Specialist Electrofusion Solutions - Brochure | PLASSON UK

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www.plasson.co.uk

LARGE BORE ELECTROFUSION SADDLES Why fit a PLASSON Saddle? Making a connection to a new or existing polyethylene pipeline with a PLASSON saddle reduces costs and minimises disruption on site compared with the traditional methods, e.g. installing a ductile iron or polyethylene tee. The saddle connection can be made in a small excavation and does not require separating the pipe. They can be fitted after the pipe has been completely installed and offer under-pressure connection to live main options too. Fitting the saddle after the main is laid allows it to be positioned to account for variances between the drawing and ‘as laid’. Making a branch connection with a PLASSON branch saddle is as quick and far easier than cutting in a tee with less excavation and reinstatement. The saddle and tooling are light weight, lifting equipment is not needed. The range of outlets permits the connection to branch mains connections, air valves and washouts. A simple, highly reliable clamping tool has been developed to provide PN16 full pressure connections to a 16-bar pipe.

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Spigot Saddle

Flanged Saddle

Repair Saddle

Ease of Installation The PLASSON saddle requires no specialist skills to fit, the Saddle Clamp is purpose designed to provide the most reliable weld on a prepared pipe. The straps that pass round the main mean a small gap around the main is needed but a few mm only. These saddles have been fitted through windows cut in Cast Iron mains where the new PE main was inserted in the old CI pipe. The saddle has a built-in test point to simplify weld integrity testing before tapping the main. The clamp is simple to use and requires no additional equipment.

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Applications 9 Pressurised and de-pressurised branch connections for Gas & water. 9 Making fabricated tees by fixing onto a piece of pipe. (cheaper and shorter)

9 Fitting air valves and hydrants on to water lines.

9 Suitable for pipelines SDR11 - SDR41 (please check suitability)

Quality & Approvals PLASSON Electrofusion fittings are certified to EN 1555 and EN 12201. All Plasson EF fittings comply with DWI Reg31 and Water Regulation 4. LD, XL and XXL Branch Saddles PLASSON’s Large Diameter Branch Saddles are available for all pipe sizes from 280mm to 1200mm with an range of spigot outlets 90mm - 400mm and flanged outlets from 80mm to 400mm with PN16 coated backing rings.

Pressure ratings PN 16 (Water) PE100 SDR11 (Gas)

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FEATURES AND BENEFITS

Simple Clamping System Our unique clamping system has been engineered to ensure it’s quick and easy to use. Simply pick the correct saddle plate and attach this to the tension straps around the pipework. Tighten until the orange indicators touch, signalling that the saddle is secured and ready for electrofusion on our LD range. Our XL and XXL range tension is controlled by use of a torque wrench. Large Diameter Saddles PLASSON saddles are uniquely designed to allow cost effective connections and branches from large diameter PE pipework. Simple and easy to install with confidence, for all Gas and Water pipelines up to 1200mm. Here we have highlighted some of the many benefits and safety features.

Embedded heating wires ensure large weld zone All PLASSON saddles are designed with large weld zones to give confidence to the installer. The embedded wires overlap the cut out area to ensure the maximum surface weld area is created.

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Built-in test point Each saddle has an injection moulded test point built into the body of the outlet. The test point provides a quick and simple way to test weld integrity of the saddle prior to drilling. The connection to a standard pressure test pump is by 16mm push-fit fitting. Ensure 3x cooling period prior to testing and drilling. Maximum Bore The full bore of the saddle is opened by using the PLASSON core drill. All saddles can be welded in place on pressurised or de-pressurised mains. Please see chart on page 8.

Key Features PN16 rating Full bore outlet Fits pipe diameters 280mm to 1200mm Suitable for SDR11 - 41 Spigot outlets D90 to 400mm Flanged outlets DN80 to 400mm Simple pressure test point built-in Fast and simple installation Lightweight clamping

system designed to obtain full contact along the welding zone, even when the pipe is oval or deformed

Repair Saddle Our repair saddle is a simple and efficient way to repair PE pipework. One repair saddle fits all 250mm to 900mm. The repair saddle can cover and repair damaged areas up to 70mm diameter. Suitable for all pipes with walls 14.7mm thick and above. Once the surface area is cleaned and prepared for Electrofusion, our repair saddle is fixed to the pipework using the LD saddle kit over the damaged surface area. Quickly and efficiently repairing the pipeline, is

Allows branch

connections to pressurised or non-pressurised mains pipes Clamping and drilling tools available for purchase or hire from leading utility hire companies One weld time for all temperatures -10°C to +45°C

a more cost effective solution than cutting out and replacing the damaged area.

