Electrofusion (often called EF) is a trusted way to join PE pipe when butt fusion isn’t practical for example, when adding valves, elbows or tees, or when working in tight spaces where moving pipe just isn’t an option.

Because electrofusion joints are permanent and often used in critical assets (gas, water, sewer, mining slurry lines), the work must be carried about by those who are PMBWELD302 accredited, and in the case of civil or industrial work, are approved by the asset owner or principal contractor in line with Australian Standards and industry specifications.

In addition, asset owners and corporate clients expect the appropriate insurances to be in place and installation of any electrofusion fittings by unaccredited installers will void all manufacture warranties which has flow on implications for insurance cover and indemnity.

During welding, the electrofusion control box sends electrical current through metal coils inside the fitting. As the coils heat up, the plastic around them melts and forms a pool of hot material. This molten plastic comes into contact with the pipe surface, which also begins to melt as the heating process continues.

Each electrofusion fitting has its own weld settings based on the type of fitting, the size and the manufacturer specificactions. These are usually captured in the barcode on the fitting. When the barcode is scanned by the welding control box the parameters are sent straight to the machine or, with some machines, they are also detected automatically as soon as the fitting is connected.

As the plastic melts, pressure builds up inside the fitting due to its design. This pressure forces the softened pipe and fitting material together so they mix fully. Once the weld cycle finishes, the joint is left undisturbed to cool, allowing the plastic to solidify to form a permanent connection.

As the coils heat and cool, hot and cold zones (sometimes called melt and freeze zones) form within the fitting. The length and position of these zones are carefully designed to generate the right melt pressure and even heat distribution, which is critical for weld quality.