Butt Fusion of Pipes and Components With

Different Wall Thicknesses

According to ASTM F2620, section X1.4 of Appendix X1 addresses, “butt

fusion joining of pipes and fittings that have the same outside diameter but
unlike wall thickness (different by one standard DR or more) is possible.”
ISCO recommends following accepted industry practice that the wall
thickness difference should not exceed 26% in order to maintain the
pressure rating of the lowest rated component (the thinner of the two wall
thickness) involved in the butt fusion. Wall thickness differences in excess
of this recommendation may induce a stress riser that could affect the
quality of fusion joint to withstand events like pressure surges and external
loading that may not affect welds with the same wall thickness.

Example: Pipe or fittings that have a wall thickness of 1” would be

welded to a pipe or fitting with a wall thickness of .74” or 1.35” to
maintain full pressure rating.

CONSIDER:
• The pipe line is only as strong as its weakest link or lowest rated
component
• Beveling or counter-boring the thicker wall can help reduce or
eliminate the difference in wall thickness
• The fusion pressure used to join two different wall thicknesses is
always that of the thinner wall pipe/component.
* See chart on page 37 for more information.

Install Clamping Inserts

Select and install appropriate clamping

inserts for the pipe that is being fused.

No. 1LC & Mini-Mc® Machines

(1/2” CTS - 1” IPS Pipe)
1” CTS and smaller inserts are fitted to jaw
castings using flat head fasteners.

No. 2LC & No. 2CU Machines (1/2” CTS - 2” IPS Pipe)
1-1/2” and smaller inserts are fitted to jaw castings using flat head fasteners.

No. 14 Pitbull Machines (1” IPS - 4” DIPS Pipe)

2” Master, 3”, and 4” inserts are held in place by spring pins located
on upper and lower jaws. 1-1/2” and smaller inserts are fitted to 2” IPS
Master inserts using flat head fasteners.

No. 26 Pitbull Machines (2” IPS - 6” DIPS Pipe)

2”, 3”, and 4” inserts are held in place by spring pins located on upper
and lower jaws.

Fusion Hotline 1-800-345-4726 ext. 4790

© Copyright 2018 ISCO Industries, Inc. All rights reserved. 21
Butt Fusion of Pipes and Components With
Different Wall Thicknesses

According to ASTM F2620, section X1.4 of Appendix X1 addresses, “butt

fusion joining of pipes and fittings that have the same outside diameter but
unlike wall thickness (different by one standard DR or more) is possible.”
ISCO recommends following accepted industry practice that the wall
thickness difference should not exceed 26% in order to maintain the
pressure rating of the lowest rated component (the thinner of the two wall
thickness) involved in the butt fusion. Wall thickness differences in excess
of this recommendation may induce a stress riser that could affect the
quality of fusion joint to withstand events like pressure surges and external
loading that may not affect welds with the same wall thickness.

Example: Pipe or fittings that have a wall thickness of 1” would be

welded to a pipe or fitting with a wall thickness of .74” or 1.35” to
maintain full pressure rating.

CONSIDER:
• The pipe line is only as strong as its weakest link or lowest rated
component
• Beveling or counter-boring the thicker wall can help reduce or
eliminate the difference in wall thickness
• The fusion pressure used to join two different wall thicknesses is
always that of the thinner wall pipe/component.

Range of PE Wall Thickness Fusion Compatibility

Can be fused to a pipe or fitting with a
Pipe or Fitting DR
Min DR of or Max DR of
7 5.5 9
9 7 11
11 9 13.5
13.5 11 17
17 13.5 21
21 17 26
26 21 32.5
32.5 26 41

Fusion Hotline 1-800-345-4726 ext. 4790

© Copyright 2018 ISCO Industries, Inc. All rights reserved. 37