Project Overview
The Utilities Department replaced process pipework used to transfer 96% sulphuric acid.
The highly corrosive chemical required a pipework system with reliable joints and strong chemical resistance. The team also needed a joining method that would provide consistent results and support quality control.
For this project, the team selected GF IR PVC-U technology and used the IR-63 M infrared fusion machine. This system creates controlled fusion joints without using traditional solvent cement.
The technology also records key welding data. This gave the team greater control and traceability throughout the installation.
Project Objective
The main objective was to replace the existing 96% sulphuric acid pipework with a reliable system designed for the chemical service.
The project also aimed to remove the need for traditional solvent-cemented joints. IR PVC-U technology uses infrared heat to join PVC-U pipework without chemical adhesive at the joint.
Quality and traceability were also important requirements. The IR-63 M controls the welding process and produces a record for each fusion.
This allows the team to identify individual joints and link them to their welding records.
Project Detail
Pipe Preparation
The team secured each pipe section in the IR-63 M using the correct clamping inserts.
They then used the machine’s built-in planer to face the pipe ends. This created flat and parallel surfaces ready for fusion.
The team cleaned each prepared surface using lint-free wipes and an approved cleaning agent. This removed dust, fingerprints and other surface contamination.
Infrared Heating
The IR-63 M positioned a non-contact infrared heater between the prepared pipe ends.
The machine controlled the heating cycle and applied the required energy to the PVC-U surfaces. Because the heater does not touch the pipe ends, it reduces the risk of contamination during heating.
Joining and Fusion
After completing the heating cycle, the machine retracted the infrared heater.
It then brought the heated surfaces together under controlled fusion pressure. The machine manages this process to produce consistent and repeatable joints.
Controlled Cooling
The machine kept each joint securely clamped during the cooling cycle.
This protected the newly formed joint from movement while it cooled. Once the controlled cooling period ended, the team could remove the completed joint from the machine.
Weld Traceability
The IR-63 M created an individual record for each completed fusion.
The team used these records to support project quality control and joint traceability. This provided documented evidence of the fusion process for the completed installation.
Project Outcome
The project delivered a PVC-U pipework system for the transfer of 96% sulphuric acid using infrared fusion technology.
The installation removed the need for traditional solvent cement at the fused joints. It also gave the team a controlled and repeatable joining process.
Digital welding records provided additional traceability for the completed joints. This supported the project’s focus on safety, quality and long-term reliability.
