Pipe and Tubing Extrusion: Technical Guide

7
Alkadyne™
PIPE AND TUBING
EXTRUSION
TECHNICAL GUIDE
Front Cover:
Polyethylene pipe is an engineered product, required to withstand
internal pressure and external influences for up to 100 years.
Qenos has invested in the largest pipe pressure testing facility
in the southern hemisphere, where Alkadyne PE100 pipe resin
is extruded for testing and then subject to high pressure and
elevated temperature for up to three years. This testing is also
applied to specially notched pipe samples to ensure damage
during installation does not result in premature failure. Alkadyne
PE100 pipe resin – Engineered to Outperform.
Qenos and Alkadyne are trade marks of Qenos Pty. Ltd.
PIPE AND TUBING
EXTRUSION 7
7 PIPE AND TUBING EXTRUSION
CONTENTS
INTRODUCTION 6
PIPE APPLICATION REQUIREMENTS 6
CLASSIFICATION OF POLYETHYLENE PIPE AND PIPE COMPOUNDS 6
ALKADYNE GRADE SELECTION FOR PIPE 7
PIPE EXTRUSION TECHNOLOGY 7
Granule Pre-treatment 7
Extruder 8
Pipe Dies 9
Sizing and Cooling 10
Downstream Equipment 11
Process Control 13
MECHANICAL PERFORMANCE OF POLYETHYLENE PIPE GRADES 13
Short-term Behaviour at Low Deformation Rates 13
Long-term Behaviour 14
Creep Behaviour Under Uniaxial Stress 14
Creep Test 14
Relaxation Test 15
Behaviour at High Deformation Rates 15
QUALITY TESTING OF POLYETHYLENE PIPE 15
PE 100: a Package of Good Properties 15
Hydrostatic Pressure Tests 15
Creep Test Under Internal Pressure 15
Pipe Pressure Curve And Service Life Extrapolation 17
Determining The Temperature Of The Pipe Wall 18
Determining The MAOP Value 19
NOTCH RESISTANCE (SCG) OF PE PIPES 20
Pipe Notch Test 20
RESISTANCE TO RAPID CRACK PROPAGATION (RCP) OF PE PIPES 20
S4 Test 21
JOINING PE PIPES 22
Butt Fusion Jointing of PE Pipes and Fittings 23
Relevant Standards 23
Jointing Procedures 23
Electrofusion Jointing of PE Pipes and Fittings 24
SDR Pipe to Fitting Fusion Compatibility 25
Electrofusion Socket Jointing 26
2 Qenos Technical Guides

PIPE AND TUBING EXTRUSION 7
Equipment 26
1. Control Box 26
2. Peeling Tools 27
3. Re-rounding and Alignment Clamps 27
4. Pipe Cutters 28
5. Weather Shelter 28
Electrofusion Jointing Method 28
Preparation of Pipe Ends 28
Jointing Procedure 29
Electrofusion Indicator Pins 31
Maintenance, Servicing and Calibration 31
Records 31
1. Job Supervision 31
2. Equipment Servicing and Calibration 31
3. Training 31
Electrofusion Saddle Jointing 32
Equipment 32
Preparation 33
Jointing Procedure 33
Top Load Electrofusion Branch Saddle Jointing 36
Maintenance, Servicing and Calibration 37
Records 37
1. Job Supervision 37
2. Equipment Servicing and Calibration 37
3. Training 37
Quality Assurance 37
Management Responsibility 38
1. Customer Focus 38
2. Planning 38
3. Responsibility, Authority and Communication 38
Control of Documents 38
1. Purchasing 38
2. Fusion Jointing Control 38
4. Corrective Action 38
5. Preservation of Product 38
6. Control of Records 38
7. Competence, Awareness and Training 39
Qenos Technical Guides 3

APPENDIX 1 – RECORD SHEETS 40

APPENDIX 2 – PIPE EXTRUSION TROUBLESHOOTING GUIDE 41
BIBLIOGRAPHY/FURTHER READING 43

INTRODUCTION
Alkadyne polyethylene grades are used for the extrusion
of pipe. The application areas in which Alkadyne pipe resin
is typically used include:
• Mining for conveyance of corrosive and abrasive
slurries and tailings
• Water management projects such as large scale
irrigation for agriculture
• Residential water distribution
• Civil work such as sewers
• Residential and industrial gas distribution
• Gas and water management in Coal Seam Gas
extraction
• Management of industrial fluids
• Drainage
• Rural applications such as management of water
on farms, etc.
Disclaimer
All information contained in this publication and any further information, advice, recommendation or assistance given by Qenos either orally or
in writing in relation to the contents of this publication is given in good faith and is believed by Qenos to be as accurate and up-to-date as possible.
The information is offered solely for your information and is not all-inclusive. The user should conduct its own investigations and satisfy itself as to
whether the information is relevant to the user’s requirements. The user should not rely upon the information in any way. The information shall not
be construed as representations of any outcome. Qenos expressly disclaims liability for any loss, damage, or injury (including any loss arising out of
negligence) directly or indirectly suffered or incurred as a result of or related to anyone using or relying on any of the information, except to the extent
Qenos is unable to exclude such liability under any relevant legislation.
Freedom from patent rights must not be assumed.

INTRODUCTION of PE-HD pipes, such as weldability, flexibility, chemical

Alkadyne polyethylene grades (Table 1) are used for the resistance and abrasion resistance, PE 100 pipes also
extrusion of pipe. The application areas in which Alkadyne bring marked improvements in important properties such
pipe resin is typically used include: as creep strength, notch resistance and resistance to rapid
crack propagation.
• Mining for conveyance of corrosive and abrasive
slurries and tailings PIPE APPLICATION REQUIREMENTS
• Water management projects such as large scale
The operating pressures for pipe systems could be
irrigation for agriculture
as high as 2.5 MPa (25 bar) for example in the
• Residential water distribution transportation of water. For gas applications the pressure
• Civil work such as sewers is usually contained below 1.0 MPa (10 bar). The ability
• Residential and industrial gas distribution of the pipe to withstand sustained pressure is important
• Gas and water management in Coal Seam Gas extraction and dimensions and pressure ratings for pipe made from
• Management of industrial fluids polyethylene are specified by relevant standards. A very
• Drainage high resistance to cracking is required, because of the
• Rural applications such as management of water wide range of environments and installation techniques
on farms, etc. that can be encountered in the field. The pipe must have
excellent weathering resistance because of extended
Pipe materials have high strength and exceptionally outdoor exposure.
high toughness. At present PE 100 is the highest Specifications for polyethylene resins to be used in pipes
classification for polyethylene resins and compounds from for the transportation of fluids under pressure are outlined
which to make pressure pipe. This means that in addition in relevant standards.
to retaining the generally acknowledged good properties
ALKADYNE GRADE SELECTION FOR PIPE

Table 1: Alkadyne Pipe Extrusion Grades
Melt Index
@ 190oC, 5kg Density
Grade (g/10min) (g/cm3) Application
HDF193B 0.3 0.961 High Density black PE100 Type resin certified to AS/NZS 4131, for use in
pressure pipes and fittings. Excellent low sag properties and throughput,
suitable for the majority of PE100 pipe dimensions.
HDF193N 0.3 0.952 High Density natural resin designed for extrusion into a full range of
non-standards pipe products and as a base for PE100 Type striping and
jacket compounds. HDF193N is not UV stabilised.
HDF145B 0.2 0.961 High Density black PE100 Type resin certified to AS/NZS 4131, for
use in pressure pipes and fittings. Exceptional low sag properties and
throughput, suitable for the most challenging pipe dimensions.
MD0898 0.7 0.952 Medium Density black PE80B Type resin certified to AS/NZS 4131 for
use in pressure pipes and fittings.
MD0592 0.6 0.942 Medium Density natural resin designed for extrusion into a full range
of non-standards pipe products and as a base for PE80Type striping
and jacket compounds. MD0592 is not UV stabilised.
MDF169 1.0 0.943 Medium Density natural high molecular weight resin designed for
extrusion into a full range of non-standards pipe products. MDF169
is not UV stabilised.
LL0228 1.7* 0.923 Linear Low Density resin for use in pipe extrusion applications such as
trickle irrigation. LL0228 is not UV stabilised.
* LL0228 @ 190°C, 2.16 kg. Melt Index according to ASTM D1238. Density accodring to ASTM D1505.

CLASSIFICATION OF POLYETHYLENE PIPE PIPE EXTRUSION TECHNOLOGY

AND PIPE COMPOUNDS A pipe extrusion line consists of a number of pieces of
Specifications for polyethylene compounds for use equipment. An extruder converts the polyethylene raw
in pressure pipes and pipes for pressure applications material to a continuous tubular melt by extrusion through
in Australia are covered by two Australian Standards: an annular die. The molten pipe then proceeds through a
sizing or calibration device (which fixes its dimensions) to
• AS/NZS 4131 “Polyethylene (PE) compounds for
a cooling trough. After being cooled, the pipe passes via a
pressure pipes and fittings”
haul-off to handling equipment for cutting into final lengths
• AS/NZS 4130 “Polyethylene (PE) pipes for pressure
or coiling. Printing devices may also be inserted into the
applications”
line to mark the extruded pipes with specific details.
The maximum allowable working pressure (and therefore A portion of a pipe extrusion line is shown in Figure 1.
class) of the pipe at 20°C is determined by:
• The type of compound used to make the pipe, and
• The dimensions of the pipe
Polyethylene compounds for pipe extrusion are designated
by the material type (PE) and an appropriate level of
Minimum Required Strength (MRS), details of which are
given in Table 2.
Table 2: MRS and Hydrostatic Design Stress

Requirements for PE 100 and PE 80 Compounds
Minimum Required Hydrostatic Figure 1: Illustration of a Pipe Extrusion Line
Strength (MRS) Design Stress
Designation (MPa) (MPa)
PE/MRS100 10.0 8.0 Granule Pre-treatment
PE/MRS80 8.0 6.3 Polyethylene is a hydrophobic material. However, for
polyethylene compounds that contain carbon black
The value of the minimum required strength is based on that is hygroscopic in nature, problems can arise if the
the long-term hydrostatic stress in the pressure pipe when moisture content of black polyethylene compound reaches
extrapolated to a 50-year life at 20°C. The hydrostatic > 0.03 w/w%. During extrusion, moisture could cause
design stress is arrived at by applying minimum safety formation of voids in pipe wall and rough pipe surface.
factor of 1.25 to the value of MRS. Reference should
be made to the data sheets for Alkadyne pipe grades for
details of their conformance to these requirements.
For each of the above designations, there are several
pressure classes with different wall thicknesses for each
nominal pipe diameter.
Figure 2: Photograph illustrating a Pipe with Voids

and a Rough Pipe Surface due to Excessive Moisture
in the Polymer Compound

Such problems can be overcome by drying the polymer

granules in a hopper dryer at 70 – 90°C for 1.5 – 2 hours
immediately before feeding them into the extruder. The
duration of drying and the drying temperature should be
such that the moisture content is reduced to < 0.02 w/w%.
Extruder
For processing HDPE and MDPE into pipes, single screw
extruders are used. To achieve the high throughput
required for pipe production, high-speed extruders with
forced-conveying feed systems have been developed and
widely used throughout the industry (see Figure 3).
Figure 4: Schematic of a Barrier Flighted Screw
incorporating a Pin Mixer
Figure 3: Illustration of a Single Screw Extruder

with a Spiral Grooved Feed Bush used for High Polymer
Throughput
These extruders have a cooled, grooved feed bushing

which is thermally insulated from the extruder barrel. As a
result, the conveying efficiency of the pelleted feedstock is
greatly enhanced achieving higher extruder throughput. For
optimal operation of a grooved bush system, it is required
to keep the bush cold to prevent melting of the pellets and Figure 5: Photos Illustrating some more Commonly
fouling of grooves. In order to ensure effectiveness of the Employed Mixing Sections Located at the Melt Delivery
grooved zone, these systems are cooled with a high flow End of the Screw
of chilled water (e.g. water flows of ~10 L/min and water
The typical screw length used in modern pipe extruders
temperature of approximately 10–20°C).
is generally around 30 L/D (e.g. screw length is described
Recent developments in screw design have seen the as a ratio of length divided by the screw diameter that
creation of barrier screws with enhanced melting capability is measured at the flight). The newest generation high
through the incorporation of a second spiral flight that throughput pipe line extruders have even higher screw
separates the polymer melt from the unmelted product lengths of 40 L/D.
(see Figure 4).
For example, a 90 mm well designed grooved feed
In addition to the barrier screw, mixing elements are extruder, would operate at an output of close to
generally used at the melt delivery end of the screw 1,000 kg/hr and some advanced extruders may achieve
to assist with homogenisation of the polymer melt an output of 1,500 kg/hr.
(see Figure 5).

