Welding methods

The welding methods used in plastics, and the equipment that goes with them.

MethodsOverview of all welding processes: materials and diameter rangesButt fusion, socket fusion, electrofusion, extrusion, hot air and other processes in one table: which materials they cover and which diameters they are used for.Read the guide · 5 minMethodsButt fusion of PE pipes: heated tool (mirror) welding step by stepThe standard method for joints in PE pipes from Ø63 upwards, also known as butt welding. Read about the four phases and the parameters that decide whether the joint lasts 50 years.Read the guide · 6 minMethodsButt welding of PVC: the narrow temperature window and why t2 dictates everythingPVC-U cannot withstand the same treatment as PE. The heating element operates at approx. 190 degrees, the changeover time must be short and consistent, and servo- or CNC-controlled machines make the difference.Read the guide · 7 minMethodsExtrusion welding: strong joints in thick-walled materialWhen the pipe wall is thick, or the joint requires extra strength, new material is melted into the weld seam using a handheld extruder (extrusion welding).Read the guide · 5 minMethodsElectrofusion welding (coupler welding): the joint controlled by the fittingWith an electrofusion fitting, the welding process is built into the fitting itself. Well-suited for narrow trenches, repairs and small diameters.Read the guide · 4 minMethodsSocket fusion: small diameters with sockets and mandrelsBead welding with hand or machine tools for pipes from Ø20 to around Ø125. The classic method for geothermal probes and installations.Read the guide · 4 minMethodsHot gas (hand) welding: for welding in the detailWith a hot air gun, welding rod and a speed welding nozzle you can weld linings, details and repairs where machines cannot reach.Read the guide · 4 minMethodsVertical butt welding: uphill and downhillWhen the pipe cannot lie horizontally, gravity changes the rules of the game for the machine. Here is how to keep pressure, setup and jointing under control.Read the guide · 7 minMethodsWelding of pipe branches, tees and Y-branchesA branch on the main pipe requires different equipment than straight joints: clamping range, angles, space and weight. Here is how to prepare for the job.Read the guide · 5 minMethodsTrade terms and synonyms in plastics weldingA glossary of the trade's language: from butt fusion and mirror welding via bead, angleich and heat soaking to calibration under DVS 2208. The synonyms also power the site's search field.Read the guide · 6 minMethodsUltrasound, vibration and rotation: hot-tool-free weldingThree methods that generate heat via friction or oscillation instead of a heating element. How they work, and when they are the right choice.Read the guide · 6 minMethodsWedge and membrane welding: leak-tight joints in geomembranes and sheetsHot wedge or hot air, overlap and pressure roller. How to weld film, liners and membranes, and how to inspect the seams.Read the guide · 6 minMethodsSheet welding of PE and PP: butt welding in sheets and componentsSheets are welded with a heating element just like pipes, but setup, edges and inspection differ. Here is how you do it.Read the guide · 6 minMethodsSaddle welding: branch connection on a pressurized main pipeSaddle, heating element and subsequent drilling. How to make a tight branch connection without cutting the main pipe.Read the guide · 5 min

Equipment & machines

Machines, tools and accessories for plastics welding and pipe installation.

EquipmentHow to choose the right butt fusion machinePipe diameter, job type and working location decide the choice between manual and hydraulic. Here are the questions to ask yourself before you buy.Read the guide · 5 minEquipmentDimensions and weight of a butt fusion welding machine: footprint, lifting and portabilityThe dimensions of the carriage, the weight per size and what it means when the machine needs to fit into a van, up a staircase or be lifted on-site.Read the guide · 6 minEquipmentMachine types and control levels: manual, WeldControl and CNCHydraulic without control, WeldControl (assisted control) or full CNC: here is the difference in practice and what you actually get at each level.Read the guide · 5 minEquipmentCompact butt fusion welding machine: when the machine needs to fit in the vanLightweight range, lower weight and fewer units to carry: how to assess whether a compact machine is sufficient or whether the standard frame is the right choice.Read the guide · 5 minEquipmentElectrofusion welding equipment: control units, documentation and generatorsWhat an electrofusion control unit must be capable of, why memory for fusion records and scanners matter, and what power requirements to expect on site.Read the guide · 5 minEquipmentExtruders: output capacity, sizes and what kg/h meansFrom 1.4 to 6.5 kg of melted rod per hour: how to read the data sheet and select the right extruder for pipes, tanks and repairs.Read the guide · 5 minEquipmentCalculators and tools: full overviewAll calculators and lookup tools on the site gathered in one place: welding rod consumption, welding tables, material selection, generator sizing and power bank capacity.Read the guide · 3 minEquipmentSelecting equipment: complete overview of machines and toolsStart here: a brief overview pointing to butt fusion, branch and electrofusion welding, extrusion, and practical matters concerning power supply and servicing.Read the guide · 4 minEquipmentNO-DIG: pull heads and pipe pulling for underground boringNew pipelines are pulled under roads and buildings without a trench. How to choose and use pull heads so the pipe does not come off mid-pull.Read the guide · 4 minEquipmentPipe plugs and pipe stoppers for PE pipes: types, dimensions and backpressureTemporarily seal a PE pipe from the inside using a plug or pipe stopper: discover the available types, how to determine the size based on diameter and SDR, and what you need to know about backpressure and safety.Read the guide · 7 minEquipmentPressure Testing and Backpressure: Keeping the Plug and Pipe Bladder Under ControlBackpressure, confined space safety, and the requirements that apply when shutting off a pipe for pressure testing or repair.Read the guide · 8 minEquipmentRe-rounding tools: restore the round shape of squeezed PE pipesPE pipes become oval when squeezed. Re-rounding tools restore their shape before welding or clamping.Read the guide · 4 min

