With snapfuse® you set new standards in pipeline construction

STAR Engineering Systems (SES), a subsidiary of the STAR Piping Group, presents snapfuse®, a revolutionary solution for PE pressure pipe connections - extremely durable, highly efficient and superior to conventional methods.

Joining pipes has never been so easy.

snapfuse®

Based on our extensive patent portfolio, snapfuse® offers exceptional durability, unmatched efficiency and a superior alternative to traditional joining methods.

SES offers a complete solution - from proprietary manufacturing capabilities to the precise formulas and adjustments required to consistently produce DIN EN 12201-3 compliant, tested products.

Table of contents:

Find out more about snapfuse® in our video

Watch the video on YouTube

Conventional welding techniques vs. snapfuse®

Polyethylene (PE) pipes are widely used in various applications due to their flexibility, durability, and resistance to corrosion among other environmental benefits. Its market is expanding and material innovations makes its application range defying other conventional materials. The adoption of PE pipes has increased since the 1950s, with standards and manuals developed to guide their implementation.

Among the methods of joining PE pipes, Butt Fusion Welding and Electrofusion Welding stand out as the most efficient and reliable techniques. Let’s delve into these techniques and introduce snapfuse® a novel welding technology that promises to enhance the process further.

Butt Fusion Welding

Butt fusion welding is a process used to join two pieces of PE pipe end-to-end using heat and pressure. This method ensures a strong and homogeneous joint, making it a popular choice for creating long, continuous runs of pipe.

The Butt Fusion Process:

1. Preparation

The pipe ends are cut cleanly and squared off to ensure proper alignment. The surfaces to be joined are then cleaned to remove any contaminants.

2. Heating

The prepared pipe ends are brought into contact with a heating plate, which is heated to a specific temperature, causing the pipe ends to soften and melt.

3. Joining

Once the pipe ends are adequately melted, the heating plate is removed, and the pipe ends are pressed together under controlled pressure.

4. Cooling

The pressure is maintained while the joint cools down and solidifies, forming a strong, leak-proof bond.

Benefits of butt fusion welding:

Strong and Reliable Joints: The process creates a homogeneous weld that is as strong as the original pipe material, ensuring long-term durability and resistance to leakage.
Versatility: Suitable for a wide range of pipe diameters and can be used for both low and high-pressure applications.
Cost-Effective: While requiring specialized equipment, the overall cost of butt fusion welding can be competitive, especially for large-scale projects.
Environmentally Friendly: The process does not involve the use of harmful chemicals or adhesives, and it doesn’t involve extra parts.
Consistent Quality: When performed correctly, butt fusion welding produces joints with consistent strength and reliability.
No Weak Points: The welded joint when performed correctly creates a seamless connection, eliminating potential weak points in the piping system.

Limitations of butt fusion welding:

Time-consuming process: Compared to other joining methods, butt fusion welding requires more time to complete due to the heating, cooling, and pressure application phases.
Requires specialized equipment: The process necessitates the use of specific welding machines, which can be costly to purchase or rent. This disadvantage becomes extreme as the pipe diameter gets bigger.
Skill-dependent: The quality of the weld is heavily reliant on the operator’s skill and experience. Inconsistent welding can lead to joint failures.
Environmental sensitivity: Extreme weather conditions (e.g., cold temperatures) can impact the welding process and the quality of the joint.
Energy consumption: Cold weather can make the preheating phase of the heating plate extremely challenging, making the temperature control impossible, due to heat convection.
Site constraints: In some cases, the welding process may be difficult to perform due to space limitations or accessibility issues.
Joint preparation: Proper pipe end preparation is crucial for a successful weld, which can be time-consuming and requires attention to detail on site.
Internal and external bead formation: Internal bead can cause flow problems in some application, debeading operations after welding is an extra cost.

Electrofusion Welding

Electrofusion welding is a method of joining PE pipes using specialized fittings with built-in electric heating elements. This technique is particularly advantageous in situations where space constraints or difficult on-site conditions are present.

The Electrofusion Process:

1. Preparation

The pipe surfaces to be welded are cleaned and prepared to ensure optimal fusion. This involves scraping the pipe surface to remove the oxide layer and contaminants.

2. Heating

The cleaned pipe ends are inserted into the electrofusion fitting. An electrical current is then applied to the heating elements within the fitting, causing the surrounding polyethylene to melt and fuse with the pipe surfaces.

3. Cooling

The assembly is held stationary during the cooling phase to allow the molten materials to solidify and form a strong, leak-proof joint. External clamps are used to prevent movement during this critical phase.

Benefits of Electrofusion Welding:

Versatility: It is ideal for use in confined spaces and challenging conditions where traditional methods may be impractical.
Reliability: The resulting joints are strong and leak-proof, ensuring long-term system performance.
Ease of Use: The process is straightforward and can be performed with minimal equipment, making it accessible for various applications.

Limitations of Electrofusion welding:

Higher Cost: Electro couplers represents a considerable cost specially when it comes to diameters exceeding 630mm.
Extra logistic costs: Electro couplers are bulky and needs space for transportation specially for large dimensions.
Joint Preparation: Proper preparation of the pipe and fitting surfaces is essential for a successful weld, which can be time-consuming.
Ovality challenge: it is challenging to compensate pipes ovality to fit the perfectly round electrofusion coupler, the challenge becomes extreme on big dimensions, where re rounding clamps reach their limits.

