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January 2009

DVS – DEUTSCHER VERBAND Welding of thermoplastics

FÜR SCHWEISSEN UND Heated tool welding of pipes, piping parts Technical Code
VERWANDTE VERFAHREN E.V. and panels made of PVC-U DVS 2207-12

R&D INTAKE MANIFOLDS Translation of the German edition from December 2006

Contents: heated tool butt welding of panels as well as to pipeline

construction.
1 Scope of application
The machines and jigs used for the welding must comply with the
2 General requirements
requirements in DVS 2208-1.
3 Measures before the welding
3.1 Prerequisites for the welding
3.2 Cleaning 3 Measures before the welding
3.2.1Cleaning agents
3.2.2Cleaning of the heated tools 3.1 Prerequisites for the welding
3.2.3Cleaning of the joining faces
4 Heated tool butt welding of pipes, piping parts, fittings and The immediate welding area must be protected from
panels unfavourable weathering influences (e. g. wind or the action of
4.1 Process description moisture). If suitable measures (e. g. preheating, tenting or
4.2 Preparation for the welding heating) ensure conditions permissible for the welding, the work
may be carried out at any outdoor temperature – provided that
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

4.3 Execution of the welding

5 Testing of the welded joints
6 Standards, technical codes and guidelines which are also
applicable
7 Explanations
Appendix: Processing instructions (short versions)
Welding record sheets
1 Scope of application
This technical code applies to the heated tool butt welding of
panels according to DIN EN ISO 1163-1 for the fabrication of
tanks and construction elements as well as of pipes and fittings
which are made of PVC-U and serve to transport gases, liquids
and solids.
Paying attention to the following instructions and on the basis of
the practical experience, it may be assumed that panels
according to ISO 11833-1, Group 2 and DIN 16927 as well as
pipes and fittings according to DIN 8061 and DIN 8062 are
suitable. If necessary, reference may be made to the data sheets
of the suppliers of the semi-finished products – in cases of doubt,
Works Certificate 2.1 according to DIN EN 10204.
2 General requirements
The quality of the welded joints is dependent on the qualification
of the welders, on the suitability of the utilised machines and jigs
as well as on the compliance with the technical codes for
welding. The weld can be tested using non-destructive and/or
destructive procedures.
The welding work must be monitored. The contracting parties
must reach agreement on the type and scope of the monitoring. It
is recommended to document the process data on welding
record sheets (for a specimen, see the appendix) or on data
carriers.
Within the framework of the quality assurance, it is recommended
to manufacture and test trial welds in the given working
conditions before commencing and during the welding work.
Every welder must be trained and must possess a valid
qualification certificate. The planned area of application may
determine the type of the qualification. DVS 2212-1 applies to the
the dexterity of the welder is not hindered (see the explanations).
If necessary, additional evidence must be provided by manufacturing
trial welds in the specified conditions (see Section 5).
If the semi-finished product is heated non-uniformly due to solar
radiation, the temperatures must be equalised by covering the
area of the welding point in good time. It is necessary to avoid
any draught-induced cooling during the welding operation. When
pipes are welded, the pipe ends must be closed in addition.
The joining faces of the parts to be welded must not be damaged
and must be free from contaminations (e. g. dirt, grease and
chips).
3.2 Cleaning
For the manufacture of flawless welded joints, it is decisively
important that not only the joining faces but also the tools and the
heated tools are clean and free from grease.
3.2.1 Cleaning agents
The cleaning fluid or cloths which have already been moistened
with it in the factory and are kept in a lockable plastic box must
consist of a solvent with 100 % vaporisation, e. g. of 99 parts
ethanol with a degree of purity of 99.8 % and one part MEK
(methyl ethyl ketone, denaturation). Agents tested according to
DVGW VP 603 comply with this stipulation. The use of spirit may
lead to a quality reduction because of the water contained in it.
The paper for the cleaning must be clean, unused, absorbent,
non-fraying and undyed.
3.2.2 Cleaning of the heated tools
The heated tools must be cleaned with a cleaning cloth or paper
before every welding operation. No residues of cleaning agents
or paper may remain on the heated tool. Ensure subsequent
extraction.
3.2.3 Cleaning of the joining faces
Before the chip-producing machining of the joining faces, it must
be ensured that the utilised tools and the workpieces are clean
and free from grease beyond the welding area. If necessary, the
cleaning must be carried out with a cleaning agent. Ensure
subsequent extraction.