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PRODUCT RANGE

Spigot Outlet

Pipe dia 90 110 125 160 180 200 225 250 280 315 355 400 280

315 355 400 450 500 560 630 710 800 900

M M M M

• • • • • • • • • •

• •

M M

• • • • • • • • •

• • • • • • • •

• • • • • • •

M M

M M M M

• • • • •

• • •

1000 1200

Flanged Outlet

M Multi-size saddle (stocked) M Multi-size saddle ( made to order) • Single size (stocked) • Made to order

Pipe dia 80 100 150 200 250 300 400 280

315 355 400 450 500 560 630 710 800 900

M M M

Repair Saddle

• • • • • • • •

Pipe dia 70 250mm - 900mm M

• • • • •

M M M

• • •

•

All Plasson saddles are suitable for gas and water applications, drilling either under pressure or not. All Plasson saddles are suitable to weld to any point on the pipeline, regardless of pipe ovality. All Plasson Multi sized saddles are suitable for non standard pipe sizes.

The PLASSON range is always evolving, please ask if you require a saddle size not shown on our charts.

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INSTALLATION TOOLS

Saddle Pressing and Clamping Tools

LD Saddle clamping kit Our LD saddle kit has everything you need to install saddles on to pipes 280mm to 900mm with spigot outlets 90mm to 160mm and flanged outlets dn 80mm to dn 150mm. PLASSON’s uniquely engineered clamping system is designed to make clamping in the trench simple, easy and 100% effective to ensure the pipe and saddle surface areas come together as one prior to electrofusion. Leaving a stamp to prove the correct plate and system has been used.

XL / XXL Saddle clamping kit When you move into our large diameter outlet saddles an XL tensioning strap kit is required for all outlets 180mm to 400mm flanged and spigot. All size outlets use the same tensioning strap. Then select the correct size fixing plate (and flanged bar for saddles) to suit the outlet size. Each plate kit comes complete with a re-rounding tool for the outlet. Available Clamping Plates 200mm to use on 180/200mm flanged & spigot 250mm to use on 225/250mm flanged & spigot 315mm to use on 280/300 & 315mm flanged & spigot 400mm to use on 350/355 & 400mm flanged & spigot

HOT TAP DRILL FOR FLANGED SADDLES

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The Hot Tapping Drill is available with a choice of electric or hydraulic motors. Housings for flange sizes DN80, 100, 150, 200, 250, 300 and 400 are designed specifically for the drilling of Plasson branch saddles for large pipes with core cutters. The drive offers a high torque at low RPM. The hot tapping of pressurised PE pipes can only be done after the welding of the saddle and a following pressure test.

PE Cutter sizes Our range of PE cutters are designed to maximise the internal bore of the branch to allow maximum flow through the fitting. All cutters are designed to retain the PE coupon and swarf once drilled.

Outlet d1 d90 / dn80 d110 / dn100

Outlet Bore Cutter Size

73mm 90mm 102mm

71mm 87mm 99mm

d125

d160 / dn150

131mm 127mm 147mm 143mm 164mm 159mm 189mm 179mm 205mm 199mm 230mm 223mm 259mm 251mm 292mm 283mm 329mm 319mm

d180

d200 / dn200

d225

d250 / dn250

d280

d315 / dn300

d355

d400 / dn400

INSTALLATION STEP BY STEP GUIDE

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1. Once pipe is cleaned and scraped. 2. Select plate for spigot size. 3. Attach straps ready for tightening. 4. Note the gap on the tension indicator.

5. Tighten straps until tension indicator gap closes. 6. Tension indicator gap has closed. 7. For spigot fittings select suitable re-rounder. 8. Fittings now ready for electrofusion.

