Saddle Fusion

Saddle Joint Connection

When installing branch lines, a saddle joint is far more advantageous especially compared with traditional reducing tees. Saddle joints are installed directly on the side of the pipe and can be installed additionally even after installing the main lines. Using saddles for extended manifolds becomes extremely easy while saving time, cutting costs and more importantly increasing the performance of the system. Saddle joints also enable decreased friction, significantly more decreased than can be achieved by a reducing tee. As a result, pressure loss of the entire system is much lowered. The tables show whether a regular or threaded saddles are available for a particular branch size.


BORING FOR SADDLEDrilling for the outlets requires special bore, designed to take out all the material during the boring process, so no material ends up clogging the piping system. The bids for making the drill holes offered by PESTAN make adequate and precise holes. When the bits are larger than 2” drill press is required. When bids produced by other companies are used, it is important to have them between 1mm and 3mm smaller than the branch size. It is important to drill the bore into the pipe at a precise 90 degree angle. The saddle weld and welding heads can fit flush against the pipe. Double-check to ensure that no extra material or burrs are inside the pipe once you have drilled the hole, and make sure to remove any pipe fragments that have not come off fully. Check the hole and saddle joint for purity and dryness. If necessary, clean and dry them. Remove any possible dirt around edges or sawdust.

Heating up the pipe and saddle fitting

HEATING OF THE SADDLEUpon heating the tools, heat up the drill hole and the saddle joint. Outside surfaces are heated as shown in the picture. Insert the heating tool into the drill hole in the pipe wall and, at the same time insert the saddle joint into the heating tool. The heating time starts when the welding tool is completely inserted into the hole in the pipe wall and when the saddle joint is completely inserted into the welding head. It is important to point out that this has to be done without turning the fitting and the heating tool, and the elements inserting have to be vertical against the heating plate.

The relevant heating time is the time related to outside pipe diameter. Without turning pull the saddle joint out of the welding head and at the same time pull the heating tool out of the drill hole in the pipe. Do this vertically against the heating plate.


COOLING OF THE SADDLE JOINTAfter removing the fitting from the welding head and the heating tool from the drill hole, connect the pipe to the saddle joint by inserting the saddle joint vertically against the pipe axis without turning. Pay attention to dent position on the welding part of the saddle joint.

Cooling of the connection

Cooling of the connection is necessary before system is fully pressurized. Note: The relevant cooling time is the time related to pipes with larger outside diameters whereas the correction time relates to smaller diameter pipes.