Learn with HAYES
About Socket Fusion
What is Socket Fusion
PROCEDURE / APPLICATION
The socket fusion technique is an effective way of joining plastic pipes and fittings for various industrial applications. This technique involves heating both the outer surface of the pipe and the internal surface of the socket fitting simultaneously until they reach the recommended fusion temperature, ensuring a strong bond.
DESCRIPTION
The HAYES Digital socket fusion heating iron is a reliable tool for welding PE (Polyethylene), PPR (Polypropylene), PB (Polybutene) pipes and fittings. This machine’s versatility makes it ideal for various applications in the industry, providing a convenient and efficient way of fusing plastic materials together.
Apparatus—General Recommendation
Heating Tool—Electric heating tools come in a variety of sizes that match the fusion machines capabilities. They are designed with enough wattage and electronic control to maintain the specified heater face temperature required in this procedure. The range of the heater control shall be larger than the heating temperature specification (the typical control range is 50°F (30°C) above and below the maximum and minimum required heating tool surface temperatures. Electric heating plates maintain consistent fusion temperatures when provided with an adequate power source.
Temperature Indicator—Heating tools shall be equipped with a thermometer or other built-in temperature indicating device. This device indicates the internal temperature of the heating iron, which is usually higher than temperature of the heating tool surfaces. Use a pyrometer, or other temperature measuring device, on the first joint of the day and periodically during the day to verify the temperature of the tool face surfaces within the pipe or fitting contact area. Select multiple checkpoints to ensure uniform surface temperature. An infrared pyrometer is calibrated by comparison to a calibrated surface pyrometer and adjusted to agree on each heating tool.
A significant temperature variation, that is, cold spots, on the heating tool surfaces may indicate a faulty heating iron which may need to be serviced before it can be used.
Heating Tool Faces—Heating tools may be made from materials such as aluminum, stainless steel, copper, or copper alloys. Polyethylene material may stick to hot metal heating surfaces. This sticking may be minimized by applying a non-stick coating to the heating surfaces or by fitting a high-temperature, non-stick fabric over the heating surfaces. The heating plate surfaces, coated or uncoated, shall be kept clean and free of contaminants such as dirt, grease and plastic build-up, which may cause excessive sticking and create unsatisfactory joints. Most of these contaminants are removed from the hot tool surfaces using a clean, dry, oil-free lint-free cloth. Do not use synthetic fabrics which may char and stick to the fusion surface. Some pigments, such as carbon black, may stain a heating surface and probably cannot be removed; such stains will not contaminate the joint interface.
After a period of time in service, non-stick coatings or fabrics will deteriorate and become less effective. Deteriorated fabrics shall be replaced, and worn, scratched, or gouged non-stick coatings shall be re-coated when they lose effectiveness. Heat fusion quality may be adversely affected by deteriorated non-stick surfaces. Spray-on chemicals, such as nonstick lubricants or oils shall not be applied to heating iron surfaces as they will contaminate the joint.
Tools for socket fusion procedure
Socket fusion heating iron
The HAYES HY PRO-X Series is the new digital socket fusion pipe welder (heating tool) that is suitable for joining a variety of thermoplastic pipes and fittings for different applications in the industry. This machine can weld HDPE (Polyethylene), PP-R (Polypropylene), PB (Polybutene).
Our heating tool is designed and manufactured according to the American international standard ASTM F2620. Our line of ancillary accessories such as heating adapters, cold ring pliers and chamfer/depth gages are manufactured to ASTM F1056 guidelines, which will assist in completing a quality fusion consistently if the pipe manufacturer’s procedures are followed carefully.
Teflon coated heating tool faces
Non-Stick Socket faces are high-quality, heat-conductive blocks that easily attach to your heating tool for welding plastic pipes. The male socket will melt the internal surface of the fitting socket and the female socket will melt the external surface of the pipe. They are available in 1/2" CTS, 1/2" IPS, 3/4" IPS, 1" IPS, 1-1/4" IPS, 1-1/2" IPS, 2" IPS, 3" IPS, and 4" IPS sizes. With three durable layers of non-stick coating and adhering to ASTM F1056 standards, this product is an indispensable tool for any socket pipe welding project.
