Skip to content

Method Statement 3.7 - Butt Fusion of PE Pipes

Document Information

Field Value
Document Reference MS 3.7
Issue Number 2
Issue Date 1 June 2026
Next Review 1 June 2027
Prepared By Sean Ashton
Approved By Aaron Mason, Director
Task No Task PPE to be worn Plant required Reference is made to the Team Pack risk assessment
3.7 Butt Fusion of PE Pipes As defined by on-site risk assessment. Works vehicle and hand tools. Butt fusion equipment. Pipe rollers. Fusion tent. N/A

Hazards

  • Manual Handling
  • Stored Energy in the Pipe
  • Defective Plant and Equipment
  • Towing Techniques
  • Incorrect Loading
  • Insufficient Space

Environmental Impacts

  • Noise
  • Dust
  • Light From Night working

Customer Impacts

  • Noise
  • Dust
  • Access

Training Required

As Per specific contract training matrix

Additional Plant and Equipment

  • Winch/Tractor Winch
  • Pipe Bursting/Slip Lining Rig
  • Mechanical Excavator

Permits Required

As Per specific contract specifications and Client requirements.

COSHH Assessment Required

  • 2 Stroke Oil
  • Diesel/Petrol
  • Line Marker Spray
  • Lubricating Spray

Sequence of Operations and Control Methods

The main will be pieced through using suitably approved internally and externally coated couplings that have been washed in disinfectant. A connection will be planned and the new main will be brought into commission.

Equipment Maintenance

  • Do not use faulty equipment, check hydraulic operations, and report any faults immediately. Keep equipment clean and working well.

Pipe End Trimming

  • Both sides of the cutter should shave pipe ends cleanly, replace blades if worn, or out of alignment. Support pipes adequately during the butt fusion process.

Alignment

  • Check for end offset (max 1mm for pipes up to 180mm, 10% of wall thickness for larger sizes). Check for gaps.
  • Re-trim if necessary. Clear swarf, but do not touch pipe end faces.

Hotplate

  • Continually check for cleanliness.

Fusion Conditions

  • Follow procedures given on machine, if in doubt, inform your Agent/Supervisor.
  • Inspect the beads by removing, checking as follows and save the beads as required by the GT.
  • All Fusion to take place within a covered shelter.
  • Pipe strings to be supported on Rollers.

Cleaning Cold

  • Use clean water and wipe with clean, lint free cloth or paper towel.

Cleaning Hot

  • A small amount of PE can be removed with a stick before it burns on. Disconnect power supply, and then use scrubbing brush, (not plastic) with plenty of water to remove dirt. NOTE: a wet cloth is not adequate.

Bead - Up Cleaning

  • Remove residual dust by bringing pipe end into contact with hotplate to form weld bead. Do not fuse this joint. Allow ends to cool, and then trim back. Do this each day prior to jointing or for any change of pipe size and after washing heater plate.

Insulation Bags / Boxes

  • Keep clean replace when internal decay begins

Automatic Hotplates

  • These are protected and stay cleaner, but inspect every day and use bead - up cleaning.

Trimmer Cleaning

  • After heavy use, trimmers acquire a waxy deposit, remove this with aluminium cleaner or scouring powder, followed by water.
  • Completed butt fusion bead to be checked with gauge. (Refer to butt fusion bead check guidance note)
  • External and if required internal bead to be removed and check in accordance with quality procedures (see guidelines)