Table 3 shows expected specific screw output ranges High production extruder throughput has resulted in the
(expressed as kg/hr/rpm) of pipe extruders versus screw polymer experiencing low residence times in the extruder.
diameter for high-speed-extruders with forced-conveying This lack of residence time can lead to concerns about
feed sections. Advanced extruders will have outputs close melt homogeneity and whether an even temperature
to the maximum of the designated output specification. distribution has been achieved throughout the melt.
Modern pipe resin grades also have high melt viscosity
Table 3: LDPE and HDPE Specific Screw Output Data
and elasticity that are required for the strength of the final
Versus Screw Diameter
product, as well as for the ability to make large and thick
Specific output [kg/hr/rpm] walled pipes within dimensional tolerances respectively.
Screw diameter
mm LDPE HDPE These polymer features make the extrusion line die
45 0.4 – 0.6 0.5 – 0.8 absolutely essential for the successful manufacture of
60 0.9 – 1.2 1.2 – 1.7
pipe, especially with respect to its capacity to even up any
melt inhomogeneity and shape it into the pipe without the
75 1.8 – 2.4 2.5 – 3.0
generation of weld lines or any other memory effects which
90 3.0 – 4.0 4.0 – 5.0 could potentially compromise the strength or appearance
120 6.0 – 8.0 8.0 – 11 of the final product.
150 10 – 13 12 – 16 One of the established die designs is a “Spiral Mandrel“.
The wide acceptance of this die has seen it incorporated
The economics of a pipe production plant will depend on into many new pipe production line designs. This die design
the following: has an excellent capability to homogenise melt and shape
• The range of pipe sizes – e.g. diameter sizes it into pipe without generating any imperfections which
• The length of pipe runs – e.g. producing pipe of a set could compromise the final quality or integrity of the pipe
dimension (see Figures 7 and 8).
• The available length of the cooling unit in the production
building
Bearing this in mind, increasing plant production capacity
might not be as straight forward as installing larger and
higher throughput extruders.
Pipe Dies
Today, manufacturers of pipe extrusion lines supply pipe dies
(see Figure 6) which they have developed themselves but
which are essentially based on a common design principle.
Figure 6: Photograph of a Pipe Die

Figure 7: Schematic Diagram Detailing the Components
of a Spiral Mandrel Die

These concerns are associated with potential of building

up excessive internal pressure within the pipe and leading
to an uncontrolled rupture including release of the floating
plug. Vacuum sizing technology enables quick starting up
of an extrusion line. In addition, the melt emerging from
the die can be drawn down to obtain a range of final pipe
diameters so that it is possible to produce at least two
standard pipe sizes with a single die/calibrator combination.
The pipe is shaped by a slotted sizing sleeve commonly
referred to as a “calibrator”. The calibrator is placed at
the entrance of the first vacuum tank and it is the first
downstream piece of line that the polymer melt sees
Figure 8: A Spiral Distributor and its Operating Principle after having exited the die. Calibrators are usually made
for Melt Homogenisation from non-ferrous metal for rapid removal of heat (see
Figures 10 and 11). A film of water is fed to the inlet
of the calibrator to enable rapid cooling (e.g. below the
Another die design which has found wide approval and
cyrstallisation temperature of the polymer) to solidify
use in pipe manufacture, for its performance, is the
the external pipe layer in order to pull the pipe into the
Lattice-Basket type die. This design results in relatively low
calibrator without tearing the molten tube apart. Water also
extrusion melt pressure and consequently relatively low
acts as a lubricant to reduce frictional forces on the pipe’s
melt temperature, both favourable for high extruder output
surface whilst it is being pulled through the calibrator. The
(see Figure 9).
vacuum tank, in which the calibrator is placed, applies a
vacuum which pulls the still hot, malleable tube against the
wall of the calibrator, thereby setting the outer pipe
diameter to ensure conformance to the pipe’s dimensional
specification. The vacuum is operated at about 0.05 MPa,
absolute pressure, which could vary depending on the pipe
dimensions. The calibrator is usually 3 – 5% larger than the
required final outer pipe diameter to provide for shrinkage
which takes place during pipe cooling.
Figure 9: A Lattice-Basket Die and the Basket Part

of the Die
Sizing and Cooling

In the state-of-the-art pipe manufacturing lines produced
today, vacuum tank sizing is the predominant method
used to shape the pipe from the melt. This includes the
manufacture of the very largest pipes that have dimensions
of 2000 mm. Unlike vacuum sizing, the internal pressure
sizing method, where a positive pressure is built up Figure 10: Sizing Sleeve for Vacuum-tank Sizing
within the pipe through the use of a floating plug, has
been rapidly phased out due to safety concerns.

Using these assumed temperatures, the total cooling-zone

length can be calculated as follows:
L = Lspec . Q (m)
where
Lspec = specific cooling-zone length (m.hr/kg)
Q = output (kg/hr)
Lspec relative to the pipe dimension is outlined in Table 4
below:
Table 4: L spec Relative to the Pipe Dimension
Figure 11: Vacuum Tanks for Sizing Pipes up to Pipe SDR* 41 33 26 17.6 11 7.4
1,400 mm in Diameter Lspec for HDPE 0.016 0.02 0.024 0.036 0.06 0.08
*SDR = Standard Dimension Ratio; a nominal ratio of the pipe outside
Downstream of the 1st vacuum tank there could be diameter to its wall thickness
another vacuum tank and certainly more cooling tanks
to ensure that the pipe completely solidifies by the time it Downstream Equipment
gets to the saw (see Figure 12). The additional cooling is Downstream equipment covers all other plant units
important to achieving the final pipe dimensions within the besides the extruder, die, sizing and cooling systems
desired tolerances. (see Figure 13). Most pipe manufacturing lines will have:
• Ultrasonic Thickness Meter – that continuously
measures the wall thickness around the circumference
of the pipe
• Caterpillar Haul Off Unit – with concentrically arranged
caterpillars held under pneumatic pressure against the
pipe to transmit the haul-off forces. For start-ups, the
haul-off unit can be switched to operate in the reverse
to enable a pipe to be run back through the cooling and
sizing systems to the point where the melt exits from the
pipe die. There the pipe can be welded to the extrudate.
• Marking Unit – where the pipe is marked with standard
specifications
• Automatically Adjustable Saw – mounted on a table
cuts the pipe into the desired lengths
• Coiling Unit – where smaller diameter pipes can be
Figure 12: Photographs of Spray Water Bath wound into coils or onto reels up to the appreciable
pipe size of 250 mm pipe diameter
The length of the cooling zone is dependent on the
output and the given dimensions of the pipe. The total
length (L) of the required cooling zone, can be calculated
on the assumption that a molten polymer extrudate, at
a temperature of ~220oC, has to be cooled with water to
an external pipe temperature of ~20oC, at which point the
internal surface temperature of the pipe is a maximum
of 85oC.

Figure 13: Schematic of a Pipe Extrusion Line showing Haul Off and Automatic Pipe Cutter

Process Control MECHANICAL PERFORMANCE OF

In new pipe production lines, process control computers POLYETHYLENE PIPE GRADES
are used to automate production.
Short-term Behaviour at Low Deformation Rates
To produce pipe in the required dimensions, the relevant
A typical stress/strain curve for HDPE pipe (PE 100 type
operating data is entered, for example:
pipe compound) is shown in Figure 15.
• Required throughput
The tensile test reveals the characteristic stress/strain
• Pipe dimensions
curve for cold stretching of an unreinforced, partially
• Screw speed crystalline polymer. Initially, tensile stress increases up to
• Haul-off rate the yield point. This is followed by spontaneous necking-
The set-point values and permissible deviations are suitably down of the test specimen accompanied by an apparent
fed-back to the controller for process data monitoring. decline in tensile stress, since the stress is related to the
initial cross section and not to the necked-down cross
In pipe manufacture, material costs represent a substantial
section at the yield point. When the necking-down has
proportion of the overall costs of production. It is therefore
progressed along the entire length of the test specimen
advisable to use computerised process control for optimum
to the clamps, tensile stress increases again as a result
production of pipes with the least possible waste of
of material strengthening due to macromolecular network
material and the best possible thickness uniformity around
straining and orienting until the breaking point is reached
the pipe circumference. Figure 14 shows a schematic
(ultimate tensile strength, elongation at break).
diagram of a computerized process control system for a
pipe production line. Because of the special deformation characteristics of
polyolefins, it is advisable to use an extensiometer to
determine elongation at break. Assessment is only
possible when the necking-down has progressed beyond
the measuring zone at each end. A polyolefin only retains
its useful application properties up to the yield point and
so it is better to dispense entirely with measurement of
ultimate tensile strength and elongation at break.
Figure 14: Computerized Process Control System for

a Pipe Production Line
The most commonly employed control system operates on

the basis of interaction between the following options:
• Weigh Feeder – the extruder is equipped with a
weigh feeder. Weighed granule portions are fed to the
extruder operating at required speed to achieve set
off-take of the weighted granulate feed. Any deviation
Figure 15: Typical Stress/Strain Curves for HDPE
from the set output resulting from the constant weight
Measured in a Tensile Test on Test Specimen Prepared
feed is compensated for by speed adjustment of the
from Compression Moulded Sheet; Test Temperature
extruder screw via the control system.
23°C, Testing Rate 50 mm/min
• Haul Off Control – the haul-off is set to a speed calculated
from the specified output and the required weight per
metre of the pipe. Pipe wall thickness is measured around
the circumference with an ultrasonic wall thickness meter.

