Instructions for soldering polypropylene pipes. How to properly solder polypropylene pipes. Soldering pipes in difficult areas
Due to their affordable cost and ease of connection, plastic pipes have taken a leading position in the installation of water supply and even heating networks. Despite the fact that these structures are less strong and durable than metal ones, many prefer them when planning to change engineering Communication in their houses and apartments. Particularly attractive quick installation products, since soldering polypropylene pipes allows you to create a durable and reliable connection literally in a few minutes.
Classification of polypropylene pipes
Particularly durable plastic used for the production of pipes is not subject to corrosion, resists salt deposits and the appearance of limescale. Polypropylene structures are designed for long-term operation. The manufacturer guarantees 50 summer term facilities services.
This is indeed possible provided that the pipelines are operated under the pressure and temperature conditions specified in the instructions. The parts are designed for prolonged exposure to high pressure at a low temperature of the transported liquid, and vice versa - high temperature of the liquid at low pressure.
All polypropylene pipes can be divided into four categories
Polypropylene pipes are available in four colors, which does not mean any restrictions in use, with the exception of black, which are produced to be the most protected from UV radiation. The structures are used in water supply and heating systems; they can be connected to metal structures. Can be used in all types of pipelines: open, closed and wall. Polypropylene pipes are divided into categories:
- PN 10 – version with thin walls. Used for heated floors whose temperature is not higher than 45C or for wiring cold water.
- PN 16 – used for organizing cold water supply in systems with high pressure or in heating pipes with low pressure.
- PN 20 is a universal pipe, it can be used for both hot and cold water supply, where the temperature is not higher than 80C.
- PN 25 – the structure is reinforced with aluminum foil. Is used for central heating and summing up hot water temperature not higher than 95C. Can be used to connect a metal pipeline to a plastic one.
Preparation for welding + nuances of the process
The manuals that describe soldering technology indicate that structures with a diameter of less than 63 mm are usually connected using socket welding. At the joints of pipes, fittings are used, special connecting parts to which elements are welded. Larger diameter pipes are connected without fittings using butt welding. This method is considered the most reliable for them.
Soldering of polypropylene pipes is carried out using a manual welding machine, which is popularly called an iron. For parts with a diameter greater than 40 mm, experts recommend using devices with centering devices, which are somewhat more difficult to operate. Welding machines are equipped with special removable nozzles for pipes. They are heating elements made in the form of a sleeve for melting the outer part of the pipe or a mandrel for heating inner surface details.
Manual machine for welding polypropylene pipes
The diameters of the nozzles vary from 14 to 63 mm. The heating elements are coated with Teflon, a non-stick material. During the welding process, be sure to keep the nozzles clean and wipe them after each use with special wooden scrapers or tarpaulin rags. This must be done while the elements are still hot; cleaning cold parts is unacceptable.
Work order
Stage #1 - preparing the welding machine
The device must be installed on a flat surface so that it is easily accessible. Before starting work, you need to determine what diameter pipes will be soldered and prepare the necessary heating elements. The design features of the device allow you to use several attachments at once.
It is recommended that you install everything you need before warming up the device. The device heats up evenly, so the location of the heating element does not affect the temperature of the nozzle. They are fixed in the way that will be most convenient for work. To install attachments, use special keys. The desired temperature is set on the control panel of the device; for polypropylene pipes this is 260°. The device turns on and warms up, which takes about 10-15 minutes.
At negative temperatures, welding is prohibited. In addition, the time for soldering polypropylene pipes depends on the temperature in the room: in hot weather it is reduced, in cold weather it increases.
Stage #2 - pipe preparation
Using a pipe cutter or special scissors, the part is cut at a right angle. The cut area is cleaned and, together with the fitting, degreased using a soap or alcohol solution. The parts dry well. If work is carried out with pipes of grade PN 10-20, welding can be performed. If with PN 25, you need to additionally clean the top layers of aluminum and polypropylene. The work is performed using a shaver accurately but to the welding depth, which can be determined by the size of the welding machine nozzle.
You only need to cut a polypropylene pipe at a right angle
Stage #3 - heating the parts
The elements are put on the nozzles of the device required diameter. The pipe is inserted into the sleeve up to the limiter indicating the welding depth, and the fitting is installed on the mandrel. The heating time of the parts is strictly maintained. It is different for each type of pipe; the values can be found in a special table.
Stage #4 - welding elements
The heated parts are removed from the apparatus and connected to each other with a confident, quick movement while maintaining the alignment of the elements. When connecting parts, they must not be rotated axially or bent. You also need to strictly ensure that the pipe enters to the depth determined by the inner boundary of the fitting socket.
The parts are heated for a strictly defined time
Stage #5 - cooling the connection
Heated parts must be allowed to cool, this is especially important for thin-walled pipes. Any deformation of parts at this time is unacceptable; they can lead to sealing of the internal lumen of the pipe. After the parts have completely cooled, it is necessary to blow or pass water through them to ensure that they pass through.
