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Pipe Fusion Series: What Is Saddle Fusion?

Pipe Fusion Series: What Is Saddle Fusion?

by | Apr 15, 2024 | HDPE Piping, Piping

What Is Saddle Fusion?

Saddle fusion is a specialized form of heat fusion, a process used to join two pipes or fittings made from thermoplastic materials like polypropylene (PP)  and high-density polyethylene (HDPE). This technique involves creating a saddle-shaped connection by melting the surfaces of both the main pipe and the branch or saddle fitting. The heat applied fuses the materials together, resulting in a strong, leak-resistant joint.

Saddle Fusion Process

The key steps involved in saddle fusion are:

1. Preparation

Before starting the saddle fusion process, it’s essential to thoroughly clean and prepare the pipe and fitting surfaces. Any dirt, debris, or contaminants should be removed to ensure a clean fusion.

2. Clamping

Securely clamp the saddle fusion machine onto the pipe, then secure the saddle fitting into the machine. The clamps hold the components in place during the fusion process, ensuring they do not move or misalign.

3. Marking and Alignment

Mark the position where the saddle fitting will be attached to the main pipe. Proper alignment is crucial for a successful fusion, so take care to align the fitting accurately.

4. Heating

Use a specialized heating tool to heat the surfaces of both the main pipe and the saddle fitting. The heating tool typically includes heating plates or a heating element that is placed against the surfaces to be fused.

5. Heating Time

Allow sufficient time for the heating process. The duration will depend on factors such as the type and thickness of the thermoplastic material. It is crucial to follow the manufacturer’s guidelines for the specific materials being fused.

6. Cooling

Once the heating is complete, remove the heater and apply proper fusion force, per manufacturer’s recommendations, and allow the fused joint to cool. Cooling times can vary, and it’s important not to disturb the joint during this phase to ensure proper solidification of the melted thermoplastic material.

7. Inspection

After the joint has cooled, inspect the joint visually to ensure there are no irregularities, and that the fusion is uniform and without any visible defects. The fusion bead should have a characteristic “three-bead” shape. 

8. Testing

Conduct pressure tests or other relevant quality checks to verify the integrity of the saddle fusion joint. This step is crucial to ensure that the joint is leak-resistant and meets the required performance standards.

9. Documentation

Maintain detailed documentation of the saddle fusion process, including the fusion parameters, cooling times, and any quality control tests performed. Proper documentation is essential for quality assurance and compliance.

Saddle Fusion vs. Other Types of Pipe Fusion

Saddle fusion isn’t the only effective method of pipe fusion. See how it compares to other popular pipe fusion methods like butt fusion, socket fusion and electrofusion.

Saddle Fusion

Method:
Used to create branch connections by attaching a saddle-shaped fitting to an existing pipe. The saddle is heated, and pressure is applied to weld it to the main pipe.

Advantages:

  • Ideal for creating branch connections in a pipeline.
  • Requires minimal excavation, making it suitable for repairs and retrofits.
Butt Fusion

Method:
Involves joining two pipe ends by heating them to their melting point and then pressing them together. The melted material fuses, creating a seamless, end-to-end connection.

Advantages:

  • Produces leak-proof and long-lasting joints.
  • Suitable for a wide range of thermoplastic materials.
  • No need for additional adhesives or solvents.
  • Minimal maintenance is required.
  • Consistent and repeatable results.
Socket Fusion

Method:
Involves heating the outside of a pipe and the inside of a fitting, then inserting the pipe into the fitting, creating a secure joint when the material cools.

Advantages:

  • Suitable for small-diameter pipes and fittings.
  • No need for external clamps.
  • Creates joints that are resistant to pull-out forces.
Electrofusion

Method:
Involves connecting two ends by sliding and coupler over the ends. The coupler has coils inside that are heated up to make a leak-free pressure rate weld.

Advantages:

  • Provides a strong, continuous connection.
  • Suitable for creating complex shapes and custom profiles.
  • Great for tight area repairs

When to Use Saddle Fusion

Saddle fusion finds applications in various industries, including plumbing, irrigation, and industrial piping systems. It is particularly useful in scenarios where a branch connection needs to be added to an existing pipeline without disrupting the entire system.

