HDPE jointing methods

Butt-weld
Butt-weld process
Butt-welding is a very economical and reliable jointing technique for making welded The butt-welding of Marley HDPE operates according to the following steps:
joints, requiring only butt-welding equipment. All pipes and fittings can be joined
by this welding method. Fittings for which a k-dimension is shown in the product (The five steps below relate to the image on page 26).
section, (pages 6-17), can be shortened by no more than this amount. Butt-welding
is extremely suitable for prefabricating pipe sections and for making special fittings.
1. Machining the surface 3. Heating up with less pressure 5. Welding and cooling
Both sides should be machined until they HDPE is a good insulator, therefore at After the jointing areas have made contact
run parallel. When the machining is finished, this stage it is necessary that the correct they should be joined with a gradual
Preparations open the carriages (the plastic shavings must heating depth of the pipe ends is increase in pressure up to the specified
be continuous and uniform in both sides to obtained. Only a small amount of pressure value. Keep the specified welding pressure
The following guidelines are of importance O Clean the heating element before O Put the pipe parts into the welding weld). Take off the milling cutter. 0.01 N/mm2 is required to maintain the at a constant level during the cooling
when making an accurate butt-weld: each jointing operation with a lint- machine to facilitate a firm hold
Verify the alignment between the contact of the pipe ends with the heating period. Do not cool artificially.
O Establish a work space where the free cloth and suitable cleaner (see during the jointing process. element. The heat will gradually spread
machined surfaces. Remove the plastic
jointing can be done without being instructions supplied with the O A digital thermometer can be used to through the pipe/fitting end. The size of
shaving. Do not touch or get any dirt on
effected by major weather conditions. welding machine). check the temperature of the heating the bead will increase a little. The time
the machined surfaces.
O Cut the pipe and/or fitting with a pipe plate. The temperature should be and pressure needed for this phase can be
O Check the equipment functions
cutter to make the end square. checked at several points around found in the table on page 28.
properly. Welding equipment used on
site deserves special attention. Make sure that once the pipe and/or the plate and should be between
O Without removing the
fitting ends have been machined, they 200ºC and 220ºC. Maximum deviation
O The fittings and or pipes need to be between points is given in the table.
oxygen layer a weld The welded components can be removed
aligned in the welding machine. do not get dirty. Do not touch them cannot be guaranteed. from the machine when 50% of the
Mis-alignment can be up to 10% of with your hands. The surface needs to cooling period has elapsed, providing that
the wall thickness. be clear of oil, grease and dirt. this is done carefully, with no load or strain
being placed on the joint. The joint must
Maximum temperature variation heating element then be left undisturbed for the remainder
4. Change over
of the cooling period.
Used surface of heating element for welding Remove the heating element from the
Δt max
diameter (d1) jointing areas and immediately make those
areas touch each other. Do not push the
d1 = 40-160 8ºC pipe ends abruptly onto each other.
d1 = 200-315 10ºC The removal of the heating element needs
to be done quickly to prevent the pipe
ends from cooling down. The times for
pressure N/mm2 2. Preheating under pressure changing over can be found in the table
Press the two ends to be jointed gradually on page 28.
(PE)
HDPE
preheating pressure (Fo) welding pressure (FL) on to the heating element until a bead is
0,15 created. The size of the bead is a good
indication that the appropriate pressure
and time is used. For pressure and bead
size see the table on page 28.

heating pressure (Fd)

0,01
time

1 2 3 4 5
pressure time
building-up
changeover

preheating time heating time

machine the
time

surface cooling time

total welding time

height welding bead

total time welding process

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