When buying a fusion machine, there are several important factors to consider to ensure the right equipment for the application.

Figure 1: Safety of the operator is the top priority. Source: McElroy

1. Safety

Safety of the operator is the top priority. Consider the operators’ manual and whether it’s well-written and easy to understand. Has the manufacturer made safety improvements over time? Does the machine have hydraulic assist to do a job previously done manually? Is the machine well-marked for operator safety in accordance with industry standards?

For machines that fuse larger pipes (12 inches/315 mm and above), does the machine improve safety with hydraulic assist functions to help to lift the pipe and move the heater and the facer? In addition, a self-contained fusion machine, in which the engine and generator are built into the machine, helps create a safe environment by reducing the ancillary equipment like external generators or cranes.

2. Quality

Quality is a broad topic, but it’s critical to finding the right equipment to an application’s needs. Consider how long the manufacturer has been making fusion equipment, and whether their older equipment is still being used. Does the equipment wear out after a few years, making the investment a short-lived one?

Also, customers will want to ensure the machine can do the work necessary. Is the machine robust enough to work in the conditions on the job site? There are several fusion standards worldwide, including ISO low, ISO high, U.K. dual and DVS. Can the machine fuse in accordance with all those fusion standards, or only one or two? Is it capable of manual, semiautomatic and fully automatic processes?

Figure 2: Butt fusion machines optimized for HDPE are often built to be rugged and used outdoors. Source: McElroy

3. Type of material and joining method

There are several different types of thermoplastics that can be fused, such as HDPE, PE, PP, PPR and fusible PVC. It’s important to know which type of pipe is in use, since each type has its own acceptable practices and fusion standards.

Along with the material type, the type of fusion that will be performed should also be considered. It is best to pick a machine that has been optimized for the application and the material. For example, butt fusion machines optimized for HDPE are often built to be rugged and used outdoors, whereas PP or PPR equipment is often optimized for use in spaces where weight and tight conditions often prevail. Most of the time it makes sense to use a machine optimized for the application rather than an all-purpose piece of equipment that does several types of fusion but is not optimized for any one type.

4. Ability to log joint data

All fusion procedures follow a specific time and pressure protocol. It is important to ensure those things are correct, and for the operator to be able to record them. Fusion joint records should be accessible both electronically and in print format.

Does the data collected provide analytics that offer insight into things like operator effectiveness, GPS location, number of joints performed in a day and so on? Good data collection can also mean a system that automatically flags joints that might be out of standard. Consider whether the joint log shows pressure and time graph, or if it provides just a basic “go/no go” record.

A good quality fusion machine should work alongside a data logging device that allows operators to record and share fusion data.

5. Productivity

The most basic way to measure operator productivity is to measure the number of fusion joints performed per workday. However, joints per day is not the only consideration: it’s important to assess how many operators and assisting equipment are needed. A single-operator machine may produce the same number of joints per day, but if it also reduces — or eliminates — the need for additional personnel or equipment, it is a more productive machine. Productivity is a combination of joints per hour, the amount of labor required and the amount of necessary assisting equipment.

Figure 3: Every piece of construction equipment needs maintenance at some point in its lifespan. Source: McElroy

6. Service and warranty

Every piece of construction equipment needs maintenance at some point in its lifespan. But more important is minimizing the amount of time until the machine can be back up and running. Does the fusion equipment manufacturer offer a local service technician or distributor? Is the manufacturer’s distribution network developed enough to have parts in stock, trained technicians and rental fleets? Does the manufacturer have tutorials online to assist customers in fixing the equipment?

Take those considerations a step further. Does the manufacturer offer classes to assist in equipment operation and repair? Those classes can translate into thousands of dollars — and countless hours — saved when a machine breaks down, since it can be done in-house by the company that owns the machine. If the training can be brought to the customer, or even delivered virtually, that can further increase time and money savings.

Warranties can be a lifesaver when it comes to keeping a machine up and running smoothly. Look closely at the warranty offered by the manufacturer and determine if the type and timeline of repairs offered suits is appropriate.

7. Value

The cost of a fusion machine is obviously important, but only in that it must be weighed against the total value of the equipment itself. Customers want a machine that will last, while continuing to operate at the same level as it did when it was first acquired. While that may translate into a higher price at the time of purchase, it can also drastically reduce the cost of repairs or replacements further down the line.

When it comes to fusion machines, there are options. What works for one job site may not work for another. But by carefully considering a machine purchase, customers can make an informed decision and be confident in their choice.

McElroy believes in these seven tenets when designing equipment, and they work hard to deliver products that customers can rely on. Whether it’s fusion machines, productivity-enhancing accessories, or quality assurance tools such as the data logger, McElroy strives to meet the needs of the industry in everything they do.