This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles

for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

Designation: D2657 − 07 (Reapproved 2023) An American National Standard

Standard Practice for

Heat Fusion Joining of Polyolefin Pipe and Fittings1
This standard is issued under the fixed designation D2657; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the U.S. Department of Defense.

1. Scope 1.7 This international standard was developed in accor-

1.1 This practice describes general procedures for making dance with internationally recognized principles on standard-
joints with polyolefin pipe and fittings (excluding polyethylene ization established in the Decision on Principles for the
pipe and fittings) by means of heat fusion joining techniques in Development of International Standards, Guides and Recom-
either a shop or field environment. These procedures are mendations issued by the World Trade Organization Technical
general ones. Specific instructions for heat fusion joining are Barriers to Trade (TBT) Committee.
obtained from product manufacturers. See Practice F2620 for 2. Referenced Documents
heat fusion joining of polyethylene pipe and fittings.
2.1 ASTM Standards:2
1.2 The techniques covered are applicable only to joining F1056 Specification for Socket Fusion Tools for Use in
polyolefin pipe and fittings of related polymer chemistry, for Socket Fusion Joining Polyethylene Pipe or Tubing and
example, polypropylenes to polypropylenes, or polybutylenes Fittings
to polybutylenes. Material, density, and flow rate shall be taken
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into consideration in order to develop uniform melt viscosities
and formation of a good fusion bond when joining the same
F2620 Practice for Heat Fusion Joining of Polyethylene Pipe
and Fittings

chemistry. (https://standards.iteh.ai)
material to itself or to other materials of related polymer 3. Summary of Practice
3.1 Heat-fusion joining uses a combination of heat and force
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present ASTM specifications are required to produce sound Preview
1.3 Parts that are within the dimensional tolerances given in resulting in two melted surfaces flowing together to produce a
joint. Fusion bonding occurs when the joint cools below the
joints between polyolefin pipe and fittings when using the melt temperature of the material. There is a temperature range
joining techniques described in this practice. within which any particular material is satisfactorily joined.
ASTM D2657-07(2023)
The specific temperature used requires consideration of the
1.4 The values stated in inch-pound units are to be regarded
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as standard. The values given in parentheses are mathematical properties of the specific material, and the joining environment.
conversions to SI units that are provided for information only With Techniques II or III (3.3.2 or 3.3.3), there is also an
and are not considered standard. appropriate force to be applied which depends upon the
material, the fusion equipment being used, and fusion tempera-
1.5 The text of this practice references notes, footnotes, and
ture. See Practice F2620 for heat fusion procedure for poly-
appendixes which provide explanatory material. These notes
ethylene pipe and fittings.
and footnotes (excluding those in tables and figures) shall not
3.1.1 Electrically powered heat fusion tools and equipment
be considered as requirements of the practice.
are usually not explosion proof. When performing heat fusion
1.6 This standard does not purport to address all of the in a potentially combustible atmosphere such as in an excava-
safety concerns, if any, associated with its use. It is the tion where gas is present, all electrically powered tools and
responsibility of the user of this standard to establish appro- equipment that will be used in the combustible atmosphere
priate safety, health, and environmental practices and deter- shall be disconnected from the electrical power source and
mine the applicability of regulatory limitations prior to use. operated manually to prevent explosion and fire. For the
See specific safety precautions in 3.1.1, 5.2, 8.2.3.1, Note 8 and heating tool, this requires bringing the heating tool up to or
Note 9, and A1.1. slightly above temperature in a safe area, then disconnecting it
from electrical power immediately before use. This procedure
1
This practice is under the jurisdiction of ASTM Committee F17 on Plastic
2
Piping Systems and is the direct responsibility of Subcommittee F17.20 on Joining. For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Current edition approved Feb. 1, 2023. Published February 2023. Originally contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
approved in 1967. Last previous edition approved in 2015 as D2657 – 07(2015). Standards volume information, refer to the standard’s Document Summary page on
DOI: 10.1520/D2657-07R23. the ASTM website.

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States

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 D2657 − 07 (2023)

FIG. 1 Socket Fusion

is limited to smaller sizes where heating is accomplished force. See Fig. 2. An alignment jig shall be used to obtain and

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before the heating tool drops below acceptable temperature.
3.2 Adequate joint strength for testing is attained when all
maintain suitable alignment of the ends during the fusion
operation.