Benefits of Saddle Fusion

Saddle fusion offers several advantages that make it a preferred choice for many applications:

  • Precision: Saddle fusion offers a precise and controlled fusion process, ensuring a reliable joint without compromising the integrity of the pipes.
  • Versatility: Compatible with various thermoplastic materials, saddle fusion proves versatile for a wide array of applications.
  • Reduced waste: The focused heating technique minimizes material waste, making it an environmentally and economically sound option.

Contact US FUSION’s Pipe Fusion Experts

Saddle fusion emerges as a valuable addition to the repertoire of pipe fusion techniques. Its unique characteristics make it well-suited for specific applications, offering a precise and efficient means of joining thermoplastic pipes.

If your project requires any type of on-site plastic fusion work, the US FUSION team is here to serve you. Our technicians are ASME Section IX certified and have nearly four decades of HDPE and welded plastic pipe fusion experience. Get in touch to learn more about how we can help, or request a free quote online here.

Pipe Fusion Series: What Is Socket Fusion?

Pipe Fusion Series: What Is Socket Fusion?

by | Jan 30, 2024 | HDPE Piping, Piping

Socket fusion is a popular pipe fusion method known for its versatility, flexibility, and effectiveness in a range of settings. This article explores the details of socket fusion, points of differentiation from other fusion techniques, preferred applications, as well as benefits associated with its use. 

What Is Socket Fusion? 

Socket fusion is a pipe joining technique that involves the use of heat to melt both the outside surface of the pipe and the inside surface of a hole cut into pipe or fitting. Once the surfaces are melted, the pipe and fitting are pressed together to form a strong and durable connection. This fusion method is widely used for joining pipes made of thermoplastic materials, such as polyvinylidene fluoride (PVDF) and high-density polyethylene (HDPE).

Socket Fusion Process

Here’s an inside look at the socket fusion process. Please remember that this process should be carried out by certified professionals to ensure safety and quality.

1. Prepare the Pipes

Cut the pipes to the desired length using a pipe-cutting tool. Ensure the cuts are clean and at right angles. Check the pipes for any dirt, debris, or contaminants. Clean the pipe ends thoroughly.

2. Prepare the Fittings

Ensure the fittings are clean and free from any contaminants. Insert the depth gauge or use a marking tool to mark the proper insertion depth for the pipe into the fitting.

3. Assemble the Fusion Machine

Set up the socket fusion machine, ensuring that the heating plate or element is clean and in good condition. Adjust the machine settings according to the pipe and fitting specifications, including heating time and temperature.

4. Heat the Pipes and Fittings

Place the pipe ends and the fitting onto the heating plate or element of the fusion machine. Ensure that the heating is uniform across the entire circumference of the pipe and fitting. Heat the materials to the specified temperature, following the guidelines provided by the pipe and fitting manufacturers.

5. Remove from Heat

Once the pipe and fitting reach the correct fusion temperature, carefully remove them from the heating plate.

6. Insert the Pipe into the Fitting

Quickly but carefully insert the heated pipe into the fitting, ensuring that it reaches the marked insertion depth. Hold the pipe in place until the joint cools and solidifies.

7. Cooling and Inspection

Allow the joint to cool completely before handling or pressurizing the system. Inspect the joint visually to ensure there are no visible signs of defects, and check for proper fusion.

8. Pressure Test 

Depending on the application, a pressure test may be conducted to ensure the joint’s integrity.

9. Repeat for Additional Joints

If there are multiple joints to be made, repeat the process for each joint, ensuring proper heating and fusion.

Socket Fusion vs. Other Types of Pipe Fusion

Socket fusion isn’t the only method of plastic pipe fusion. See how it compares to other popular pipe fusion methods like saddle fusion, butt fusion, and electrofusion.

Socket Fusion

Method: Involves heating the outside of a pipe and the inside of a fitting, then inserting the pipe into the fitting, creating a secure joint when the material cools.