Range of Tools

Bar PN16 saddles with branches 280-400mm and PN10 saddles with 225 branches, use a bar across the offtake to apply an even force over the fusion zone.

Rounding Ring PN16 saddles with branches 180-250mm use a re-rounding ring to maintain the circular shape of the offtake during fusion.

Core Cutter Especially designed core cutters enable cutting through thick and thin wall pipe.

Torque Wrench A torque wrench applies high tension to the straps and force to the clamp plate.

LARGE DIAMETER COUPLERS RANGE

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PLASSON’s unique range of Large diameter couplers allows the installer to choose the correct pressure rated fitting for the project. Designed for reliable high performance pipe joining. All fitted with 4mm pins. With a fitting to suit all pipework from SDR7.4 to SDR41 and pressures to suit all applications: Please check details for pipe SDR compatibility.

6.4 bar Super Lightfit 10 bar Lightfit 16 bar Standard

Super LightFit Coupler

LightFit Coupler

Coupler

Max Pressure

PN6.4

PN10 • 40v • 40v • 40v • 40v • 40v • 42v • 44v • 45v • 42v

PN16 • 40v • 40v • 40v • 40v • 40v • 42v • 43v • 45v

450 500 560 630 710 800 900

• 44v • 44v • 44v • 44v • 44v • 44v • 44v

1000 1200

The PLASSON range is always evolving, please ask if you require a coupler size not shown on our charts.

FEATURES AND BENEFITS LARGE DIAMETER COUPLERS

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Key Features Insulating weld straps prevent expansion during weld process DWI approved EN12201 water, EN1555 gas certified No requirement for preheating Suitable for pipes SDR7.4 to SDR41 All made from Virgin PE Full range fitted with 4mm Pins Extensive range 450mm to 1200mm Coupler design optimised to suit pipe SDR rating Superlightfit 6.4 bar 500mm to 1000mm Lightfit 10 bar 40mm to 1200mm Standard 16 bar 20mm to 1000mm

Electrofusion fittings for D 450 – D 1200 PE Pipe

Insulating Weld Straps Prevent expansion during weld process Does not require tightening or intervention from the operator Will be loose after cooling Can be removed after cooling - not a structural element of the finished weld

Product Geometry Extra material at areas of maximum load Customised profile at weld zones to improve weld quality Long insertion depths allow longer cold zones to help prevent melt out

Dual Weld Zones Can be welded simultaneously or in a sequence. Please consult PLASSON for advice Allows flexibility with installation procedures

Rising Pin Weld Indicator Located in the middle of strap buckles Tapered design prevents melt out

Wires Embedded In Coupling

Prevents damage during assembly Ensures even heat transfer during welding Internal machining after wire embedding to control internal

diameter and provide a smooth welding surface

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SENSOR SADDLE

Key Features Designed for instrumentation connections Permanent welded fixing Robust welded attachment provides PN16 rating Can be installed on live pipework The installation footprint is small - easy to accommodate

The PLASSON Sensor Saddle provides a simple and reliable solution for providing a through wall connection into PE pipes, both new and existing. Equipment such as pressure sensors, sampling points and flow sensors can easily be connected to both new and existing pipelines, by way of the BSP (ISO-7) thread in the saddle. 2 saddle sizes cover connection by Electrofusion to all PE pipes between 110mm and 1200mm and are PN16 rated and suitable for pipes SDR7.4 to SDR26.

Brass threads are standard. (Stainless steel threads are available for corrosive fluids on special request).

The use of the two unique yet simple clamping device options (strap for live or bolt for non-live systems) ensures professional, robust and leak-free component attachment.

Sensor Saddle With Brass Thread Size

Voltage

110-400 x 1/2” 110-400 x 3/4” 110-400 x 1” 450-1200 x 1/2” 450-1200 x 3/4” 450-1200 x 1”

30v 30v 30v 31v 31v 31v

Installation Saddles are fitted to unpressurised pipes by a simple single bolt clamp. For fitting to pressurised systems, a strap clamp is required.