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of the joint material cools to ambient temperature. The joint 3.3.3 Procedure 3, Saddle Fusion—The saddle-fusion tech-
shall not be disturbed or moved until it has cooled. See Practice nique involves melting the concave surface of the base of a
F2620 for heat fusion procedure for polyethylene pipe and saddle fitting, while simultaneously melting a matching pattern
fittings. Document Preview on the surface of the pipe, bringing the two melted surfaces
together and allowing the joint to cool while maintaining the
NOTE 1—Polybutylene undergoes a crystalline transformation for appropriate applied force. See Fig. 3.
several days after cooling below its melt temperature. Although this
phenomenon has an effect on the ultimate physical ASTM propertiesD2657-07(2023)
of the
material, its effect on testing of joints has not been found to be significant. 4. Significance and Use
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If there is any question of its effect, a comparison should be made between 4.1 The procedures described in Sections 7, 8, and 9, when
joints that have been conditioned for different periods of time in order to
establish the conditioning-time relationship.
implemented using suitable equipment and procedures in either
a shop or field environment, produce strong pressure-tight
3.3 Three fusion techniques are covered in this practice as joints equal to the strength of the piping material. Some
follows: See Practice F2620 for heat fusion procedure for materials are more adaptable to one technique than another.
polyethylene pipe and fittings. Melt characteristics, average molecular weight and molecular
3.3.1 Procedure 1, Socket Fusion—The socket-fusion tech- weight distribution are influential factors in establishing suit-
nique involves simultaneously heating the outside surface of a able fusion parameters; therefore, consider the manufacturer’s
pipe end and the inside of a fitting socket, which is sized to be instructions in the use or development of a specific fusion
smaller than the smallest outside diameter of the pipe. After the procedure.
proper melt has been generated at each face to be mated, the
two components are joined by inserting one component into the 5. Operator Experience
other. See Fig. 1. The fusion bond is formed at the interface
resulting from the interference fit. The melts from the two 5.1 Skill and knowledge on the part of the operator are
components flow together and fuse as the joint cools. Optional required to obtain a good quality joint. This skill and knowl-
alignment devices are used to hold the pipe and socket fitting edge is obtained by making joints in accordance with proven
in Logitudinal alignment during the joining process; especially procedures under the guidance of skilled operators. Evaluate
with pipe sizes 3 in. IPS (89 mm) and larger. operator proficiency by testing sample joints.
3.3.2 Procedure 2, Butt Fusion—The butt-fusion technique 5.2 The party responsible for the joining of polyolefin pipe
in its simplest form consists of heating the squared ends of two and fittings shall ensure that detailed procedures developed in
pipes, a pipe and a fitting, or two fittings, by holding them conjunction with applicable codes and regulations and the
against a heated plate, removing the plate when the proper melt manufacturers of the pipe, fittings, and joining equipment
is obtained, promptly bringing the ends together, and allowing involved, including the safety precautions to be followed, are
the joint to cool while maintaining the appropriate applied issued before actual joining operations begin.

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 D2657 − 07 (2023)

FIG. 2 Typical Butt Fusion Operation

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ASTM D2657-07(2023)
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FIG. 3 Saddle Fusion

6. Apparatus: General Recommendations plates for general fusion use shall be controlled thermostati-
6.1 Heating Tool—The tool may be heated by gas or cally and most are adjustable for a set point temperature
electricity. Gas-fired heaters for 2 in. IPS and smaller socket ranging from 300 °F to 575 °F (150 °C to 300 °C). Some tools
and butt fusion joints only, shall have heat sinks of sufficient may have a fixed set point for a particular application.
capacity to prevent excessive draw down of the tool 6.2 Heating Tool Faces—Heating tools may be made from
temperature, and are used only in above-freezing conditions. materials such as aluminum, stainless steel, copper, or copper
Electric heating plates maintain consistent fusion temperatures alloys. Copper or copper-alloy heating faces are not suitable,
when provided with an adequate power source. Electric heating unless chromium-plated or clad with another suitable metal,

