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Electrofusion Welding Services

Get professional electrofusion welding services for pipes and fittings from the experts at Pipe Testing Services. Our skilled technicians use industry-leading equipment and techniques for reliable electrofusion welds.

Specialist Electrofusion Welding Services for PE Pipes

Pipe Testing Services (PTS) provides expert electrofusion welding services across the UK, a cutting-edge technique for joining polyethylene (PE) pipes and fittings. This advanced method creates exceptionally strong, reliable, and leak-proof connections, making it an ideal choice for a wide range of water and gas infrastructure projects, especially for repairs or where access is restricted.

    What is Electrofusion Welding?

    Electrofusion welding is a fusion process that uses specialised fittings with built-in heating coils. The process involves the following key steps:

    Key Benefits of
    Electrofusion Welding

    Electrofusion welding offers numerous advantages over traditional pipe joining methods, particularly in challenging site conditions:

    • Leak-Proof Joints: The fused joints are monolithic and homogenous, completely eliminating the risk of leaks that can occur with mechanical joints.

    • Strength and Durability: The resulting joint is often stronger than the pipe itself, providing exceptional resistance to pressure and ground movement.

    • Simplified Installation: As it does not require heavy hydraulic machinery like butt fusion, electrofusion is ideal for repairs in confined spaces or existing trenches.

    • Versatility: It is an excellent method for joining pipes of different wall thicknesses, connecting fittings like branches and saddles, and for performing tie-in connections.

    • No Additional Adhesives or Solvents: The process creates a strong bond using heat and fusion alone, reducing environmental contamination risks.

    Electro fusion welding services - rising main
    electro fusion welding services - rising mains. PTS

    Common Applications of Electrofusion Welding

    Our electrofusion welding services cater to a wide range of industries and applications:

    A close-up photograph of a completed black electrofusion joint on a PE pipe, installed neatly within a soil trench.

    Quality Assurance and Data Logging

    At Pipe Testing Services, we prioritise quality assurance and traceability in every electrofusion welding project. Our modern control boxes feature data logging technology to capture and record critical parameters for each weld, including:

    • Fusion and cooling times.
    • Applied voltage and current.
    • Operator and joint identification.
    • Ambient temperature.

    This data is invaluable for ensuring compliance with industry standards and provides a permanent quality record for your project handover and future maintenance activities.

    Case Study: Electrofusion for a Critical Rising Main Connection

    We were recently commissioned by a long-standing client to install a rising main and connect it to a pumping station. Ensuring a secure, leak-proof joint was crucial for uninterrupted water supply. For this critical project, PTS deployed a team of highly experienced engineers specialising in electrofusion welding techniques. They meticulously joined high-density polyethylene (HDPE) pipes, creating a robust monolithic joint stronger than the pipes themselves. The outcome was a seamless main connection to the pumping station, with leak-free joints capable of withstanding demanding operating conditions for years to come.
    Read On.

    Quality Assurance and Data Logging

    We champion sustainable practices in electrofusion welding, minimising waste, emissions, and resource use. Unlike other methods using adhesives or solvents, electrofusion welding creates strong, leak-proof joints without additional materials or chemicals. This reduces environmental contamination risks while enhancing joint strength. Additionally, we utilise energy-efficient equipment, implement strict waste management protocols, and promote the use of recycled and recyclable PE pipes, further contributing to a circular economy.

    Choose Pipe Testing Services for Your Electrofusion Welding Needs

    Pipe Testing Services is your trusted partner for all electrofusion welding requirements across the UK. With our nationwide contracting service, state-of-the-art equipment, and highly trained professionals, we deliver unparalleled electrofusion welding solutions tailored to your specific project needs. For a comprehensive overview of our capabilities, please see our main Pipe Fusion Welding Services page.

    Contact us today to discuss your project requirements or to schedule a consultation with our experts.

    Contact Us - Pipe Testing Services.
    Pipe Testing Services on sight at Manchester City FC academy - for chlorination of water pipe. CCTV Surveys
    Specialist electrofusion welding services for PE pipes by Pipe Testing Services, showing a completed joint in a trench.

    Electrofusion Welding FAQs

    What is the typical size range for electrofusion welding?

    At Pipe Testing Services, our electrofusion welding capabilities extend from 20mm up to 800mm pipe diameters, catering to a wide array of applications and project sizes.

    Yes, electrofusion welded joints can be easily repaired or modified through the installation of additional electrofusion fittings, such as branch connections or repair couplings. This flexibility allows for seamless integration with existing infrastructure or project-specific requirements.

    Absolutely. Electrofusion welded joints are extensively used in underground piping systems, such as water mains, gas distribution networks, and telecommunication infrastructure. Their leak-proof nature and durability make them ideal for buried applications.

    While electrofusion welding can be performed in various weather conditions, extreme temperatures or precipitation may affect the welding process. Our teams are trained to assess site conditions and take appropriate measures, such as using shelters or climate-controlled environments, to ensure optimal electrofusion welding results.

    The duration of an electrofusion weld depends on factors such as pipe diameter, ambient temperature, and the specific welding parameters. Typically, electrofusion welds may require 20-45 minutes to complete, including preparation, fusion, and cooling time.

    Yes, electrofusion welding is compatible with various trenchless pipe installation techniques, such as horizontal directional drilling (HDD), pipe bursting, pipe ramming, and slip-lining. Our electrofusion welding expertise allows us to create continuous, leak-proof pipe strings, facilitating efficient installation via trenchless methods.