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Butt fusion welding of PE, PP and PVDF pipes

We join pipes and fittings end to end using a heater plate and controlled pressure. This is how we build process pipelines, manifolds and prefabricated sections, on construction sites or in plants.

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Butt fusion welding of PE, PP and PVDF pipes

How butt fusion welding works

We clamp the pipe ends in the welding machine on a common axis and square their faces with a facing tool. We then press them against the heated plate until the material softens. After removing the plate, we bring the ends together under controlled pressure and leave the joint to cool.

A properly made butt fusion joint is as strong as the pipe itself, and no fittings are needed. That is why it is the standard method for PE and PP pipelines, both pressure and gravity.

When to use this method

  • pressure and process pipelines in PE and PP
  • manifolds and headers with multiple outlets
  • prefabrication of pipe sections before installation
  • long runs laid on construction sites and in trenches
  • larger pipe diameters, where fittings would be expensive

When another method is better

  • no space for a welding machine, e.g. in a manhole or next to a wall: electrofusion welding
  • tie-in to an existing pipeline that cannot be moved: electrofusion welding
  • sheets, tanks and nozzles: extrusion welding
  • PVDF and PP installations where joint cleanliness matters: IR welding

Materials

  • PE
  • PP
  • PVDF

How the welding is carried out

  1. 01

    We clamp the pipes in the machine

    We align the ends on a common axis so that there is no misalignment around the circumference.

  2. 02

    We face the ends

    The facing tool removes a thin layer of material. The faces must be in contact around the entire circumference.

  3. 03

    We heat with the plate

    We press the ends against the heater plate until the material softens to the right depth.

  4. 04

    We join under pressure

    We remove the plate and immediately press the ends together. An even weld bead forms at the joint.

  5. 05

    We cool and inspect

    The joint cools under pressure. We then assess the weld bead around the entire circumference.

We set the welding parameters for the material, diameter and wall thickness of the pipe.

Inspection and documentation

We visually inspect every joint: the shape and uniformity of the weld bead say a lot about its quality. Every joint is recorded: semi-automatic machines log the data themselves, and with manual machines we fill in the record on the form for this method. Before handover, we carry out a leak or pressure test. We hold DVS certificates and a TÜV certificate for this method.

From our projects

PE pipeline in a trench
PE pipeline in a trenchButt fusion welding on a construction site.
PE pipe manifold
PE pipe manifoldButt fusion welding, installation in a plant room.

See all projects

Questions about butt fusion welding

Do you weld pipes directly on the construction site?

Yes. We bring our own welding machine and work in production halls, on construction sites or in trenches, if there is room for the machine.

Can you prefabricate a manifold in advance and install it later?

Yes, we can weld manifolds and pipe sections in advance and only install them on site. This shortens the work on site, which matters during a plant shutdown.

What should I include in my enquiry?

The pipe material and diameters, the approximate number of joints, the location and the date. A drawing or a photo from your phone helps a lot.

Other methods

Send an enquiry about this method

Describe the installation and attach a drawing or photo. We will confirm the method in our quote.

Additional information (optional)

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