Video example of soldering work
Also, this whole process can be observed in this video instruction:
Recommendations on how to solder polypropylene pipes are quite simple. You can handle this work yourself. Experienced welders suggest that beginners solder the first part, cool it, and cut it to make sure everything is done correctly. If there are errors, they will be immediately noticeable. In this way, you can quickly learn how to make reliable connections of polypropylene pipes, which will certainly come in handy during the installation or repair of pipelines.
Pipes are firmly established in every home. Their versatility makes it possible to install water supply systems not only in houses, apartments, but also in summer cottages.
The use of such elements for a heating system is also one of the most popular areas. In order for the work to be completed efficiently, you should study the rules and secrets of soldering polypropylene pipes. And you should start by studying the characteristics and features of the material.
Types of PP products
There are several options for execution. They can be distinguished by markings along the length of the product:
- PN-10. It is used for systems with low pressure not exceeding 1 MPa and temperatures not exceeding 45°C. As an option, install a water heated floor.
- PN-16. The pressure in such a system should not be higher than 1.6 MPa, and the temperature should not exceed 65°C. Used for supplying cold water.
- PN-20. One of the most popular types. Used for supplying hot and cold water. The pressure in such a system can be up to 2 MPa, the temperature is allowed up to 80°C.
- PN-25. Used in heating systems. System pressure up to 2.5 MPa, temperature up to 95°C.
For private use, pipes with a diameter of 16 to 110 mm are used.
Product color on individual characteristics does not affect. Most often, products are found in white. The exception is black pipes. They have additional protection against ultraviolet radiation.
Is it difficult to do it yourself? The work instructions must be followed exactly, but otherwise the process is not complicated. There is a whole list of fittings for pipes, which should also be studied.
Advantages and disadvantages of PP products
Such systems have a decent list of advantages:
- Durability of the material. Service life up to 50 years. Achieved due to the absence of corrosive processes.
- Environmentally friendly. High quality material- guarantee of safety for human health.
- Possibility to hide in boxes under tiles. Achieved due to the durability and tightness of the system.
- Aesthetics. Even in open space, the pipes look neat.
- Virtually no plaque is formed inside the system. Achieved due to the smooth inner surface.
- Lightness of design.
- Simplicity of installation work.
- Versatility due to a large number of connecting elements.
- They do not conduct current.
- This material makes the system less noisy.
- Does not freeze. Has a good
The disadvantages include the fact that you will get low-quality material.
Types of soldering
There are two types of connections - butt and socket. The connection according to the first option may not withstand high pressures in the system. Therefore, the most popular and in a simple way is a socket connection using fittings and a special welding machine. As his instructions show, it must be performed with strict adherence to technology.
Then the quality of the system will meet all requirements and can last up to 50 years.
Types of fittings and their features
These systems have a large list of connecting parts, which allows for the most efficient wiring:
- Angled 45° and 90°. With their help, you can rotate the system from 45° to 135°. They can be with or without thread.
- Adapters are double, triple, four-way. These options also include threaded options.
- Contours. When soldering the system, they allow you to bypass the intersections of pipes.
- Compensators. They look like a loop. They are installed to stabilize the pressure in the system. This significantly extends the service life of the pipeline. You can assemble it manually using fittings, but it is cheaper to buy a ready-made option.
- Taps and valves. Shut-off elements used during pipeline operation.
- Plugs. At repair work, for example, in a bathroom, some of the pipes are plugged before tiling is completed. This helps avoid blockages before installation begins. plumbing equipment and water leaks.
- Fastening elements. Allows pipes to be fixed to surfaces.
Selection of pipes and fittings for them
First of all, you should draw a connection diagram to correctly calculate the material.
Next, the connection characteristics are analyzed. As mentioned earlier, PN 20 models can be used to connect cold and hot water, PN 25 - for heating system. Pipes are usually sold in lengths from 2 to 4 m, or in coils.
The soldering instructions indicate that the fittings are selected taking into account the required parameters and must match the outer diameter of the pipes.
Tool for the job
The following list will be required:
- welding machine for polypropylene pipes with nozzles;
- roulette;
- marker;
- special cutter;
- equipment stand;
- carrier or extension cord;
- protective gloves;
- instructions.
Soldering should occur after familiarization with technical documentation to the equipment.
Welding machine for PP products
As a rule, such equipment is sold in a separate suitcase. The kit includes:
- Cutter for PP material. Sometimes you have to buy this tool separately, because the kit may contain a low-quality one.
- Nozzles for different pipe diameters.
- The welding machine itself.
- Keys for installing nozzles.
- Instructions. Soldering of polypropylene pipes, as well as maintenance of equipment must be carried out in accordance with this technical documentation.
Instructions - preparation for work
Welding system temperature environment should be at least five degrees.
If this is external work, soldering is not allowed in wet weather.
Place pipes and fittings so that they do not interfere with the work, but at the same time they must be within easy and quick tolerance. Pull out the cutter and place it next to the material.