Chamfer tool with depth gauge
A chamfer tool with depth gauge is your solution to a perfect pipe fitting. The depth gauge ensures a consistent distance for the clamp to fit while the chamfer allows for a seamless, easy fit into the pipe heater face. Our chamfer tool with depth gauge is made with an aluminum body and stainless steel blade and conveniently available in 1/2″ CTS, 1/2″ IPS, 3/4″ IPS, 1″ IPS, 1-1/4″ IPS, 1-1/2″ IPS, 2″ IPS, 3″ IPS, and 4″ IPS. Trust in our product, which is manufactured according to the American international standard ASTM F1056.
Rounding clamps-Cold rings-Vicegrip
Use these pliers to quickly and easily round pipes and limit the distance of the pipe end that goes into the fitting. Cold rings are essential for perfect socket fusion. Limiting pipe movement and preventing leaks or damage. Our locking pliers are made from 1022 carbon steel, meet industry standards and provide a tight grip with reduced slippage. Available in sizes ranging from 1/2" CTS to 4" IPS and manufactured according to ASTM F1056. Perfect for any plastic pipe fitting job. Trust in the quality and effectiveness of these Cold Ring Locking Pliers.
Socket fusion procedure
A manual is only a manufacturer´s guide. It does not take the place of proper training by qualified instructors and does not exceed the experience of a professional. The information in this manual is operational and cannot cover all the situations that may occur in the field such as environmental temperature, pipe material, thickness, selected welding standard, etc.
BEFORE THE WELDING PROCESS
A. Cut and chamfer the pipe.
B. Place the cold ring at the proper depth on the pipe as determined by the depth gauge.
C. Attach the coated heating adapters to the heating tool when the tool is cold.
D. Connect to a 110V grounded power source only and begin operating the welding machine. Permit enough preheating to stabilize the temperature.
MACHINE SET UP
- Once the unit is connected to proper power source it will automatically turn on and begin to heat to the temperature that is set.
- Set the desired temperature by pressing the button and then using the “up/down” buttons to choose the proper temperature and then press SET button again to start the heating process.
- Red light displays when the unit is in process of heating up.
- Green light displays when the unit has reached the desired temperature.
WELDING PROCESS
Put the pipes and fittings into the heating adapters, remove pipes and the fittings from the heating adapters when they reach the proper heating time cycle. Connect the pipes and fittings together until the bead is formed.
IMPORTANT NOTES
Welding procedure
- Skill and knowledge are required to obtain a good quality joint.
- Ensure you select the proper temperature according to the pipe manufacturer’s recommendation.
- It is important to know the technical information before you use your heating tool.
Non-stick coating
The heating adapters have a coated surface that has been treated to reduce polymer adhesion. If the polymer adheres to the heating plate, lightly wipe with a clean cotton cloth to remove. Do not use a wire brush or an abrasive.
Welding parameters
Pipe and fitting manufacturers have established qualified fusion procedures which should be followed precisely. You should obtain a copy of the pipe manufacturer’s procedures or appropriate joining standard for the pipe being fused.
Heating iron temperature
To meet pipe manufacturer’s temperature specifications, the surface temperature of the heating adapters should be measured with a surface pyrometer prior to initial use and at reasonable time intervals thereafter.
Ensure you test the temperature on the surface of the heating adapters and not on the heating plate itself. The heater’s built-in thermometer indicates internal temperature and should only be used for reference.
CAUTION
Heating iron
- The heater is to be used with AC power only. Check heater to confirm correct power requirements and only use a power source with the correct voltage and current capacity.
- Connect heating tool to power and permit sufficient preheating to stabilize the temperature before the welding process.
- When welding, if temperature adjustment is needed, please turn off the heating tool first and turn it on again to adjust the new temperature. Adjustment of the temperature when it is already set will damage the temperature control components.
It is recommended to use an insulated heater bag to store the heating tool when it is hot.
¡WARNING!
Avoid Injury
This unit must be operated by trained personnel only.
Industrial Safety
RISK MATRIX
Be alert and report anything that you see, feel, smell or hear differently than expected, or that you think is unsafe.