The effect of temperature on the yield stress, ultimate Creep Test

tensile strength and elongation at break of a typical HDPE In the creep test, the increase in deformation with time
pipe grade is shown in Figure 16. of a specimen held under a constant stress is measured
and from this, the creep modulus is calculated.
Measurement can be carried out in a flexural creep test
or a tensile creep test. It should be noted that the creep
modulus is dependent on the level of stress as well as on
temperature and time. Typical creep curves are shown in
Figures 17 and 18.
Figure 17: Typical Tensile Creep Modulus Curves of HDPE

Figure 16: Yield Stress, Ultimate Tensile Strength and Determined at 23°C
Elongation at Break of HDPE as Functions of Temperature
Long-term Behaviour
High density polyethylene is a viscoelastic material. Like
all thermoplastics, it exhibits the property known as creep,
i.e. over a period of time it undergoes deformation even at
room temperature and under relatively low stress. After
removal of stress, a moulding more or less regains its
original shape, depending on the time under stress and the
magnitude of the stress. The recoverable deformation is
known as elastic deformation whereas the permanent
deformation is called plastic deformation.
It should be remembered that the mechanical properties of Figure 18: Typical Tensile Creep Modulus Curves of
a plastic are dependent on the three important parameters HDPE, Determined at 40°C
of time, temperature and stress.
In design calculations for moulded components, the Similar tests have been carried out to determine creep
mechanical property values (which in most cases are moduli under compressive stress. Taking scatter into
determined by long-term tests) must be divided by a account, these gave approximately the same results as
safety factor. those for tensile stress.
The creep modulus can be used in design calculations for
Creep Behaviour Under Uniaxial Stress moulded parts which are to be exposed to constant stress
A distinction is made between creep and relaxation tests. over an extended period of time.

Relaxation Test QUALITY TESTING OF POLYETHYLENE PIPE

In the relaxation test, the stress decay with time of a PE 100: A Package of Good Properties
specimen held under constant deformation is measured The designation PE 100 indicates that a PE-HD material
and from this, the relaxation modulus is calculated. has been assigned to performance class MRS 10 where
MRS stands for Minimum Required Stress. The minimum
creep strength is thus 10 MPa stress in the pipe wall at
20°C and 50 years. However creep strength alone does
not determine assignment to material class 100 but rather
a whole range of improved properties resulting from the
much improved toughness of these materials, the most
notable being:
• High resistance to Slow Crack Growth (SCG)
• High resistance to Rapid Crack Propagation (RCP)
Hydrostatic Pressure Tests

Undoubtedly the most important property of plastic pipes
is their hydrostatic strength behaviour under internal
pressure or “Creep Strength”. This is what determines the
service life expectancy of the pipe under internal pressure.
Figure 19: Typical Relaxation Modulus Curves of HDPE,
Determined at 23°C The equivalent stress (resulting from the action of the applied
pressure within the pipe) corresponds in practice to the hoop
It should be noted that the relaxation modulus is stress acting on the pipe internal surface. Knowledge of the
dependent on the level of strain as well as on temperature permissible stress for the material concerned forms the
and time. basis for designing a pipe under a given internal pressure
using the calculation formula for pressure vessels.
The relaxation modulus (see Figure 19) can be used in
design calculations for moulded parts that are to be The pressure to be used in the test is calculated from the
exposed to constant strain or compression over an extended equation below, knowing the dimensions of the pipe and
period of time. the required hoop stress.
Behaviour at High Deformation Rates P= 2ST

Dm min. + T
Information on the toughness characteristics of polymer
materials at high deformation rates is provided by flexural where:
and tensile impact strength tests. The results of impact P = maximum working pressure at 20oC (MPa)
strength tests (values for impact strength, notched impact S = hoop stress of hydrostatic design stress at 20oC (MPa)
strength and tensile impact strength) are considerably T = minimum wall thickness (mm)
influenced by the conditions under which the test specimen Dm min. = minimum mean inside diameter (mm)
is prepared. Injection moulded test specimens because of
their rapid cooling rate are less crystalline when solid and Creep Test Under Internal Pressure
therefore more impact resistant than those prepared from
The stress that leads to rupture in plastic pipes depends
compression moulded sheet. The orientation produced by
on the time under stress and the temperature of the test.
injection moulding also has an effect.
Creep behaviour has been studied in long-term tests over
many years, in some cases, since 1956 (see Figure 20).
ISO 9080 standard “Plastics piping and ducting systems
—Determination of the long-term hydrostatic strength of
thermoplastics materials in pipe form by extrapolation”
sets out rules for the determination of the long-term
hydrostatic strength of polyethylene pipes.

The hydrostatic tests that are carried out on pipe sections

under internal pressure take into account the effect of the
multi-axial strain occurring in practice. The pipes are filled
with water and suspended in a temperature-controlled
environment such as a water bath (see Figure 22).
Figure 20: The First Creep Rupture Test Started In

1956 In HOECHST (today known As Lyondell Basell)
Laboratory, Frankfurt
The same test rig, and “original” pipes are still in operation
today (see Figure 21). On 18th October 2006, two pipe
specimens on this “historical“ test stand finally confirmed
the predicted service of 50 years.
Figure 22: Extensive Hydrostatic Pipe Testing at Qenos

Technical Centre
Figure 21: The First Creep Rupture Test Started in 1956

in HOECHST (today known as Lyondell Basell) Laboratory,
Frankfurt, is still on test

Pipe pressure Curve and Service Life

Extrapolation
The results of these tests are plotted on a log-log scale.
Test stress is plotted against endurance time. After
sufficiently long testing times, the typical pipe curve
obtained from this plot shows three different regions or
stages (see Figure 23).
Figure 24: Pipe Failed in Ductile Mode
Ductile failure indicates ultimate pressure bearing

capability of the pipe. The flat branch therefore marks the
stress limit for ductile failure.
Figure 23: Representation of Pipe Curve According to the

3-stage Model (Illustration by Studsvik Material AB now
known as Exova)
Starting with short endurance times, a flat, straight

branch can be seen which is followed by a straight, steep Figure 25: Qualitative Interpretation of Pipe Curve as
branch. With the PE 100 grades currently used, this steep Generated on PE 80 Pipe Grade. Testing was According
branch does not begin for 10 000 hours, even at elevated to ISO 9080.
temperature (e.g. 80°C). After very long endurance times,
a vertical, stress-independent branch of the curve could
For the long-term properties of a pipe material, the position
be expected to follow for testing at 80°C, effectively
of the steep branch is crucial (e.g. in practice the steeper
indicating resin has degraded due to long exposure to
branch in the pressure test is referred to as a “knee”). It is
high temperature.
determined by the resistance of the material to slow crack
Each of the three curve stages is associated with three propagation. This material property, also referred to as
different failure mechanisms. In the flat stage of the brittle fracture resistance, determines the service life of the
pressure curves at 20°C and 80°C represented on pipeline. In other words pipelines are designed to operate in
Figure 25, only ductile fractures are observed. Ductile a “ductile” failure regime. The inflection point (the transition
type failure shows a visible deformation on the pipe in between the flat and steep branches) can be observed, if at
the failure region. Figure 24 shows a section of pipe that all, only at high temperature and after very long endurance
has failed in a ductile mode. times. This position denotes the transition from “ductile” to
“brittle” type behaviour of pipe under pressure.
Pipe that has failed in a brittle mode doesn’t show visible
ductility in the failure region (see Figure 26).

TEMPERATURE RE-RATING OF PE PIPES

The Maximum Allowable Operating Pressure (MAOP)
of a polyethylene (PE) pipe system is influenced by the
temperature of the pipe wall. The nominal pressure rating
(PN) assigned to an AS/NZS 4130 PE pipe equates to
performance at 20°C, i.e. a PN16 pipe is capable of
withstanding a MAOP of 160 m head (or 1.6 MPa or 16 bar
pressure) when operating continuously at 20°C. However,
as the temperature of the pipe wall increases, the MAOP of
the pipe is reduced progressively, in other words the pipe
system is re-rated with increasing temperature.
The guidance provided in this document is based on
typical PE compounds used in Australia and New Zealand
to manufacture AS/NZS 4130 PE pipe and listed in PIPA
Guideline POP004, Polyethylene Pipe Compounds.
Figure 26: Pipe Failed in Brittle Mode
Note: These guidelines apply to pipe used for the
Modern pipe grades such as PE 100 should not show conveyance of water. Where other incompressible fluids are
“brittle” like pipe failures in hydrostatic tests, even at 80°C, being considered, the designer must assess the effect of
within the required one year testing time (see Figure 27). the fluid on the PE pipe system at the operating temperature.
For example internal fluids such as aggressive condensates
when absorbed may have the effect of reducing the material
strength upon which design stress is based.
The rerating factors in this guideline are expressed in
terms of metre head of water and are not for use with
compressed air or gas applications.
The following information details how to determine
the temperature of the pipe wall and, then using Table 5
and 6, determine the de-rated MAOP value for the system.
These recommendations are not to be taken as detailed
specifications.
Figure 27: Creep Rupture Curve for Qenos PE 100 Grade
Alkadyne HDF193B. Testing was According to ISO 9080. Determining the Temperature of the Pipe Wall
The pressure rating of PE pressure pipe systems is based
When a PE piping system is to operate at a continuous on the temperature of the pipe wall, which may be
temperature higher than “designated standard” determined from either:
temperature of 20°C, ISO 9080 analysis could be used a. An assumption of a constant pipe wall temperature
to demonstrate capability of the pipe network in terms typical for continuous service at a set temperature,
of extrapolated values for application stress and life time. e.g. cold water service; or
Actual service life time of the PE pipe network will depend b. The determination of an average service temperature
on application conditions and ISO 9080 extrapolation where temperature variations are likely to occur in a
should not be used to infer actual service life time of the predictable pattern (refer below), e.g. in cavity walls or
PE network. roof spaces; or
c. The maximum service temperature less 10°C for
installations where large unpredictable temperature
variations occur up to a maximum of 80°C, e.g. above-
ground installations such as irrigation systems.

Predictable Temperature Variations Tm = T1L1 + T2L2 + ... + TnLn

For installations where predictable temperature variations where:
occur, the average material temperature is determined Tm = average pipe material temperature for the period
from Item (d) or Item (e) as follows: of time under consideration, in °C
d. Across the wall of the pipe — the material temperature Tn = average pipe material temperature for a proportion
taken as the mean of the internal and external pipe of pipe life, in °C
surface temperatures, where a temperature differential
Ln = proportion of life spent at temperature Tn
exists between the fluid in the pipe and the external
environmental.
Determining the MAOP Value
The pressure and temperature condition, where flow is
Once the temperature of the pipe wall has been
stopped for prolonged periods, should also be checked.
determined using any one of the methods (a), (b) or (c)
In this event, fluid temperature and outside temperature
above, the following tables can be used to determine the
may equalise.
re-rated MAOP for the PE pipe system.
e. With respect to time — the average temperature may be
considered as the weighted average of temperatures for Table 5 nominates the corresponding MAOP for a given
the proportion of time spent at each temperature under temperature for PE 80B material. Table 6 provides the
operational pressures; it is calculated with the equation: same information for PE 100 material.
Table 5: Maximum Allowable Operating Pressure – PE 80

Temp Min Life Design
(ºC) (yr) Factor PN 3.2 PN 4 PN 6.3 PN 8 PN 10 PN 12.5 PN 16 PN 20
20 100 1.0 32 40 64 80 102 128 160 200
25 1.0 32 40 64 80 102 128 160 200
30 1.2 27 33 53 67 85 107 133 167
35 1.3 25 31 49 62 78 98 123 154
40 1.3 25 31 49 62 78 99 123 154
45 1.4 23 29 46 57 73 91 114 143
50 36 1.6 20 25 40 50 63 80 100 125
55 24 1.7 19 24 38 47 60 75 94 118
60 12 1.8 18 22 36 44 56 71 89 111
80 1 2.4 13 17 27 33 42 53 67 83
Table 6: Maximum Allowable Operating Pressure – PE 100

Temp Min Life Design
(ºC) (yr) Factor PN 4 PN 6.3 PN 8 PN 10 PN 12.5 PN 16 PN 20 PN25
SDR41 SDR26 SDR21 SDR17 SDR13.6 SDR11 SDR9 SDR7.4
20 100 1.0 40 64 80 100 127 160 200 250
25 100 1.1 36 58 73 91 115 145 182 227
30 100 1.1 36 58 73 91 115 145 182 227
35 50 1.2 33 53 67 83 106 133 167 208
40 50 1.2 33 53 67 83 106 133 167 208
45 35 1.3 31 49 62 77 99 123 154 192
50 22 1.4 29 46 57 71 91 114 143 179
55 15 1.4 29 46 57 71 91 114 143 179
60 7 1.5 27 43 53 67 85 107 133 167
80 1 2.0 20 32 40 50 63 80 100 125
Note: the minimum life periods may be considered to be the minimum potential service lives and represent the maximum extrapolated periods
permitted by the ISO 9080 extrapolation rules given the available test data.