Remove the welding machine from the packaging. Select the required nozzles. One should be a mandrel, the second a sleeve. The first one is used for warming up. inside fitting, the second - for the outside of the pipe. Install on the equipment and secure. Place the device on the stand. Connect to the network, set the required temperature (usually set to 260°C), turn on. Make sure that the welding surface does not come into contact with anything.
As the instructions indicate, soldering of polypropylene pipes should be carried out only after the apparatus has been fully heated. For this purpose, the equipment has backlit buttons and when fully warmed up, the indicator goes out.
Soldering pipes has several stages that allow you to achieve an ideal result:
- Cut the pipe to the required length. Make an even, unmown cut. A cutter is used for this. It should be sharp and the blades should not dangle.
- Clean the edges from burrs and plastic crumbs. Degrease the surface. If there is water inside, wipe with a cloth. In any case, both the fitting and the cut pipe must be clean and dry. If the part is to be used, foil reinforced, should be removed upper layer. Otherwise, soldering will not be possible.
- Try on the elements. Make a mark on the pipe to ensure a smooth connection to the fitting. In principle, this is an optional procedure. Depends on the experience of the welder.
- When soldering polypropylene pipes occurs, the instructions should already be studied, including the section on safety precautions during work.
The welding process will be easier to do with two people, but it can be done alone.
To do this, remove it from the stand and press the handle to the floor with your foot. A pipe and a fitting are simultaneously put on both sides - each on its own nozzle. Movements should be with pressure, twisting clearly parallel to the ground. Alternately half a turn is done towards yourself and away from you with each hand at the same time.
Having dressed all the way, you should wait for the time according to the instructions. It will definitely contain a table with accurate data. Remove both elements at the same time and insert them into each other using a screwing motion with pressure, again wait time according to the instructions. An influx should form at the junction. It will provide a tight connection.
There are very complex transitions and connections. It is better to solder these in parts.
Several separate structures are assembled and connections are made on site. In such areas you will probably need the help of another person.
As you can see, the process is simple - soldering polypropylene pipes. The instructions should be at hand. It will give complete information on the time of heating the pipe and soldering.
note
You should adhere to safety precautions when working. Avoid contact with heated elements during welding. After work, turn off the equipment and allow it to cool before putting it away.
Main mistakes when welding and soldering polypropylene pipes
And now the system is ready. Pressure testing is done, and the joints leak. It seems that everything was done using technology, but such a nuisance came out. What could be the problem:
- The pipes were not warmed up enough. As a result, the seam turned out to be leaky.
- Poor connection. When connecting the pipe and fitting, a tight connection did not take place. Work must be carried out with pressure and inserted until it stops.
- The edges are not deburred. As a result, a gap may form.
- The fitting or end of the pipe was wet. Water will not give a complete seal.
- Pipe and fitting from different manufacturers. Poor soldering may also occur due to differences in chemical components.
Or the opposite effect may occur - water does not flow through the pipes.
This may occur due to overheating of system elements. And inside, at the place of soldering, a solder has formed, which does not allow water to pass through. Therefore, it is said that the work technology must be fully observed when soldering polypropylene pipes. Each welding machine comes with its own instructions and must be studied before starting work.
Polypropylene pipes, due to their low cost and ease of connection, are used by many owners when installing water supply in an apartment or house. There are many tools for soldering pipes, but not everyone can afford them, so I made a soldering iron from an old electric iron.
On the “sole” from the iron (heating element) (photo 1, item 1) in advance drilled hole Using a bolt on both sides, I secured the heating element for the outer (7) and inner (see photo 2) diameters of the pipes. The heat-insulating casing (photo 1, item 2) and the temperature controller module (3), mounted on a textolite plate (4), were connected to the heating element and installed on a stand (5). PTFE insulators (6) were placed between the casing and the plate.
The aluminum stand securely holds the structure, and the protruding part of the textolite plate is freely inserted into its groove (8) and easily removed, which allows you to conveniently store the device. I attached the wooden handle with self-tapping screws to the textolite. The temperature controller module was assembled according to the diagram...
When installing a water pipeline, I turn on the soldering iron and set the desired temperature. I insert 25 mm diameter pipes into the heating element on both sides for no more than 5 seconds, take them out and solder them together, connecting the heated ends.
Diagram of a homemade soldering iron for plastic pipes
1. Variable 500 kOhm (R 1)
2. Resistor 4.7 kOhm 0.5 w (R2)
3. Resistor 1 mOhm, 0.25 w(R3)
4. Dinistor DB-3(VS 1)
5. Triac TS 25-4 (VS 2)
6. Thermal electric heater 1000w(T3H)
7. Capacitor 0.1 uF, 400 v(C 1)
8. Neon lamp HL 1 (network indicator)
The temperature controller is mounted in an aluminum case measuring 130x60x90 mm on a board made of foil fiberglass. The control knob is located outside and has divisions. When the device is turned on, the red lamp lights up.
DIY soldering iron for plastic pipes - photo
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The welded connection of polypropylene pipes is characterized by higher reliability compared to other methods of combining products with each other. This connection technology does not have any differences when working with polypropylene. The only exception is reinforced products: their installation requires some specific features.