Materials & preparation

Pipe materials, pressure classes, preparation and welding data tables.

MaterialsWelding rod and extrusion materials: PE, PP, PVC-U, PVDF and ECTFEThe welding rod must match the parent material, and the temperature must suit the material. Here is how you avoid faults that first manifest as a failing weld seam.Read the guide · 5 minMaterialsWelding tables for butt fusion of PE and PP pipes up to Ø1200Heating time, changeover time and cooling time for PE (DVS 2207-1) and PP (DVS 2207-11) by wall thickness, from thin pipes to Ø1200. The values come from public sources.Read the guide · 5 minMaterialsSDR, PN and pipe classes: what do the markings on the pipe mean?PE100 SDR17 PN10: three numbers that determine pressure, wall thickness and welding parameters. How to read the pipe marking.Read the guide · 5 minMaterialsPipe preparation: the 10-minute routine that saves the jointCutting, deburring, cleaning and inspection. Good preparation is the difference between a joint that lasts and one that does not.Read the guide · 4 minMaterialsSqueeze-off of PE pipes and jacketed pipesShut off a live PE pipeline with squeeze-off tools: remove the outer jacket, set the stop blocks according to the SDR, re-round the pipe and follow DVGW GW 332.Read the guide · 6 minMaterialsThermoplastics: identification by burn test and welding temperaturesOver twenty thermoplastic types, their burn test, and the temperatures and methods that work. Look up the material before you apply heat.Read the guide · 7 minMaterialsButt welding parameters from pipe manufacturers: KWH, ProFuse, SafeTech, Egelen and PVDFJacketed pipes and specialty materials have their own tables. Here, the most important parameters are compiled along with how to read them correctly.Read the guide · 8 minMaterialsWelding parameters from KWH, Uponor, Wavin and Egeplast (PE 100, SDR 26)Manufacturer tables side by side: pressures, times and temperatures for PE 100 SDR 26 as well as PVDF, and what to do when the figures deviate from the standard.Read the guide · 7 minMaterialsPipe Data: Wall Thickness and Weight per SDR and PNLook up wall thickness and kg/m for PE and PP pipes, and calculate values yourself when the table does not cover your dimension.Read the guide · 6 minMaterialsBonding of PE and PP: why it is difficult and when it succeedsPE and PP have low surface energy and hardly bond on their own. Here is the treatment, adhesive types, pitfalls and the warnings that sales literature often skips.Read the guide · 9 min

Site work & quality

Testing and documentation, mobile site setup, safety, training, plus service and calibration.

Site workWelding log and documentation of butt fusion welding (ISO 12176)What needs to be included in a welding log, how manual, assisted and CNC-controlled machines perform the task, and what clients typically request.Read the guide · 6 minSite workService and maintenance of welding machines: what you can do yourselfMaintenance by machine type, hydraulic oil, clamps and heating element – and the boundary of what requires a workshop and calibration.Read the guide · 6 minSite workThe machine will not reach pressure: troubleshooting hydraulics, WeldControl and CNCPressure stops below the calculated value: how to distinguish between setting errors, pressure relief valve issues and true hydraulic faults - and what the difference between WeldControl and CNC means for the fault.Read the guide · 7 minSite workSite power: 230 V, 400 V, cables and generatorsWhen a welding machine requires 400 V, how long extension cables can be, and what output the generator must deliver.Read the guide · 6 minSite workGenerator and battery for welding: sizing, noise and operationWhen a generator is required, how to size according to starting current, and when a mobile power bank is the better choice on site.Read the guide · 7 minSite workChecklist: before taking the welding machine to siteA short routine that catches faults that would otherwise only appear mid-job – from clamps and heating element to memory and power supply.Read the guide · 3 minSite workMobile work site: tents, pumps and power in the fieldPlastics welding requires clean, dry and warm conditions. How to build a work site on the construction site that delivers that quality.Read the guide · 7 minSite workWeather and environmental conditions: rain, moisture, wind and cold in plastics weldingDVS 2207 stipulates that joints must be made under controlled conditions. How to protect components, machines and the welding zone against rain, moisture, wind and cold — and what to record in the log.Read the guide · 6 minSite workDVS 2203: weld testing, requirements and documentationTensile tests, bend tests and tensile impact tests verify whether the joint holds. Learn how to take samples, interpret results and document them.Read the guide · 7 min