Advantages:

  • Suitable for small-diameter pipes and fittings.
  • No need for external clamps.
  • Creates joints that are resistant to pull-out forces.
Butt Fusion

Method: Involves joining two pipe ends by heating them to their melting point and then pressing them together. The melted material fuses, creating a seamless, end-to-end connection.

Advantages:

  • Produces leak-proof and long-lasting joints.
  • Suitable for a wide range of thermoplastic materials.
  • No need for additional adhesives or solvents.
  • Minimal maintenance is required.
  • Consistent and repeatable results.
Saddle Fusion

Method: Used to create branch connections by attaching a saddle-shaped fitting to an existing pipe. The saddle is heated, and pressure is applied to weld it to the main pipe.

Advantages:

  • Ideal for creating branch connections in a pipeline.
  • Requires minimal excavation, making it suitable for repairs and retrofits.
Electrofusion

Method: Involves connecting two ends by sliding and coupler over the ends. The coupler has coils inside that are heated up to make a leak-free pressure rate weld.

Advantages:

  • Provides a strong, continuous connection.
  • Suitable for creating complex shapes and custom profiles.
  • Great for tight area repairs

When to Use Socket Fusion

Socket fusion is particularly well-suited for pipes made of thermoplastic materials. It finds widespread use in industries such as water and wastewater, gas distribution, and industrial piping systems. 

This fusion method is frequently used in residential plumbing, municipal water distribution systems, and industrial processes where reliable and leak-free joints are essential. Its adaptability to various pipe sizes and configurations makes socket fusion an attractive choice for a broad range of applications.

Benefits of Socket Fusion

There are many benefits of socket fusion, the most prominent being: 

  • Simplicity: Socket fusion is a relatively straightforward process that requires minimal training, making it accessible to a wide range of operators.
  • Space Efficiency: The compact nature of socket fusion joints makes this technique ideal for applications where space constraints are a concern.
  • Cost-Effective: Socket fusion equipment is often less expensive than the specialized machinery required for other fusion methods, contributing to cost savings.
  • Versatility: Suitable for a variety of thermoplastic materials and pipe sizes, socket fusion offers flexibility in application.
  • Leak Resistance: The resulting joints from socket fusion are known for their high integrity and resistance to leaks when properly executed.

Contact US FUSION’s Socket Fusion Experts

Socket fusion stands out as a versatile and cost-effective method for joining thermoplastic pipes in various applications. Its simplicity and adaptability make it an attractive choice for projects where space efficiency and reliable connections are crucial. However, like any fusion technique, proper training and execution are essential to ensure the integrity and longevity of the joints.

If your project requires any type of on-site plastic fusion work, the US FUSION team is here to serve you. Our technicians are ASME Section IX certified and have nearly four decades of HDPE and welded plastic pipe fusion experience. Get in touch to learn more about how we can help, or request a free quote online here.

What Is PVDF?

What Is PVDF?

by | Dec 8, 2022 | Piping

Pipe can be manufactured from all sorts of materials, sizes, and configurations. At US FUSION, we work most often with various types of plastic piping, including HDPE, PolyPro, and PVDF. 

In this article, we’re discussing PVDF. We talk about what PVDF is, how it’s made, when it’s used, and more. 

What Is PVDF? 

PVDF stands for polyvinylidene fluoride, which is a semi-crystalline, highly inert, stable thermoplastic fluoropolymer. It has a melting point of 347°F and service temperatures of up to 302°F. It boasts outstanding properties overall, such as great durability and toughness, excellent chemical resistance, high crystallinity, and good thermal stability. 

PVDF is one of the best radiation-resistant plastics available in the market, only bested by PEEK (polyetheretherketone) and polyamide. Today it is sold under different brand names with various additives and melt flow rates, all of which increase the processing capabilities and heighten properties for specific applications.

How Is PVDF Made?

PVDF resin is produced by free-radical polymerization of 1,1-Difluoroethylene (abbreviation = DFE, chemical formula = C2H4F2). The polymerization occurs in the emulsion of 50-302°C and 10-300 atm pressure. The obtained material is then processed into films, rods, tubes, and sheets.