This technique is quite simple. Welding can be carried out at home, observing the requirements of the technological process and having the entire arsenal of necessary tools.
There are several options for connecting polypropylene pipes:
- diffusion soldering;
- soldering with electrical fittings;
- cold welding.
In this article we will talk about each method of combining cylindrical products in more detail, consider their advantages and disadvantages, and also learn how to properly solder polypropylene pipes.
Before you begin, you need to prepare the installation tool. To create a reliable joint between the structures and all additional parts, you will need a special soldering iron.
It is worth noting that sometimes the connection of products made of polypropylene is called welding. However, this process has many varieties, so it is important to remember that polypropylene pipes are connected in only one way - soldering. For the installation of such a system, threaded fittings and metal-plastic are not used.
Soldering polypropylene pipes requires the use of welding machines. There are several types of devices on sale:
- heater with a round cross-section;
- flat unit.
The second type of soldering machine is popularly called an iron, which is largely due to its appearance. Such devices differ only in their design.
For the first model, Teflon nozzles are put on the heater and fixed with parts similar to clamps. In the second device, the same nozzles are screwed to the heater on both sides. The rest of the design elements are no different. The main function of the device is to perform high-quality and reliable soldering of polypropylene products.
The set of soldering devices must include nozzles. The most inexpensive device, the set of which includes a minimum number of elements, is considered to be a Chinese soldering iron. Its power does not exceed 800 W. It is presented for sale together with a stand, as well as attachments that allow soldering of PP pipes with a cross-section of 20-32 mm.
When the heating system of a private house is made of cylindrical products of this diameter, this kit will be quite sufficient. But if more is expected professional work soldering related problems, you'll need a better device.
For pipes with a cross-section of 40-63 mm, a different soldering kit is required. It will have to be purchased separately. The most expensive sets, characterized by increased reliability, are manufactured in large European countries. Their kit includes the following parts:
- soldering iron;
- stand;
- Teflon nozzles different diameters;
- scissors that allow you to cut pipes at 90 degrees;
- hexagon;
- Phillips screwdriver;
- roulette;
- gloves.
Since you have to work with hot equipment to solder polypropylene pipes, you must always wear gloves. Beginners often get burned when touching the heating element.
The design of any soldering iron is designed so that it is possible to install several nozzles at once for connecting small-diameter pipes, which saves time, especially when working with products with a cross-section of 20-40 mm.
Soldering machine power
To evenly and quickly heat a pipe with a diameter of 63 mm, greater system power is required. For domestic purposes, a device with a value that determines the amount of energy not exceeding 0.7-1 kW will be sufficient.
If the power of the iron is more than 1 kW, it becomes professional. Its cost is much higher than the price of an ordinary soldering iron.
Method one
For the manufacture of homemade soldering iron you will need:
- a broken old iron that still has a heating element;
- children's metal construction set;
- rubber handle;
- toggle switch;
- asbestos cord;
- duralumin;
- insulating tape.
Manufacturing technology
- use a grinder to cut off all unnecessary parts from the bottom of the iron;
- an aluminum cover is made;
- a box is assembled from the construction set; a light bulb and a rubber handle are installed in it;
- a toggle switch and a soldering iron regulator are connected to the wire;
- all parts are combined into one whole;
- cables are soldered;
- The heating element is bolted to the body, having previously placed an asbestos gasket.
Thus, after spending a little time using available material, you become the owner of a homemade soldering iron for welding PP pipes.
Method two
To make the tool you will need a pair of attachments costing 215 rubles. and a discarded, set fire iron. It takes approximately two hours to assemble.
First, the heating device is installed vertically. The fitting is placed on the heating nozzles simultaneously with the pipe. To make it possible to carry out operations on the wall, the iron needs to be slightly modernized: cut off the “sting” of the sole and slightly round it. It would be a good idea to use thermal paste.
It is known that several pipelines were welded with such a homemade apparatus. The quality of the work turned out to be quite high.
After heating the iron, holding it by the handle, remove the pipe first. There is no need to remove the fitting immediately, since its thickness prevents it from quickly melting. All that remains is to hold the pipe with the iron with your hand and remove the fitting.
To connect the products, you need to apply little force until an even flash is formed around the entire perimeter of the fastener.
You need to hold the connection in this position for about 15-20 seconds until polymerization begins. Welding on the wall is simple: hold the heating device with one hand, and the pipe with the other.
Method three
We manufacture an iron equipped with a temperature controller, which will act as a special power control device assembled on a thyristor. For soldering work a voltage of 170V is supplied. Aluminum or copper plates are used to create the device. The photograph shows a part with a thickness of 0.8 mm, but the value of this value may vary upward.
Flat elements are needed so that the heater does not begin to cool the moment the pipe is put on. For operation, a heating element (1 kW) from an outdated Mechta stove is used. Since the radiator hardly heats up, it can be reduced. No spacers are required to install the thyristor and diode. The design of the iron itself can have any shape, it all depends on your imagination.
