In industries where the integrity of piping systems is critical, plastic pipe fusion has become a go-to joining method. But with its growing adoption comes a heightened need for consistency, durability, and safety. That’s where quality control steps in.

At the heart of any rigorous quality control program is ASME Section IX—a key section of the ASME Boiler and Pressure Vessel Code (BPVC) that governs the qualification of welding, brazing, and fusing procedures and personnel. When applied to plastic fusion, ASME Section IX provides a standardized framework to ensure each joint meets strict performance and safety requirements.

This blog explores fusion quality control matters and ASME Section IX to drive long-term success in their plastic fusion projects.

What is ASME Section IX?

ASME Section IX is a critical component of the ASME Boiler and Pressure Vessel Code (BPVC). The BPVC is a comprehensive set of standards developed by the American Society of Mechanical Engineers to ensure that the design, fabrication, and inspection of pressure-containing systems meet the highest levels of safety and performance.

Section IX specifically addresses the qualification of procedures and personnel involved in welding, brazing, and fusing. It defines the essential variables and testing requirements necessary to demonstrate that a joining process (whether for metal or plastic) can consistently produce sound, reliable joints. This includes guidelines for:

• Welding Procedure Specifications (WPS)
• Fusing Procedure Specifications (FPS)
• Procedure Qualification Records (PQR)
• Performance qualifications for welders, brazers, and fusing operators

While originally developed for metal fabrication, ASME Section IX has evolved to include fusion processes for thermoplastics, making it highly relevant to industries utilizing plastic piping systems.

Why It Matters for Plastic Fusion

In applications where plastic pipes carry gases, chemicals, or water under pressure, the reliability of each joint is critical. A poorly fused connection can lead to leaks, failures, or safety hazards that compromise entire systems. ASME Section IX provides a standardized, proven framework to help companies:

• Validate that their fusion processes meet the required performance criteria
• Ensure operators are fully qualified to perform fusions under controlled conditions
• Maintain consistent quality across every joint in the system

By adopting ASME Section IX standards, organizations working with thermoplastic pipe fusion—especially in industries like utilities, water treatment, and energy—can confidently deliver long-lasting, code-compliant systems built for safety, efficiency, and performance.

The Role of Quality Control in Plastic Pipe Fusion

Why Fusion Quality Control is Critical

Quality control is the backbone of any successful plastic pipe fusion operation. In systems where piping is used to transport water, gas, chemicals, or waste, a single compromised joint can jeopardize the safety and function of the entire network. That’s why implementing rigorous quality control (QC) protocols isn’t just a recommendation—it’s a necessity.

Effective quality control ensures that each fused joint is formed under precise, repeatable conditions. This includes:

• Proper surface preparation to remove contaminants and oxidation
• Accurate pipe alignment to ensure even heating and uniform fusion
• Controlled heating cycles to reach the correct fusion temperature
• Consistent pressure application during the joining process
• Monitored cooling times to avoid premature handling or movement

When performed correctly and consistently, these QC steps help:

• Prevent leaks, joint failures, and unplanned downtime
• Ensure regulatory compliance and reduce liability
• Extend the lifespan and reliability of the piping system

For industries relying on thermoplastic piping, such as utilities, municipal waterworks, and industrial processing plants, strong quality control practices not only protect infrastructure but also support:

• Long-term system performance
• Environmental safety
• Public trust and confidence

Consequences of Poor Quality Control

The absence of a structured quality control program introduces significant risks. Improperly fused joints can:

• Fail under pressure, leading to leaks or bursts that cause environmental damage or system shutdowns.
• Require costly repairs and replacements, especially when buried pipelines or hard-to-access systems are involved.
• Result in regulatory non-compliance, triggering fines, legal liability, and reputational damage.

In short, poor QC doesn’t just threaten the integrity of a single weld—it can compromise an entire project. That’s why aligning fusion practices with ASME Section IX and investing in quality assurance is critical for short-term success and long-term resilience.

3 Key Elements of Plastic Fusion Quality Control (QC)

Establishing a reliable fusion quality control program requires attention to detail across three critical areas: inspection, testing, and documentation. Each plays a vital role in verifying joint integrity, maintaining compliance, and supporting long-term performance.