SOURCE: Heating tool and heating adapters
Do not adjust temperature above 575 °F. This can result in damage to the heater components and the non-stick surfaces.
| HAZARD | RISK | RISK CONTROL |
| ELECTRICAL | Electrocution | Make sure to use a power source with the correct voltage and current capacity. Connect to a 110V grounded power source only. Keep the cables away from chemical agents or water. |
| THERMAL | Risk of fire | Do not use the machine in atmospheres with explosion risk, due to the presence of gases, flammable vapors, etc Wear protective gloves. Never touch the surface of the heating tool or heating adapters when they are hot. Move the heating plate cautiously when it is hot and carefully remove the heating adapters. |
Pipe chamfer(c) and Insert depth (d)
NOTE: Some recommend using a 50-60 grit emery or garnet cloth to roughen the outside of the pipe and inside of the fitting as a means of minimizing any possible skin interface when making the fusion. Sandpaper is not recommended for this purpose, as it might disintegrate and contaminate the joint interface.
| Pipe Size (s) | Pipe Size (s) | Pipe Chamfer | Insert depth |
| Inches | mm | (c) | (d) |
| 1/2″CTS | 16 | 2 mm | 13 mm |
| 1/2″IPS | 20 | 2 mm | 14 mm |
| 3/4″ | 25 | 2 mm | 15 mm |
| 1″ | 32 | 2 mm | 17 mm |
| 1 1/4″ | 40 | 2 mm | 18 mm |
| 1 1/2″ | 50 | 2 mm | 20 mm |
| 2″ | 63 | 3 mm | 26 mm |
| 2 1/2″ | 75 | 3 mm | 29 mm |
| 3″ | 90 | 3 mm | 32 mm |
| 4″ | 110 | 3 mm | 35 mm |
Socket fusion time cycles
American National Standard – ASTM F2620
Polyethylene (PE)
Temperature: 490 – 510 °F / 254 – 266 ℃
|
PIPE SIZE |
|
PE80 MDPE |
|
PE100 HDPE |
|||||
|
Pipe Size |
|
Heating Time |
Fusion Time |
Cooling Time |
|
Heating Time |
Fusion Time |
Cooling Time |
|
|
Inches |
mm |
|
Sec. |
|
Sec. |
|
Sec. |
|
Sec. |
|
1/2″CTS |
16 |
|
6-7 |
Immediate |
30 |
|
6-10 |
Immediate |
30 |
|
1/2″IPS |
20 |
|
6-7 |
Immediate |
30 |
|
6-10 |
Immediate |
30 |
|
3/4″ |
25 |
|
6-7 |
Immediate |
30 |
|
6-10 |
Immediate |
30 |
|
1″ |
32 |
|
10-12 |
Immediate |
30 |
|
15-17 |
Immediate |
30 |
|
1 1/4″ |
40 |
|
12-14 |
Immediate |
45 |
|
18-21 |
Immediate |
60 |
|
1 1/2″ |
50 |
|
14-17 |
Immediate |
45 |
|
20-23 |
Immediate |
60 |
|
2″ |
63 |
|
16-19 |
Immediate |
45 |
|
24-28 |
Immediate |
60 |
|
2 1/2″ |
75 |
|
18-20 |
Immediate |
45 |
|
24-28 |
Immediate |
60 |
|
3″ |
90 |
|
20-24 |
Immediate |
60 |
|
28-32 |
Immediate |
75 |
|
4″ |
110 |
|
24-29 |
Immediate |
60 |
|
32-37 |
Immediate |
75 |
Operator Experience
According to the American National Standard ASTM F 2620: Skill and knowledge on the part of the operator are required to obtain a good quality joint. This skill and knowledge is obtained by making joints in accordance with proven procedures under the guidance of skilled operators. Evaluate
operator proficiency by testing sample joints.
The party responsible for the joining of polyethylene pipe and fittings shall ensure that detailed procedures developed in conjunction with applicable codes and regulations and the manufacturers of the pipe, fittings, and joining equipment involved, including the safety precautions to be followed, are issued before actual joining operations begin.
Socket fusion visual appearance guide
American National Standard – ASTM F2620
Acceptable Visual Appearance
- Melt bead flattened by cold ring.
- No gaps or voids.
- Good alignment between pipe and fitting.
Unacceptable Visual Appearance
- Melt bead not flattened against the fitting/cold ring.
- Improper insertion depth; no cold ring.
- Excessive heating.
- Misalignment.