This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.

DVS, Technical Committee, Working Group "Joining of Plastics"

Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150

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The joining faces must be machined immediately before the given to electronically controlled machines – if at all possible,
beginning of the welding. with recording.
Any chips must be removed without touching the joining faces. The nominal wall thicknesses of the parts to be welded must

R&D INTAKE MANIFOLDS

match in the joining region.
If the surface is soiled after the chip-producing machining (e. g.
because of contact with the welder's hands), the welding faces Pipes and fittings must be aligned axially before they are
must be treated with a cleaning agent if an additional chip- clamped in the welding machine. The easy longitudinal mobility
producing machining operation is not possible for process-related of the part to be welded on must be ensured, for example, using
reasons. adjustable dollies or a swinging suspension.
Immediately before the welding, the faces to be joined must be
subjected to chip-producing machining with a clean and grease-
4 Heated tool butt welding of pipes, piping parts, fittings free tool so that they have parallel faces in the clamped condition.
and panels The permissible gap widths under the alignment pressure are
shown in Table 1.
4.1 Process description
During heated tool butt welding, the faces of the parts to be Table 1. TMaximum gap widths between the machined welding
welded are aligned to the heated tool under pressure (alignment), faces.
are subsequently heated up to the welding temperature at a
reduced pressure (heating-up) and, when the heated tool has Pipe outside diameter d Gap width Panel width
been removed (changeover), are joined together under pressure mm mm mm
(joining). Figure 1 shows the principle of the process. ≤ 63 0.5 –
preparation > 63 ... ≤ 110 1.0 ≤ 1,500
> 110 ... ≤ 225 1.3 > 1,500 ≤ 2,000
> 225 ... ≤ 400 1.5 > 2,000 ≤ 2,300
– 2.0 > 2,300 ≤ 3,000

pipe heated tool pipe The misalignment must be checked at the same time as the gap
width. The misalignment of the joining faces in relation to each
heating-up other must not exceed the permissible dimension of 0.1 x wall
thickness on the outside of the pipe or on the panel. The
objective must be a minimum misalignment. A larger
misalignment results in a reduction in quality which restricts the
load-bearing capacity of the joint. In this case, an evaluation may
be carried out according to the DVS 2202-1 technical code taking
account of the requirements on the joint.

welding joint The machined welding faces must not be either soiled or touched
by the welder's hands since another chip-producing machining
operation would otherwise be necessary. An additional cleaning
operation is not required and does not give rise to any
improvement in quality. Any chips which have fallen into the pipe
must be removed.

4.3 Execution of the welding

Figure 1. Principle of heated tool butt welding using the example of In the case of heated tool butt welding, the faces to be joined are
pipes.
heated up to the welding temperature using a heated tool and,
when the heated tool has been removed, are joined together
4.2 Preparation for the welding under pressure. The heated tool temperature is 230 ± 8°C. The
The heated tool temperature necessary for the welding must be step-by-step sequence of the welding operation is illustrated on
checked before the beginning of the welding work. This is carried Figure 2.
out, for example, with a quick-display temperature gauge for
surface measurements with a contact area with an edge length of
approx. 10 mm. The control measurement must be taken within Pressure
the heated tool area corresponding to the semi-finished product.
So that a thermal equilibrium can occur, the heated tool may be Alignment pressure Joining pressure
used, at the earliest, ten minutes after the nominal temperature 0.60
has been reached.
For optimum welds, it is necessary to clean the heated tool Heating-up
according to Section 3.2.2 before every welding operation. The pressure
0.01
anti-adhesive coating or covering of the heated tool must be Time
Changeover time

undamaged in the working area.

