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Electrofusion Fittings

An electrofusion machine and fitting joining yellow gas pipe.

Electrofusion fittings are specifically designed for reliable, high performance pipe joining and long system life. Complete with automated fusion system, modern Electrofusion fittings have proven to be most economical due to the low potential for operator error.

Fittings directly compatible with the computerized control box being used give information on heating and cooling time directly without any need for operator override. Bar codes are also supplied on the fittings for manual swiping and automatic jointing. The least preferred and reliable method is for the operator to read and manually input the data for heating and cooling times.

Features & Benefits

  • Automated computer-controlled jointing to ensure safe, dependable connections
  • Computerized data retrieval for proof of a good job, well done
  • Proven high performance in gas and water distribution and industrial applications
  • Quick to install
  • Stronger pipe jointing than compression fittings
  • 16 bar rated
  • 4.7mm standard UK pin size

Applications

  • Drinking water
  • Industrial & sewage water
  • Gas – for installations under BSEN:1555 pt 3

Standards

  • BSEN 12201 - Water
  • BSEN 1555 - Gas (installations under British Gas approval should be yellow)
  • WIS 4-32-14 - Water

20 - 50mm Electrofusion Fittings

Couplers & Bends

Description 20mm 25mm 32mm 40mm 50mm
Coupler 102249010020 102249010025 102249010032 102249010040 102249010050
End Cap 102249120020 102249120025 102249120032 102249120040 102249120050
Tee 90° 102249040020 102249040025 102249040032 102249040040 102249040050
Elbow 90° 102249050020 102249050025 102249050032 102249050040 102249050050
Elbow 45° - - 102249060032 102249060040 102249060050
Spigot End Plug 102249127020 102249127025 102249127032 102249127040 102249127050
Spigot Flange Adaptor 102249027020 102249027025 102249027032 102249027040 102249027050
Description Size A (mm) Size B Code
Plated Flange Backing Ring 20 ½" 102249029020
Plated Flange Backing Ring 25 ¾" 102249029025
Plated Flange Backing Ring 32 1" 102249029032
Plated Flange Backing Ring 40 1¼" 102249029041
Plated Flange Backing Ring 50 1½" 102249029051

Reducers

Description Size A (mm) Size B (mm) Code
Reducing Coupler 20 16 102249110012
Reducing Coupler 25 20 102249110014
Reducing Coupler 32 20 102249110018
Reducing Coupler 32 25 102249110019
Reducing Coupler 40 25 102249110025
Reducing Coupler 40 32 102249110026
Reducing Coupler 50 25 102249110030
Reducing Coupler 50 32 102249110031
Reducing Tee 90° 25 x 25 20 102249140014
Reducing Tee 90° 32 x 25 20 102249140015
Reducing Tee 90° 32 x 32 20 102249140018
Reducing Tee 90° 32 x 32 25 102249140018
Reducing Tee 90° 40 x 40 20 102249140023
Reducing Tee 90° 40 x 40 25 102249140025
Reducing Tee 90° 40 x 40 32 102249140026
Reducing Tee 90° 50 x 50 20 102249140029
Reducing Tee 90° 50 x 50 25 102249140030
Reducing Tee 90° 50 x 50 32 102249140031
Reducing Tee 90° 50 x 50 40 102249140031
Spigot Reducer 50 32 102249117101
Spigot Reducer 50 40 102249117540