Below is power regulator circuit.
On each side of the spiral you can install aluminum spacers in the form of round pancakes. A handle with a regulator and a fixed toggle switch is attached to the body. In other words, you can do tuning.
The principle of all devices is always the same: to solder PP pipes, you need to maintain a certain temperature.
How to choose nozzles
When selecting heating nozzles, it is necessary to take into account the diameter of the pipes being connected and other important points:
- strength;
- how well the shape is retained after temperature changes;
- thermal conductivity.
Almost all welding machines are suitable for various attachments. This is very convenient when you need to install a complex highway.
Each wearable element has two ends. On one, the outer side of the part is heated, on the other, its inner part.
All nozzles are coated with Teflon, which protects the surface from the adhesion of molten material. The dimensions of the parts are in the range of 2-6 cm, which corresponds to the common diameters of cylindrical products.
Normal temperature for soldering For durable welding of structures, the soldering temperature of polypropylene pipes should not exceed 260 °C.
It is important to remember that the viscosity and plasticity of the polypropylene structure must have certain values, otherwise diffusion processes will not begin and the connection will lose its reliability. The service life of such pipelines will be minimal. You will have to forget about the 50-year warranty. It is better to look at the table at what temperature to connect the products.
Pipe soldering time
If you correctly comply with the technology requirements for the duration of the process of connecting structures using special tool, you can get a fairly tight joint. Polypropylene will not begin to spread after overheating. Heating time depends on certain parameters. The main ones are:
- pipe section;
- welding belt seam width;
- ambient temperature.
Below is a special table that shows the recommended soldering time for PP products, taking into account all the values mentioned above:
Socket welding of polypropylene pipes
The main method of installing plastic when you need to connect small cylindrical products different sections, the use of a bell is considered. When welding a PP structure, additional parts must be used:
- corners;
- tees;
- bends.
They are all made from the same material from which the pipes were made. Application additional elements to create a high-quality connection is not considered a disadvantage of this method. The parts in question, in addition to the connecting function, help change the direction of the pipeline.
This process consists of several operations:
- the mating surfaces are melted: the outer wall of the cylindrical product with internal part fitting;
- special heating parts are used;
- The assembled elements are cooled.
According to professionals, socket joints are considered much more reliable than butt welding. Due to the fact that when combined, the pipe enters the fitting with force, high strength is created. In this case, alignment does not require the use of a special tool. Even a beginner can combine cylindrical structures in this way.
Socket welding machine
Devices designed for connecting PP products into sockets are called soldering irons or irons. The main element of such a device was the heating head. All replacement parts are attached to it:
- couplings;
- dorns.
The first elements are designed to heat the outer surface of the pipes, the second - the inner part of the fittings. The shape of the heater in most soldering irons remains a triangular plate. Devices of other designs can be found on sale.
The size of the nozzles depends on the dimensions of the flat part. In other words, a pipe section is selected that will be freely soldered. In addition, you need to take care of the right amount heating couples for simultaneous installation. To work with a large plate you will need a powerful unit.
Additional parts (couplings, mandrels) must be secured so that their supporting surface tightly touches the plate.
With good contact, the desired temperature (260 °C) will be achieved. In this case, the power of the soldering iron does not matter much.
Today, devices are produced equipped with a heating head in the form of a rod. Their main advantage can be called compactness. On technical specifications The shape of the head does not affect it.
For quality work When using an iron, the accuracy of the temperature sensor, which maintains the required temperature, is important. If its fluctuations become minimal, this indicates high quality soldering iron
The most advanced to date are electronic thermostats. These thermistors are capable of displaying an accurate temperature value even at work surface couplings.
The use of such parts makes it possible to reduce the temperature inertia of the iron. As a result, the true readings of the heating head will be displayed on the device scale.
Bimetallic relays work more roughly, as well as capillary thermostats, whose values are inaccurate. If compared with thermistor data, the discrepancies will be quite large. Whatever the thermostat, when the device reaches operating mode (judging by the indicator data), you must wait a few minutes. During this time, the temperature of the nozzles will be compared with the one shown by the device.
Now you can start welding. Manufacturers also produce soldering irons that have two heating elements different power. Each part is equipped with a separate switch.
These products are capable of independently achieving the desired temperature regime. The master himself selects the required power.
The second part becomes a spare in case the first one fails.
The device provides the ability to simultaneously turn on both heaters in order to quickly achieve operating mode.
The equipment can be equipped with auxiliary tools, including:
- chamfer;
- calibrator;
- trimmer;
- pipe cutting scissors.
In some kits you can even find a special cleaning liquid. However, not all of the listed parts are included in the basic package. Often they have to be purchased separately. It is important that the welding machine comes with everything necessary tools for working with any pipe diameters and materials.
Technological process of socket welding
The outer diameter of a cylindrical product is always slightly larger than the nominal cross-section. The fitting, on the contrary, inner diameter less than the nominal cross-section of the pipeline.