NOTCH RESISTANCE (SCG) OF PE PIPES This pipe is then pressure creep-tested under the following
Behind the phenomenon of creep strength and notch conditions:
resistance lays the process of slow crack propagation. • PE 100: 80°C; 4.6 MPa Hoop Stress; endurance time >
The brittle fracture observed is initiated by small defects 500 hrs
or notches in the pipe. An increase in temperature • The PE 100 materials pass this test without any problem
accelerates this process. The fracture diagram (see Figure
23) shows a small crack running lengthwise along the pipe.
As a partially crystalline polymer, polyethylene reacts to
the stress concentration at the crack tip (notch root) by
forming a crazing zone. This crazing zone develops into a
fully propagating crack that leads to a “brittle” type failure.
Application stress, which could lead to craze initiation and
crack propagation, is of the magnitude that is observed for
the hoop stress the pipe experiences in operation due to
the presence of an applied operating pressure.
Therefore, it is widely accepted in the field that the most
application relevant pipe property is its resistance to slow
crack growth, in other words, its susceptibility to “brittle”
failure.
Notch Test
The notch test according to ISO DIS 13479 may be
Figure 29: Pipes Notched and Assembled to be Tested
regarded as a variant of the pressure creep test in which
for Slow Crack Growth Property as per ISO 13479. Pipes
crack propagation resistance is specially assessed. Unlike
made from Qenos Pipe Grade Alkadyne HDF193B.
the creep test under internal pressure, the failure point in
this test is predetermined by notching.
In this test, four notches are cut in the outer surface of
RESISTANCE TO RAPID CRACK PROPAGATION
the pipe specimen in the longitudinal direction, each at (RCP) OF PE PIPES
90° to the pipe circumference and with a defined geometry By rapid crack propagation we mean the following
(Vee angle 60°, notch depth = 20% of wall thickness). phenomenon: if a gas pipe during operation is damaged
See Figures 28 and 29 for details. by an external force (e.g. by construction machinery) or
by a stress-induced crack (e.g. in a defective weld) then,
under the action of internal pressure and hence of the
potential energy stored in the gas, the crack can spread
over an extended length at almost the speed of sound
(see Figure 30). In the case of PE 100, the range of
applications is widened to include higher operating
pressures; therefore pipe designers must be given highly
reliable assurances as to the resistance of the pipe
material to rapid crack propagation.
Figure 28: Illustration of Notched Pipe Test

Figure 30: Example of Rapid Crack Propagation Fracture

in Pipe Which Shows the Actions of Residual Stresses on
the Cracked Pipe During RCP
S4 Test
Commonly employed testing methodology for RCP is
based on the ISO 13477 standard. It is known in industry
as the S4 test (small-scale, steady-state test). The S4 test
is carried out as follows: a weight with a knife attached
to the end is dropped onto a pipe of standardised length
and under a constant internal gas pressure near one of
its ends to produce a rapidly progressing axial crack.
The crack initiation process should damage the pipe as
little as possible. The term crack propagation is used if
the crack length, a, is greater than or equal to 4.7 dn
(4.7 times the nominal outside diameter). See Figures 31 Figure 32: Actual Test Rig for the S4 Test
and 32 for details.
A series of tests at 0°C but varying in testing pressure lead
to the determination of the critical pressure at which there
is a sharp transition from abrupt arrest of the initial crack
to continued, steady-state, crack propagation. This method
arrives at the “Critical Pressure” at which RCP occurs.
Alternatively, tests can be carried out at the set pressure
but varying test temperatures to determine the “Critical
Temperature” at which RCP occurs (see Tables 7 and 8).
In designing a pipeline, to carry gas at high pressure or
at sub-zero temperatures the RCP property of pipe resin
needs to be considered and a safety factor must be taken
into account.
For gas pipelines made from Qenos Alkadyne PE 100
Figure 31: Schematics of a Test Rig for the S4 Test grades, the high RCP property ensures safe pipe line
operation at high operating pressures as well as sub-zero
temperatures.

Table 7: RCP Testing of PE 100 Pipe at a Fixed Pressure and Varying Temperature
Temperature Pressure Crack Length
Pipe No. (°C) (MPa) lC (mm) lC /dn Results
1 -5 0.5 120 1.1 Crack Arrest
2 -10 0.5 135 1.2 Crack Arrest
3 -15 0.5 165 1.5 Crack Arrest
4 -20 0.5 360 3.3 Crack Arrest
5 -25 0.5 300 2.7 Crack Arrest
The critical temperature Tc of the PE pipes (110 mm diameter) SDR11, Qenos grade Alkadyne HDF145B, at a pressure of
0.5 MPa, is lower than or equal at -25°C
Table 8: RCP Testing of PE 100 Pipe at a Fixed Temperature and Varying Pressure
Pressure Crack Length a
Pipe No. (MPa) (mm) a/dn Results
1 0.0 85 0.8 Initiation Test
2 0.4 110 1.0 Crack Arrest
The critical pressure Pc,S4 of the PE pipes (110 mm diameter) SDR11, Qenos grade Alkadyne HDF145B, at a temperature of
0°C, is higher than or equal to 1.0 MPa
Table 9: Collation of ISO to Australian Standards for Set Items, Equipment, Installation and Testing
International Standard Subject Matter Australian Standard
ISO 8085-2 Fittings AS/NZS4129 Section 6
ISO 4437 Gas Pipe AS/NZS4130
ISO 4427 Water Pipe AS/NZS4130
ISO 12176-1 Equipment Not applicable
ISO/TS 10839 Installation AS/NZS2033, AS/NZS 4645
ISO 13593 Tensile Test Not applicable
ISO 1167-1 Hydrostatic Pressure Test AS/NZS 4130 Clause 10.1
ASTM F2634 High speed tensile test Not applicable

JOINING PE PIPES • Dual pressure – low fusion jointing pressure

Butt fusion jointing of PE pipes and fittings This method is used by the water industry in the UK, and in
Europe for pipes with a wall thickness greater than 20 mm.
Note: Information is based on POP 003 prepared by PIPA
These parameters are not commonly used in Australia.
(Polyolefin Industry Pipe Association) as a guide to the butt
• Single pressure – high fusion jointing pressure
fusion of polyethylene pipe using AS/NZS 4130 material as
This method has been used extensively in Northern
a basis.
America. The weld interface pressure is approximately
three times the low pressure method and, as a
Relevant Standards
consequence, more of the molten material is extruded
The butt fusion procedures and parameters are specified in
from the weld zone, thereby enabling a reduced cooling
ISO 21307, Plastics pipes and Fittings – Butt Fusion Jointing
time. Extra attention is required to ensure that:
Procedures for Polyethylene (PE) Pipes and Fittings Used in
1. Welding machines have sufficient structural strength
Construction of Gas and Water Distributions Systems.
and hydraulic capacity to achieve the high pressure
ISO 21307 specifies three proven butt fusion jointing parameters in a safe manner. Confirmation should be
procedures for pipes and fittings with a wall thickness sought from the machinery manufacturer.
up to and including 70 mm, taking into consideration:
2. The welding operator is sufficiently experienced and
• The materials and components used proficient with the parameters.
• The fusion jointing procedure and equipment Where the pipe or fitting wall thickness exceeds 70 mm
• The quality assessment of the completed joint welding parameters should be agreed between the asset
This standard also covers the weld procedure for activities owner and the installer. Under these circumstances the
such as surface preparation, clamping, alignment and pipe and fitting supplier and the equipment supplier should
cooling procedures. also be consulted.
Where ISO 21307 references other International Schematically all three welding procedures are outlined in
Standards, the equivalent Australian Standard is deemed Figure 33 and Table 10 which show:
to apply. Where there is no equivalent Australian Standard • Procedures are similar in overall approach, i.e. the seven
then the International Standard applies (see Table 9). steps of fusion
• Primary differences are in applied pressure and
Jointing Procedures approach to cooling
Butt welding involves the heating of two pipe ends to fusion
• When properly performed, all methods result in
temperature and then subsequently joining the two ends
reliable joints
by the application of force. However, a successful butt weld
requires the correct combination and sequence of the
Initial Bead Up Bead Roll Over
welding parameters time, temperature and pressure. 0.517 Mpa
Fusion Pressure, MPa
Various proven butt fusion methods with minor differences

have been in use in different countries for many years.
ISO 21307 contains three distinct fusion methods
Cooling Time
described below for pipe and fittings with a wall thickness
up to and including 70 mm. 0.15 Mpa
Heat Soak
It is essential that the parameters specified for a given
0.025 Mpa
method are followed. Do not mix and match parameters
from each method. Time
Time to achieve
• Single pressure – low fusion jointing pressure Heater Plate Interface Fusion
removed Pressure
This method has been used by most European countries
Dual Pressure European Single Pressure USA Single High Pressure
and in Australia. The single pressure parameters specified
are very similar to those previously specified by PIPA.
Welders familiar with those parameters will adapt easily Figure 33: Schematic Diagram of the Various Stages of
to the ISO Single pressure – low fusion jointing method. the Polymer Butt Welding Process

