control boxes, reliable electrofusion fittings and SmartFuse tooling, the SmartFuse electrofusion system helps deliver better electrofusion welding.


PLASSON SmartFuse electrofusion fittings range from options for small diameter poly pipe, like 16mm and 20mm, to options for large diameter civil water and waste water pipes at 400mm to 800mm, 900mm and even 1000mm.

Electrofusion delivers reliable results on small and large diameter poly pipe. EF is also suitable for pipes with a small diameter since it does not shrink the inner diameter of the pipe.  So whether welding a 32mm to 1/2″ brass transition fitting or a saddle onto 63mm blue stripe pipe, PLASSON SmartFuse fittings are engineered to deliver quality electrofusion welds.

the benefits of PLASSON Australia EF branch saddles

SMARTFUSE: TECHNOLOGY THAT WORKS SMARTER SO YOU DON’T WORK HARDER



The SmartFuse system offers fully automated welding and, when paired with the SmartFuse app, delivers image capture and cloud storage for all weld records. With the click of a button, weld data is stored and accessible, anywhere, anytime.


SmartFuse helps lower operational costs, reduces mistakes and joins can be easily traced and identified via the GPS data that is part of every SmartFuse weld record.


PLASSON is committed to innovation in the EF field. As a future focused company, we are continually working to improve what we offer, to facilitate better electrofusion welding, deliver enhanced asset management and asset visibility.

SmartFuse for guided EF weld from PLASSON Australia
WELD SMARTER


SmartFuse is one way PLASSON are helping raise the bar in electrofusion

EF WELDING: HOW PIPE OVALITY PREVENTS GOOD WELDS

The non-brittle and flexible characteristics of polyethylene make it ideal for many pressure and non-pressure applications. Those useful characteristics also mean PE pipe can alter shape. Ovality generally known as ‘out of roundness’ is one of the most common issues found in PE pipe. One of the best tips to ensure a quality electrofusion weld is to ensure that polyethylene pipe is not out-of-round before attempting the electrofusion process.

To determine if out-of-round conditions exists measure the pipe diameter in numerous directions across the pipe end with a tape measure. If the measurements exceed the maximum tolerance, a re-rounding clamp or device must be used to bring the pipe back to a round condition.

HOW DOES POLYETHYLENE PIPE BECOME OUT-OF-ROUND?

MANUFACTURING
Installers need to confirm that polyethylene pipe matches all dimensional requirements for the job and the fitting being installed and that the pipe does not exceed the allowed ovality. If ovality is greater than allowed you must take steps to re-round the pipe.

STORAGE
Polyethylene pipe that is warehoused for a period of time or stacked on top of each other can experience ovality issues (more pronounced with large diameter pipe).

TIME
Large Diameter Polyethylene pipe will tend to relax a little during storage due to a combination of its weight and its natural flexibility.

INSTALLATION
Mechanical forces experienced during some trenchless installation techniques such as Pipe Bursting or Directional Drilling can temporarily leave the polyethylene pipe elongated and out-of-round.

PREVIOUS INSTALLATION
Polyethylene pipe that has been underground for awhile is subjected to earth loads. These earth loads can cause the pipe to sag and/or become out-of-round.

WHY IT IS KEY TO ADDRESS PIPE OVALITY FOR ELECTROFUSION INSTALLATIONS

One of the most critical functions of the electrofusion process is to seal the gap between the pipe and the fitting and to build up interfacial pressures for the fusion process to take place. If this gap is not sealed and interfacial pressures cannot build up, there is no way for the electrofusion joint to effectively achieve the high quality fusion it was designed for.

If a pipe is out-of-round the initial concern is that the surface area of the pipe may not adequately come in contact with the fusion zone of the electrofusion fitting. This could result in the electrofusion fittings cold zones, which are designed to contain the material generated in the melt pool, allowing the molten material to escape out of the fusion area without producing any melt penetration. This is a key concern when installing tapping and branch saddles since they do not fully encircle the pipe like an electrofusion coupling.

HOW TO CORRECT OUT-OF-ROUND PIPE

First, determine if out-of-round conditions exists. This can be done visually for extreme cases or by measuring the pipe diameter in numerous directions across the pipe end with a tape measure. If the measurements exceed the maximum tolerance, a re-rounding clamp or device must be used to bring the pipe back to a round condition.

The following table shows the approved dimensions for PE100 pipe:

The PLASSON range includes high quality tools to prepare pipe correctly for electrofusion, inlcuding re-rounding clamps.

Click here to see PLASSON’s tooling range….

SMARTFUSE POLYMATIC PLUS CONTROL BOX: OVERVIEW

The Polymatic Plus is a very powerful electrofusion control unit for welding PE pipes with electrofusion fittings. The Polymatic Plus is a workhorse that delivers ease and speed without breaking the bank.

This cutting-edge electrofusion processor is designed around PLASSON’s SmartFuse System. Whether making a single electrofusion or taking on a big project, this electrofusion processor is up to the task and will deliver the highest quality electrofusion welds.

Operators will have peace of mind with the Polymatic Plus as the control box executes and fully monitors each and every electrofusion weld. The Polymatic Plus is rugged, reliable, and conforms to industry standards for electrofusion equipment. Features include Bluetooth and GPS capability, an easy-to-use barcode scanner, safe and reliable connectors, data recording, USB interface and compatibility with the SmartFuse mobile app.

WHAT COMES IN THE BOX: POLYMATIC PLUS

SMARTFUSE FOR QUALITY EF WELDING