Take, for example, a 20 mm pipe. The actual size of its outer diameter will be in the range of 20.3-20.5 mm. A fitting designed to work with a 20 mm product will have an internal cross-section of 19.5-19.7 mm.
Moreover, the middle part of the coupling surface will exactly correspond to the nominal diameter. For a conical plane, 5 degrees are taken.
It becomes clear that if the fittings are not heated, they will not be able to be connected to the coupling.
When the pipe is combined with a hot coupling, melting of the outer part occurs. All excess is squeezed out to the top, creating a kind of roller. Next, the inner layers are heated. They begin to compress, and the pipe is able to get into the hot sleeve. A similar effect can be achieved when the fastener element is connected to a hot mandrel.
When the pipe is combined with the fitting, it is elastically compressed, and the connecting element begins to stretch. Heated surfaces are compressed, displacing air. The result is uniform mixing of the molten material.
General technological process Connecting PP pipes into a socket has several sequential operations:
- cutting of products;
- preparatory activities;
- installation of a welding machine;
- achieving operating mode;
- warming up parts;
- assembly;
- line cooling.
You can manually connect a pipe with a heated tool without much effort if you are welding small parts whose cross-section is in the range of 40-50 mm. To combine cylindrical structures with a diameter exceeding 50 mm, you must use a special centralizer designed for socket welding.
Since soldering polypropylene pipes is not particularly difficult, the work can be done alone.
To cut cylindrical products, special scissors are used that do not allow the pipe walls to wrinkle.
Before starting to solder polypropylene products, the surfaces of the parts are thoroughly cleaned and degreased. Reinforced structures undergo special preparation. Workers installing such products must remember this.
Composite pipes made of PP, which are reinforced with aluminum, are characterized by low thermal expansion. Therefore, a heating system made from such products does not require the installation of additional temperature compensators. Only in such products aluminum reinforced, oxygen diffusion is possible. After air enters the system, the water is actively saturated with oxygen. As a result, the process of cavitation of valves, as well as other parts of the structure from cylindrical structures, begins.
In the absence of a reinforcing layer, there is no need to carry out additional special preparation.
Technological map for socket welding of polyethylene pipes
How to solder reinforced polypropylene pipes
In this case, contact of aluminum with liquid is strictly prohibited. This alloy begins to deteriorate, and buying new products is unprofitable. The appearance of small internal distortions in the joints is difficult to notice with the naked eye, however, it is these zones that are the weak point of the entire system. Here it is possible for water to get on the metal surface.
To prevent this, clean thoroughly reinforced layer. Such an operation is mandatory if the surface of the pipes is wrapped in foil.
For removing metal sheet used special device- the so-called shaver. It has to be purchased separately.
The end is inserted into the device, similar to sharpening a pencil, and they begin to turn.
When working, do not forget about cleaning the aluminum layer. Welding will occur without this procedure, but the reliability of the resulting connection will be quite low.
You can get rid of this human factor by installing fiberglass-reinforced pipes.
If the aluminum reinforcing layer is located in the center of the wall, the surface is trimmed using a special tool. It helps remove the edges of aluminum that cover the end of the pipe. If such an operation is not carried out, water can get into the center of the wall, moving along microcracks in the reinforcing layer, which will inevitably lead to swelling. 
In the photograph you can see the soldered connections of the cuts: the incorrect execution in the picture without trimming and the correct one - with trimming.
To achieve the best results, special couplings are used. They seem to “brick up” the ends of the reinforcing layer, which helps to avoid contact of the metal with the liquid.
Some manufacturers give their own recommendations on how to prepare pipes before welding. Even if there is no reinforcing layer, it is necessary to calibrate the outer diameter and then remove the chamfer.
The sizing operation removes the ellipse of the pipe, making it completely round. The removed chamfer facilitates the work of connecting to the coupling. Unfortunately, when PP pipes are soldered independently, these operations are completely ignored.
How to prepare a soldering iron for use
First, the welding machine must be firmly secured. When heating begins, the parts are subjected to pressure, which is transferred to the soldering iron. To make it more convenient to work, it is important to ensure that the device remains stationary.
A heating couple is placed on the instrument. Next, the desired heating temperature is set and voltage is applied. When PP pipes are socket welded, the heating temperature should be within 260±10 °C, which exceeds the values at which polypropylene becomes viscous and fluid.
In this way, the top layer of the pipe together with the fitting quickly melts. As a result, the part can be easily removed without heating the entire wall thickness. At a different temperature, when the elements become soft, the connection will not be possible.
We put the parts to warm up
When the welding machine reaches operating mode, the light will light up. The pipe is inserted into the coupling, and the fitting is inserted into the mandrel. If it is quite difficult to carry out such work at the same time, a heavy connecting element is installed first.
Welding parts necessarily have a small allowance, which begins to squeeze out during their installation. This creates a ring-shaped roller (burr). To move such a ring, you need to make some effort, but this should be done smoothly and slowly so that the burr becomes correct form. A fitting that fits loosely onto the mandrel and does not form an annular bead is considered defective.