Table 10: Parameters Corresponding to the Three Butt Welding Processes

Single Low Single High Dual Low Pressure
Butt Welding Parameter Unit Pressure Pressure (If en > 20mm)
Heater pipe temperature °C 200 to 245 200 to 230 225 to 240
P1 Bead up pressure MPa 0.17 ± 0.02 0.52 ± 0.1 0.15 ± 0.02
T1 Bead up time Visual First indication of melt everywhere around pipe.
(Approx. 1mm, maximum 6mm)
P2 Heat soak pressure MPa 0 to drag pressure 0 to drag pressure 0 to drag pressure
T2 Heat soak time Seconds (11 ± 1)en (11 ± 1)en 10en + 60
Maximum bead size after T2 Mm 0.5 + 0.1en 0.15en + 1 0.5 + 0.1en
T3 Maximum heater plate removal time Seconds 0.1en + 4 0.1en + 8 ≤10
T4 Maximum time to achieving welding Seconds 0.4en + 2 0.1en + 8 ≤10
pressure
P3 Fusion jointing pressure Seconds 0.17 ± 0.02 0.52 ± 0.1 0.15 ± 0.02
T5 Cooling time Minutes en + 3 0.43en
T5a Fusion jointing time Seconds 10 ± 1
T5b Minimum cooling time in machine Minutes See ISO 21307
under reduced pressure
P4 Cooling cycle reduced pressure MPa 0.025 ± 0.002
T6 Additional cooling time Minutes Additional cooling time out of the machine and before rough
handling or installation may be recommended, but in most cases
is not necessary
Electrofusion Jointing of PE Pipes and Fittings recommended for use with PE pipes SDR17 or lower
Note: Information is based on POP 001 prepared by PIPA (i.e. increased wall thickness).
(Polyolefin Industry Pipe Association) as a guide to the Pipes of different PE materials- PE 63, PE 80 and PE
electrofusion of polyethylene pipes and fittings complying 100 can also be jointed successfully using electrofusion
with Australian/New Zealand Standards AS/NZS 4130 and sockets, provided that all components have adequate
AS/NZS 41291. nominal pressure rating for the operating conditions and
These guidelines set out the principal requirements for the PE materials comply with AS/NZS 4131.
equipment, jointing procedures, maintenance, servicing and Some manufacturers supply electrofusion fittings for
calibration of equipment, records and training for jointing by thinner pipes, down to SDR33 whereas others limit the
socket electrofusion (EF) and saddle electrofusion. use of some saddle type fittings to SDR11 or thicker. These
The guidelines are also applicable to electrofusion fittings limitations are usually detailed on the fitting body or on
that are available in the size range DN16 to DN800. the packaging. If in doubt, check with the supplier or
Development work is being undertaken for larger sized manufacturer, as unsatisfactory joints are likely to occur
electrofusion fittings. if the fitting/pipe combination is incorrect.
To consistently make satisfactory joints it is important to It is recommended to refer to the supplier or

follow the jointing procedure with particular emphasis on manufacturer of the electrofusion fittings for the
pipe surface preparation, avoidance of contamination, and installation instructions, as the method may be
machine calibration, as well as temperature control. specific to the fitting geometry.
Pipes and fittings of different SDR can be joined together Accurate record keeping and manual or automatic
by the electrofusion process, e.g. DN250 SDR11 pipe can electrofusion equipment that provides good control of
be successfully electrofused using a DN250 SDR17 fitting. jointing conditions are essential.
Electrofusion fittings for pressure applications are usually 1. EF fittings can be used with non-pressure drainage pipes made to
AS/NZS 4401 and AS/NZS 5065.

SDR Pipe to Fitting Fusion Compatibility

The following table provides recommendations of the fusion compatibility of PE pipe to PE electrofusion fittings
(see Table 11).
Table 11: SDR 11 Electrofusion Fittings
Electrofusion Fittings Branch Fittings Electrofusion

SDR11 SDR11 Saddles SDR11
PE Pipe SDR Rating
Pipe DN 11 17/17.6 11 17/17.6 11 17/17.6
16 + – – – – –
20 + – – – – –
25 + – – – – –
32 + – – – – –
40 + – – – + –
50 + – – – + –
63 + – – – + –
75 + – – – + –
90 + + + + + +
110 + + + + + +
125 + + + + + +
140 + + + + + +
160 + + + + + +
180 + + + + + +
200 + + + + + +
225 + + + + + +
250 + + + + + +
280 + + + + + +
315 + + + + + +
355 + + + + + +
400 + + + + + +
450 + + + + + +
500 + + + + + +
560 + + + + + +
630 + + + + + +
where: + corresponds to suitable and – corresponds to unsuitable

Consultation with the fitting supplier or manufacturer is advised for confirmation of fusion compatibility.

Electrofusion socket jointing

Electrofusion socket jointing incorporates an electrical from contamination, and that the assembly and clamping
resistance element in the socket of the fitting which, when instructions are correctly followed.
connected to an appropriate power supply, melts and fuses
The pipe is prepared for jointing by removing a layer,
the materials of the pipe and fitting together.
maximum of 0.2 mm for pipes up to DN25, 0.2 mm to
The effectiveness of this technique depends on attention 0.3 mm for pipes up to DN75 and 0.2 mm to 0.4 mm for
to preparation of the jointing surfaces, in particular the pipes larger than DN75. The minimum allowable outside
removal of the oxidised surface of the pipe over the socket diameter of the prepared pipe is shown below (see
depth, ensuring the jointing surfaces are clean and free Table 12).
Table 12: DN of Pipe Versus Minimum Outside Diameter of Prepared Pipe

Minimum outside Minimum outside
diameter (OD) diameter (OD)
of prepared pipe of prepared pipe
DN of Pipe (mm) DN of Pipe (mm)
16 15.6 200 199.2
20 19.6 225 224.2
25 24.6 250 249.2
32 31.4 280 279.2
40 39.4 315 314.2
50 49.4 355 354.2
63 62.4 400 399.2
75 74.4 450 449.2
90 89.2 500 499.2
110 109.2 560 559.2
125 124.2 630 629.2
140 139.2 710 709.2
160 159.2 800 799.2
180 179.2
If entry of the pipe or fitting spigot into an electrofusion Equipment

coupling is still restricted after the oxidised layer has been
removed, the pipe can be scraped down to the permissible 1. Control Box
minimum outside pipe diameter as in the above table. In The control box input supply should be from a nominal
this case, the thickness removed may be greater than the 240V generator suitable to drive inductive loads and phase
thickness stated above. cut systems, commonly of about 5kVA capacity. Some
fitting suppliers may consider smaller capacity generators
Pipe should also be checked for out-of-roundness (ovality). acceptable for small diameter fittings. The nominal output
Some coiled pipes may be too oval to fit into electrofusion of the generator should be 240V ± 10%, between no load
sockets and must be re-rounded with rounding tools or and full load.
clamps to enable sockets to be fitted.
It should be noted that electrofusion control boxes
The equipment and procedures described below relate may generate considerable heat. Refer to the supplier
to fittings with centre stops. If fittings without centre stops of the controller to ensure the box has an integrated
are used, the maximum insertion depth should be clearly cooling system.
marked on the pipe ends after the pipe surface has been
prepared and cleaned prior to jointing.

Control boxes should include safety devices to prevent The benefits of alignment clamps are that they:
voltages greater than 42V AC for a 40V system being • Allow for re-rounding of pipes, particularly coiled pipes
present at the control box output. The safety device should that are oval
operate in less than 0.5 sec.
• Provide correct assembly and alignment of the pipe
with the fitting
2. Peeling Tools
• Enable the joint to be stabilised during the welding
Rotational peeling tools must be capable of removing
heating and cooling cycle
a continuous and uniform chip thickness from the outer
• Are stress free joints
oxidised surface, over the required insertion depth, when
preparing the fusion zone. • Have uniform melt pressure within the joint
Hand scrapers are difficult to use, and effective

preparation is time consuming, physically demanding
and in most cases does not produce uniform scraping.
Therefore rotational scrapers or peeling tools are preferred
when welding occurs at pipe ends (see Figure 34).
Figure 35a: Re-rounding and Alignment Clamp

Assembly used for Wide Bore Pipe
Figure 34: Rotational Peeling Tool Used to Prepare

Pipe Ends
3. Re-rounding and Alignment Clamps

Re-rounding and alignment clamps or other approved
methods have to be used for restraining, aligning and
re-rounding pipes during the fusion cycle (see Figure 35a
and b).
Figure 35b: In-field Laying of Multi-Jointed Pipe

4. Pipe Cutters Electrofusion Jointing Method

Pipe cutters are mounted instruments that are used Preparation of Pipe Ends
for the accurate cutting of pipes to ensure uniform and i. Ensure hands and tools are free from surface
perpendicular pipe end. Such cutting devices should contaminants, such as barrier hand cream, sun screen,
include the saw and saw guide (see Figures 36a and b). detergent and surfactant used in horizontal directional
drilling.
ii. Check equipment is complete, clean, undamaged, in
working order and protected by shelter.
iii. Ensure there is sufficient space to permit access to the
jointing area. In a trench, a minimum clearance of 150 mm
is required all round. Larger clearances may be needed
for large nominal pipe sizes, depending on the tool used.
iv. Check that the pipe ends to be jointed are cut square to
the axis and any burrs and swarf are removed.
v. Clean the fitting bore, followed by the pipe surface with a
new approved alcohol wipe to remove traces of dirt, mud
and other contamination. When using slip couplings
clean the entire area where the fitting will pass over the
pipe. The area of the pipe to be fusion jointed may be
washed with clean water if necessary and dried with lint
free material prior to peeling. Ensure the fusion area is
completely dry before proceeding (see Figure 37). Do not
use detergent or surfactants to clean pipe surfaces.
Figure 36a: Examples of a Guillotine NOTE: Refer to fitting supplier for recommended alcohol
wipes. Personal cleaning wipes may contain lanolin and
detergent and are not to be used in electrofusion.
vi. Check ovality as described above and use re-rounding
tools as appropriate.
With the fittings still in the bag, place alongside the pipe
end and put a witness mark on the pipe at half the
fitting length plus about 40 mm to enable visual
checking of the scraped area after jointing is complete.
NOTE: Do not remove the fitting from its packaging at
this stage.
vii. Check that the pipe clamps are of the correct size for
the pipes to be jointed. Only use the correct size pipe
clamps.
viii.Check the peeling tools are clean of dirt or other
Figure 36b: Motorised Hand Circular Saw Cutter contaminants prior to use.
x. Using an appropriate peeling tool, remove the entire
5. Weather Shelter surface of the pipe to the depth of the witness mark.
Metal files, rasps, emery paper, etc. are not suitable
Suitable shelter should be used to provide shade and
end preparation tools and should not be used.
protection for the pipe, fittings and equipment against
adverse weather conditions and contamination of the xi. Mechanical peeling tools are strongly preferred, as
jointing surfaces by dust and/or moisture, which can they achieve a consistent pipe surface preparation.
result in unsatisfactory joints. Fittings should only be Hand scraping, particularly for larger diameter pipes,
removed from their original packaging immediately is time consuming and onerous to adequately prepare
before using for jointing. a complete pipe end.

