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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.

Electrofusion Welding Services from Pipe Testing Services (PTS)

    At Pipe Testing Services (PTS), we specialise in electrofusion welding, a cutting-edge technique for joining polyethylene (PE) pipes and fittings. This advanced method ensures reliable, leak-proof connections, making it an ideal choice for a wide range of applications.

    Our Services

    Pipeline Services:

    • Pipe Fusion Welding: Specialised butt fusion and electrofusion welding for leak-proof polyethylene (PE) pipe joints.
    • Trenchless Pipe Installation: Horizontal directional drilling (HDD), pipe bursting, and other trenchless methods for minimal surface disruption.
    • Flow Surveys: Advanced flow monitoring and data analysis to identify leaks and optimise water distribution networks.

    Legionella Control:

    These are just a selection of our services, for expanded view, discover our dedicated service pages above for a full scope of how PTS can elevate the efficacy of your water systems.

    What is Electrofusion Welding?

    Electrofusion welding is a fusion welding process that utilises specialised fittings embedded with a heating coil. The process involves the following steps:

    Electro fusion welding services - rising main

    Benefits of Electrofusion Welding Over Other Welding Methods

    Electrofusion welding offers numerous advantages over traditional pipe joining methods:

    Leak-proof Joints

    The fused joints are homogeneous and monolithic, virtually eliminating the risk of leaks.

    The fused connections are as strong, if not stronger, than the pipes themselves, ensuring long-lasting performance.

    PE pipes fused through electrofusion remain highly resistant to corrosion and chemical attacks.

    The process does not require any additional bonding agents, reducing potential environmental impacts and long-term maintenance issues.

    Electrofusion welding offers a cost-effective solution compared to traditional joining methods, particularly for large-scale projects. The reduced labour, material costs, and long-term maintenance requirements make it an economically viable choice.

    Electrofusion fittings are designed for easy installation, minimising the need for specialised equipment or extensive site preparation. This streamlines the installation process, reducing project timelines and associated costs.

    With its exceptional performance, versatility, and eco-friendly nature, electrofusion welding stands out as a preferred choice for a wide range of applications, from critical infrastructure projects to specialized industrial installations.

    Applications of Electrofusion Welding

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

    Water and Wastewater Systems

    Electrofusion welded PE pipes are extensively used in water distribution networks, sewage systems, and wastewater treatment facilities due to their exceptional corrosion resistance and leak-proof joints.

    The safe and efficient distribution of natural gas requires robust piping infrastructure. Electrofusion welded PE pipes minimise the risk of gas leaks and ensure reliable service.

    Across various manufacturing sectors, electrofusion welded PE pipes are employed for the transportation of chemicals, slurries, and other industrial fluids, offering superior chemical resistance and minimised risk of leaks.

    Electrofusion welded PE pipes facilitate the installation of fibre optic cables and other communication networks, protecting these sensitive systems from moisture ingress and external damage.

    Quality Assurance and Data Logging

    At Pipe Testing Services, we prioritise quality assurance and traceability in every electrofusion welding project. Our teams leverage cutting-edge data logging technology to capture and record critical parameters such as fusion voltages, cooling times, and traceability data. This data is meticulously maintained, ensuring compliance with industry standards and providing valuable information for future maintenance and repair activities.

    Electro Fusion – Water Infrastructure Project - Case Study

    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 and preventing environmental impacts.

    For this critical project, PTS deployed a team of highly experienced engineers specialising in electro fusion welding techniques. They meticulously joined high-density polyethylene (HDPE) pipes using precisely controlled electrical heat and fusion, creating robust monolithic joints stronger than the pipes themselves. The outcome was a seamless rising 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.

    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.

    Choose Pipe Testing Services for Electrofusion Welding Services

    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.

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

    Phone – 01922 451646

    Email –

    Address – Unit 27 Birchbrook Industrial Estate, Shenstone, Lichfield, Staffs, WS14 0DJ

    Experience the difference of our comprehensive electrofusion welding services and ensure the longevity and reliability of your piping systems.