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 D2657 − 07 (2023)
because some polyolefins react with copper. Plastic materials NOTE 3—The depth gage and chamfering tool may be combined into a
may stick to hot metal heating surfaces. This sticking may be single tool.
minimized by applying a non-stick coating to the heating 7.1.7 Tubing Cutter, to obtain a square end cut on the pipe.
surfaces or by fitting a high-temperature, non-stick fabric over 7.1.8 Fitting Puller, an optional tool to assist in the removal
the heating surfaces. The heating plate surfaces, coated or of the fitting from the heating tool and to hold the fitting during
uncoated, shall be kept clean and free of contaminants such as assembly.
dirt, grease and plastic build-up, which may cause excessive
7.2 Procedure:
sticking and create unsatisfactory joints. Most of these con-
taminants are removed from the hot tool surfaces using a clean, 7.2.1 Attach the proper size heater faces to the heating tool,
dry, oil-free lint-free cloth. Do not use synthetic fabrics which and heat the tool to the fusion temperature for the material.
may char and stick to the fusion surface. Some pigments, such 7.2.2 Cut the pipe end squarely, and clean the pipe end and
as carbon black, may stain a heating surface and probably fitting, both inside and outside, by wiping with a clean, dry,
cannot be removed; such stains will not contaminate the joint oil-free, lint-free cloth.
interface. 7.2.3 Chamfer the outside edge of the pipe end slightly and
6.2.1 After a period of time in service, non-stick coatings or fix the rounding clamp about the pipe as determined from the
fabrics will deteriorate and become less effective. Deteriorated depth gage.
fabrics should be replaced, and worn, scratched, or gouged NOTE 4—Chamfering may not be required by some procedures or some
non-stick coatings should be re-coated when they lose effec- fusion tools. Pipe sizes 1 in. (25.4 mm) and smaller are not usually
tiveness. Heat fusion quality may be adversely affected by chamfered, regardless of tooling design.
deteriorated non-stick surfaces. Spray-on chemicals, such as NOTE 5—Some recommend using a 50 to 60-grit emery or garnet cloth
to roughen the outside of the pipe and inside of the fitting as a means of
non-stick lubricants or oils shall not be applied to heating iron minimizing any possible skin interface when making the fusion. Sandpa-
surfaces as they will contaminate the joint. per is not recommended for this purpose, as it might disintegrate and
contaminate the joint interface. If roughening is performed, first clean the
6.3 Temperature Indicator—Heating tools shall be equipped surfaces before roughening. Clean dust and particles from the roughened
with a thermometer or other built-in temperature indicating surfaces afterwards by wiping with a clean, dry, oil-free, lint-free cloth.

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device. This device indicates the internal temperature of the
7.2.4 Bring the preheated tool faces into contact with the
heating iron which is usually higher than temperature of the
outside surface of the end of the pipe and the inside surface of
fusion surfaces. Use a pyrometer periodically to verify the
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the socket.
temperature of the tool surfaces within the pipe or fitting
7.2.5 Heat the pipe end and the fitting socket for the time
contact area. Select multiple checkpoints to ensure uniform
required to obtain a proper melt. Proper melt is a function of
surface temperature.
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material, time, tool temperature, and the size of the parts. Pipe
and fittings of larger diameters require more time to reach the
NOTE 2—A significant temperature variation, that is, cold spots, on the
fusion surfaces may indicate a faulty heating iron which may need to be proper melt consistency than those of smaller diameters.
serviced before it can be used.
ASTM D2657-07(2023)
Underheated or overheated materials will not form a good
bond.
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7. Procedure 1—Socket Fusion
7.2.6 At the end of the heating time, simultaneously remove
7.1 Apparatus—Socket fusion tools manufactured in accor- the pipe and fitting straight out from the tool, using a snap
dance with Specification F1056 are used for joining polyolefin action. Immediately insert the pipe straight into the socket of
pipe, tubing, and fittings. the fitting so the rounding clamp is flush against the end of the
7.1.1 Heating Tool—In order to obtain a proper melt, it is fitting socket. Hold or block the joint in place until the melts of
necessary for a uniform temperature to be maintained across the mating surfaces have solidified. The exact cooling time
the heating surface. Therefore, gas-fired tools are generally depends on the size of the pipe and the material being fused.
restricted to use with pipe sizes of 2 in. IPS (63 mm) or less. 7.2.7 Remove the rounding clamp, and inspect the melt
7.1.2 Heating Tool Faces—Consisting of two parts, a male pattern at the end of the socket for a complete impression of the
end for the interior socket surface and a female end for the rounding clamp in the melt surface. There shall no gaps, voids,
exterior pipe surface. Both parts shall be made to such or unbonded areas. Clean the heating tool of any residual
tolerances as to cause an interference fit. material using a wood stick or a clean, dry, oil-free, lint-free,
7.1.3 Alignment Jig—The alignment jig is an optional tool non-synthetic cloth. Take care not to damage the heating
which consists of two sets of devices holding the components surfaces. Plastic left on the tool tends to char when reheated,
in alignment to each other. One set of holding devices is fixed, causing a loss of heater efficiency and joint contamination.
and the other allows longitudinal movement for making the 7.2.8 Allow for extremes in weather when making field
joint. joints. Heating times, operation of alignment jig, dimensional
7.1.4 Rounding Clamps, (cold ring) to maintain roundness changes, and the like, are affected by extreme conditions.
of the pipe and control the depth of pipe insertion into the 7.3 Testing—Evaluate sample joints in order to verify the
socket during the joining operation. skill and knowledge of the fusion operator. Cut joints into
7.1.5 Depth Gage, for proper positioning of the rounding straps, (see Fig. 4) and visually examine and test for bond
clamp. continuity and strength. Bending, peeling, and elongation tests
7.1.6 Chamfering Tool, to bevel the end of the pipe. are useful for this purpose.

