Our PP-RCT Piping System

MECHANICAL PP-RCT pipe systems. Outstanding performance over many years.

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Easy installation

Socket welding with a hand welder

1. The welding machine should be equipped with the appropriate Teflon-coated welding tools. To avoid damaging the Teflon coating, do not use pliers or other sharp-edged tools for assembly. Please use a suitable hexagon spanner.
2. Switch on the welding device.
3. Check the welding temperature with a thermometer or a temperature control pen before you start welding.
4. The ends of the pipes must be cut straight. Use suitable pipe shears or a pipe cutter. Pipes, fittings and welding tools must be clean. If necessary, clean them with a lint-free cloth and PP/PE cleaner (ethanol-based).
5. Fitting and pipe are placed quickly and axially, without twisting, onto the corresponding welding tools. The parts to be welded are then heated without pressure in accordance with the table.
6. After the required heating time, the fitting and pipe are quickly removed from the heating element and immediately connected without twisting, until the insertion depth or markings are reached. The line markings on the fittings and pipe ensure that the pipes are correctly aligned.
7. Observe the cooling time of the connection.
8. Clean the welding tools if necessary.

Socket welding with a hand welder (from 40 mm)

1. Check the machine: Determine the welding depth setting the dimension on the device; ensure that the welding temperature is reached.
2. Fix the moulded part with the clamp and take care not to clamp it too tightly, as this can lead to ovality, which has a negative effect on the resulting weld seam. Ensure that the moulded part is positioned correctly. Use counter-tensioning to prevent possible slippage.
3. Insert the pipe loosely into the jaw chuck.
4. Set the dimension using the rotary knob to set the exact welding depth.
5. Push both tools together as far as they will go.
6. Push the pipe up to the fitting, then tighten. Ensure that the welding partners are precisely aligned. Open the welding tool.
7. Insert the welding tool. Slowly push the fitting and pipe into the device as far as it will go using the crank handle. Pay attention to the welding time.
8. The welding time starts when the pipe and fitting are tightly joined. Allow them to heat up without applying any further pressure. Once the heating time has elapsed, the tools are moved apart, the welding device is removed and the fitting and pipe are joined together.
9. Observe the required cooling time.

Weld-in saddle

1. Prepare the material and tools before starting work. Make sure that the welding saddle, the drill and the welding tool have the same diameter.
2. Expose the pipe exactly where the welding saddle is to be welded and mark the welding area. Empty existing pipes and release the pressure.
3. Prepare the welding machine and the saddle welding tools and heat it up to operating temperature (250-270° C).
4. Drill through the marked pipe wall with the POLYMELT hole saw and clear the drill hole of swarf.
5. The parts and areas to be welded must be clean and dry.
6. Insert the welding tool with a suitable and aligned saddle tool into the hole in the pipe wall until the tool reaches the stop position. At the same time, the welding saddle must be pushed in until the saddle surface reaches the curvature of the tool.
7. The heating time for the pipe and saddle depends on the bead formation, but is at least 25 seconds.
8. Once a welding bead has formed on both parts to be joined, remove the welding device and push the heated welding saddle straight into the heated bore as far as it will go without turning it.
9. After a cooling time of at least 10 minutes, the joint is fully loadable.

Butt welding from 160 mm

1. Protect the workplace from the effects of the weather and dirt.
2. Heat up the welding machine and check that it is working properly.
3. Cut the pipes at right angles to the required length.
4. Align the pipes and tighten the clamping elements.
5. Plane/straighten the front of the pipes evenly and uniformly using a milling cutter.
6. Remove chips and clean the front side with ethyl alcohol.
7. Observe pipe offset (max. 0.1 × wall thickness).
8. Join the pipes and check for a flat joint (maximum tolerance 0.5 mm).
9. Set the joining pressure (see corresponding table in the operating instructions for the welding machine).
10. Check welding temperature (210° C).
11. Check that the heating element is clean before each work step.
12. Initiate the welding process swivelling in the heating element and press the pipes onto the heating element with joining pressure.
13. Once the bead height has been reached, the pressure is reduced. This is the start of the heating time, which brings the pipe ends to the desired welding temperature.
14. Once the heating time has elapsed, quickly remove the heating element and bring the pipes together with the required pressure.
15. The pipes are now welded and cool down under pressure.
16. The welded joint may only be loosened or removed from the clamps after the prescribed cooling time has elapsed.