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FLEX RESTRAINT

Key Features Fits any PE pipe in the size range of 160mm to 1600mm Can be welded by any standard EF control box with barcode or manual input Option including bolt hole securing point Designed and tested to support 7000 LBS/3100 dN (kg) of axial force Use multiple units to achieve required force restraint

For axial restraint of PE pipe.

The restraint is a flexible bar, which is fused to the pipe by electrofusion to create a welded shoulder that can restrain the axial movement of pipes in various applications:

Anchoring the pipe to a concrete wall such as a manhole or tank.

Restraining the pipe to a gasket bell fitting to facilitate cross connection with other piping systems.

Blocking pipe movement after slip-lining.

Bolt hole for securing additional equipment.

Clips for attaching the 50mm clamping strap.

Side mounted 4.0mm terminals.

Concealed wire - eliminates risk of smoke or unintentional contact with hot wire.

Technical Details: Size:

Fits any PE pipe in the size range of 160-1600mm. Wall thickness ≥ 8.5mm

Raw Material:

Made of PE 100 / PE4710 resin.

Welding Data Input:

Can be welded by any standard EF control box with barcode or manual input. Designed and tested to support 7000 LBS/3100 dN (kg) of axial force. Use multiple units to achieve required force restraint

Axial Load Restraint Capacity:

Terminal size:

4.0mm terminals.

Installation The flex restraint is installed by using normal EF preparation (scraping and cleaning). The flex restraint(s) should be clamped by using a 11/4” or larger ratchet tie down strap. Make sure the flex restraint is in full contact with the pipe.

Allow to cool for the indicated time before removing the strap. Wait 4 times cooling period before applying full load.

Flex Restraint Tension Belt.

SPIGOT FITTINGS PE100

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Our injection moulded Polyethylene fittings are characterised by excellent physical and mechanical properties. Through the fine surface structure, injection moulded PE fittings are ideal for transporting gases and liquids.

Properties Excellent processing

properties for Butt or Electrofusion welding Good chemical resistance Excellent corrosion resistance High impact strength UV degradation protected, no additional protection required High abrasion resistance Approved for Gas and Water use according to EN1555 and EN12201 SDR11 and SDR17 options available

The excellent UV resistance allows their use for outside installation without further need for additional protection effort.

Our fittings have been approved and used for decades in the gas and water industries.

Material High density Polyethylene (PE100). Colour: Black. Approved to BSEN1555, BSEN12201 and Reg 4/WRAS.

Joining technology Butt-welding Electrofusion socket-welding Flange connection

Geometric Properties Outside diameter and wall thickness according to EN 1555 and EN 12201. Size range from 20mm - 1000mm.

SPIGOT FITTINGS SIZE RANGE

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Short Spigot Range

Size range 25 - 315 25 - 315 20 - 315 25 - 315 20 - 1000 25 - 1000

SDR17

SDR11

• • • • • •

Elbow 90 Elbow 45 Bend 90

Tee 90

Reducer

Flange adaptor

Long Spigot Range

Size range

SDR17

SDR11

• • • • • • • • •

Elbow 90 Elbow45 Elbow 30

25 - 500 25 - 500 75 - 225 25 - 500 40 - 315 32 - 500 20 - 630 25 - 630 25 - 630

Tee 90

Y tee 45 Red tee Reducer End cap

Flange adaptor

Seamless Bends Range

Size range

SDR17

SDR11

• • • • • •

Bend 90 Bend 60 Bend 45 Bend 30 Bend 22 Bend 11

63 - 900 63 - 900 63 - 900 63 - 900 63 - 900 63 - 900

To find out more about our range of Spigot Fittings, please visit www.plasson.co.uk

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PLASSON’s extensive range of solutions for connecting PE pipe is found in over 80 countries world-wide. The combination of PLASSON’s high quality products and first class customer service make it a world leader in the production of plastic pipe fittings.

Plasson UK Ltd. Plasson House, Albert Drive, Burgess Hill, West Sussex. RH15 9TN

Tel: 01444 244446 Email: sales@plasson.co.uk

ISO 9001:2015 ISO 14001:2015 ISO 45001:2018 C E R T I F I E D

www.plasson.co.uk

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