1. Inspection Procedures

Routine visual inspections are the first line of defense against fusion defects. These checks ensure that every joint meets the Fusing Procedure Specification (FPS) standards.

Key inspection practices include:

• Checking for proper pipe alignment before fusion
• Assessing bead uniformity for consistent melt patterns
• Identifying surface contamination that could weaken the joint
• Using standardized checklists to ensure repeatability
• Verifying compliance with FPS parameters

2. Testing Methods

Testing confirms that fusion joints meet mechanical and performance requirements. Depending on the application and criticality, destructive and non-destructive techniques may be used.

Destructive Testing:

• Tensile tests – Measure the joint’s strength under pulling force
• Bend tests – Assess ductility and resistance to cracking
• Peel tests – Used in some plastic applications to evaluate bond strength

Non-Destructive Testing (NDT):

• Ultrasonic inspection – Detects internal flaws without damaging the joint
• Hydrostatic pressure testing – Validates pressure-holding capacity

Macro/Micro Examination:

• Analyzes the internal structure of the joint to detect:
  • Voids
  • Incomplete fusion
  • Material inconsistencies

3. Documentation and Record-Keeping

Thorough documentation not only supports internal quality assurance but is often required for regulatory or third-party audits.

Critical documentation includes:

• Procedure Qualification Records (PQR): Validate the fusion process through test results
• Fusing Procedure Specifications (FPS): Detail the step-by-step process for creating compliant joints
• Fusing Performance Qualifications (FPQ): Certify that technicians are qualified to execute the FPS
• Audit trails and inspection logs that:
  • Track operator performance
  • Record testing outcomes
  • Demonstrate ongoing compliance with ASME Section IX

Why Certified Technicians Matter

When it comes to plastic pipe fusion quality control, even the most precise procedures and standards mean little without qualified people executing them. That’s why certified technicians trained and tested under ASME Section IX standards are essential to the success and safety of any fusion project.

Fusing Performance Qualification (FPQ)

ASME Section IX requires plastic pipe fusion technicians to pass a Fusing Performance Qualification (FPQ). This certification process:

• Demonstrates the technician’s ability to follow an approved Fusing Procedure Specification (FPS)
• Verifies that they can consistently produce reliable, structurally sound joints under defined conditions
• Helps ensure the fusion process meets the required mechanical and performance standards

Technicians must remain active and maintain their qualifications through ongoing practice, routine observation, and requalification if performance lapses.

Benefits of Using Certified Technicians

Employing certified technicians ensures:

• Adherence to documented procedures (FPS): Reduces the chance of human error and inconsistent results.
• Fewer defects and rework: Minimizes downtime and costly repairs.
• Stronger regulatory compliance: Ensures your team is constantly working within the bounds of ASME Section IX, especially critical during inspections or audits.
• Greater confidence in project outcomes: Certified personnel are better equipped to troubleshoot, maintain quality under pressure, and accurately document performance.

Built-In Compliance through Competency

Certified technicians are the front line of compliance. Their training ensures they understand how to:

• Control “essential variables” like material type, fusion temperature, pressure, and alignment—all of which, if altered, could compromise joint integrity and trigger the need for requalification
• Use proper inspection and testing methods to catch defects before they become failures
• Maintain clear, auditable records of procedures and performance qualifications in alignment with ASME Section IX

In short, certified fusion operators are both quality enforcers and compliance protectors. 

Quality Control Isn’t Optional at US FUSION

Quality isn’t an afterthought at US FUSION—it’s a commitment. From certified technicians to detailed inspection protocols and robust documentation, we follow the highest standards to deliver work that holds up under pressure.

For organizations operating in utility, infrastructure, or industrial sectors, adopting ASME Section IX isn’t just about meeting standards—it’s about setting them. When you choose a partner who prioritizes quality at every step, you’re choosing performance you can trust.

Protecting infrastructure and assets from wear and tear is crucial. That’s where polyurea coatings come in, offering a powerful solution for various industrial equipment. From exceptional durability to rapid curing times, polyurea coatings offer several advantages over traditional coatings such as epoxy, polyurethane, and acrylics.

