Worldpoly1000 Hydra HF

Worldpoly1000 HF hydraulically operated butt-welding machine, suitable for welding PE pipes and fittings from 500 to 1000mm OD ISO High Pressure Standards. The machine is the result of more than 60 consecutive years of direct involvement in the PE p

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Worldpoly1000 Hydra HF butt welding machine including hydraulic main frame with steel clamps 1000mm. Supplied with facing tool and heating plate in fitted stand.

Standard Features

  • Welding range 500mm to 1000mm: SDR 11 to SDR17. 500 to 630 SDR 9 / alt 20" to 36" SDR 11. 22" & 24" SDR 9.
  • Complete and ready to weld.
  • Main frame includes 4 laser cut steel main clamps of 1000mm.
  • Main clamps hydraulically open / close and lock.
  • German hydraulic seals.
  • Electrohydraulic pump with controls, accumulator and quick release hoses. Includes countdown timers for heating and cooling phases.
  • Optional stub end device for welding end fittings.
  • Wired ready to accept Worldpoly or other data logger.
  • Tool box including tools, bolts etc.
  • 400 volt 3 phase 50/60 Hz (33.4 kw, 50 A). Alt. 480 volt for North America.
  • Minimum generator required: 400 volt 43 KVA. Provide full machine details to generator supplier before purchase.
  • Weight 2,980kg (including stub device)
  • Total cylinder area: 43.60cm2, maximum pump pressure 180 bar
  • Genuine 2 year International warranty.
  • Please note technical specifications of Worldpoly machines may change without notice

Technical Specifications

General

Welding range 500mm to 1000mm: SDR 11 to SDR17. 500 to 630 SDR 9 / alt 20" to 36" SDR 11. 22" & 24" SDR 9.
Complete and ready to weld.
Main frame includes 4 laser cut steel main clamps of 1000mm.
Electrohydraulic pump with controls, accumulator and quick release hoses. Includes countdown timers for heating and cooling phases.
Wired ready to accept Worldpoly or other data logger.
Tool box including tools, bolts etc.
Weight 2,980kg (including stub device)
Genuine 2 year International warranty.

Warranty

Main clamps hydraulically open / close and lock.

Hydraulic

German hydraulic seals.
Total cylinder area: 43.60cm2, maximum pump pressure 180 bar

Options

Optional stub end device for welding end fittings.

Electric

400 volt 3 phase 50/60 Hz (33.4 kw, 50 A). Alt. 480 volt for North America.
Minimum generator required: 400 volt 43 KVA. Provide full machine details to generator supplier before purchase.

Please note technical specifications of Worldpoly machines may change without notice

MORE ABOUT BUTT WELDING MACHINES

What is butt welding?

Butt welding is the principal method used for joining HDPE pipes and fittings. To perform a butt weld correctly and consistently, you will require a butt welding machine capable of aligning the elements to be welded, shaving their ends smooth and parallel, uniformly melting the ends of the pipe under various pressures, then pushing the ends together at a controlled pressure for a specific period.

Australian and international butt welding standards

Various International and National Standards exist for butt welding, where the temperature/pressure/time profile of the weld is detailed. Some of the most relevant for general use are:

The ISO Standard covers butt welding of metric pipe and is relevant in most of the world. ASTM Standards are for IPS & DIPS (inch) pipe which is specific to North America, while DVS is a well-respected and conservative standard from the German Welding Institute, successfully specified world-wide.

Sizes of butt welding machines available

Worldpoly manufacturers butt welding machines to weld HDPE pipes from 40mm to 3000mm OD. However, HDPE pipe and fittings of any diameter can be butt welded, but diameters beneath 63mm are not generally recommended as it becomes difficult to align the pipe ends accurately and consistently within the specifications of the relevant standard. Although Worldpoly manufactures machines to weld down to 40mm, when a welded joint is required, the preference for small diameters is to use electrofusion. Large diameter pressure and non-pressure pipes to 3000mm and above are now regularly welded, with fittings machines already producing to 2000mm/80”.

Types of butt welding machines

Two distinct styles of field butt welding machines are produced. These include what is commonly known as a ‘European style’ and ‘North American style’ machine.

Features and benefits of Worldpoly butt welding machines

'European Style' Machines

'North American' Style Machines

"North American" style machines have all of the components on-board, with the tracked versions carrying their own power supply.

"European style" machines are by far the most popular world-wide, due to their significantly lower price. On a Dollar for Dollar comparison it looks like a no-brainer, but site location, labour costs and availability, the requirement for speed and accuracy, local health and safety considerations remind me what I was told decades ago ‘the Dollar sign is the last elements of the value equation, otherwise Mercedes Benz wouldn’t exist’. You can buy a machine from us to weld 630mm/24” pipe for AUD 18,000 /  USD 15,000 (Worldpoly630), or for AUD 400,000 / USD 300,000 you get a fully optioned PolyForce630i Tracked.

Worldpolys’ PolyForce tracked machines are completely designed, engineered and manufactured in Australia, according to the requirements of our particularly stringent health and safety requirements,  difficult environment and climate, and the requirements of clients welding under difficult conditions.

The availability of parts has always been an issue for imported machines, which is why PolyForce uses only locally supplied components. Whatever you need we can take from either work-in-progress or our normal supplier, and have you working ASAP, so there’s no need to cannibalise a $400,000 to keep another one working. If you are in North America our suppliers Rexroth, Danfoss, Yanmar, MecAlte etc. have extensive cover over your way, so were more than happy to do any warranty work with them and your favourite hydraulics or electrical specialist.

Some specifics of our PolyForce Tracked machines are:

Do you provide a poly welding time and pressure chart?

Correct poly welding procedure will follow the requirements of the welding standard specified by your customer, which includes the temperature, time and pressure needed for each step. If these are done correctly, and the pipe is made from the correct material, you can expect the weld to be stronger than the pipe.

A poly welding time and pressure chart has already worked these out for all of the pipe which will fit the machine, providing the temperature, time and pressure required for each one. First the diameter, next the SDR/DR or wall thickness, then all of the times and pressures are shown. Worldpoly provides this on their free app, so please go the Play Store or Appstore and enter ‘Worldpoly’.

Temperature, time and pressure are not the only requirements for a good weld, and we absolutely recommend at least OEM if not international level training for all operators, supervisors and specifiers. If this raises questions, please contact Worldpoly for assistance.

Why HDPE pipe systems?

HDPE pipe systems provide exceptional service, with the gas and water systems installed in countries like the UK expected to provide 100+ years of useful life. Of course installation must be carried out correctly, but as a ductile material the pipe is unlikely to fail when other services nearby are excavated, enlarged or repaired, or other significant soil movement occurs. The same is not the case with rigid pipe systems, excellent examples of which were the Kobe (Japan) earthquake of 1995, and more recently Wellington (New Zealand).

In the past welded HDPE pipe systems were the domain of city gas companies and the mining industry, where the high comparative cost was offset by other significant factors in their value equation. Over the past 15 years a significant increase in the volume of the raw material being produced has reduced the pipes comparative cost significantly, and welding technology has increased dramatically, meaning that today HDPE pipe is now a staple for water, mining, gas, sewer and industrial applications from Norway to Bolivia, Germany to Chad.

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