Introducing a Novel Welding Technique:

snapfuse®

To further enhance the efficiency and reliability of PE pipe welding, we introduce snapfuse®, a novel welding technique that combines the best features of both butt fusion and electrofusion.

snapfuse® is your go-to for pressure class applications, offering unmatched reliability and performance. Meanwhile, snapfuse®Lite is a mature technology that has been on the market for more than 5 years with a list of successfully executed projects in Europe. Suitable for non-pressure applications such as cable protection, sewage and water to name a few.

Our patented technology integrates a heating element at one end of the pipe, removing the need of extra parts and streamlining the connection process like never before. Particularly interesting for large diameters, snapfuse® electrofusion welding becomes a breeze, ensuring seamless connections and proven reliability.

snapfuse® welding Process:

1. Preparation

Remove the packaging and press the pipe ends together until they fit.

2. Heating

An electrical current is then applied to the heating elements within the fitting, causing the surrounding polyethylene to melt and fuse the two pipe ends.

3. Cooling

The assembly is held stationary during the cooling phase to allow the molten materials to solidify and form a strong, leak-proof joint. The snapping mechanism locks the two pipe ends in place, guarantying stability during the welding phases.

Benefits of snapfuse®

Norm conformity: snapfuse® is conform to EN 12201-3, and has successfully passed a battery of both pressure and strain tests.
Independent of pipe ovality: the geometry of the machined pipe ends offers flexibility to meet the challenge of ovality and achieve a perfect fit, whatever the ovality.
Versatility: Suitable for a wide range of pipe diameters (OD250mm up to OD3500mm) and can be used for both non-pressure application (snapfuse® lite) and high-pressure applications (snapfuse®). It is ideal for use in confined spaces and challenging conditions where traditional methods may be impractical
Cost-Effective: Requires a standard DC inverter as of electrofusion, no additional shipping costs for extra parts, Short setup time on site no oxide layer scraping, easy pipe alignment, less manpower involved on site.
Environmentally Friendly: practical on tight tranches, needs less excavation and earth works, less transportation of excavated material, no additional CO2 footprint due to transportations, the pipes are all you move.
Consistent Quality: snapfuse® produces joints with consistent strength and reliability, with no risk of axial or angular misalignment.
No Beads: The welded joint creates a seamless connection, assuring perfect laminar flow.
Reliability: The resulting joints are strong and leak-proof, ensuring long-term system performance.
Ease of Use: The process is repeatable and straightforward and can be performed with minimal personnel training, making it less operator sensitive.

Conclusion

Both Butt Fusion Welding and Electrofusion Welding are essential techniques for joining PE pipes, each offering unique advantages.

However, with the introduction of snapfuse®, the industry can now benefit from a new technology that combines the best aspects of both processes.

This innovative technique promises to set new standards in PE pipe welding, ensuring stronger, more reliable, and efficient joints for a wide range of applications.

snapfuse® FAQ:

In what situations is snapfuse® particularly advantageous?

snapfuse® offers significant advantages, particularly for large-diameter PE pipes: Its versatility allows for integration across a wide range of pipe sizes, from OD250mm to OD3500mm. However, it truly shines in larger diameters where traditional methods often face challenges.

Unlike conventional techniques, snapfuse® requires no additional equipment or components, significantly reducing logistical costs. Furthermore, it addresses the common issue of pipe ovality, which becomes more pronounced in larger diameters. This, combined with the potential cost and availability constraints of large-diameter couplers, makes snapfuse® a compelling choice.

How does snapfuse® address the challenges of pipe ovality compared to traditional welding methods?

Pipe ovality limit by norm (DIN EN 12201-2 table 01/ ISO 4427-2 Table 1) is XXX for large diameter it can reach XXX. While traditional methods like butt fusion and electrofusion rely on workarounds (Re rounding systems) that can introduce stress or compromise weld quality, snapfuse® addresses the issue directly.

snapfuse®’s innovative design incorporates a machined profile on the sleeve end of the pipe, enhancing its flexibility and allowing it to adapt to irregularities in shape. This, combined with the snapping mechanism that applies uniform pressure during the welding process, ensures a secure and reliable connection, even when dealing with oval pipes.

What are the typical installation time savings achieved with snapfuse® compared to butt fusion and electrofusion welding?

The answer is highly dependable on pipe diameter and the conditions on-site, here is a qualitative comparative of the main steps of the installation process.

STAR-Engineering-Systems-Grafik-snapfuse-savings

What are the tests that snapfuse® joints did pass?

A pipe after the wire integration operation is considered as a fitting, and thus is subject to DIN EN 12201-3. So far, an OD 630mm SDR 17 pipe has passed the 1000h 80°C water in water pressure test at 6,3Bar successfully.

A burst test has been performed and showed that the burst area happened at the level of the pipe and not at the joint level.

We are currently amending an external test lab as a third-party testing organism for snapfuse® development.

Is it possible to integrate snapfuse® in fittings?

Indeed, snapfuse® works for pipes as well as for fittings, the fitting design should include enough material to plow the wire and you have a plug and play integrated solution.

The Horizontal Wire plowing machine HWP

For the production of snapfuse®, STAR Engineering Systems offers a machine designed for performance and durability. This model embodies German engineering with a focus on precision, reliability and high-quality workmanship. It sets new standards in the production of PE pipe joints.

To the HWP