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LEARN ABOUT BUTT FUSION PROCEDURE
The principle of BUTT FUSION joining of HDPE or PPR pipe is to heat two prepared surfaces to a designated temperature, then fuse them together by application of a sufficient force. This force causes the melted materials to flow and mix, thereby resulting in fusion.
FEATURES ABOUT HAYES BUTT FUSION MACHINES
The Hayes manual COMBAT PROX series butt fusion machines will give many years of service if operation procedures and maintenance are followed carefully and correctly.
- The COMBAT PROX series is suitable for butt fusion pipes and fittings made of HDPE and any other kind of thermoplastic pipes.
- Machine consists of pipe alignment carriage, insert sets, Teflon-coated heating plate, electric trimmer and electric stand.
- Designed and manufactured according to the American international standard (Inches) ASTM F2620.
- This machine is rugged, reliable and manually-operated. Capable of fusing pipe consistently with high-quality results.
- This machine requires only one operator and minimal maintenance.
- Additional DIPS and Metric pipe inserts are available and sold separately
BUTT FUSION APPLICATION
The HAYES Butt fusion machine is used for welding thermoplastic pipes and fittings made of HDPE (Polyethylene), PPR (Polypropylene), PB (Polybutene) and PVDF by heat fusion and manually controlled force. This method plays a crucial role in joining pipes and fittings, ensuring leak-proof connections and long-lasting joints when maintaining the integrity of fluid transportation networks.
What is Butt Fusion?
Butt fusion is a thermal welding process used for joining thermoplastic pipes and fittings, as result of heat fusion and pressure, the molecules of the two pipes melt and mix together and when the joint cools, the molecules of plastics return to their original form, and the two parts finally become one monolithic pipe, creating a seamless, end-to-end connection.
When to Use Butt Fusion
Butt fusion is commonly used in various industries and applications, including:
- Water and Gas Distribution: It provides leak-free connections that are critical for the safe and efficient transport of these essential utilities.
- Wastewater Management: In sewage and wastewater systems, where pipes are subjected to a variety of harsh chemicals and environmental conditions, butt fusion is the go-to method for reliable, long-lasting connections.
- Industrial Pipelines: Industries such as chemical processing, mining, and agriculture often rely on butt fusion to join pipes that transport a wide range of materials, from corrosive chemicals to irrigation water.
- Geothermal and HVAC Systems: Butt fusion is used to connect pipes in geothermal heating and cooling systems, ensuring efficient heat transfer and long-term durability.
Benefits of Butt Fusion
Butt fusion offers several advantages that make it a preferred choice for many applications:
- Leak-Proof Joints: The resulting joints are seamless and completely leak-proof, ensuring the integrity of the fluid or gas being transported.
- Longevity: Butt fusion joints are highly durable and can withstand the test of time, making them ideal for applications where longevity is crucial.
- No Need for Solvents or Adhesives: Unlike other joining methods, butt fusion does not require the use of solvents or adhesives, reducing the risk of chemical contamination.
- Low Maintenance: Once a butt fusion joint is made, it requires minimal maintenance, reducing operational costs.
- Consistency: Butt fusion offers a high degree of repeatability and consistency in joint quality.
Butt fusion Procedure
The butt-fusion procedure consists of heating the ends of two pipes, a pipe and a fitting, or two fittings, by holding them against a heated plate, removing the heater plate when the proper melt is obtained, promptly bringing the ends together, and allowing the joint to cool while maintaining the appropriate applied force/pressure.
An appropriately sized butt fusion machine is used to clamp, align and face the pipe or fitting ends and to apply the specified fusion force/pressure.
Parts of the Manual butt fusion machine
Teflon-coated heating plate The heater is coated to reduce polymer adhesion. The heater temperature is controlled by a microprocessor installed in the electric power unit support.
Electric Trimmer/Facer
A trimmer or facer is a rotating cutting device used to square-off the pipe or fitting ends to obtain properly mating fusion surfaces. This a heavy-duty trimmer/Facer with a robust electric motor will simultaneously prepare the ends of the pipes to be joined.
Electric control unit / support
For more accurate and stable connection, the electric system and temperature display are controlled by the power unit support. It is also a stand for the heater and trimmer.
Pipe alignment carriage This pipe alignment carriage has a stationary and a movable clamping fixture for aligning and holding each of the two parts to be fused to assist with pipe welding process. It also includes all the appropriate inserts for clamping different pipe sizes or fitting shapes.