The most common methods to produce PVDF polymer are chlorotrifluoroethylene (CTFE) or hexafluoro propene (HFP). HFP-made PVDF copolymer shows higher flexibility compared to PVDF homopolymer grades. Copolymers made by CTFE are superior even yet to polymers made by HFP. They are more flexible, have low shrinkage, and have a fantastic low-temperature performance range.

Furthermore, polyvinylidene fluoride is exposed to ionizing radiation using crosslinking, making various modifications to the thermal and mechanical properties possible. Additionally, different resins like methacrylic and acrylic rubbers have partial compatibility with the polymer.

Mechanical Properties of PVDF

PVDF has a good tensile modulus but fairs weak in the impact strength department. Rearrangements done using HFP and CTFE can help improve the flexibility and impact strength, as well as decrease the tensile modulus.

PVDF is also non-flammable and won’t drip. It is self-extinguishing and has decent resistance to UV light.

IS PVDF Acid Resistant?

PVDF exhibits excellent chemical- and acid-resistant properties. It can withstand a variety of aggressive fluids and solvents. It mainly shows impressive physical resistance toward organic and inorganic acids, halogenated solvents, and hydrocarbons.

PVDF Applications

PVDF has many applications, in all sorts of industries. Here are a few common examples. 

Electrical/Electronics

PVDF has many applications in the electrical and electronics industries, such as:

  • Wires and cables in aircraft
  • High-temperature wirings
  • Home appliances
  • Wire coating
  • Industrial power control systems

Heavy Industries 

With help from common additives, PVDF’s good corrosion properties can improve its applicability to heavy industries like oil and gas, automotive, marine, and petrochemicals used for gaskets, seals, and linings. Lately, it is most commonly used in filtration equipment like housings, filters, membranes, etc.

Batteries

PVDF is also used for making separators in lithium-ion batteries, thanks to their reliable thermal and chemical stability. These membranes are in demand as the market for electric mobility will see sizable growth in the future.

Piping and Liners 

Chemical processing equipment depends on PVDF resin to make flexible piping, tubing, and liners to be used in water systems, chemical pipes, automobile fuel lines, and storage. Piezoelectric films are very sensitive transducers. They are malleable, rigid, and lightweight; thus, they can be shaped into various geometries resulting in unique and innovative applications.

Coatings 

PVDF is also used for coating and layering applications on metals like aluminum and galvanized steel. The coatings improve these materials’ chemical resistance and weatherability.

What Is Red PVDF?

PVDF red piping systems have been used successfully in outdoor applications for over 25 years. Red PVDF provides the same pressure/temperature range and chemical resistance as traditional Kynar® PVDF with no pigmentation.

Natural, unpigmented PVDF is unaffected by ultraviolet (UV) light, but is does permit UV rays to pass through it, affecting the media within the pipeline. Since UV rays pass through natural Kynar®  PVDF, chlorine or peroxide can cause stress cracks in Kynar®  components.

By adding a specific red pigment to Kynar®  PVDF, the UV light spectrum is unable to pass through the polymer. This protects the media within and eliminates the potential of UV rays to radicalize the chemicals.

Red PVDF not only protects the material chemistry but also extends the service life of the piping system. The red pigment also enables the material to better withstand weathering and outdoor exposure. 

However, red pigmented Kynar®  PVDF is not usually recommended for indoor use with high-purity systems such as deionized water, as it can potentially leach impurities into the media.

Contact US FUSION for Your PVDF Pipe & Fittings Needs

At US FUSION, we have the capabilities to supply, fuse, and install high-performance PVDF pipes and fittings. Our cost-effective solutions, comprehensive inventory, and custom services can meet any demand or project scope. Give our team a call or contact us online to get started.

Sliplining Pipe: How It Works and Why It’s Beneficial

Sliplining Pipe: How It Works and Why It’s Beneficial

by | Feb 16, 2022 | Piping

Although it’s one of the oldest methods in the industry, sliplining is still a popular choice for underground pipe rehabilitation projects. Let’s take a closer look into what it is, how it works, and why it’s beneficial for a number of specialty construction applications.

