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Method Statement 3.8 - Electro fusion

Document Information

Field Value
Document Reference MS 3.8
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
3.8 Electro fusion As defined by on-site risk assessment Works vehicle and hand tools. Fusion equipment. 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

  • Keep all electro fusion fittings in plastic bag until required
  • Select compatible pipe and fittings
  • Select correct tools and pipe/fitting clamps
  • Visually check the control box and leads
  • Cut pipe ends square
  • Mark and scrape pipe ends
  • Wipe with lint free cloth
  • Scrape pipe in line with manufacturers requirement

NOTE: The fusion will fail if:

  • The pipe is not adequately scraped
  • The pipe ends are not cut square
  • Pipe or fittings have moisture on them.
  • Pipes are not restrained during fusion process.
  • Centre the coupler over the pipe ends making use of the central register (stops) and mark the pipe with a felt tip pen.
  • Place both ends of the coupler in the restraining clamp, centralise the coupler between the pen marks and tighten the clamp.
  • Connect the leads to the fitting
  • Check the fusion time marked on the fitting, even for automatic fittings
  • For manual fittings, set the control box timer
  • Start fusion

WARNING STAND CLEAR OF THE FITTING WHILST FUSION IS IN PROGRESS

Check that:

  • The full fusion time has elapsed.
  • The indicators have risen
  • Allow the fitting to cool for the correct time.
  • In the case of an unsuccessful fusion, cut out fitting and repeat procedure with new fitting. Never attempt to re heat or re use a failed fitting.
  • Ensure the pipe has not moved out of the fitting.
  • Remove the clamp