When installing the part, be sure to monitor the installation depth. As soon as the element rests against the top of the mandrel, the pressure must be stopped, otherwise the end of the pipe can be damaged and the fitting stop can be dented. To control the depth of immersion of the part into the coupling, a corresponding mark is made at a certain distance from the end. However, this procedure is not necessary since the fitting is basically inserted into the mandrel until it touches the stop.
After the parts have been installed in the apparatus coupling and its mandrel, you need to wait a few seconds until the surfaces are well melted. It is important to determine the heating duration correctly. This time should be enough to obtain a viscous and fluid state of polypropylene.
If the heating period is too long, the parts will become very soft. Manufacturers plastic pipes We have developed special tables that indicate the heating time for a certain brand of polypropylene. In this case, the wall thickness and cross-section of the pipe are also taken into account.
When fittings are combined with cylindrical products, the angle of rotation of the parts should not exceed 5 degrees. If the joint is made correctly, the flash will have the same thickness on all sides.
Cooling the connection
If it is necessary to correct the work performed, the technology allows this to be done within a few seconds. The parts should not be subjected to any pressure until the material has completely hardened, which lasts approximately 2-4 minutes.
Approximate parameters for the duration of welding operations can be viewed in a special table. More exact values indicated by manufacturers of fittings and PP products.
When soldering PP products end-to-end, the ends of the parts are heated with a hot tool until they melt. Then the elements are pressed with force until the seam cools. This technology is distinguished by its simplicity.
In this case, there is no need to use additional devices. If everything is done correctly, the result is a fairly reliable seam, not inferior to the strength of the pipe. The technological operation is performed in a certain sequence:
For all its simplicity, butt welding only seems so accessible. In practice, this requires solving several problems, which is almost impossible to do in everyday conditions.
The pipes must align exactly along their axis, with only a 10% deviation from the wall thickness allowed. Pressure on the parts that press cylindrical products to the plane of the heating mirror when exposed to high temperature should be applied only for a certain time. This is the only way to achieve a high-quality connection. When performing trimming, it is necessary that the end has perfect perpendicularity.
The conditions listed above are quite difficult to follow without an additional device - a special centralizer. It is equipped with an electric drive that creates a certain compression force. In addition, this device is equipped with a trimmer.
In other words, to carry out butt welding polypropylene pipes of small diameter, you will need large quantity special equipment compared to the previous connection method. Considering the fact that when socket welding, a better joint is obtained due to lock connection, home craftsmen prefer to use this particular method of combining pipes.
Butt welding of PP products is mainly used in production when it is necessary to connect structures large section when installing a straight section engineering structure from cylindrical products.
After listening to numerous pieces of advice, you decided not to hire craftsmen to install the heating system and make all the connections of polypropylene pipes yourself. If you are confident of success and are good at working independently, then feel free to start preparing and producing work.
For our part, we will tell you what tools and equipment will be required for installation and how to properly solder polypropylene pipes. By default, we will assume that all the materials have already been purchased, all that remains is to assemble everything according to the scheme.
Welding machines for polypropylene pipes
Let's start with preparation installation tool. Since all connections of PPR pipes and fittings are made by soldering, you will need a special soldering iron for this purpose.
Note. The joining of PPR parts is sometimes called welding. In order not to get confused, remember that when it comes to polypropylene pipes, there is only one connection method - soldering, but it is often called welding. Using press or threaded fittings such as metal-plastic pipes, these systems are not mounted.
The welding machine used for polypropylene pipes is offered on the market in two types:
- with a round heater;
- flat heating element.
The latter was popularly nicknamed “iron” due to some external resemblance to this household appliance. Different welders They have no fundamental differences, only constructive ones. In the first case, nozzles for Teflon pipes are put on and attached to the heater like clamps, and in the second case they are screwed to it on both sides. Otherwise, there is not much difference, and the device has one function - soldering polypropylene.
Soldering machines are usually sold complete with attachments. The cheapest and most minimal set made in China– this is a soldering iron with a power of up to 800 W, a stand for it and nozzles for 3 standard sizes of the most common pipes – 20, 25 and 32 mm. If your heating scheme contains only such diameters and you do not plan to solder polypropylene pipes anywhere other than your home, or do it professionally, then a budget set will be quite enough.
If, in accordance with the calculation and diagram, you need to join pipes of sizes 40, 50 and 63 mm, then you will have to spend money and purchase another soldering kit, which contains the corresponding parts. Well, the most expensive kits are produced in European countries, they are distinguished by their reliability and durability. Similar kits include the following tools:
- soldering iron with stand;
- Teflon nozzles for soldering iron of all the above diameters;
- scissors for cutting pipes at a precise angle of 90º;
- hex wrench;
- Phillips screwdriver;
- roulette;
- gloves.
Important! Since soldering polypropylene pipes involves working with heated equipment, it is strongly recommended to always use gloves, regardless of whether they are included or not. This is especially true for beginners, who in 99 cases out of 100 accidentally touch the heating element.
