Formular

F-AWT 126 AGRU–Kunststofftechnik GmbH

Training Program

For hot gas string bead- hot gas extrusion- and hot wedge welding* for Concrete Protective Liner

According to this training program a confirmation for hot gas string bead- hot gas extrusion- and hot
wedge welding technology can be issued. The training consists of a theoretical and practical part and will
be confirmed by issuing a certificate.

Introduction
 Duration of the training:
8 hours for 5 - 7 participants (for material HDPE or PP**)
 Participants:
o Installation company
o QA / QC
o End user
 Objectives:
The participants should...
o Be able to do a welding alone.
o Understand the materials and parameter.
o Be able to do a visual control of the weld and be able to evaluate the result.
o Be able to handle and operate the machine and protect it from environmental impacts.
 Exam:
The exam consists of a theoretical and a practical part. During the manufacturing of the test
specimen the participant has to inspect, adjust and operate the welding machine unassisted. The
trainer fills in the check list and checks the test specimen. A confirmation will only be handed
out after a successful exam.

Content
1. Basics in material
 Knowledge about weldable materials (HDPE or PP):
o Finger nail test
o Flammability test
o Smell test
 Same dimension, wall thickness, material
 Marking of components

*
acc. to current valid DVS standard
** hot wedge welding method is only applicable for HDPE CPL up to max. 3.0mm wall thickness
Erstellt: Eitzenberger P Rev. 001 Dokumenten ID: 31321 Seite 1 von 3 Freigabe:
Gruber, Ing.
E. -
ge@agru.at
 Formular
F-AWT 126 AGRU–Kunststofftechnik GmbH
Training Program

Content
 Safety instructions:
o Beware of hot gas Fan. Do not touch the heated up surfaces
o Beware of moving parts. Do not touch into the running machine
o Be careful when lifting heavy loads. Do not go under the load
o Beware of overheated material
o Beware of electrical parts and wires under power

2. Tool set-up
 Packaging
 Check
o Is the machine complete (machine + all accessories like nozzles/welding shoes)
o Check of the machine on visual damages
o Sufficient power supply according to the specification of the manual of the specific
machine
o Component description
o Hot gas temperature/Plasticized Material Temperature
 Welding location (weather, in workshop, on site, inside of a tank…)
 Mechanical check (only weld the same material type)
 Choosing and change the right nozzles or welding shoes for different welding geometrics
 Sheet support/clamping (to avoid moving of the sheets during welding, …)
 Welding groove preparation acc. DVS 2207-4
 Scrapers for removing the oxidation layers

3. Welding process
 Welding tool configurations
o General information (power supply, start up, description of the welding method,
explanation of the parameters, …)
o Configuration of the welding equipment, hot gas temperature, temperature of Plasticized
material, environment; , material, dimensions,
o Hot gas (on/off switch, voltage, ampere, required and current temperature, environment
temperature, …)
o Hot wedge (on/off switch, voltage, ampere, required and current temperature, setting of
correct welding pressure, environment temperature, …)

 Operating of the welding machine

o Machine description
o Difference in output amount of plasticised material
o Difference in corner welds/ straight welds
o Alignment / offset
o Wind and dust protection
o Pre heating of the sheet material
o Cooling time ( PP covered)
o Visual control (inspection acc DVS DVS 2202/ DVS 2225/ DVS 2227, documentation,
…)
o Check of the welding parameter, Welding protocol, GPS data…
Erstellt: Eitzenberger P Rev. 001 Dokumenten ID: 31321 Seite 2 von 3 Freigabe:
Gruber, Ing.
E. -
ge@agru.at
 Formular
F-AWT 126 AGRU–Kunststofftechnik GmbH
Training Program

Content

4. Quality control
 Explanation of the welding parameter)
 Inspection of previous welds
 Visual control of the weld according to DVS 2202/ DVS 2225/ DVS 2227
 High voltage spark test (DVS 2227)
 Hot wedge welding seam test by compressed air (DVS 2225)
 Weld identification, documentation (welding protocol)
 Special instruction of welding joint evaluation to Quality Controllers (QC)
 Check of legal certification and welder cards by the QC.
5. Maintenance
 Proper storage (transport, storage, complete equipment, …)
 Cleaning of the machines and accessories
 Hot gas fan cool down before switch off
 Maintenance intervals (see manual), only actual maintained machines must be used (see
maintenance interval in the manual)
 Trouble shooting
6. Considerations for the operation
The following aspects concerning transportation, storage and handling have to be taken into
consideration:
 Avoid wind (protect welding zone)
 No moisture, dust (outdoor installation - tent, …)
 Welding limited by the environment temperature (see manual)
 Protection of the machine (site, placement - parts of the machine must not fall down, turn over,
etc., not allowed operation, power supply, …)
 Support of heavy loads to avoid stress/ cracks in the welding area
 Always store the machine and the material at the same place (dew point).

7. Recommendations / miscellaneous
 Electronic equipment (careful handling, power supply, …)
 Cleaning of the parts to be welded (e.g. Tangit or IPA) after the scraping process. Hazard of
residues.
 Cleaning of the machine with dry towels only (never when the machine is hot!!)
 Perform a test welding prior to the first job welds. Visual control of the weld
 Read instruction manual of machine and fittings
 Hot gas string welding must be removed the Oxidation layer also on the filler/welding rod

AGRU Kunststofftechnik GmbH wishes an interesting and successful welding training.

Erstellt: Eitzenberger P Rev. 001 Dokumenten ID: 31321 Seite 3 von 3 Freigabe:
Gruber, Ing.
E. -
ge@agru.at