When constructing a new house or during the overhaul of an apartment, you have to solve the problem of installing new heating elements. Moreover, the problem here is not only in the choice of radiators and pipes along which the coolant will move, but also in the method of combining disparate parts of the structure into one reliable working system.
There are several options for connecting pipes: replacing heating batteries with gas welding, electric welding or a threaded method. Although each technology has its pros and cons, most masters are inclined specifically to gas welding. Why? Let's consider in detail and on examples.
Features of gas welding technology
Bonding of heating pipes by gas welding is performed according to the following principle: the end parts of the two elements are combined, and then gradually heated in the tribe of the gas-oxygen mixture to high temperatures.
It is best to replace the radiators in the warm season, since in the cold season you will have to turn off the house heating for at least a few hours, which is unlikely to please the neighbors
For extra strength of the seam, filler material in the form of a wire or a rod is used. When the hot metal cools, a monolithic compound is formed.
Advantages and disadvantages of joining pipes by welding
One of the main reasons for the popularity of the gas welding method is the specifics of our heating systems. During the circulation of the coolant, all structural elements are constantly under pressure, deforming the joints.
Therefore, a durable welding seam reliably protects against breakthroughs and helps to prevent an accident during short pressure surges and even water shocks, which often accompany the start and shutdown of central heating.
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When welding radiators, gas welding is used in houses of the old housing stock, in which heating pipelines are made of black metal pipe
Welding is used mainly for open pipe laying, since black metal pipes are rarely monolithic in the walls. However, battery connection is also possible with a hidden installation option for the pipeline
When making a welded joint, the flow area does not decrease, which very positively affects the further operation of the heating circuit
During welding, the metal of the parts to be joined is melted and connected at the molecular level. The result is the most durable of plumbing connections
With the help of welding, any type of radiator is installed, including aluminum and bimetal models. Products cannot be spoiled by welding, as pipelines are not directly welded to them, connections are made through adapters and valves
Before welding, the welding zone must be cleaned of old paint with a grinder or wire brush. After connecting the stripped black pipes should be painted again.
All steel pipes, both black and galvanized, can be bent to form turns. But it’s simpler, easier, and faster to turn with a corner fitting
If the welded work is performed efficiently, the unit will last for many years without the slightest leakage. True, welding is used only in the device of permanent connections
Installation of a radiator using gas welding
Concealed gas welding
Weld Benefits
Solidity in the weld zone
Mounting a bimetallic radiator
Welds on pipes of the heating circuit
Welded steel corner for turning the pipe
Reliable, non-leaking weldment
Advantages of the gas welding method:
- Durability and reliability of the connection (it is believed that the strength of the joints after gas welding even exceeds the strength of the radiators themselves!).
- The ability to use parts of any shape and size. The only requirement is that the elements be made of metal with a thickness of not more than 3.5 mm (in case of exceeding it is more economical to use electric arc welding).
- Aesthetic moment - pipes and batteries welded by gas welding become a solid monolith, which is easy to repaint in a suitable color for the interior.
- It is possible to carry out work without connecting to the power grid (especially relevant for a new building).
- Many metals from which pipes are made, for example, copper, cast iron, brass and lead, form the strongest connection precisely by gas welding.
The main disadvantage of this installation method is the large heating area. As a result, it is easy to damage furniture and flammable finishing materials, such as parquet, wallpaper, wall panels made of plastic, chipboard or MDF.
To avoid damage, it is recommended to remove thermally unstable elements from the working area, and non-mobile ones to cover with an asbestos cloth or other protective material.
If replacing batteries with gas welding is carried out after finishing finishing work, be sure to use insulating gaskets between the wall and pipes
In addition, during gas welding, substances that are harmful to health enter the air - it is strictly forbidden to work without special protection means. That is why everyone who wants to learn how to use a gas welding machine in practice should study the safety rules and obtain work permits.