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 D2657 − 07 (2023)
clamp is closed; however, do not force the pipe into alignment
by pushing it against the side of an open alignment jig clamp.
8.2.4 Bring the piping components together and check for
high-low alignment, and out-of-roundness. Adjust as required.
Re-face after adjustment. The ends of the piping components
shall be square to each other around their full circumference.
8.2.5 Place the heater plate between the component ends,
and move the component ends against the heater plate with
sufficient force to ensure complete circumferential contact
against the heater plate. Hold the components against the
heater plate briefly, using limited force to ensure that proper
contact with the plate has been made. Release the force, but
hold the components against the heater plate until an appro-
priately sized bead of molten plastic develops circumferentially
around each component end as a result of the thermal expan-
sion of the material. Do not push the components into the
heater plate as the melting progresses.
8.2.6 Move the melted component ends away from the
heater plate, and remove the heater plate. Quickly inspect the
melted surfaces per 8.2.1. If the melt is acceptable, immedi-
ately bring the melted ends together with enough force to roll
both component melt beads over to the pipe surface around the
entire circumference of the joint. When the bead touches the
pipe surface, stop moving the component ends together, but do
not release the force. Hold the force on the joint until the joint
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8.2.6.1 Do not use excessive or insufficient force. If the

(https://standards.iteh.ai) components are brought together with too much force, all
molten material may be pushed out of the joint and cold

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material brought into contact forming a “cold” joint. If too little
FIG. 4 Bent Strap Test Specimen force is used, only the melt in the beads may be fused together
and, as the molten material in the joint cools and contracts,
voids or non-fused areas may be formed. If the softened
8. Procedure 2—Butt Fusion ASTM D2657-07(2023)material sticks to the heater plate, discontinue the joining
8.1 Apparatus: procedure. Clean the heater plate, re-square the component
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8.1.1 Heating Tool—The heating tool shall have sufficient ends, and repeat the process from the beginning (8.2.2).
area to adequately cover the ends of the size of pipe to be 8.2.6.2 Inspect the component ends quickly when the heat-
joined. ing tool is removed. The melt should be flat. A concave melt
8.1.2 Alignment Jig—The alignment jig is three basic parts: surface indicates unacceptable pressure during heating. If a
(1) a stationary clamping fixture and a movable clamping concave melt surface is observed, do not continue. Allow the
fixture for holding each of the two parts to be fused in component ends to cool, and start over from 8.2.1.
alignment; (2) a facer for simultaneously preparing the ends of 8.2.6.3 For any pipe size and wall thickness, the actual
the parts to be joined (Note 6); and (3) appropriate adapters for fusion joining force is determined by multiplying the interfa-
different pipe sizes. Alignment jigs are manually or hydrauli- cial pressure by the area of the pipe end. To determine a fusion
cally powered. pressure gauge setting for hydraulic butt fusion machines, the
NOTE 6—A facer is a rotating cutting device used to square-off the pipe force is divided by the area of the hydraulic cylinders that
or fitting ends to obtain properly mating fusion surfaces. move the fusion machine carriage. The hydraulic fusion
8.2 Procedure: machine gauge pressure setting may need to be increased to
8.2.1 Bring the heater plate surfaces to proper temperature. overcome internal machine friction drag or to provide addi-
8.2.2 Clean the inside and outside of the components (pipe tional force to move pipes attached to the butt fusion machine.
or pipe and fitting) to be joined. Remove all foreign matter 8.2.7 Allow the assembly to stand at least until cool before
from the surface of the component where it will be clamped in removing the clamps or other aligning device (Note 7). Do not
the alignment jig. subject the joint to high stress until it has cooled to less than
8.2.3 Align each component with its alignment jig clamp, approximately 130 °F. Do not apply internal pressure until the
and close the clamp. Check component to component joint and surrounding material have reached ambient air
alignment, adjust as needed, and face off the ends. temperature.
8.2.3.1 Take care when placing pipe or fittings in the NOTE 7—The joint is usually cool enough to remove from the alignment
alignment jig. Pipes shall be aligned before the alignment jig if a bare hand can be held against the beads without discomfort (less