Electrofusion is a precise and reliable method for joining HDPE (High-Density Polyethylene) pipes and fittings, especially in applications requiring high integrity such as gas, potable water, and industrial systems. Electrofusion fittings contain embedded heating coils that, when energized, fuse the pipe and fitting together. Below are detailed installation instructions to ensure a successful and long-lasting joint.
Required Tools and Equipment
Pipe cutter or saw
Rotary scraper or manual pipe scraper
Isopropyl alcohol and lint-free cloths
Pipe alignment and clamping device
Electrofusion control unit (EF welder)
Barcode scanner (optional)
Personal protective equipment (PPE)
Step-by-Step Installation Procedure
1. Cut the Pipe Square
Cut the pipe square using a pipe cutter or saw.
Ensure clean, smooth, and perpendicular cuts.
Check pipe ends for damage or deformation.
2. Mark the Insertion Depth
Measure the socket depth of the fitting.
Mark the pipe at the same distance to confirm full insertion during assembly.
3. Scrape the Pipe Surface
Use a rotary scraper to remove the oxidized layer from the pipe surface—usually about 0.2–0.3 mm.
Scrape slightly beyond the insertion mark.
Do not touch the scraped area with bare hands to avoid contamination.
4. Clean Pipe and Fitting
Wipe both the scraped pipe surface and inside the fitting socket with isopropyl alcohol using a clean cloth.
Allow to air-dry fully.
Do not blow on or touch the cleaned surfaces.
5. Insert and Align the Pipe
Push the pipe into the fitting until it reaches the depth mark.
Use an alignment clamp to hold the pipe and fitting in place during fusion.
Ensure both components are correctly aligned with no bending stress.
6. Connect the Electrofusion Machine
Attach the electrofusion control unit leads to the fitting terminals.
If the fitting has a barcode, scan it with the control unit scanner for automatic fusion parameters.
If manual input is required, enter the fusion voltage and time as specified by the fitting manufacturer.
7. Start the Fusion Process
Initiate the fusion cycle on the control unit.
The control unit energizes the heating wire inside the fitting, melting the inner surface and bonding it to the pipe.
The unit will alert you when the process is complete.
8. Allow Proper Cooling
Do not disturb or move the pipe and fitting during the cooling time.
Cooling allows the joint to solidify and gain full strength.
Wait for the time specified by the fitting manufacturer (often 5–30 minutes depending on size).
9. Inspect the Joint
Check visual indicators (usually small pins) on the fitting; they should protrude if fusion was successful.
Look for symmetrical fusion bead, proper alignment, and absence of gaps or cracks.
10. Pressure Testing (if applicable)
After cooling, conduct pressure testing according to project or regulatory standards to ensure leak-free performance.
Installation Tips and Warnings
Use only new, undamaged electrofusion fittings.
Never reuse fittings once fusion has been attempted.
Do not fusion-weld in rain or wet environments without proper protection.
Ensure the electrofusion control unit is calibrated and compatible with the fitting brand.
Keep pipe and fittings free from oil, grease, dirt, and moisture throughout the process.
Correct installation of HDPE electrofusion fittings is essential for creating strong, leak-proof joints. By carefully preparing the pipe, following manufacturer specifications, and using proper tools and techniques, installers can ensure the long-term reliability and performance of HDPE piping systems.