Restrictions on working with a gas welder
Installation of the heating system using gas welding is allowed to be carried out only by professional welders who, in addition to special education, have permission to carry out work from the fire service.
Note that the document is issued only for a certain period, so when hiring a master, you should not just look at the “crust”, but also examine its validity period.
Of the other mandatory requirements for welders: serviceability of the gas apparatus and mandatory protective equipment - glasses, work gloves, a shield.
It is advisable that the master use filler wire for seams and modern equipment working on a mixture of oxygen and acetylene. Other combustible gases, such as methane or propane, are permissible provided that their combustion temperature is twice the melting temperature of the filler rod.
A certificate of this type confirms that the specialist is appropriately qualified and has completed safety training. A prerequisite for authenticity is printing.
If you are not a professional gas welder, you can contact your local heating network or home organization for work. For this, the owner of the apartment draws up a statement on the need to replace the batteries and agrees on a date for blocking the movement of the coolant in the communal main.
After welding and installation of radiators, the invited master must perform a pressure test and verify that the system is working. It is strictly forbidden to independently stop and start heating in apartment buildings.
Differences from other installation methods
An alternative to connecting pipes when replacing batteries is the threaded method. It is especially popular among home masters who do not have in their arsenal such expensive equipment as a gas welding machine and working skills with it.
In this case, the system is assembled and the batteries selected for replacement are installed using threaded threads and special connecting elements - tees, fittings, nuts and other adapters.
Mounting using threaded technology is not possible without differences and visible fasteners - when replacing one radiator, more than 12 joints come out, while when welding, only 5-6
The main (and perhaps the only) advantage of the threaded method over gas welding is the ability to quietly and without fire hazardous heating to assemble the system with your own hands, without resorting to the expensive services of professional craftsmen. And also such a design can be further disassembled if it becomes necessary to clean or replace any element.
But the assembly process requires a detailed study, precise fit and proper selection of all the connecting elements. And even if you manage to do everything right and start the system, over time it will still fail.
As a result, the water will quickly detect “weak points”, undermine the gaskets and break out. Therefore, in high-pressure pipelines, threaded connections quickly “give up” under the onslaught of hydraulic shocks.
Another popular alternative to gas welding is electric heating. Both technologies work on a similar principle - heating to the melting point and joining the metals. At the same time, electric welding costs a little cheaper, and the scale of “destruction” after such work is small, since the heated area of the electric device is much smaller.
But despite these advantages, gas welding has an important feature - the ability to adjust the melting rate by changing the angle of the flame. Unlike almost instantaneous heating by electric welding, gas technology works gradually, without violating the structure and strength properties of the metal.
That is why gas welding with a good margin leads in choosing a method for replacing batteries among those who like to make repairs efficiently and reliably.
Radiator Replacement Process Requirements
Modernization of house heating is impossible without preliminary calculations and the selection of batteries suitable for the design. Moreover, it is not necessary to replace the old radiators with identical ones.
It makes sense to consider models from other materials, add / reduce the number of sections. But here it is important to observe the rule of the "golden mean" and calculate the power of the heating system in order to obtain maximum efficiency with minimum costs.
General recommendations for determining the number of sections for radiators with different capacities, designed for rooms with different area and ceiling heights
On your own, you can find out the right size, working power and number of batteries for a room in several ways. The simplest option is applicable for rooms with a ceiling height of 2.4-2.65 m. To calculate the sections, you should find out the area of the room and multiply by 100 W (design power for heating 1 m2 according to building standards).
The resulting figure must be divided by the heat transfer of 1 radiator section, which can be found out from the product passport (the standard value is 170 W) and rounded up to an integer.
For rooms with high ceilings, it will be better to use volume calculation. To do this, you need to multiply the area of the room by its height, and then by the recommended heat output for your home (in a panel building it is 41 W, for a brick building - 34 W).
It remains to divide the resulting value into the same efficiency of one section, then round the number. Of course, such calculations can only be averaged.