xii. It is important in Australia that pipe and fittings are Jointing Procedure
stored in the shade. If left in the sun, pipe and fittings i. Wipe the prepared pipe surface only with a
become very hot which may affect weld conditions, recommended alcohol wipe to remove any dust residue
particularly with thin pipe. When jointing in high ambient and other contaminants. For larger diameter pipes use a
temperature, it is important that the pipe jointing area is multiple number of alcohol wipes.
shaded by an appropriate shelter. Some fittings do not
NOTE: Cleaning of the prepared surface is a critical step
require adjustment to the heat cycle time for ambient
and one that has the potential to introduce contaminates
temperatures in the range -10°C to +45°C, whereas
if not done correctly – remember this is the surface that
others require heat cycle time variation to compensate
is about to be welded and the presence of contaminates
for ambient temperature within this range.
can readily result in a poorly welded joint. To avoid
ENSURE THE PREPARED SURFACES ARE COMPLETELY contamination, ONLY wipe the peeled fusion zone area.
DRY BEFORE PROCEEDING Do not under any circumstances use methylated spirits,
DO NOT TOUCH THE PREPARED PIPE SURFACE acetone, methyl ethyl ketone (MEK) or other solvents to
clean the fusion area. Rags are not recommended for
use with any alcohol solvent to clean the fusion area
given the possibility of dirt, detergent or fabric
conditioner being transferred into the fusion zone.
Other important factors relating to this procedure:
• Ensure wipes are saturated with alcohol i.e. have not
dried out.
• To avoid contamination ONLY wipe the peeled fusion
zone area.
• Only use the wipe once.
• Do not touch the prepared pipe surface – sweat,
sunscreen, barrier cream, dirt and skin oils are all
potential sources of contamination. Disposable latex
or nitrile gloves are recommended when handing the
wipes for preparation of the surface.
• Ensure alcohol left by the wipe on the cleaned surface
has evaporated and the prepared surfaces are
completely dry before assembling the joint.
• Refer to the electrofusion fitting supplier for the correct
selection of alcohol wipes.
ii. Remove the fitting from its packaging and check that the
bore of the fitting is clean. The bore of the fitting may be
wiped with an approved isopropyl wipe if necessary.
NOTE: Ensure the cleaned bore is completely dry before
proceeding.
iii. It is good practice to install the fitting to both pipe ends
at the same time. However if this is not possible, open
only one end of the fitting package and install the fitting
to the pipe end. The package can then be fixed in place
to enclose the exposed end of the fitting to keep the
fitting bore free from contamination.
Figure 37: Illustration of Pipe End Preparation Prior
to Welding

iv. Inscribe an accurate witness mark or insertion depth NOTE: Automatic control boxes are available which
onto the pipe and then insert the pipe ends into the obviate the need to enter the fusion time.
fitting so that they are in contact with the centre stop x. If the control box is equipped with a barcode reader or
and witness mark. It is critical that the pipe be fully barcode scanner, scan the fusion data barcode into the
inserted, particularly for larger pipes or when there is machine to ensure a fully automated and controlled
no centre stop. Ensure an aligned pipe arrangement in data entry. Barcode reading control boxes automatically
order to avoid any stress during the jointing process, adjust for variable temperature conditions. For manual
especially when using coiled pipes. input of the heat fusion time into the control box,
v. The pipe end(s) and the fitting must be correctly refer to the manufacturer’s parameters, supplied with
aligned and free of any bending stress. Use pipe the fitting.
clamps, or other suitable means, to secure the pipe(s)
so they cannot move and ensure that the fitting is
satisfactorily supported to prevent it sagging during
the fusion procedure (see Figure 38).
Figure 39: Attachment of Control Box Leads to

Pipe Fitting
xi. Press the start button on the control box and check
that the heating cycle is proceeding as indicated by
the display.
xii. On completion of the heating cycle, both melt indicators
Figure 38: Illustration of Pipe Clamps and Fitting within the processed part of the fitting should have
Attached to Pipe Ends Prior to Welding risen. If there is no apparent movement of either
indicator the joint could be unsatisfactory (see Figure
vi. Check that there is sufficient fuel for the generator to 40) – refer to discussion on electrofusion indicator
complete the joint. Start the generator and check that pins below.
it is functioning correctly.
NOTE: Ensure the generator is switched on and
running satisfactorily before connecting the
electrofusion control box to the power source.
vii. Switch on the control box. Check that the reset button,
if fitted, is in the correct mode.
viii. Connect the control box output leads to the fitting
terminals and check that they have been fully inserted
(see Figure 39).
ix. The jointing time is generally indicated either on the
Figure 40: Diagram illustrating Locating of Melt
fitting or on a data carrier supplied with the fitting.
indicators
Check that the correct time is shown on the control
box display. If required for the control box, enter the
fusion jointing time into the control box timer.

xiii. If the fusion cycle terminates before completion of Maintenance, Servicing and Calibration
the countdown, check for faults as indicated by the All equipment should be well maintained and kept in
control box warning lights or display. Check for a a clean condition at all times.
possible cause of the break, e.g. inadequate fuel in
the generator, or power supply failure, etc. The equipment should be serviced and calibrated regularly.
The frequency at which this is carried out will be different
NOTE: Do not attempt a second fusion cycle until
for individual items of equipment and will also depend on
the entire fitting has cooled to less than 45°C. Some
usage, but should be at least once every 12 months.
manufacturers recommend replacement of the fitting
Guidance should be sought from the equipment
rather than a second fusion cycle. Refer to the fitting
manufacturer and a scheme of calibration and servicing
manufacturer for details.
should be implemented. Particular attention should be
xiv. The completed joint should be left in the clamps for given to the control box, the generator and the scraping
cooling. The time needed will be specified on the (or peeling) tools. The sharpness of the cutter head of the
fitting, or by its data carrier, or in the display of the tools should be checked at least on a monthly base.
automatic control box.
xiv. When the joint has cooled, remove it from the clamps Records
and inspect. 1. Job Supervision
Electronic or written records of appropriate fusion
Electrofusion Indicator Pins
procedure for each joint should be kept as required.
The fusion indicator protrusion following the completion
of the fusion process indicates that fusion pressure has 2. Equipment Servicing and Calibration
developed but does not guarantee the quality of the joint. Electronic or written records of appropriate servicing and
The height of the extended pin is dependent upon the calibration should be kept. The minimum information to be
fitting in use, component tolerances and the pipe material. recorded is given in Appendix 1.
The pins are used as a pointer to whether a more detailed
inspection of the joint is required so in the event that the 3. Training
pin does not rise, the supervisor or operator must investigate Instructions should be provided by Registered Training
the following to determine if the joint is satisfactory. Organisations (RTO’s) that are accredited by State/Territory
Training Authorities under the Australian National Training
• Dimensional check and compliance of the pipe spigot
Authority (ANTA) guidelines and complying with PMB 01–
OD and ovality.
Competency Standards prepared by Manufacturing
• The fitting socket internal diameter by measurement
Learning Australia, Qualification Framework for the plastics,
or batch traceability.
rubber and cable making industry.
• In the case where the pipe and socket are concentric,
the maximum gap between the two should not exceed The RTO’s providing training in all forms of welding plastics
1% of the nominal diameter. If the socket and spigot are pipeline systems must have staff qualified in presenting
eccentric the gap should not exceed 2%. courses that meet competency standards covered by
• That there is no disruption to the input power supply from sections PMBWELD301A through to PMBWELD311A in
the fusion box with no control box error messages. PMB 01.
• That the heat fusion parameters are correct. The RTO’s normally issue an accreditation certificate to
• The pipe to fitting alignment is correct with no visible successful candidates completing the training course and
plastic extruded out from the fitting. maintain a register of accredited welders.

Electrofusion Saddle Jointing Electrofusion tapping saddles are available to fit all

Electrofusion saddle jointing incorporates an electrical commonly used main sizes from DN40 to DN560 with
resistance element in the base of the saddle which, when service connection outlet sizes from DN20 to DN63 and
connected to an appropriate power supply, melts and fuses branch saddle spigot off-takes from DN32 to DN125.
the materials of the pipe and fitting together (see Figure 41). NOTE: Some saddle type fittings are limited to SDR11.
Refer to the fitting manufacturer for further details.
Tapping tee saddles are usually supplied complete with
the manufacturer’s recommended installation procedure.
Generally recommended installation parameters are
similar to the procedure described here, which refers
to fittings supplied with an underpart with bolts for
assembling the two parts on the pipe.
The nominal pipe diameter should be within the tolerances
specified in AS/NZS 4130. Pipe ovality in excess of 1.5%
of the nominal pipe diameter (DN) will require re-rounding
tools to allow satisfactory contact between tapping saddle
and pipe. Some full circle tapping saddles may effectively
re-round pipe when correctly fitted but a constant and
reliable joint quality can always be achieved by using
re-rounding tools. If in doubt, refer to the fitting supplier.
Equipment
i. The control box input supply should be from a nominal
240V generator suitable to drive inductive loads and
phase cut systems, commonly of about 5kVA capacity.
Some fitting suppliers may consider smaller capacity
generators acceptable for small diameter fittings. The
nominal output of the generator should be 240V +15%,
-15% between no load and full load. It should be noted
Figure 41: Polymer Fitting that can be Welded onto a that electrofusion control boxes may generate
Pipe by Electrofusion Saddle Joining considerable heat. Refer to the supplier of the controller
for details. Control boxes should include safety devices
The effectiveness of this technique depends on attention to prevent voltages greater than 42V AC for a 40V
to preparation of the jointing surfaces, in particular the system being present at the control box output. The
removal of the oxidised surface of the pipe over an area safety device should operate in less than 0.5 sec.
equivalent to the saddle base, and the cleaning of the ii. Pipe surface preparation tool (scraper or peeler) has to
jointing surfaces and freedom from contamination. be capable of removing the oxidised surface of the pipe
Although PE is comparatively inert, the outer surface over the full area of the saddle base. The tool should
of the pipe will become oxidised when exposed to the remove a surface layer of between 0.2 mm and
atmosphere. This oxidised outer layer will interfere with 0.4 mm. Hand scrapers can be difficult to use in trench
the bond between the pipe and fitting and must therefore conditions, and effective preparation by hand may be
be removed before joint assembly. time consuming and physically demanding. Therefore
rotational scrapers or peeling tools are preferred.
iii. Re-rounding clamps or other approved methods of
re-rounding pipes should be used, particularly if pipe
out of roundness exceeds 1.5%.

