Handling & Cleaning Pipe Fittings

  • Prepare the pipe immediately prior to installation.
  • Fittings are packaged in a protective plastic bag and should remain bagged until ready for use. To prevent contamination, the bag should be used to hold the fitting during installation.
  • Never store fittings in direct sunlight.
  • Check that the pipe SDR is compatible with the Plasson Fitting (if unsure, refer to the literature or contact your local Plasson representative).
  • To clean dirty pipes, remove excess dirt with clean non coloured dry lint free cloth or paper towel. Thoroughly clean with authorised cleaner for ElectroFusion welding. Area must be dry before scraping.
  • Marking Scraping - Before scraping the pipe, measure the insertion depth of the fitting. Add a further 20mm (in order to be able to check that the pipe has been scraped). This is the correct length to mark on the pipe for scraping.
  • Avoid any contamination of the prepared surfaces. Do not touch inside of fitting or pipe surfaces with your hand, and always weld in a shelter.
  • Cutting the pipe square and insertion pipe depth are extremely important. Failure to cut the pipe square or insert the pipe to the stops may leave the heating wire uncovered. This can lead to short circuit overheating, uncontrolled melting and the possibility of sudden ignition.
  • Do not adjust the welding time for any reason, the Plasson product naturally compensates for site temperatures between -10ºC and +45ºC and no manual adjustment should be made.

Caution: The welding process should be performed in a gas-free environment only. Since the welding device is electronic, the possibility of ignition during the joining process does exist.

Fittings - Installation Steps

Installation Steps

  1. The pipe ends be cut square.
  2. Remove any burrs or shavings from the pipe ends.
  3. Clean pipe ends inside and out with authorised cleaner to remove any dirt or contaminants, and allow to dry.
  4. Measure the insertion depth of the fitting and add a further 20mm to this and mark this length on the pipe.
  5. Scrape pipe up to measured mark to remove and oxidation. Plasson recommends the use of a mechanical rotary scraper. Do not use metal files of emery paper.
Diameter Scraping Depth
20mm - 25mm 0.2mm
32mm - 75mm 0.25mm
>90mm 0.3mm

Scraping should remove a minimum thickness of 0.2mm. Do not touch the scraped surfaces.

Note: Spigot Fittings must also be scraped.

6. Open the plastic bag and slide the fitting on to the pipe until it reaches the centre stops of the fitting. Check by measuring, if required and mark the penetration depth of the fitting on the pipe. If the fitting can not be correctly inserted on to the pipe due to ovality, the pipe will need to be re-rounded using the correct tools.

7. Repeat steps 1 through 6 for the opposite end of the fitting.

8. While maintaining the correct insertion depth, place the pipes and fittings into a suitable clamping device in order to prevent movement and avoid stresses during the fusion cycle and tighten the clamp.

9. Block the pipe ends to stop wind from blowing through the pipe.

10. Once the fitting is properly clamped, follow the instructions supplied with the Control Box to complete the welding process. Plasson Fittings can be welded in the temperature range of -10ºc to +45ºc.

11. Ensure the welding time shown on the Control Box is the same as shown on the fitting. Fusamatic, Barcode or Manual. The Plasson fittings have melt indicators. These will rise to show that fusion has taken place. They do not indicate the weld quality.

12. Ensure the cooling time, as shown on the fitting, has elapsed before removing the fitting from the clamps.

13. Do not pressurise the system before the following times have elapsed:

Pipe Diameter (d) Time in Minutes
20mm - 63mm 20
75mm - 110mm 30
125mm - 140mm 45
160mm - 180mm 70
200mm - 250mm 80
280mm - 355mm 90
400mm - 560mm 150