The working part of a soldering iron (heater) of any design is designed in such a way that 2-3 nozzles for small-diameter pipes can be installed on it. This allows you to save a lot of time when working with lines ranging in size from 20 to 40 mm.
A little about the power of the soldering machine. High power necessary for quick and uniform heating of large diameter parts, which are considered to be sizes 63 mm or more. For home purposes, it is enough to have an iron with a power of 0.7-1 kW. Soldering irons with heaters above 1 kW are considered professional, and accordingly, they are more expensive than regular ones.
In addition to the iron, you should prepare another tool for soldering polypropylene pipes; its composition is given above in the list. If you don’t have scissors for cutting the pipe at an angle of 90º, then for this purpose you can use a hacksaw and a carpenter’s miter box, or make it yourself, guided by the drawing:
Note. When there are no scissors for polypropylene pipes and they are cut with a hacksaw, then the end must be cleaned of burrs outside and inside the product.
Before cutting a section of the required length, it must be accurately marked. The fact is that when connecting, part of the pipe fits into a tee or any other fitting; this is called soldering depth. Therefore to required size area determined using a tape measure, you need to add the value of this depth by measuring its value from the end and putting a mark with a pencil. Since soldering technology provides different depths immersion for different pipeline diameters, then its values can be taken from the table:
Note. The table shows soldering depth ranges, since it varies within these limits among different manufacturers of PPR pipes. The value can be determined by measuring several fittings with a depth gauge.
When installing heating systems, reinforced polypropylene pipes are soldered; they differ from conventional ones by the presence of a layer of aluminum foil, fiberglass or basalt fiber. Moreover, this layer can be made differently in products from different manufacturers. When the reinforcement is not located in the center of the wall thickness, but near the outer edge, then stripping will be required before soldering the polypropylene pipes. There is a special device for this:
Welding process
Before you start working, you need to put attachments on the soldering iron that match the size of the pipes, and then turn it on and configure it. Here you need to know at what temperature to solder polypropylene pipes. Most manufacturers indicate an operating temperature of 260-270 ºС; you should not raise it higher, otherwise overheating cannot be avoided. Underheating is also fraught with poor-quality and leaky connections, where a leak will then quickly form.
It must be understood that heating time, product diameter and welding temperature are interconnected. In the table we indicate the welding time intervals at a standard temperature of 260 ºС.
Note. The duration of welding is the time until the plastic completely hardens, when the joint gains maximum strength.
When setting up the iron is completed, we proceed to welding, following the instructions for soldering polypropylene pipes:
- Taking the pipe in one hand and the fitting in the other, we put them on the nozzle of a heated soldering iron on both sides simultaneously, without turning them around their axis.
- We maintain the allotted time.
- Carefully remove both connecting parts from the Teflon nozzle, again, without rotating.
- Smoothly insert the pipe into the fitting up to the mark without turning and fix it for the time indicated in the table, at this point the joint is ready. The operation is shown in more detail in the video:
It is more convenient to use the soldering iron correctly when it is installed on the table, so it is recommended to solder several practice joints first. After this, you can assemble all possible nodes with short sections in a convenient position. Next comes the laying of highways with the connection of tees in place, here it will be more difficult. A heated iron for soldering will need to be put on one side of the laid pipe, and the tee will need to be pulled on the other side, holding the device suspended. Then the soldering iron is removed from both parts and they are joined.
Paving main pipelines, follow the order of installation of sections and elements. Start assembling the system from the heat source and go to the end, and to connect two polypropylene pipes, try to use only tees, from which branches will go to the batteries. Use couplings for this purpose when it is impossible to do otherwise. Avoid joints in hard to reach places, otherwise to complete them you will have to work with two soldering irons at once in order to simultaneously heat the parts being connected.
Advice. Many manufacturers of polypropylene systems develop their own instructions for installing their products. You can get a lot of useful information from there, take advantage of it.
How to connect a metal-plastic pipe with a polypropylene pipe
Due to various circumstances, it happens that it is necessary to connect different kinds pipes, for example, PPR and steel, metal-plastic with polypropylene and so on. Such situations happen in apartments where it is difficult to change a section of a common water supply or heating riser laid with a steel or metal-plastic pipe, but you need to connect to it. This is not a big problem, you just need to take into account that all such connections are made through threaded fittings.
Since the connection is metal plastic pipes can be carried out using press and collapsible fittings, then for joining with polypropylene it is more convenient to take a detachable fitting with external thread. In turn, a fitting with an external thread is soldered to the end of the polypropylene pipe, after which the connection is twisted traditional way, with winding of flax or fum tape.
When you need to cut into metal-plastic pipes, it is most convenient to install a tee with a threaded outlet, where you can subsequently screw the fitting, and then solder the polypropylene pipe to it. True, you will have to tinker with the installation of the tee: you need to turn off the water or empty the heating system, and then cut the metal-plastic and carry out the installation.
Conclusion
It should be noted that working with polypropylene pipes is not the most difficult task, although it requires concentration, attention and patience. Even if you spend three times as much time on the process as experienced professionals, you will do everything for yourself with high quality, and most importantly, for free.