63 - 125mm Electrofusion Fittings

63 - 125mm Electrofusion Couplers & Bends

Description 63mm 75mm 90mm 110mm 125mm
Coupler 102249010063 102249010075 102249010090 102249010110 102249010125
Light Fit Coupler (10 bar) 102236010063 102236010075 102236010090 102236010110 102236010125
End Cap 102249120063 102249120075 102249120090 102249120110 102249120125
Tee 90° 102249040063 102249040075 102249040090 102249040110 102249040125
Elbow 90° 102249050063 102249050075 102249050090 102249050110 102249050125
Elbow 45° 102249060063 102249060075 102249060090 102249060110 102249060125
Elbow 22.5° - - 102249020090 102249020110 102249020125
Adjustable Elbow - - - 102249470110 102249470125
Adjustable Elbow One Sided - - - 102249471110 102249471125
Duckfoot Elbow 90° - - 102249150090 - -
Duckfoot Elbow 90° (with 32mm Outlet) - - 102249650066 - -
Spigot End Plug 102249127063 102249127075 102249127090 102249127110 102249127125
Spigot Flange Adaptor 102249027063 102249027075 102249027090 102249027110 102249027125
Description Size A (mm) Size B (mm) Code
Plated Flange Backing Ring 63 2" 102249029009
Plated Flange Backing Ring 75 2½" 102249029075
Plated Flange Backing Ring 90 80 102249029010
Plated Flange Backing Ring 110 100 102249029020
Plated Flange Backing Ring 125 100 102249029020

63 - 125mm Electrofusion Reducers

Description Size A (mm) Size B (mm) Code
Reducing Coupler 63 32 102249110046
Reducing Coupler 63 40 102249110047
Reducing Coupler 63 50 102249110048
Reducing Coupler 75 63 102249110060
Reducing Coupler 90 50 102249110068
Reducing Coupler 90 63 102249110070
Reducing Coupler 90 75 102249110071
Reducing Coupler 110 63 102249110081
Reducing Coupler 110 90 102249110083
Reducing Coupler 125 90 102249110095
Reducing Coupler 125 110 102249110096
Reducing Coupler 125 110 102249110096
Reducing Tee 90° 63 x 63 20 102249140044
Reducing Tee 90° 63 x 63 32 102249140046
Reducing Tee 90° 63 x 63 40 102249140047
Reducing Tee 90° 63 x 63 50 102249140048
Reducing Tee 90° 75 x 75 63 102249140767
Reducing Tee 90° 90 x 90 64 102249140070
Reducing Tee 90° 110 x 110 63 102249140081
Reducing Tee 90° 110 x 110 90 102249140083
Reducing Tee 90° 125 x 125 90 102249140095
Reducing Tee 90° 125 x 125 110 102249140096
Flanged Tee 90° 90 x 90 80 102249940072
Flanged Tee 90° 110 x 110 80 102249940083
Flanged Tee 90° 110 x 110 100 102249940110
Flanged Tee 90° 125 x 125 80 102249940095
Flanged Tee 90° 125 x 125 100 102249940096
PE Cast Iron Flange Transition Coupler 63 50 102249770063
PE Cast Iron Flange Transition Coupler 90 80 102249770090
PE Cast Iron Flange Transition Coupler 110 100 102249770110
PE Cast Iron Flange Transition Coupler 125 100 102249770125
PE Cast Iron Spigot Transition Coupler 90 80 102249570090
PE Cast Iron Spigot Transition Coupler 110 100 102249570110
PE Cast Iron Flange Transition Coupler 125 100 102249570125
Spigot Reducer 63 32 102249117102
Spigot Reducer 63 40 102249117640
Spigot Reducer 63 50 102249117103
Spigot Reducer 75 63 102249117763
Spigot Reducer 90 50 102249117100
Spigot Reducer 90 63 102249117104
Spigot Reducer 90 75 102249117975
Spigot Reducer 110 63 102249117105
Spigot Reducer 110 75 102249117175
Spigot Reducer 110 90 102249117106
Spigot Reducer 125 63 102249117107
Spigot Reducer 125 90 102249117108
Spigot Reducer 125 110 102249117125