iv. A pipe clamp of suitable dimensions for making the vii. It is important in Australia that pipe and fittings are
service or branch connection is needed. stored in the shade. If left in the sun the pipe and
v. Pipe cutters should include a saw and saw guide. fittings become very hot which may affect weld
conditions, particularly with thin pipe. When jointing in
vi. Suitable shelter should be used to provide adequate
high ambient temperature, it is important that the pipe
protection for pipe, fittings and equipment against
jointing area is shaded by an appropriate shelter. Some
adverse weather conditions and contamination of the
fittings do not require adjustment to the heat cycle
jointing surfaces by dust and/or moisture, which can
time for ambient temperatures in the range -10°C to
result in unsatisfactory joints. Fittings should only be
+45°C, whereas others require heat cycle time
removed from their original packaging immediately
variations to compensate for ambient temperature
before using for jointing.
variation within this range.
Preparation Jointing Procedure
i. Ensure hands and tools are free from surface i. Wipe the prepared surface only with the manufacturer’s
contaminants, such as barrier hand cream, sun screen, approved alcohol wipe to remove any dust residue and
detergent and surfactant used in horizontal directional other contaminants. For larger diameter pipes a multiple
drilling. number of alcohol wipes shall be used.
ii. Expose the pipe onto which the tapping tee or saddle is NOTE: Cleaning of the prepared surface is a critical
to be assembled, ensuring there is clear space around step and one that has the potential to introduce
the pipe. In a trench a minimum clearance of 150 mm is contaminates if not done correctly – remember this is
required all round. Larger clearances may be needed for the surface that is about to be welded and the presence
larger nominal sizes, depending on the tool used. of contaminates can readily result in a poorly welded
iii. Wipe the joint area, where the saddle is to be fitted, with joint (see Figure 42).
alcohol wipes to remove traces of dirt, mud and other Do not under any circumstances use methylated spirits,
contamination. The joint area may be washed with clean acetone, methyl ethyl ketone (MEK) or other solvents.
water if necessary and dried with lint free material prior Do not use rags or other cloth soaked in these
to scraping. Ensure the joint surface is completely dry materials to wipe the prepared fusion surface as they
before proceeding. Do not use detergent or surfactants have the potential to contaminate the surface with dirt,
to clean pipe surfaces. grease and fabric conditioner. These are not suitable
NOTE: Refer to fitting supplier for recommended alcohol options for wiping the prepared surface.
wipes. Personal cleaning wipes may contain lanolin and Other important factors relating to this procedure:
detergent and are not suitable for use in electrofusion.
• Ensure wipes are saturated with alcohol i.e. have not
iv. Without removing the fitting from its packaging, place
dried out.
it over the required position on the pipe. Mark the
• When using the wipe work from the prepared (peeled)
pipe surface outlining the saddle base area plus about
surface towards the unprepared area and discard the
20 mm with a suitable marker pen to allow for visual
wipe after it has come in contact with any unprepared
checking of the scraped area after jointing is complete.
areas. Wiping from unprepared areas towards the
v. Check ovality as described above and use re-rounding prepared surface can contaminate the fusion surface
tools as appropriate. and similarly using a wipe which has been used on an
vi. Using an appropriate preparation tool remove the entire unprepared can also introduce contaminants.
surface of the pipe over the full area marked. If hand • Only use the wipe once.
scrapping, ensure long even scrapes starting outside • Do not wipe over the witness mark.
the marked area to ensure craters do not occur in the
• Do not touch the prepared pipe surface – sweat,
fusion zone, which can produce an excessive gap
sunscreen, barrier cream, soap, detergent, dirt and skin
leading to a brittle weld. Remove the swarf. Metal files,
oils are all potential sources of contamination.
rasps, emery paper, etc. are not suitable scraping tools
Disposable latex or nitrile gloves are recommended when
and should not be used.
handing the wipes for preparation of the surface.

• Ensure alcohol left by the wipe on the cleaned ii. Position the fitting base onto the prepared pipe surface.
surface has evaporated and the prepared surfaces Bring the lower saddle into position. Then gradually and
are completely dry before assembling the joint. equally tighten the bolts and nuts until the upper saddle
• Refer to the electrofusion fitting supplier for the makes firm contact with the prepared surface of the
correct selection of alcohol wipes. pipe (see Figure 43). Carefully inspect the fitting to
ensure a firm contact with the pipe is achieved over the
ENSURE THE PREPARED SURFACES ARE COMPLETELY entire upper saddle contact area. Install re-rounding
DRY BEFORE PROCEEDING tools if pipe out of roundness exceeds 1.5% or if a firm
DO NOT TOUCH THE PREPARED PIPE SURFACE contact is not achieved over the entire upper saddle
contact area.
Figure 42: Illustration of Pipe Preparation Required Prior

to Welding of Pipe Fitting
Figure 43: Installation of Saddle Fitting onto Pipe Prior
Remove the fitting from its packaging and check that the to Welding
jointing surface of the saddle fitting is clean. The bore of
the fitting may be wiped with a recommended alcohol wipe iii. Check that there is sufficient fuel for the generator to
if necessary. complete the joint. Start the generator and check that it
is functioning correctly.
NOTE: Ensure that the bore is completely dry
NOTE: Ensure the generator is switched on and running
before proceeding.
satisfactorily before connecting the electrofusion
control box to the power source.
iv. Switch on the control box. Check that the reset button,
if fitted, is in the correct mode.
v. Connect the control box output leads to the fitting
terminals and check that they have been fully inserted
(see Figure 44).

Figure 44: Attachment of Control Box Leads to

Pipe Fitting Figure 45: Diagram illustrating Locating of Melt
indicators on Fitting
vi. The jointing time is indicated either on the fitting label
or on a data carrier supplied with the fitting. Check that Refer to the fitting supplier or manufacturer for details on
the correct time is shown on the control box display. If branch outlets and specific installation instructions.
required enter the fusion jointing time into the control
x. If the fusion cycle terminates before completion of the
box timer.
countdown, check for faults as indicated by the control
NOTE: Automatic control boxes are available which box warning lights or display. Check for a possible
obviate the need to enter fusion time. cause of the break, e.g. inadequate fuel in the
vii. If the control box is equipped with a barcode reader or generator, or power supply failure, etc.
barcode scanner, scan the fusion data barcode into the NOTE: DO NOT attempt a second fusion cycle until the
machine to ensure a fully automated and controlled entire saddle fitting has cooled to less than 45°C. Some
data entry. Barcode reading control boxes automatically manufacturers recommend replacement of the fitting
adjust for variable temperature conditions. For manual rather than a second fusion cycle. Refer to
input of the heat fusion time into the control box, refer manufacturer for details.
to the manufacturer’s or supplier’s parameters, which
xi. The completed joint should be left in the clamps for
should be supplied with the fitting.
cooling. The time needed will be specified on the fitting
viii. Press the start button on the control box and check label, or by its data carrier, or in the display of the
that the heating cycle is proceeding as indicated by the automatic control box.
display.
xii. The connection of the service pipe to the spigot
ix. On completion of the heating cycle, the melt indicator outlet should be carried out in accordance with the
on the fitting should have risen (see Figure 45). If procedure of the appropriate section of these
there is no apparent movement the joint could be guidelines (see Figure 46).
unsatisfactory – refer to the manufacturer’s
instructions for further information.

Figure 46: Illustration of Tapping Process used to

Connect Spigot Outlet to Main Service Pipe
xiii. DO NOT attempt to tap the main with the integral Figure 47: Installation of Detachable Rotary Peeler to
cutter before the completion of the required cooling Service Pipe
cycle as specified by the supplier.
Additional cooling time is recommended before tapping iii. Clean pipe in the fusion zone with an approved alcohol
if the pipeline is to be field pressure tested as soon as wipe (see Figure 48).
practical:
• DN40 saddle minimum 10 minutes for field test
pressure ≤ 6 bar and minimum 30 minutes for field
test pressure > 6 bar ≤ 24 bar
• DN63 - DN560 saddle minimum 20 minutes for field
test pressure ≤ 6 bar and minimum 60 minutes for
field test pressure > 6 bar ≤ 24 bar
Top load Electrofusion Branch Saddle Jointing

Top load electrofusion branch saddles are typically used
for large diameter branch connections ≥ 90 mm.
Applications include: new installations, renovation, repair
and under pressure live branch connections on existing
PE mains for sizes to DN630 mm.
Typical installation instructions are detailed below: Figure 48: Illustration of Prescribed Cleaning of Pipe
i. Ensure hands and tools are free from surface Fusion Zone
contaminants, such as barrier hand cream, sun screen,
detergent and surfactant used in horizontal directional iv. Mount the fitting to the pipe using a top-load tool and
drilling. tightening clamp device to ensure a positive contact is
ii. Clean pipe in the fusion area with an approved alcohol made between the pipe and saddle. The joint gap should
wipe as detailed above in the Jointing Procedure, then not exceed 0.5 mm (see Figure 49).
remove the oxidised layer with a rotary peeler (see
Figure 47).

Records
1. Job Supervision
Electronic or written records of appropriate fusion
procedure for each joint should be kept as required.
2. Equipment Servicing and Calibration

Electronic or written records of appropriate servicing and
calibration should be kept. The minimum information to be
recorded is given in Appendix 1.
3. Training
Instructions should be provided by Registered Training
Organisations (RTO’s) that are accredited by State/Territory
Training Authorities under the Australian National Training
Authority (ANTA) guidelines and complying with PMB 01 -
Figure 49: Illustration of Top-load Tool Attached to Both Competency Standards prepared by Manufacturing
the Saddle and Pipe Learning Australia, Qualification Framework for the plastics,
rubber and cable making industry.
v. Connect the terminals and apply the fusion voltage The RTO’s providing training in all forms of welding
following the method outlined above in Jointing plastics pipeline systems must have staff qualified in
Procedure. presenting courses that meet competency standards
vi. The completed joint should be left in the clamps for covered by sections PMBWELD301A through to
cooling. The time needed will be specified on the fitting PMBWELD311A in PMB 01.
label, or by its data carrier, or in the display of the
The RTO’s normally issue an accreditation certificate to
automatic control box.
successful candidates completing the training course and
maintain a register of accredited welders.
Maintenance, servicing and calibration
All equipment should be well maintained and kept in a
Quality Assurance
clean condition at all times.
To achieve consistently good quality fusion joints as
The equipment should be serviced and calibrated regularly. outlined by these guidelines, manufacturers and installers
The frequency at which this is carried out will be different should operate a quality system in accordance with the
for individual items of equipment and will also depend on principles of AS/NZS ISO 9001.
usage, but should be at least once every 12 months.
Guidance should be sought from the equipment Assessment of the achievement would take the form of
manufacturer and a scheme of calibration and servicing an audit against the points below. Independent testing of
should be implemented. Particular attention should be fusion joints may also be required.
given to the control box, the generator and the scraping
(or peeling) tools. The sharpness of the cutter head of
tools should be checked at least on a monthly base.

Management Responsibility 3. Inspection and Testing

1. Customer Focus a. Inspection of goods received and used on site
The organisation responsible for the jointing operation should The installer should ensure that incoming pipe, fittings
ensure that customer requirements are determined and are and fusion jointing equipment are not used until they
met with the aim of enhancing customer satisfaction. have been inspected and confirmed as conforming to
specified requirements including appearance and
2. Planning marking. Any non-conforming items should be identified,
The organisation responsible for the jointing operation recorded and segregated.
should ensure that all aspects of the jointing operation are b. Final inspection and testing
given adequate consideration prior to the commencement At the commencement of each contract, the frequency
of work. and type of inspection by the installer should be agreed
3. Responsibility, Authority and Communication with the client and documented.
On each site where pipes and fittings are to be jointed in c. Inspection and test records
accordance with these guidelines, a person should be The installer should establish and maintain electronic
nominated to supervise work affecting the jointing quality. and/or written records of appropriate fusion jointing
The person should: procedures, servicing and calibration details in
• Have the responsibility and authority to ensure effective accordance with these guidelines.
jointing operations 4. Corrective Action
• Ensure that processes needed for jointing operations are The installer should establish and maintain procedures
established, implemented and maintained to show evidence of:
• Be able to communicate the requirements for effective
• Review of non-conformities (including customer
jointing operations
complaints) as a result of poor quality joints
Control of Documents • Determining the causes of poor quality joints
Document control should ensure that: • Evaluating the need for action to ensure poor quality
joints do not recur
• Documents are approved for adequacy prior to use,
• Determining and implementing action needed
• The relevant versions of applicable documents are
available at points of use, • Recording the results of action taken, and
• Documents remain legible and readily identifiable, • Reviewing corrective action taken
• The unintended use of obsolete documents is prevented, 5. Preservation of Product
and to apply suitable identification to them if they are
The installer should establish and maintain appropriate
retained for any purpose.
procedures for handling and storage of pipe, fittings and
1. Purchasing fusion jointing equipment on site.
The installer should ensure that purchased items including NOTE: Damaged packaging can permit ingress of dirt and
pipe, fittings and fusion jointing equipment conform to moisture, which can adversely affect joint integrity.
specified requirements.
6. Control of Records
2. Fusion Jointing Control The installer should establish and maintain procedures for
The installer should ensure that fusion jointing procedures collection, indexing, filing and storage of quality records for
as well as servicing and maintenance of fusion jointing a minimum period of 6 years from the date of installation.
equipment are carried out in accordance with the specified
guidelines.

