Maya Ellison
There are several methods for welding plastic pipes together. The most common approach is solvent welding, which involves using solvent cement to chemically weld the pipes. This method is simple, reliable, and requires no special tools. Another technique is heat welding, which can be done with a soldering iron or a hot air fan welder. Friction or ultrasonic welding is also an option, where friction is used to heat and fuse the pipes. Additionally, extruded bead welding involves applying hot plastic between the pipe sections, while hot gas welding uses heat guns to soften the join surfaces. For small repairs, a simple soldering iron may be sufficient. It is important to note that only plastics of the same type can be welded together, and the welding process must be carefully executed to ensure a durable and secure bond.
| Characteristics | Values |
|---|---|
| Types of welding | Friction or ultrasonic welding, extruded bead welding, hot gas welding, hot plate welding, laser welding, induction welding, solvent welding |
| Tools required | Soldering iron, hot air fan welder, handheld extrusion welder, heat guns, hot plate, laser, conductive metal piece, high-frequency generator |
| Plastic types | HDPE, PVC, CPVC, PVDF, ABS, PE, PP, polystyrene |
| Welding process | Heating and/or melting the material at the join surfaces, pressing the pieces together, allowing them to cool and bond at the molecular level |
| Advantages | Bonds material without requiring mechanical fasteners or adhesives, joins materials that are difficult to bond with solvent, assembles components with complex geometries or unusual bonding angles, forms an airtight seal, creates joined assemblies without adding significant weight |
| Disadvantages | PVC releases toxic gas when heated to melting point, solvent fumes are obnoxious and carcinogenic |
| Best practices | Use solvent cement and primer, ensure proper ventilation, wear gloves and goggles, cover the work surface, wipe off excess cement, finish with plumber's tape |
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What You'll Learn
Use a hot air fan welder
Welding plastic pipes together can be achieved using a hot air fan welder. This method is inexpensive compared to a handheld extrusion welder, which is commonly used by welding shops. A hot-air fan welder can be purchased at a much lower price, making it a more cost-effective option for occasional welding projects.
To use a hot air fan welder, it is important to ensure that both the welding rod and the plastic surfaces to be welded are heated sufficiently. This allows the surfaces to reach a level of fusion necessary for a durable and secure weld. For thicker plastic sheets, a thicker welding rod is recommended to achieve the desired level of fusion.
When welding thick sheets of plastic, it is recommended to allow each weld seam to cool completely before creating a new weld on top of it. This helps ensure that the welds are strong and secure. Any protruding or overflowing welds can be removed later with a cutter knife or a sanding block to create a flat, flush weld.
The hot air fan welder is a suitable option for welding plastics, offering good results and making it a convenient choice for those who need to weld plastic pipes together.
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Prepare the area and wear PPE
Welding plastic pipes can be a potentially dangerous task, so it is important to take the proper precautions to prepare the area and protect yourself. First, ensure that you are working in a well-ventilated area. If you are welding PVC, the fumes can be obnoxious and carcinogenic. Cover your work surface with paper towels or something similar, as cement can get everywhere.
Next, put on your personal protective equipment (PPE). Gloves and goggles are essential when working with solvents or other chemicals. Gloves will protect your skin from the cement, which can be difficult to remove and can cause skin discolouration. Goggles will protect your eyes from any fumes or debris. Depending on the type of welding, you may also want to wear a mask to protect your lungs from inhaling smoke or fumes.
Finally, ensure that you have all the necessary tools and materials within easy reach. This includes your welding equipment, as well as any solvents, cements, or primers you will be using. If you are using a hot air fan welder, a soldering iron, or another heat-based method, make sure you have a way to safely contain and control the heat, such as a heat-resistant mat or similar.
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Choose the right solvent cement
When welding plastic pipes, choosing the right solvent cement is critical. The first step is to determine the type of plastic pipes you are joining. For instance, if you are working with PVC (Polyvinyl Chloride) pipes, you should select PVC cement. Similarly, ABS (Acrylonitrile Butadiene Styrene) pipes require ABS cement, and CPVC (Chlorinated Polyvinyl Chloride) pipes require CPVC cement. This compatibility between the cement and pipe material is essential for a successful chemical fusion.
The size of the pipes is another crucial factor in choosing the right solvent cement. Larger pipes necessitate a cement with higher viscosity or thicker consistency. Regular, medium, and heavy-bodied cements are available, and the maximum recommended pipe size is usually indicated on the cement packaging. For example, if you are working with a 6-inch diameter pipe, a medium-bodied cement is suitable, whereas an 8-inch pipe would require a heavy-bodied cement.
The application site conditions, such as temperature and humidity, should also be considered when selecting solvent cement. If you anticipate working in temperatures below 40°F, opt for a cement formulated to cure in such conditions, like Oatey's All Weather Cement. Conversely, if you're working in damp conditions, choose a cement designed for wet applications, like Oatey Rain-R-Shine or one of their Lava cut-in cements.