What is a Polyurea Coating?

Polyurea is a high-performance synthetic polymer that excels at protecting surfaces. It is a plastic made from two chemicals: diamine and diisocyanate. When these two chemicals react, they create a strong and waterproof material called polyurea. This reaction is similar to how polyurethane is made. However, instead of creating polyurethane, it forms urea links. These are chemical bonds that cultivate unique properties.

Applications of Polyurea Coatings

This versatility and exceptional performance of polyurea, make it a highly sought-after solution for a wide range of industries. In the industrial sector, polyurea protects vital equipment and infrastructure. Pipelines, tanks, and secondary containment areas all benefit from polyurea’s exceptional chemical resistance and durability. In cases of primary containment failures, such as leaks or breaches in storage tanks or pipelines, polyurea can be swiftly applied to contain spills and prevent further environmental contamination.

The construction industry often uses polyurea to waterproof roofs, floors, and foundations. The automotive industry utilizes polyurea for truck bedliners and undercoating, providing a tough and waterproof layer that shields against scratches and corrosion. Even the marine industry leverages polyurea’s properties to safeguard boat decks and other structures from saltwater and water infiltration.

6 Unique Benefits of Polyurea Coatings

Polyurea’s unique combination of waterproofing, durability, chemical resistance, rapid curing, seamless application, flexibility, and heat resistance makes it an ideal protective coating for vital equipment and infrastructure. By applying polyurea, industries can significantly enhance the longevity, safety, and reliability of their assets. This leads to reduced maintenance costs and improved operational efficiency.

1. Waterproofing and Moisture Resistance

Polyurea’s unique chemical structure, which forms urea, prevents water and moisture from penetrating surfaces. In industrial construction, structures are constantly exposed to harsh weather conditions and potential water intrusion. Polyurea offers a game-changing solution that locks out leaks.

2. Seamless Application

Materials applied in sections, such as traditional coatings or sealants, are prone to developing weak points at seams and joints. Polyurea is sprayed as a continuous layer, eliminating vulnerable areas where leaks or damage can occur. The seamless membrane provides uniform protection, creating a stronger and more reliable barrier against water, chemicals, and other threats. This eliminates the need for complex joint sealing processes.

3. Durability and Impact Resistance

Polyurea is highly durable in demanding work environments where structures face constant force from heavy machinery and shifting loads. Unlike traditional coatings that chip or crack under pressure, polyurea maintains its integrity. This ensures lower maintenance costs and a longer lifespan for infrastructure.

4. Chemical Resistance

Polyurea is resistant to a wide range of chemicals, including acids, alkalis, solvents, and oils. This makes it an excellent choice in industrial environments. This resistance prevents corrosion and degradation of surfaces such as storage tanks, pipelines, and chemical processing equipment. By forming a protective layer, polyurea prevents oxygen, water, and other corrosive agents from reaching metal surfaces. This is particularly important for pipelines, storage tanks, and other structures where corrosion can lead to structural failure.

5. Rapid Curing Time

When the two main components of polyurea, a resin blend and an isocyanate, are mixed together, a chemical reaction called polymerization occurs almost instantly. By curing within seconds, polyurea reduces downtime during application. This allows for quick turnaround times in construction and maintenance projects, minimizing disruption to operations and reducing costs associated with downtime.

6. Heat and Weather Resistant

Polyurea maintains its flexibility even in extreme temperatures, allowing it to expand and contract with the substrate without cracking or peeling. This property is particularly beneficial for structures and equipment exposed to temperature fluctuations, ensuring long-term protection and stability. Polyurea is also resistant to ultraviolet radiation. It doesn’t degrade or lose its protective properties when exposed to sunlight, rain, or temperature extremes. This makes it suitable for outdoor applications, such as roofs, bridges, and exterior pipelines.

Experience the Benefits of US FUSION’s Polyurea Spray Installation

Polyurea’s seamless application eliminates weak points, while its rapid cure time minimizes downtime. Its exceptional chemical resistance safeguards your structures from aggressive materials, ensuring a longer lifespan for your valuable assets and reducing maintenance costs. Polyureas even offer no Volatile Organic Compounds (VOCs). With little to no odor, this makes them compliant with most environmental regulations.