What Is Sliplining?

Sliplining is a trenchless underground pipe rehabilitation technique that involves installing a pipe of a slightly smaller diameter into a larger “host” pipe, then grouting the space between the two and sealing the ends. This process helps to restore the structural integrity of the existing pipeline, and helps to prevent the need for a more costly, time-consuming, and labor-intensive pipe replacement.

6 Steps of the Sliplining Process

The sliplining process can vary depending on a number of factors, from field conditions to pipe materials and host pipe conditions. However, it most commonly follows a six-step process, which we’ll outline below.

1. Inspect the Host Pipe

The first, and arguably most critical step, of the sliplining process is to inspect the condition of the host pipe. During the inspection, you’ll assess the level of pipe deterioration, which is critical in determining how feasible the sliplining procedure may, or may not, be. In some cases, a host pipe inspection is done manually, but the preferred method is to use remote controlled closed circuit television (CCTV) equipment to inspect the pipe. High definition cameras inside the pipe allow you to inspect the existing pipelines safely.

2. Clean Out the Host Pipe

After you’re done with inspection and you’ve determined that sliplining is a feasible solution, you need to thoroughly clean and clear out the host pipe. This prepares the pipe for lining installation and can be accomplished using a variety of tools and methods. Some of the most common pieces of cleaning equipment include plugs, cleaning buckets, water jets, and pipeline pigs.

3. Join the Carrier Pipe(s)

Before you can install a carrier pipe into the host pipe, you’ll have to join various sections together to reach your desired length. These sections are usually welded together using butt fusion technology. Bell and spigot pipe can also be used, and the joints can be pushed together during installation.

4. Access the Host Pipe

As a final step before installation can begin, you need to access the host pipe via two small excavations, commonly known as the entry and exit pits. The areas of these excavations serve as the beginning and end of your liner installation.

5. Install the Carrier Pipe

Once you’ve done everything to prepare both pipes, you’re ready to install! You can install the carrier pipe by either pushing or pulling it through the host pipe until it reaches its intended placement. Then, in some cases, a 24-hour resting period is required following the installation. If necessary, you can use one of several ways to restore lateral pipe connections.

6. Restore the Terminal Connections and Grout the Annular Space

The final step of sliplining is to restore connections at the terminal ends of the carrier pipe and grout the annular space surrounding it. Not only does this help stabilize the new liner, but it also helps ensure that the pipe doesn’t experience any substance leakage that could potentially harm the environment.

Once your newly lined pipe is fully grouted and stabilized, you’ve completed the sliplining process. However, it’s best to keep an eye on how the new parts are performing for a couple of days, just to make sure everything still goes as planned.

4 Key Advantages of Sliplining

The sliplining process dates all the way back to the 1940s, but it’s stuck around for good reason! And with newer systems and technologies available each year, the process has only become more efficient over time.

If you’re in need of an underground pipe rehabilitation, sliplining is one of your best options. Here are a few reasons why:

  • Affordable – When compared to a complete pipe replacement, the cost of a sliplining procedure is considerably less expensive.
  • Efficient – With the help of an experienced technician and innovative technology, sliplining is a fast and simple process — helping you ensure your operations are back up and running with minimal downtime and environmental concern.
  • Less excavation – Sliplining involves much less excavation than a full pipe replacement. This means you’ll have to worry about far less disruption, waste, and cleanup.
  • Long-lasting performance – Sliplining is guaranteed to repair any deteriorating pipes and restore them to full capacity, helping you remove any risks of corrosion or leakage for years to come.

Want to learn more about our sliplining capabilities at US FUSION? Check out our downloadable brochure!

Need to rehabilitate your underground piping system? Choose US FUSION. With decades of experience in pipe rehabilitation, our team has a long history of applying the latest technologies, construction methods, and safety practices within our operations. Complete your project with us and discover why we’re the best choice in the industry. Request your free quote today.