Pexgol's Industrial Pipe Fittings: Welding Instructions

To connect Pexgol (PE-Xa) cross-linked polyethylene pipes with electrofusion fittings. Fusion welding connects the pipes and fittings and create a leak-proof seal. With these fittings, you don't need to use sealing rings.

In the electrofusion process, a heating wire is used to transport a current. Then the material around that wire is melted, welding the pipe to the fitting.

Our fittings feature the following benefits:

  • This electrofusion process is a connection technology that works for all Pexgol pipes.
  • They are economical, especially for pipes with large diameters used for water transportation.
  • Electrofusion fittings are used in municipal water and industrial distribution systems as the main means of connection.
  • According to the European standards, our fittings have been tested to have a 50-year lifespan and working pressures of up to 16 atm in water networks.
  • The welding connectors are low-volume and lightweight
  • Pexgol connectors are offered in 20 mm to 630 mm diameters
  • Pexgol supplies a wide variety of options: couplers, tees, elbows, saddles, and tapping saddles

The entire electrofusion process is executed and fully monitored by the computerized control box ensuring safe, reliable connections.

 

Installation Instructions for Electrofusion Fittings:

Only trained workers with a valid certificate can install Pexgol electrofusion fittings. Their certificate must show that they have been trained by authorized Pexgol personnel.

Use electrofusion fittings that have been approved for safe fusion with Pexgol (PE-Xa) cross-linked polyethylene pipes.

Wall thickness defined as follows:

Pressures:

PN 16 electrofusion fittings are compatible with Pexgol pipes that are rated up to pressures of 10 bars in gas or P.N.15 in water. (PE spigot connectors are only produced in two levels: P.N. 16 and P.N. 10.)

 

Rounding the pipe:

Rounding the pipe is necessary for successful, high-quality fusion and easy insertion. Use rounding tools on the pipe end. These tools will keep the pipe rounded throughout the welding process.

 

Support of the fitting during the welding process:

Pipes should be inserted into the fitting by using spanners (come-alongs) when welding pipes are in diameters of 90mm and higher. This will allow controlled insertion, ensuring the coupler stays stationary throughout the welding process.

 

Cooling time:

Each fitting features a sticker that indicates its cooling time. You should not disassemble rounding devices and spanners before this cooling time has elapsed.

We advise that, at the end of the fusion process, note the hour and add the cooling time. This is when you should disassemble the spanners and rounding devices. We recommend that you mark this time on the fitting.

Pexgol electrofusion fittings can be used in the following temperatures:

 

welding manual 1

 

For higher pressures, consult the Pexgol Field Service.

 

Preparations:

  1. How to prepare the fittings for welding: Welding and preparation can be conducted at ambient temperature in windy, rainy, or human conditions, but the welding area must protected by a cover. Or, halt the welding process until weather conditions improve.
  2. Preparation (scrubbing and cleaning) must be completed close to the welding time. Do not prepare fittings and pipes for welding if your welding is scheduled for a later stage.
  3. Pipe scraping and peeling: Universal scrapers or hand scrapers should have sharp blades and be in perfect working conditions. Replace the universal scraper's blade when it is no longer sharp. Sharpen the hand scraper blade when needed with a fine iron file.

    The scraped layer thickness should be as follows:
  • Diameter: 20-25 mm, 0.15–0.20 mm
  • Diameter: 32-75 mm, 0.15-0.25 mm
  • Diameter: 90–355 mm, 0.20–0.30 mm

 

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