Thermoplastic Welding Inspection Course

Course Description: The Thermoplastic Welding Inspection course provides an excellent overview for everyone in the plastics fabrication industry. The program focuses on plastics as a material of choice and various fabrication methods such as butt welding, socket fusion, electro-fusion, hot air, hot air extrusion and solvent welding, with the main focus being on the inspection of plastics fabrication welded joints.

Learning Material Content

Session1: Introduction to Plastic Materials (Basic Chemistry)

  • Where do plastics come from?
  • Properties of plastic
    • Good things about plastics
    • Bad things about plastics
  • Basic chemistry
    • Atoms, molecule, monomer and polymer
  • Thermoplastics and thermosets
  • Amorphous and crystalline
  • Degradation

Session 2: Plastics Material (Identification)

  • Volume and engineering thermoplastics
  • Identifying process
    • Density
    • Flammability
      • Ignition
      • Flame colour
      • Melt behaviour
      • Smell
  • Plastics Application Area

Session 3: Plastics Materials (Test methods)

  • Specifications
    • BS
    • ASTM
    • SABS
    • DVS
    • ISO
  • Tests
    • Density
    • Melt flow index
    • Flexibility (bend test)
    • Impact strength
    • Tensile strength and elongation at break
  • Softening temperature
  • Clarity/transmittance
  • Environmental stress cracking resistance (ESCR)
  • Tensile creep test

Session 4: Pipe Materials

  • PVC
    • Molecular repeating unit
    • Physical properties
    • Additives
    • Outstanding properties
    • Classification of PVC
      • PVC-U
      • PVC-M
      • PVC-O
      •  PVC-C
  • PE-HD
    • Molecular repeating units
    • Various forms of PE
      • HD
      • LD
      • LLD
    • Outstanding properties of PE-HD
    • Polymerisation of PE-HD
    • Identification of PE-HD
    • Mechanical properties of PE-HD
    • Major application of PE-HD
  • PP
    • Molecular repeating units
    • Polymerization of PP
    • Identification of PP
    • Mechanical properties
    • Processing
    • Major application

Session 5: Manufacturing and Fabrication Standards

  • SANS 966-1: 2010
    • Scope
    • General requirements
    • Effect of material on water
    • Specific requirements of pipes
    • Resistance to hydrostatic pressure for pipes and fittings
    • Marking and packaging requirements
  • SANS 966 – 2: 2010
    • Scope
    • General requirements
    • Specific requirements
    • Resistance to hydrostatic pressure for
      • Plain pipes
      • Pipes with integral joint of pipe and socket
    • Marking and packaging requirements
  • SANS 967: 2011
    • Scope
    • General
    • Specific requirements of pipes and fittings
    • Marking and packaging requirements
  • SANS 791:2010
    • Scope
    • Requirements for the material
    • Specific requirements for pipes and fittings
    • Marking and packaging requirements
  • ISO 4427 – 1(Material)
    • Scope
    • Specific requirements
    • Fusion compatibility
    • Classification and designation
  • ISO 4427 – 2 (Pipes)
    • Scope
    • Specific requirements
    • Marking requirements
    • Marking requirements
  • ISO 4427 – 3 (Fittings)
    • Scope
    • Specific requirements
    • Appearance of a factory made fittings
    • Marking requirements
    • Packaging
  • SANS 6269: 2005
    • Scope
    • Tensile test
    • Tensile creep test
    • Bend test
    • Peel test
  • SANS 10269:2009
    • Scope
    • Testing skills and knowledge
    • Welding of test pieces
    • Assessment and evaluation of test pieces and test specimen
    • Test results: Practical, Theoretical and Overall
    • Test certificate
    • Annual repeat test
  • SANS 10270: 2011
    • Scope
    • Requirements
    • Qualification of welding personnel
    • Extend of examination and test
    • Validity range (parameters)
    • Thickness of the material
    • Summary of approval procedure
    • Qualification file

Session 6: Fabrication Methods

  • Butt welding
    • Important parts of butt welding equipment
    • Suitable materials for butt welding
    • Step by step butt welding procedure
    • Common mistakes and how to prevent them
    • General requirements
  • Socket fusion
    • Important parts of the socket fusion equipment
    • Suitable materials for socket fusion
    • Step by step socket fusion procedure
    • Common mistakes and how to prevent them
    • General requirements
  • Electro-fusion
    • Important parts of the coupler and saddle
    • Suitable materials for electro fusion
    • Step by step electro fusion procedure
    • Common faults and how to prevent them
    • General requirements
  • Hot air welding
    • Important parts of the hot air gun
    • Suitable materials for hot air welding
    • Step by step hot air welding procedure
    • Common mistakes and how to prevent them
    • General requirements
  • Hot air extrusion
    • Important parts of the hot air extrusion equipment
    • Suitable materials for hot air extrusion welding
    • Step by step hot air extrusion welding procedure
    • Common mistakes and how to prevent them
    • General requirements
  • Solvent welding
    • Important tools and equipment for solvent welding
    • Suitable materials for solvent welding
    • Step by step solvent welding procedure
    • Common mistakes and how to prevent them
    • General requirements

Contact Marley Pipe Systems

Marley Building Division
t. +27 11 739 8600
f. +27 11 739 8680

Marley Mining & Industrial Division
t. 0861 MARLEY (627539)
t. +27 12 045 0997

e. info@marleypipesystems.co.za

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