The respective joining forces or joining pressures must be Heating-up time Cooling time
stipulated for the machines to be used. These may refer, for Alignment Joining pressure build-up time
example, to information from the manufacturer or to calculated or time
Total joining time
measured values. In the case of pipe welding, it is also necessary
to read the movement force or movement pressure arising during Total welding time
slow movement of the workpiece off the display instrument of the
welding machine and to add this to the previously determined
joining force or to the joining pressure. Preference should be Figure 2. Process steps in heated tool butt welding.

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Alignment A mechanical load on the joint is permissible, at the earliest, after

the end of the cooling process. For this purpose, the full joining
In this respect, the joining faces to be welded are pressed on to pressure must be maintained during the cooling time at the
the heated tool until the entire faces are in contact with the ambient temperature (see Table 2, Column 5).

R&D INTAKE MANIFOLDS

heated tool with parallel faces. This can be recognised by the
formation of the beads. The alignment is finished when the bead A uniform double bead must exist after the joining. The bead
heights around the entire pipe circumference or on the entire top formation provides orientation with regard to the uniformity of the
side of the panel have reached the values specified in Table 2, welds with each other. Different bead formations may be caused
Column 2. The bead heights are regarded as an indicator that the by the different types of flow behaviour of the joined materials.
whole area of the joining faces is in contact with the heated tool. On the basis of the experience with the commercially available
The alignment pressure of 0.60 N/mm² is effective throughout the semi-finished PVC-U products according to the standards, it may
alignment operation. be assumed that these are weldable even if this may lead to
asymmetric welding beads. K must always be > 0 (see Figure 3).
Heating-up
For the heating-up, the faces must be in contact with the heated
tool at a low pressure. To this end, the pressure is reduced to
nearly zero (≤ 0.01 N/mm²). During the heating-up, the heat
penetrates into the faces to be welded and heats these up to the
welding temperature. The heating-up times are shown in Table 2,
Column 3.
Changeover
After the heating-up, the joining faces must be detached from the
heated tool which must be taken out without damaging or soiling
the heated joining faces. The joining faces must then be moved
together quickly until they almost touch. The changeover time Figure 3. Bead formation in the case of heated tool butt welding
should be kept as short as possible (see Table 2, Column 4) (principle using the example of a pipe).
since the plastified faces would otherwise cool down. This would
exert a detrimental influence on the weld quality. For a short version of the processing instructions, see the appendix.
Joining
The faces to be welded should come into contact at a speed of 5 Testing of the welded joints
nearly zero. The required joining pressure is applied, if at all
possible, with a linear rise. The times necessary for this purpose Various test procedures are applied for the individual welding
are shown in Table 2, Column 5. The joining pressure is processes. A distinction is made between non-destructive and
0.60 ± 0.01 N/mm². The low melt viscosity demands exact control destructive test procedures. They are listed in Table 3.
of the joining pressure build-up in order to obtain a sufficient Depending on the agreement, checking and sampling operations
melting zone depth. should be carried out on a random basis during the welding work.

Table 2. Guide values for the heated tool butt welding of pipes, fittings and panels made of PVC-U at an outdoor temperature of approx. 20°C
with moderate air movement (intermediate values must be interpolated).

1 2 3 4 5
Nominal wall Alignment Heating-up Changeover Joining
thickness
s Heated tool temperature 230 ± 8°C
Bead height at the Heating-up time Changeover time Joining Cooling time
heated tool at the = 15 x wall thickness (maximum time) pressure = 2 x wall thickness
end of the alignment (heating-up build-up time under joining pressure
time p ≤ 0.01 N/mm2) = 1+0.5 x wall p = 0.60 N/mm2 ± 0.01
(minimum values) thickness (minimum values)
(alignment
p = 0.60 N/mm2)
mm mm s s s min
1.9 28.5 2 4
3 0.5 45 6
3
4 60 8
6 90 4 12
8 1.0 120 5 16
≤2
10 150 6 20
12 180 7 24
15 225 9 30
1.5
20 300 11 40
25 375 14 50