Additionally, consider whether you are working on a potable water system or a non-pressure DWV (drain, waste, and vent) system. For potable water systems, select a cement suitable for this purpose, ensuring it complies with relevant codes and standards. For example, FlowGuard Gold 1-Step Yellow Cement is ideal for CTS (Copper Tube Size) cold and hot potable water pipes.
Finally, pay attention to the specific manufacturer guidelines for the solvent cement you choose. These guidelines will provide important information on application methods, drying times, and any safety precautions you should take during the welding process.
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Apply the cement and primer
When welding plastic pipes, it is important to ensure that the welding rod and the plastic surfaces to be joined are sufficiently heated to achieve a durable and secure weld. There are several welding methods available, including friction or ultrasonic welding, extruded bead welding, hot gas welding, hot plate welding, laser welding, and induction welding. However, one of the most common methods for joining plastic pipes is solvent welding, which involves using solvent cement and primer to create a strong and permanent bond.
To apply the cement and primer for solvent welding, follow these steps:
Prepare the Workspace: Before beginning, ensure you are in a well-ventilated area as solvent welding can release obnoxious and potentially harmful fumes. Cover your workspace to protect it from any excess cement, and have paper towels readily available to quickly clean up any messes. It is also recommended to wear gloves and goggles for safety.
Open the Primer: Start by opening the can of primer, which is typically purple but can also be clear. If it is your first time opening the can, you may need a pipe wrench to break the seal. The applicator is usually attached to the lid.
Apply the Primer: Dip the applicator into the primer and allow any excess to drip off. Thoroughly cover all surfaces that will be welded, being careful to avoid any runs or drips. Primer chemically softens the plastic surfaces, allowing the glue to penetrate and creating a stronger bond. You can prime multiple fittings ahead of time, as long as they remain clean before cementing.
Choose the Right Cement: Select a solvent cement specifically designed for the type of plastic pipe you are working with, such as PVC or CPVC. Using the wrong type of cement can lead to unsatisfactory results. Ensure the cement is compatible with the pipe diameter and installation conditions.
Apply the Cement: Using an applicator that is at least half the width or length of the pipe's diameter, apply the solvent cement to the prepared surfaces. Work quickly, as the cement will start to eat away at the PVC if left too long. The cement temporarily softens the pipe and fitting surfaces, creating a cross-molecular bond that results in a strong and permanent joint.
Clean Up Excess: Wipe off any excess cement immediately. If cement dries on your skin, it will peel off, but it is best to avoid prolonged skin contact. Use paper towels to clean up any spills or messes.
By following these steps for applying cement and primer, you can effectively solvent-weld plastic pipes together, creating a secure and long-lasting joint.
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Smooth the surface
When welding plastic, it is important to smooth the surface of the repaired area. This can be done using a hot soldering gun or iron. For simple repairs, a simple soldering iron is often sufficient. However, it is important to note that this is not recommended for proper welding seams. A more inexpensive option is a hot air fan welder, which can be purchased for a much lower price than a handheld extrusion welder.
To smooth the surface of the repaired area, run the soldering gun or iron over the repaired area until the plastic is melted and smooth. Be sure to wear proper protection, such as a mask and gloves, as the smoke that will emerge from the gun tip can be hazardous to your lungs. Allow the repaired area to cool off before handling.
If using a soldering iron, it is recommended to use a power range of 50W to 75W. A flat face tip is also suggested if possible. Before beginning the welding process, it is important to pre-warm the area to be repaired using a heat gun on a low heat setting. This will help to ensure a smooth finish.
After welding, it is important to check for leaks and seal any gaps with plumber's tape. Start by rolling the tape around the pipe, beginning one to two inches before the repaired gap area, and finish one to two inches past the repaired gap area. When applying the tape, overlap by half the tape's width on each turn around the pipe.
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Frequently asked questions
Friction or ultrasonic welding uses friction to heat and fuse two pieces of PVC together. Extruded bead welding involves the application of hot plastic between two sections of PVC. Hot gas welding uses heat guns to soften a filler rod and the join surfaces on the PVC pieces before they are pressed together. Hot plate welding employs a heated metal plate to heat the join surfaces before they are pressed together. Laser welding utilizes a laser to heat the join line between two pieces of PVC as they are held together. Induction welding involves the placement of a conductive metal piece between the two pieces of PVC and heating it with a high-frequency generator. Solvent welding uses chemicals and plastic resins to weld plastic pipe and fittings.
PVC welding can bond materials without requiring mechanical fasteners or adhesives, helping to reduce material and equipment costs. It can join materials that are difficult to bond with solvent. It can assemble components with complex geometries or unusual bonding angles. It can form an airtight seal. It can create joined assemblies without adding a significant amount of weight.
A hot air fan welder is most suitable for welding plastics as it is inexpensive and effective. For simple repairs, a simple soldering iron is often sufficient. For thicker sheets of plastic, a thicker welding rod is recommended.
First, find a well-ventilated area and cover the surface you are working on. Put on gloves and goggles. Open the can of primer and use an applicator to cover each surface to be welded. Then, apply the solvent cement with an applicator. Finally, press the pieces together and wipe off any excess cement.