140 - 225mm Electrofusion Fittings

140 - 225mm Electrofusion Couplers & Bends

Description 140mm 160mm 180mm 200mm 225mm
Coupler 102249010140 102249010160 102249010180 102249010200 102249010225
Light Fit Coupler (10 bar) 102236010140 102236010160 102236010180 102236010200 102236010225
End Cap 102249120140 102249120160 102249120180 102249120200 102249120225
Tee 90° - 102249040160 102249040180 102249040200 102249040225
Elbow 90° 102249050140 102249050160 102249050180 102249050200 102249050225
Elbow 45° 102249060140 102249060160 102249060180 102249060200 102249060225
Elbow 22.5° - 102249020160 102249020180 - -
Adjustable Elbow - 102249470160 102249470180 - -
Adjustable Elbow One Sided - 102249471160 102249471180 - -
Spigot End Plug 102249127140 102249127160 102249127180 102249127200 102249127225
Spigot Flange Adaptor 102249027140 102249027160 102249027180 102249027200 102249027225
Description Size A (mm) Size B (mm) Code
Plated Flange Backing Ring 140 125 102249029140
Plated Flange Backing Ring 160 150 102249029040
Plated Flange Backing Ring 180 150 102249029040
Plated Flange Backing Ring 200 200 102249029200
Plated Flange Backing Ring 225 200 102249029061

140 - 225mm Electrofusion Reducers

Description Size A (mm) Size B (mm) Code
Reducing Coupler 160 90 102249110121
Reducing Coupler 160 110 102249110122
Reducing Coupler 160 125 102249110123
Reducing Coupler 180 125 102249110138
Reducing Tee 90° 160 x 160 90 102249140121
Reducing Tee 90° 160 x 160 110 102249140122
Reducing Tee 90° 160 x 160 125 102249140123
Reducing Tee 90° 180 x 180 90 102249140136
Reducing Tee 90° 180 x 180 110 102249140137
Reducing Tee 90° 180 x 180 125 102249140138
Reducing Tee 90° 180 x 180 140 102249140139
Reducing Tee 90° 180 x 180 160 102249140141
Reducing Tee 90° 200 x 200 90 1022491400200090
Reducing Tee 90° 200 x 200 110 1022491400200110
Reducing Tee 90° 225 x 225 90 1022491400225090
Reducing Tee 90° 225 x 225 110 1022491400225110
Flanged Tee 90° 160 x 160 80 102249940121
Flanged Tee 90° 160 x 160 100 102249940122
Flanged Tee 90° 180 x 180 80 102249940136
Flanged Tee 90° 180 x 180 100 102249940137
PE Cast Iron Flange Transition Coupler 160 150 102249770160
PE Cast Iron Flange Transition Coupler 180 150 102249770180
PE Cast Iron Flange Transition Coupler 110 200 102249770225
PE Cast Iron Spigot Transition Coupler 160 150 102249570160
PE Cast Iron Spigot Transition Coupler 180 150 102249570180
PE Cast Iron Flange Transition Coupler 225 200 102249570225
Spigot Reducer 140 90 102249117190
Spigot Reducer 140 110 102249117109
Spigot Reducer 140 125 102249117425
Spigot Reducer 160 90 102249117110
Spigot Reducer 160 110 102249117110
Spigot Reducer 160 125 102249117625
Spigot Reducer 160 140 102249117111
Spigot Reducer 180 90 102249117112
Spigot Reducer 180 125 102249117113
Spigot Reducer 180 140 102249117125
Spigot Reducer 180 160 102249117180
Spigot Reducer 200 140 102249117250
Spigot Reducer 200 160 102249117260
Spigot Reducer 200 180 102249117280

250 - 400mm Electrofusion Fittings

250 - 400mm Electrofusion Couplers & Bends

Description 250mm 280mm 315mm 355mm 400mm
Coupler 102249010250 102249010280 102249010315 102249010355 102249010400
Light Fit Coupler (10 bar) 102236010250 102236010280 102236010315 102236010355 102236010400
End Cap 102249120250 102249120280 102249120315 - -
Tee 90° 102249040250 - - - -
Elbow 90° 102249050250 - - - -
Elbow 45° 102249060250 - - - -
Spigot End Plug 102249127250 102249127280 102249127315 - -
Spigot Flange Adaptor 102249027250 102249027280 102249027315 102249027355 102249027400
Description Size A (mm) Size B (mm) Code
Plated Flange Backing Ring 250 250 102249029250
Plated Flange Backing Ring 280 250 102249029280
Plated Flange Backing Ring 315 300 102249029315
Plated Flange Backing Ring 355 350 102249029355
Plated Flange Backing Ring 400 400 102249029400

250 - 400mm Electrofusion Reducers

Description Size A (mm) Size B (mm) Code
Reducing Tee 90° 250 x 250 90 1022491400250090
Reducing Tee 90° 250 x 250 110 1022491400250110

Installation

Jointing different types of PE

Any PE80 pipe can be joined to another PE80 pipe either by Butt-fusion or Electrofusion. Different manufacturers may have alternative material grades, but as long as the materials are the same i.e. both PE80, they can be joined with the same technique. This also applies to PE100 pipes.

