Electrofusion Poly Pipe Welding (PPW) SWMS

Electrofusion and poly pipe welding covers the jointing of polyethylene (PE) pipe by electrofusion and butt fusion — fusing PE pipe and fittings together by controlled heating to form a homogeneous joint, used for water, gas and other PE pipe systems. It is a specialised jointing task with specific hazards: the electrical hazards of the electrofusion equipment, the heat and hot plates of butt fusion, the fumes from the heated polyethylene, the high forces of the fusion machine, and — where the pipe is a gas main — the gas hazards. This document is written on the basis that electrofusion and fusion welding are carried out by competent operators to the relevant fusion standards, with the electrical, heat, fume and force hazards controlled.

Electrofusion and butt fusion of PE pipe are carried out in connection with the relevant parts of AS/NZS 3500 and, for PE gas pipe, the gas and pipeline requirements, to the fusion jointing standards and procedures. The electrofusion equipment is electrical, the butt fusion process uses heated plates, the heated polyethylene gives off fumes, and the fusion machine applies high forces. This document coordinates the electrical, heat, fume, force and gas controls so the joints are fused safely and correctly.

Hazards identified

9 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Engineering: use the electrofusion equipment to its safe working requirements with the appropriate electrical protection, inspected leads, and the correct fusion parameters for the joint.
2. 2Engineering: manage the heat and hot plates in butt fusion — keeping clear of the hot plate and heated pipe ends, and following the heating and jointing procedure — to control the burn hazard.
3. 3Engineering: control the fumes from the heated polyethylene with ventilation, particularly in enclosed areas, and provide respiratory protection where required.
4. 4Engineering: operate the fusion machine to its safe working requirements, keeping clear of the high forces and the moving parts.
5. 5Administrative: where the PE pipe is a gas main, apply the gas controls — isolation, purging, ignition control and leak testing — and carry out the gas work to the gas and pipeline requirements.
6. 6Administrative: follow the fusion jointing standard and procedure, with the correct parameters, clean and prepared pipe, and protection from weather and contamination, so the joint is sound.
7. 7Engineering: use mechanical aids for heavy PE pipe and equipment, and manage the work area and leads against trips.
8. 8Administrative: ensure the work is carried out and certified by an appropriately licensed plumber or drainer under the relevant state or territory plumbing licensing scheme, with the relevant competencies and a compliance certificate issued where required.
9. 9Administrative: all workers must hold a valid White Card (General Construction Induction Training, CPCCWHS1001) before entering any construction workplace, with the plumbing, excavation, confined space and any other competencies and licences required for the work.
10. 10Administrative: conduct a daily pre-start toolbox talk covering the day's work, identified hazards, isolations, required PPE and emergency procedures, and record attendance in the consultation section.
11. 11Administrative: consult workers and any health and safety representatives on the work and its risks, record the consultation, and keep this document available at the workplace.
12. 12PPE: eye protection to AS/NZS 1337.1, hearing protection where required, gloves appropriate to the task, high-visibility clothing, and Class I or Class II safety footwear with protective toecap to AS/NZS 2210.3.
13. 13Administrative: review and update this SWMS whenever the work scope changes, after any incident or near miss, when a worker or health and safety representative raises a concern, when new hazards are identified, or at minimum every 12 months.

Applicable Codes of Practice

Worked example

A competent operator is engaged to joint PE water pipe by electrofusion and butt fusion. The electrofusion equipment is used to its safe working requirements with the appropriate electrical protection, inspected leads, and the correct fusion parameters for each joint. In the butt fusion, the heat and hot plates are managed, the operator kept clear of the hot plate and heated pipe ends, and the heating and jointing procedure followed. The fumes from the heated polyethylene are controlled with ventilation, with respiratory protection where required. The fusion machine is operated to its safe working requirements with the operator clear of the high forces and moving parts. The fusion jointing standard and procedure are followed, with the correct parameters, clean and prepared pipe, and protection from weather and contamination, so the joints are sound. Mechanical aids are used for the heavy PE pipe, and the work area and leads managed against trips. The joints are fused, and the records retained.

Related legislation

• Model Work Health and Safety Act — primary duty of care; the duty to consult workers; the reckless-conduct offence; and notifiable-incident provisions, as enacted in each jurisdiction.
• Model Work Health and Safety Regulations — Section 291 high risk construction work and the SWMS preparation and review duties, and the excavation, confined space and pressurised-pipe provisions where applicable, as enacted in each jurisdiction.
• The relevant plumbing and drainage standards AS/NZS 3500 (Parts 0–5), the excavation and confined space Codes of Practice, the pressure equipment and pipework standards, and the silica Code of Practice where cutting concrete, are called up by the relevant legislation, together with the Before You Dig Australia information and the relevant utility requirements.
• Plumbing and drainage work is licensed under each state and territory's plumbing licensing scheme, with the relevant competencies for excavation, confined space and specialist work, and compliance certification required for notifiable work; electrical work is carried out by a licensed electrician.
• Victoria operates under the Occupational Health and Safety Act 2004 and the Occupational Health and Safety Regulations 2017, with the high risk construction work, excavation and confined space provisions applying in place of the model instruments.

Frequently asked questions