US FUSION’s polyurea installation services cover primary containment, secondary containment, and corrosion control, providing a cost-effective solution ideal for various industries and applications. Whether you need to contain materials, prevent leaks, or enhance structural integrity, our experienced team tailors polyurea spray installations to meet your project’s specific requirements. Trust US FUSION to deliver excellence in every application of polyurea spray solutions.

Soil reinforcement and stabilization are important considerations for construction applications across a variety of industries, and geogrid is a valuable tool for improving soil-bearing capacity and stability.

But what is geogrid? Read on for a synthesis of what geogrid is, how it works, plus its benefits and applications.

Defining Geogrid

Geogrid is a geosynthetic material, a class of man-made materials used for soil reinforcement and other construction applications. There are several types of geosynthetic materials, each with different structures and specific purposes. Geogrids are flat, intersecting grids, generally made of polymers such as polyethylene, polypropylene, or polyester. 

Geogrids can be created via the weaving of separate yarns or fibers, welding strips of geosynthetic material into grids, extrusion, or by punching a grid pattern into a solid sheet of geosynthetic material. The holes in geogrids are referred to as apertures, and the grid material as ribs or spines. 

How Does Geogrid Work? 

Geogrids increase soil stability by redistributing loads over greater areas and lending the soil into which they are installed their tensile strength. The geometric grid pattern and stiff but flexible material of the geogrid has good tensile strength and can resist stresses that soil — particularly nutrient-poor, eroded, or uncovered soil — does not. Soil settles into the apertures of the geogrid, strengthening the soil.

What is Geogrid Used For?

Geogrids are used in a variety of construction applications for soil stabilization, reinforcement, and erosion control. They are also used to increase resistance to seismic activity (i.e., earthquakes). Geogrids are used in industries such as

• Road construction
• Natural disaster recovery and reconstruction
• Environmental restoration
• Berm or levee construction
• Landfills
• Drilling and mining
• Energy transmission
• Water transport
• Wastewater treatment

Geogrids are commonly used for applications where the soil needs to withstand heavy loads, such as roadbeds, parking lots, or airport runways. Geogrids are also frequently used on steep slopes to prevent soil erosion and improve seismic stability.

What Are the Benefits of Using Geogrid?

The primary benefit of geogrid use for construction applications is reinforcing soil. But some of the benefits of using geogrids for this purpose, as opposed to other methods, include cost, increased speed of construction, and performance characteristics.

Geogrids can be less costly than other methods, especially since they work with a variety of fill soils and materials. They can also be installed quickly and to a shallower depth than other soil reinforcement methods, reducing costs and time to install by reducing the required depth of excavation.

Additionally, geogrids are highly resistant to damage from a variety of sources, including UV exposure, mechanical damage, and chemicals. They have a long life and resist creep and damage from enduring high loads.

Contact US FUSION for Expert Geogrid Installation

If geogrids sound like the right solution for your application — whether for slope stabilization and erosion control, increasing load-bearing capacity for heavy equipment roads on your construction site, or reinforcing soil for seismic resistance — US Fusion delivers. Our unique polypropylene geogrid offers excellent tensile strength and modulus for reinforcement and stabilization. 

Reach out to learn more about how geogrid can work for your application.

Concrete protective liners are generally formed plastic sheets or inserts that cover concrete surfaces to protect them from damage. They can be made of high-density polyethylene (HDPE), polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF), Ethylene Tetrafluoroethylene (ETFE), or polypropylene and are fused or welded at the seams. These liners are a cost-effective method of protecting concrete structures, like storage tanks.

Protective liners can be used to protect various concrete structures, including

• Storage tanks
• Culverts and tunnels
• Sewer and water treatment
• Sumps
• Storage pads
• Concrete piping
• Secondary containment walls
• Manholes

They come in a variety of thicknesses, depending on the needs of the application; at US FUSION, we offer concrete protective liners in thicknesses ranging from 2.0mm to 12.0mm

6 Benefits of Concrete Protective Liners

But what are the benefits of protective liners for concrete structures? Here are six of the crucial benefits that concrete protective liners offer to industrial construction projects.

