PLASSON has been manufacturing innovative electrofusion fittings for decades.  The SmartFuse system brings together the best electrofusion fittings and a systemised installation and weld recording process.

All SmartFuse fittings have smart resistors built in that feed the correct weld parameters into PLASSON’s SmartFuse EF welders as soon as the fitting is connected.

No manual entry and no scanning means it’s not only faster to set up each and every weld but the potential for costly input errors is eliminated.

The SmartFuse system is designed to guide each weld so that installers have clear steps to follow and there are prompts to ensure stages are fully completed.

Take a look at the full range of fittings here.

the benefits of PLASSON Australia EF branch saddles


Electrofusion fittings have different weld parameters and SmartFuse fittings have built-in resistors that feed these details directly into PLASSON’s SmartFuse control boxes.

The SmartFuse mobile app is also designed to make every job easier with guided installation, weld recording and reporting. Through the app, installers are not only guided through systemised welds, the app records photographs of each step.

Visual records are stored along with details for the fitting, precise location, installer ID, all control box weld stage times and data.

This data can be saved on site via USB, which is handy in remote areas with limited internet access, or automatically in the cloud. This gives managers and asset owners a real-time comprehensive picture of what is happening on any job, anywhere, anytime


Large diameter EF fittings require heavy-duty controllers and generators to supply the necessary power for long weld times. This high load means the control box will need to cool between welding cycles.

For those jobs where time is crititcal, PLASSON has developed a new controller called the PolyControl Plus.  With built-in cooling and novel power transformer technology, the PolyControl Plus reduces time between welds to a minimum.

see the best practice method to install a 125mm electrofusion coupler
How the PLASSON SmartFuse App helps make electrofusion quicker and easier

Using tooling specficially designed to EF welding is key to achieving successful weld. Also ensure equipment that requires calibration has been calibrated.

Equipment may vary depending on the product welded or the diameters being fused but should generally include the following:

Means of measuring the pipe (Pi tape, meter, etc) • Pipe cutting equipment

Marking pencil or pen

Scraping tools

Cleaning material, ensure wipes are saturated with alcohol (have not dried out)

Re-rounding tools

Pipe clamping tools

Power generator – generators must be capable of supplying the required power

Electrofusion control box with correct leads, barcode reader (not on manual boxes) and sufficient output power

PLASSON Fittings are weldable to PE80, PE100 and PEX* pipes. Check pipe SDR is compatible with the PLASSON fittings.

Pipe compatibility guidelines:

PLASSON’s Electrofusion Fittings:
• Up to 75mm (inclusive) are Weldable to Pipes SDR ≤ 11
• Elbows and Tees of main diameter 40mm-75mm ≤ 17
• 90mm & Up are Weldable to Pipes SDR ≤ 17
• 63-75mm Tapping Saddles and Valves are suitable for SDR11

• 90mm are Weldable to Pipes SDR ≤ 26
• 110mm – 800mm are Weldable to Pipes SDR ≤ 33

Wastewater Saddle:
• 200 mm & Up are Weldable to Pipes SDR ≤ 26

Wastewater Adjustable Elbow:
• 160 mm is Weldable to Pipes SDR ≤ 17

The pipe external diameter must be within the tolerances defined in International standards such as ISO 4437-2, AS/NZS 4130, EN 1555-2 and EN 12201-2.

Pipe preparation is key to successful electrofusion. Regardless of manufacturer, fittings will not perform to their full ability if preparation is not performed according to best practice as instructed by the manufacturer.

The pipe ends must be cut square and even.  Failure to cut the pipe square may leave the heating wire uncovered. This can lead to short circuit, overheating, uncontrolled melting and even sudden ignition.

It is also imporant to remove any burrs or shavings from the pipe ends.

The outer oxidized surface of the pipe must be peeled off prior to electrofusion.

Mark the required peel length by measuring the insertion depth of the fitting. With the fitting still in the bag, place it alongside the pipe end and place a witness mark on the pipe at half the fitting length plus about 2cm.  Peel the pipe up to this point.

Electrofusion fittings are designed to work on a round pipe. PE pipes, being manufactured from a flexible material, have the tendency to become out of round due to various reasons.

In order for the EF process to work properly, it is essential that the pipe is as round as possible. Do not perform an ElectroFusion weld if the pipe does not meet the criteria defined below at the section where the EF fitting is to be welded. Use a pipe re-rounder to correct pipe ovality.

Only authorized personnel are to perform electrofusion welds.  EF fittings must be installed according to best practice and a range of industry regulations and requirements. It is the installer’s sole responsibility to inquire as to the existence of such rules, regulations and requirements and to implement them fully.