Jointing pipes with different SDRs

Butt-fusion should only be used for jointing pipes of the same OD and SDR value.

Electrofusion can be used to weld pipes of the same OD with different SDR values and therefore wall thickness. However the maximum working pressure of the pipe must not:

  • exceed the pressure rating marked on the fitting
  • exceed the lower pressure value of the two pipes, if different SDR values

Electrofusion Jointing Guide

This guide is an overview only, if using Electrofusion to joint fabricated fittings and pipe, installation must be carried out by an operative trained in Electrofusion and in accordance with manufacturer’s guidelines.

Installation Review

  • Ensure equipment that is clean, in good condition and regularly maintained
  • Use mechanical pipe preparation tooling wherever possible
  • Ensure that cutters/blades of mechanical scrapers are clean and in good condition
  • Check that you have somewhere clean and dry to place tools and equipment during the Electrofusion process
  • Jointing surface of pipe must be dry, clean and suitably scraped
  • Check Electrofusion equipment is compatible with fittings – different Electrofusion fittings can have different pin sizes (UK standard is 4.7mm) and automated capability
  • Check that the fusion time displayed matches that on the fitting
  • Fittings should be dry clean and within their protective wrapping
  • Only use alcoholic wipes if the pipe has been previously scraped (>1 minute) to ensure grease removal. A freshly scraped pipe inserted into the fitting immediately is preferred Alcoholic wipes should not be used on Gas pipelines.
  • Coiled pipes tend to suffer from ovality. As a result they need to be re-rounded prior to Electrofusion
  • Always follow the manufacturer’s installation instructions

A basic electrofusion kit for jointing polyethylene pipes should include:

  • Automatic or manual Electrofusion control box compatible with fittings & appropriate leads
  • Compatible generator
  • Pipe scraper (mechanical / hand)
  • Restraining, aligning and insertion equipment
  • Re-rounding clamp
  • Rubber hammer
  • Alcoholic wipes
  • Marker pen
  • Data retrieval & barcode scanner (if not built in to control box)

Butt-fusion Jointing Guide

This guide is an overview only, if using Butt-fusion to joint fabricated fittings and pipe, installation must be carried out by an operative trained in Butt-fusion and in accordance with manufacturer’s guidelines.

Installation Overview

  • Ensure equipment that is clean, in good condition and regularly maintained
  • Ensure that the correct jointing parameters for the machine type and pipe are known
  • Check the heating plate is clean and dry
  • Check the trimmer is clean and that the blades are not damaged and in the correct position for the required pipe size
  • Ensure that the generator is in good condition and has sufficient fuel
  • A tent is available to provide shelter during welding and end caps are available
  • Check that the pipe and fittings are compatible – size of pipe, wall thickness (SDR) and material (PE80 or PE100) is the same
  • The pipes and fittings to be jointed are of the same size
  • Jointing surface of pipe must be dry, clean and suitably scraped
  • Always follow the manufacturer’s installation instructions

A basic electrofusion kit for jointing polyethylene pipes should include:

  • Butt-fusion machine with correct sized clamp shells, trimmer, heater plate, hydraulic pump and timer
  • Compatible generator
  • Pipe support rollers
  • Welding tent / shelter and groundsheet
  • Cleaning material, lint free cotton cloth or paper towel
  • Pipe cutters
  • External/ internal de-beading tool
  • Data transfer options
  • Printer / Minitran
  • Pipe end cover caps
  • Indelible marker pen