1. Protection from Mechanical Damage

Concrete, though a strong, durable material, is prone to fracturing and chipping. If you’ve ever dropped a hammer on a concrete shop floor, you know what we mean. The crystalline structure of concrete makes it unable to bend or flex when it receives an impact, but the polymer structure of plastic liners gives them greater flexibility, allowing them to bend without catastrophically breaking or chipping.

2. Protection from Corrosion Damage

Concrete can be corroded by a variety of substances present in the environment, including microbes, salty or acidic water, chlorides, sulfates, sulfides, slag and industrial waste, and more. Increasing the lifespan of concrete structures necessitates preventing this damage. A protective liner in a corrosion-resistant material like HDPE or PVDF (like Teflon) will shield the concrete from these corrosive, damaging substances.

3. Minimal Lateral Movement 

Concrete protective liners have minimal lateral movement, which is necessary for ensuring the protection of the concrete structure and maintaining a leak-proof seal. 

4. Resists UV Degradation

HDPE and other plastics used for concrete protective liners can be made with different additives, depending on the desired performance characteristics. This includes UV resistance, which can be incredibly useful for protective liners that will be exposed to the elements.  

5. Cost Effective

Other options for concrete protection include epoxy resins, polyurethane resins, rubber emulsions, silicons, and cement coatings. These other options, however, have their drawbacks — one of which is price. 

Generally speaking, an HDPE protective liner will have a lower price point for large civil, municipal, and industrial concrete protection needs.

6. Can Be Pre-Fabricated

Most methods of concrete protection are either substances with which the concrete is impregnated at the time of mixing or pouring or coatings or sealants applied to the concrete. Concrete protective liners, on the other hand, are a separate product placed over the concrete being protected. Rather than having to apply a coating to the concrete — which can be a lengthy process, requiring certain weather conditions — protective liners can be pre-fabricated off-site and then delivered ready to install.

Get Expert Concrete Protective Liner Installation From US FUSION

HDPE-embed protective liners provide concrete protection from mechanical damage and corrosive environments in various industrial, municipal, and civil applications, such as concrete storage tank protection. US FUSION also provides and installs PVDF, polypropylene, and PVC concrete protective liners. Learn more about our offerings here, or download our Concrete Protective Liners brochure.

Water and construction generally don’t mix. Just like a rainy day can halt work on your site, so can the standing water it leaves behind once the sun is shining — along with other surface and groundwater in areas slated for construction or excavation. If this is a problem for your construction project, your site may need dewatering. But what exactly does that entail?

What is Dewatering? What Is Dewatering in Construction?

Dewatering is removing water from an area. In construction, this means removing water from a construction site — whether it’s removing ponded water from the surface or removing unwanted or excessive groundwater. 

Water can be an impediment to most construction activities, particularly anything involving concrete, which needs time to cure before it can tolerate moisture. Therefore, dewatering is a must for particularly wet sites, such as those with poor surface water drainage or high water tables.

4 Common Dewatering Methods

There are several methods for dewatering; the best method is dependent on a variety of factors specific to the application. Some of the most common dewatering methods are

• Pumping (open sumping)
• Channeling
• Well points
• Deep wells

1. Pumping

One of the methods for dewatering a site is to place a sump pump into wet, ponded areas and pump the water to another location. This method works specifically for surface water; for moving groundwater, more sophisticated pumping solutions are needed.

2. Channeling 

Channeling is one of the oldest, and lowest-tech, methods of dewatering surface water. It involves digging channels or ditches, into which water will drain. These channels harness the power of gravity to move water away from the worksite. 

To prevent this water from draining into the channel soil and prevent soil washout, some kind of geosynthetic liner or erosion control system may be used to line the channel.

3. Well points

For dewatering groundwater, one method is to drill a series of small, shallow wells around the work area, known as well points. From these wells, groundwater can be pumped out of the soil.

4. Deep wells

For applications where well points are insufficient, such as construction sites that are large or that require deep excavation, large, deep wells can be installed to draw up groundwater.

