Electrofusion 90° elbows symbolize advances in the technology of joining polyethylene pipes; a fitting that, relying on engineering design, embedded copper conductors, and shape-memory PE100 plastic, creates a precise, tight, and stable elbow for changing the flow direction at a right angle. This component is manufactured in accordance with ISO 17855, EN 12201 (water), and EN 1555 (gas), and thanks to SDR11 (or SDR17 if needed) it can withstand working pressures up to 16 bar at 20 °C. High chemical resistance, a service life of more than 50 years, and ease of installation with barcode-reading control boxes are the main reasons for this elbow’s popularity in urban, industrial, and agricultural projects.
Electrofusion mechanism and key advantages
In electrofusion, heat is uniformly generated by the copper coil embedded inside the fitting body, melting the inner layer of the fitting and the outer surface of the pipe; thus the polyethylene of both parts integrates in the joint area and, after cooling, produces a homogeneous weld that is seamless and leak-tight. The absence of open flame, high (second-by-second) control precision, reduced human error, and the ability to log welding data (Data-Logging) have made electrofusion the first choice for critical gas distribution lines and high-quality water networks.
Sample dimensional and technical specifications in SDR11
| Outside diameter (mm) | Wall thickness (mm) | Nominal pressure PN (bar) | Fusion energy (kJ) | Cooling time (s) |
|---|---|---|---|---|
| 25 | 3.0 | 16 | 1.4 | 90 |
| 32 | 3.0 | 16 | 1.8 | 110 |
| 63 | 5.8 | 16 | 4.5 | 240 |
| 90 | 8.2 | 16 | 8.0 | 420 |
| 110 | 10.0 | 16 | 10.2 | 520 |
| 160 | 14.6 | 16 | 18.5 | 780 |
| 200 | 18.2 | 16 | 26.0 | 1 050 |
| 250 | 22.7 | 16 | 39.0 | 1 320 |
| 315 | 28.6 | 16 | 56.5 | 1 740 |
Practical installation steps
- Accurate cutting and beveling of the pipe with a dedicated saw or polyethylene guillotine.
- Scraping the oxidized layer to a depth of 0.2 mm in the weld area.
- Cleaning with 99% isopropanol and a lint-free wipe.
- Marking the insertion depth to ensure the pipe is fully seated in the fitting.
- Clamping with a centering clamp to minimize misalignment.
- Connecting cables, scanning the barcode, and running the fusion cycle per factory data.
- Cooling without movement until the end of the cooling time, then releasing the clamp.
- Hydrostatic pressure test at least 1.5× the system operating pressure before commissioning.
Quick comparison of joining methods
| Indicator | 90° electrofusion | Angled butt fusion | Threaded metal fitting |
|---|---|---|---|
| Required working space | Low (half the pipe radius) | High (two pipe diameters) | Medium |
| Long-term leak risk | Very low | Medium | High |
| Data traceability | Yes (Log) | No | No |
| Corrosion resistance | Complete | Complete | Limited |
| Installation speed in small diameters | High | Low | Medium |
| Compatibility with explosive environments | Excellent (no flame) | Poor | Poor |
Specialized applications
- Urban and rural gas distribution: reduces incident rates and repair costs.
- High-pressure potable-water transmission lines: permanent sealing and resistance to water hammer.
- Mechanized irrigation and pressurized systems: minimal head loss and long life in corrosive environments.
- Mineral slurry and industrial wastewater transfer: higher wear and chemical resistance than metal alternatives.
- Firefighting networks and cooling towers: works with frequent on/off cycles.
- Power plant and petrochemical infrastructure: safety near heat sources without sparks or open flame.
Tests and quality certificates
- Partial-melt test and Peel test for weld penetration depth.
- Short Time Hydraulic burst pressure per ISO 1167.
- 3D scan analysis to check internal coaxiality.
- Approval from Iran’s gas authority for sizes 20 to 315 mm.
- NSF/ANSI 61 sanitary compliance certificate for potable use.
Storage and handling instructions
Store parts in the shade, on flat pallets, away from direct sunlight, mineral oils, and open flame. During handling, use soft or padded hooks so that no scratches or impacts are applied to the weld area.
Tamam Baha, as one of the selected suppliers of Sorena Pipe polyethylene fittings, stocks the full range of 90° electrofusion elbows in all commonly used sizes and—together with other vendors—provides swift delivery, authenticity assurance, and technical support during installation for contractors and consultants. At the same time, our competitive pricing policy and multi-brand options give buyers the freedom to choose the best solution for their budget and project specifications—making it a practical choice for English-speaking teams working with regional projects.