7. Competence, Awareness and Training

The installer should:
• Determine the necessary competence for personnel
performing fusion jointing
• Provide training or take other actions to satisfy these
guidelines
• Evaluate the effectiveness of the actions taken
• Ensure that personnel are aware of the relevance and
importance of their activities and how they contribute to
the achievement of effective fusion jointing, and
• Maintain appropriate records of education, training, skills
and experience

APPENDIX 1 – RECORD SHEETS The information recorded on the sheet should include,
Record sheets should be maintained for all equipment but not be restricted to:
required for all fusion jointing operations. The sheet should • The date of servicing or maintenance
be headed: • The name, address and telephone number of the
‘SERVICING AND CALIBRATION RECORD SHEET’ undertaking or contractor operating the equipment
• The name, address and telephone number of the
Followed by:
company conducting the service or maintenance
‘ELECTROFUSION SOCKET EQUIPMENT OR
• The member (or members) of staff responsible for
ELECTROFUSION SADDLE EQUIPMENT’
servicing or maintenance
Then the appropriate sub-title from the following list • The serial number of the equipment
(additional record sheets may be kept if required): • The details of service and/or maintenance carried out.
• Electrofusion socket jointing: This should include relevant details of test equipment,
• Generators procedures and/or manuals used, and relevant ambient
• Electrofusion control box conditions.
• Electrical safety test • The signature(s) of the member (or members) of staff
responsible for the servicing or maintenance operations
• Electrofusion saddle jointing: conducted
• Generators
• Electrofusion control box
• Electrical safety test

APPENDIX 2 – PIPE EXTRUSION TROUBLESHOOTING GUIDE

Problem/ Issue Cause(s) Potential Solution(s)/ Action(s)
Die (extrudate) Damage to the exit edges of the tip or die. Refinish tip or die exit edges to sharp and uniform
lines. about the diameters.
Die drool or build-up on the tip or die faces. Adjust temperature of the die exit accordingly
Extruder surging Too fast extruder throughput relative to OEM Check OEM guaranteed extruder throughput and
Extruder specifications run extruder within specifications
Improper extruder temperature settings Adjust temperature setting according to OEM
recommendations
Poor resin- extruder design match versus extruder Discuss with resin supplier and implement actions
OEM specifications for throughput to ensure extruder runs within OEM specifications
Extruder not set as per OEM design specifications Check with OEM and ensure compliance with design
specifications
Gels and other Resin contains foreign particles/ contaminated Check with resin supplier for presence of gels etc.
contaminations with gels etc Check regrind for contaminants
in pipe
Degraded resin coming off the die during extrusion Follow proper shut-down procedures for extruder
to avoid long exposure of resin to excessive
temperatures
Localised thick Improper die setting Adjust the die setting
spots in pipe wall Hot and cold spots in die profile temp Check for uniformity in die heating
Uneven pipe drag downstream of the extruder Check for spots in cooling baths which could cause
pipe drag
Haul-off slippage Check and adjust haul-off
Uneven melt delivery from die -extruder surging Check remedies for extruder surging
Vacuum calibrator and die not levelled well Adjust the position of the vacuum bath relative
to the die
Pipe out of round Sizing device (calibrator) in adequate or out Check the calibrator for concentricity.
of shape Ensure it is 3–5% larger than the final pipe diameter
Pipe is too warm when it reaches the haul off unit Ensure sufficient downstream cooling length before
pipe gets to the haul off unit
Decrease throughput
Wrong vacuum setting in vacuum tanks Ensure proper vacuum setting in vacuum tanks
Pipe tear Haul-off too fast Check and adjust the speed of haul off
Pipe too hot at the entrance to calibrator Check for water flows on calibrator and adjust to
avoid hot spots
Ensure adequate calibrator size
Pipe dragging in cooling tanks Check and eliminate drag spots
Pipe sag Melt temperature too high Adjust extruder temperature setting and throughput
to lower melt temperature
Die gap not adjusted to accommodate sag Adjust die gap – wider at the top and narrower at the
bottom of the die
Resin’s inherent resistance to sag is not adequate Use low-sag resin
for the pipe wall thickness
No enough cooling capability in line Ensure adequate water temperature in cooling baths
and enough cooling length

Problem/ Issue Cause(s) Potential Solution(s)/ Action(s)

Rough surface Moisture in resin Ensure minimum of 1.5 hrs drying of resin at
inside or outside 70–90°C
Not adequate water flows setting to the calibrator Adjust water flows to calibrator
Melt temperature too low Increase die/ and or extruder temperatures
Thermal Too high melt temperature Adjust extruder/ and or die temperatures accordingly
degradation of Excessive extruder screw speed Lower extruder throughput
pipe-failed OIT
Die too small for required throughput Ensure adequate die size
Die pin too hot Check operation of pin cooling otherwise decrease
throughput
Extruder surging Check remedies for extruder surging
Uneven pipe cut The saw blade is flexing Get thicker/ larger blades
The saw blade is lose Check and fix
Saw arm is entering pipe too quickly and with Adjust as required
insufficient revolutions
The saw arm is lose or bushes worn and is ‘floating’ Check and fix
There is wear/slack in slip rings of the saw Check and fix
planetary components
Uneven speed of haul-off or cutting carriage Check uniformity of the speed of haul-off and
cutting carriage
Saw is not capable of cutting the pipe Check with OEM for saw specifications
Uneven wall Uneven melt delivery from the die -extruder surging Check remedies for extruder surging
thickness Uneven take-off speed Check haul-off unit
Improper alignment of die and haul-off units Check for alignment
Die and pin not centred evenly Even die gap
Excessive sag of a polymer Check remedies for pipe sag
Voids in pipe Moisture in resin Ensure minimum of 1.5 hrs drying of resin at
70–90°C
Trapped air Adjust extruder temperature setting and back
pressure accordingly
Disclaimer
The proposed solutions in this guide are based on conditions that are typically encountered in the manufacture of products from polyethylene.
Other variables or constraints may impact the ability of the user to apply these solutions. Qenos also refers the user to the disclaimer at the beginning
of this document.

BIBLIOGRAPHY/FURTHER READING
1. Janson, L. E.; Plastic Pipes for Water Supply and Sewage Disposal (4th Ed.), Borealis, 2003.
2. Brömstrup, H.; PE100 Pipe Systems (2nd Ed.), Vulkan-Verlag GmBH, 2004.
3. Hensen, F.; Plastic extrusion Technology, Hanser Verlag, 1997.
4. Michaeli, W.; Extrusion Dies, Hanser Verlag, 2003.
5. Technical Manual – Materials for Pipe Extrusion, Hostalen, Lupolen, -Processing and Applications, Basell Polyolefins.
6. Reliable Pipelines with Hostalen CRP 100, Properties, Practical Experience and Standards, Hoechst.
7. Battenfeld Extrusionstechnik – SMS Group, Pipe Extrusion Plant.
8. AS/NZS 4131:2010, Polyethylene (PE) compounds for pressure pipes and fittings.
9. AS/NZS 4130:2009, Polyethylene (PE) pipes for pressure applications.
10. ISO 9080:2003, Plastic piping and ducting systems – Determination of the long-term hydrostatic strength of
thermoplastics materials in form by extrapolation.
11. ISO 13479:2009, Polyolefin pipes for the conveyance of fluids – Determination of resistance to crack propagation –
Test method for slow crack growth on notched pipes (notch test).
12. ISO 13477:2008, Thermoplastic pipes for the conveyance of fluids – Determination of resistance to rapid crack
propagation (RCP) – Small-scale steady-state test (S4 test).
13. ISO 4437:2007, Buried polyethylene (PE) pipes for the supply of gaseous fuels – Metric series – Specifications.
14. ISO 4427 – 1:2007, Plastics piping systems – Polyethylene (PE) pipes and fittings for water supply.
PMBWELD301B Butt Weld PE Pipelines Resource Manual, Chisholm Institute, 2010
15. Industry Guidelines, Butt Fusion Jointing of PE Pipes and Fittings, PIPA, 2011.
16. Industry Guidelines, Butt Fusion Jointing of PE Pipes and Fittings for Pressure Applications, PIPA, 2011.
17. Industry Guidelines, Temperature Rerating of PE Pipes, PIPA, 2010.
Issued January 2014.

Qenos Pty. Ltd.
ABN: 62 054 196 771
Cnr Kororoit Creek Road & Maidstone Street,
Altona Victoria 3018, Australia
T: 1800 063 573 F: 1800 638 981
qenos.com AS4131 Lic. 20138
SAI Global

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7

2 Qenos Technical Guides

Qenos Technical Guides 3

APPENDIX 1 – RECORD SHEETS 40

4 Qenos Technical Guides

Qenos Technical Guides 5

INTRODUCTION of PE-HD pipes, such as weldability, ﬂexibility, chemical

ALKADYNE GRADE SELECTION FOR PIPE

6 Qenos Technical Guides

CLASSIFICATION OF POLYETHYLENE PIPE PIPE EXTRUSION TECHNOLOGY

Table 2: MRS and Hydrostatic Design Stress

Figure 2: Photograph illustrating a Pipe with Voids

Qenos Technical Guides 7

Such problems can be overcome by drying the polymer

Figure 3: Illustration of a Single Screw Extruder

These extruders have a cooled, grooved feed bushing

8 Qenos Technical Guides

Figure 6: Photograph of a Pipe Die

Qenos Technical Guides 9

These concerns are associated with potential of building

Figure 9: A Lattice-Basket Die and the Basket Part

Sizing and Cooling

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Using these assumed temperatures, the total cooling-zone

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Process Control MECHANICAL PERFORMANCE OF

Figure 14: Computerized Process Control System for

The most commonly employed control system operates on

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The effect of temperature on the yield stress, ultimate Creep Test

Figure 17: Typical Tensile Creep Modulus Curves of HDPE

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Relaxation Test QUALITY TESTING OF POLYETHYLENE PIPE

Hydrostatic Pressure Tests

Behaviour at High Deformation Rates P= 2ST

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The hydrostatic tests that are carried out on pipe sections

Figure 20: The First Creep Rupture Test Started In

Figure 22: Extensive Hydrostatic Pipe Testing at Qenos

Figure 21: The First Creep Rupture Test Started in 1956

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Pipe pressure Curve and Service Life

Figure 24: Pipe Failed in Ductile Mode

Ductile failure indicates ultimate pressure bearing

Figure 23: Representation of Pipe Curve According to the

Starting with short endurance times, a ﬂat, straight

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TEMPERATURE RE-RATING OF PE PIPES

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Predictable Temperature Variations Tm = T1L1 + T2L2 + ... + TnLn

Table 5: Maximum Allowable Operating Pressure – PE 80

Table 6: Maximum Allowable Operating Pressure – PE 100

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Figure 28: Illustration of Notched Pipe Test

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Figure 30: Example of Rapid Crack Propagation Fracture

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