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Table 3. Test procedures for welded joints. DIN 16963-5 Pipe joints and fittings for pressure piping made
of PE – General quality requirements and
Test Heated tool butt welding testing
procedure Panels, pipes and fittings

R&D INTAKE MANIFOLDS

DVS 2202-1 Defects in welded joints between thermoplastics
Visual DVS 2202-1, Table 1 – Characteristics, description and evaluation
inspection DVS 2203-1 Testing of welded joints between thermo-
Radiographic DVS 2206 applicable; plastics; test procedures – requirements
and ultrasonic Statement possible, for example, about voids, Supplement 1 Requirements in the tensile test
tests not about quality Supplement 2 Requirements in the tensile creep test
Tensile test DVS 2203-2; Supplement 3 Requirements in the technological bending test,
bending angle / bending path
Short-time tensile welding factor according to
DVS 2203-1, Supplement 1 DVS 2203-2 –, tensile test
DVS 2203-4 –, tensile creep test
Tensile creep DVS 2203-4;
test DVS 2203-5 –, technological bending test
Tensile creep welding factor according to
DVS 2206 Testing of components and structures made of
DVS 2203-1, Supplement 2
thermoplastics
Technological DVS 2203-5; DVS 2208-1 Welding of thermoplastics – Machines and
bending test Minimum bending angle according to devices for the heated tool butt welding of
DVS 2203-1, Supplement 3, Figs. 5 and 6 pipes, piping parts and panels
Minimum bending path according to DVS 2212-1 Qualification testing of plastics welders –
DVS 2203-1, Supplement 3, Figs. 11 and 12 Qualification Test Groups I and II
DVGW VP 603 Provisional test basis for cleaning agents and
Internal With reference to DIN 16963-5, Section their receptacles for the preparation of welded
pressure 5.4.3.1; length of each pipe piece according to joints between polyethylene pipes
creep test Table 6
Betr.Sich.V Operational Safety Ordinance
Testing temperature: 60°C, testing stress:
11.3 N/mm², creep rupture time: ≥ 200 hours
Not meaningful for long-time tensile welding 7 Explanations
factor > 0.5
The technical code was elaborated according to the state of the
art.
6 Standards, technical codes and guidelines which are
The welding of thermoplastics at ambient temperatures below
also applicable
5°C is generally considered to be problematical. This relates not
ISO 11833-1 Plastics – Panels made of unplasticised poly- so much to the material-specific properties of the plastic but, to a
vinyl chloride – Panels with a thickness greater greater extent, to the restricted dexterity of the welder. Therefore,
than 1 mm the prerequisite for open-air welding at any outdoor temperatures
is an environment which enables the welding personnel to
DIN EN ISO Plastics – Unplasticised polyvinyl chloride perform the individual work steps without any quality-reducing
1163-1 (PVC-U) moulding materials – Designation influences. In this respect, it is necessary to pay attention to the
system and basis for specifications information from the manufacturers and to the dew point curve.
DIN EN 10204 Metallic products – Types of test certificates The parts to be joined must exhibit an identical temperature level.
DIN 8061 Pipes made of unplasticised polyvinyl chloride – Trial welds must be produced and tested.
General quality requirements With regard to the condition of the pipe ends, it must be ensured
DIN 8062 Pipes made of unplasticised polyvinyl chloride – that, within the framework of the welding preparations, any white
Dimensions frost, ice and moisture are removed from the area of the joining
zone (≥ 0.5 x fitting length) by supplying heat (e. g. hot gas
DIN 16927 Panels made of unplasticised polyvinyl chloride
device). Fittings must be stored in closed, frost-free rooms and
– Technical terms of delivery
may only be transported to the welding location in the number
required in each case.