How is Excess Water Managed After Dewatering?

In all of the methods mentioned above, the water that is being removed from the construction area is generally redirected to another area of the site, where ponding will not be an issue for construction activities. Water may be diverted to densely vegetated areas of the property, which can absorb the excess water without risking extreme soil erosion or runoff. In some cases, detention ponds, tanks, or other infrastructure are needed to contain the excess water after it has been removed from the dewatered areas of the site. 

Regardless of where it is diverted, except when using the channeling method of dewatering, water is pumped and transported through pipes to the designated release or containment area. Water, as a fluid, is heavy and difficult to transport via other means. Temporary or permanent piping networks are established to divert water removed from the surface and soil. 

HDPE piping is often used for this purpose, as it is light and flexible, and can be installed using any of a variety of methods, depending on the application. Unlike other types of pipe, the sections of which are joined together with additional pipe components and adhesives, HDPE pipe is connected via plastic fusion: pipes are essentially melted together at high heat. This creates truly seamless piping, meaning that there are no opportunities for leaks. 

Need Dewatering Solutions? US FUSION Can Help

HDPE pipe is the natural choice for specialty construction dewatering needs, as it’s durable, flexible, affordable, and corrosion-resistant, with leak-free performance. To discuss how US Fusion’s HDPE offerings can meet the dewatering needs of your site and application, contact us today.

Once a plastic pipe system is installed, you may think a pipe specialist’s job is done. It’s not. 

Before plastic pipes can be considered safe and ready for use, hydro testing must be completed. Below, we’ll define what hydro testing is, why it’s important, and how it’s carried out. 

What is Hydro Testing? 

Hydro testing, short for hydrostatic testing, is a pressure-based process where piping systems are tested for performance and leaks. It’s most often completed right after a plastic pipe system has been installed, but can also be done later on for routine inspection and maintenance checks. 

Hydro Testing Process

Here are five steps for what the general hydro testing process looks like for plastic pipe or HDPE pipe applications:

1. Fill up the pipe system completely with water. 
2. Remove all air within the system (this is done by filling completely with water). 
3. Pressurize the system up to 1 ½ times its design pressure limit. 
4. Hold this pressure for a specified amount of time. 
5. Inspect the pipe system for leaks. Sometimes pipe specialists use dyes to find the exact location of any leaks.

Why Is Hydro Testing Important? 

Hydro testing isn’t just a recommendation. In most cases, it’s a post-installation requirement. 

Hydro testing is so important because it helps to ensure that the system passes inspection and safety standards for plastic piping. It’s a proactive approach that reduces the chance of an emergency and ensures the safety of your people, facilities, and environment. It also helps you save resources and money because you can catch leaks before they become a larger issue.

3 Hydro Testing Methods for Plastic Pipe Systems

There are three common hydro testing methods used for plastic pipe systems and other vessels/cylinders. There are certainly other methods that specialists use, but these popular ones will help give you a better understanding of what any test typically involves. 

Water Jacket Method

The pipe system is filled with water and loaded into a sealed chamber called a test jacket. The test jacket is also filled with water. The pipe is then pressurized inside the test jacket for a specific amount of time, causing it to expand within the test jacket. This results in water being forced out into a glass tube that measures total expansion. That expansion is recorded, then the pipe is depressurized, and then it shrinks to its original size.

Direct Expansion Method

The pipe system is filled with a certain amount of water, then pressurized. Then the amount of water that’s expelled upon pressure release is measured. The permanent expansion and total expansion values are calculated using the amount of water forced into the pipe, the test pressure, and the amount of water expelled.

Proof Pressure Method

Internal pressure is applied to the pipe to see if it has any leaks or weaknesses in the wall lining. In the United States, the proof pressure method is only permitted when the Code of Federal Regulations (CFR) doesn’t require permanent and total expansion values to be recorded. 

Trust US FUSION For Your Plastic Pipe & Hydro Testing Needs

Hydro testing is an important practice to ensure plastic pipes are installed and working properly on your site. If you need help completing this specialized process, contact the experts at US FUSION. With decades of industry experience, we have the knowledge and mastery it takes to get quick, accurate results.