420

Appendix: Processing instructions (short versions)
Re. 4.1 Heated tool butt welding of pipes, piping parts,
fittings and panels
1. R&D INTAKE MANIFOLDS
Processing instructions (short version)
Create permissible working conditions, e. g. welding tent.
2. Connect the welding device to the mains or to the alternating
current generator and check its function.
3. Align and clamp the parts to be welded, e. g. with dollies.
4. Close the pipe ends against draughts.
5. Clean the joining faces beyond the welding area with a
cleaning agent according to Section 3.2.1 with unused,
absorbent, non-fraying and non-dyed paper.
6. Machine the joining faces, in the case of pipes using a plane
(for example).
7. Take out the plane in the case of a pipe welding machine.
8. Remove the chips from the welding area without touching
the joining faces.
9. Check the plane parallelism by moving the joining faces
together (max. gap width according to Table 1).
10. Check the misalignment (max. 0.1 x wall thickness).
11. Check the heated tool temperature (230 ± 8°C).
12. Clean the heated tool with a cleaning agent according to
Sections 3.2.1 and 3.2.2 with unused, absorbent, non-
fraying and non-dyed paper and ensure extraction.
13. Determine the movement pressure or the movement force
before every welding operation and make a note of it on the
welding record sheet.
Page 5 to DVS 2207-12
14. Determine the setting values for the alignment, heating-up
and joining pressures.
15. Stipulate the guide values according to Table 2.
16. Move the heated tool into the welding position.
17. Align the faces to the heated tool until a bead arises
(according to Table 2, Column 2).
18. Heating-up at a reduced pressure ≤ 0.01 N/mm², heating-up
time according to Table 2, Column 3.
19. At the end of the heating-up, detach the joining faces to be
welded from the heated tool and move this out of the welding
position.
20. Within the changeover time (Table 2, Column 4), quickly
move together the faces to be welded until they almost
touch. The faces must come into contact at a speed of nearly
zero. Immediately afterwards, build up the joining pressure
with a linear rise in the joining pressure build-up time (Table
2, Column 5).
21. A bead must exist after the joining at a pressure of 0.60 N/
mm². According to Figure 3, K must be > 0 at every point.
22. Cooling under the joining pressure according to Table 2,
Column 5.
23. Unclamping of the welded parts when the cooling time has
elapsed.
24. Complete the welding record sheet.
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422
Welding record sheet for the heated tool welding of Material Page of

panels
Constructor Executing company
Welding device:
Page 6 to DVS 2207-12

Manufacturer:
Job description Name of welder ID-No.
Type:

Machine-No.:
No. of job Name and company of welding supervisor
Year built:

Seam Date Panel thickness Measured heating- Parameters Heating-up Changeover Joining pressure Cooling time Ambient- Remarks
No. element temperature time time built-up time under joining temperature
Alignment Heating-up Joining pressure
min max
[mm] [ C] [ C] [bar] [bar] [bar] [s] [s] [s] [min] [ C]
R&D INTAKE MANIFOLDS

Welder signature: Date and signature of welding supervisor:

From control-interval, frequency see section 4.2.

Values from manufacturer of welding machine or from machine-check.
Insert measured values.
 Welding record sheet for the heated tool welding  above ground Material Page of

of pipes  underground

Constructor Executing company Welding device: Weather conditions: Protection mesures:

1 = sun 1 = none

Order description Name of welder ID-No. Manufacturer: 2 = dry 2 = umbrella

Type: 3 = rain or snow 3 = tent

No. of Order Name and company of welding supervisor Machine-No.: 4 = wind 4 = heating

Year built: If several Conditions apply, order of numbers as above

(e. g. 34 = rain and wind)

Seam Date Pipe Measured heating- Moving Joining Parameters Heating-up Changeover Joining Cooling time Ambient Key-number
No. dimension element temperature pressure pressure time time pressure under joining temperature
ød×s (Machine table) Alignment Heating up Joining built-up time pressure weather protection
min max
[mm] [ C] [ C] [bar] [bar] [bar] [bar] [bar] [s] [s] [s] [min] [ C]
R&D INTAKE MANIFOLDS

Welder signature: Date and signature of welding supervisor:

From control-interval, frequency see section 4.2.

Values from manufacturer of welding machine or from machine-check plus moving pressure.
Insert measured values.

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