For more accurate indicators, a number of individual factors should be additionally taken into account:
- climate specific to your area;
- number of storeys and the location of the heated premises;
- the number of windows and the quality of their glazing (plain glass or energy-saving packages);
- the presence of a balcony or loggia adjacent to the room;
- internal or external insulation of the apartment.
It is also important to determine whether it is planned to install decorative screens, which many cover radiators with when decorating.
To accurately determine the thermal power of the system, you need to take into account all the heat losses that are possible in the room where you plan to replace the batteries
As for the materials from which the radiators are made, the most popular options for today are: steel, aluminum, copper, bimetallic (an alloy of several metals) and time-tested cast-iron appliances. Each of them has its own nuances and advantages, but most importantly - all are available for installation by gas welding.
Basic Battery Replacement Steps
In order to dismantle radiators in an apartment with an open heating system, you must obtain permission in the local housing office and heating systems. Separately, you need to coordinate and modernize the design, for example, if you plan to move the batteries to another place, add or remove several sections.
Welding work, as already mentioned, is allowed to be carried out only by specialists with access and vocational education - independent initiatives can result in a decent fine. Therefore, we will consider the main stages of the upcoming repair in order to avoid unpleasant surprises.
Preparatory work
To begin with, it is worth minimizing the possible consequences of the gas welding apparatus. Furniture adjacent to radiators must be removed or protected from possible damage. Also protect the area of the floor and wall adjacent to the battery.
Then, water is drained from the heating system. If we are talking about a private house or other room with independent heating, a special crane is used, which should be provided for during the design.
In an apartment with central heating, it is impossible to disconnect and drain the coolant from the system yourself - you should call a specialist from the service organization. Next, you must disconnect the old radiators. This is easiest to do with a grinder.
To safely dismantle the old battery with the grinder, be sure to use protective equipment for yourself and auxiliary materials for sheltering the floor and the adjacent wall
But here, you will need a good skill to work with the tool, because in order to connect new heating appliances with a minimum of effort, it is important to make a neat and even cut.
Assembly of a new design
Next, a new radiator is packaged. If you want to save on the services of masters, this work is quite feasible to do yourself.
Necessary materials and tools:
- A set of nuts (for radiators).
- Ball valve American.
- Mayevsky crane.
- Adjustable wrench.
- Inner paste.
- Sealant (flax or fum tape).
To assemble the battery, you need to tighten the nuts, process with paste and screw onto the pipes at the joints. The radiator layout is being completed by installing cranes.
Mayevsky cranes can work from a special key or screwdriver, the latter being much more practical, because a small key is so easy to lose
From the side of the connection to the heating system, an “American” is mounted in order to be able to block the access of the coolant to a specific battery. Above, on the opposite side of the pipe entrance, a Mayevsky crane is screwed with a wrench, with which it will be possible to remove the “plugs”, dumping air from the system.
Gas welding method
The assembled radiator is suspended in place of the old battery using special fasteners, and it is mandatory to check the evenness with the building level. Before starting welding, thoroughly clean the ends of the connected elements from dirt, dust and degrease.
In order to be able to turn off the radiator for replacement or repair, but not interfere with the circulation of the coolant, a special jumper is additionally welded between the pipes - bypass
Next, the inlet and outlet pipes are welded with a verified slope, which helps prevent the formation of air jams.To do this, the connecting section is heated with a burner, at the same time using a filler wire filling the gaps between the fragments of the system.
The metal bar filling the space between the two ends to be welded should be as close as possible to the material of the pipe.
The type of seam and the heating rate are chosen by the master, based on the wall thickness, pipe material and other professional nuances.
Suturing and finishing
After the gas welder works, the pipes look unaesthetically: black taps and stains are unlikely to become an interior decoration. But this is fixable.
To process the welding spot, you need to follow the following algorithm:
- Strip the pipe with sandpaper with a grain size of 3 or 4 numbers. With inaccurate work of the welder, there can be a thick influx at the junction, which some try to level with the help of the same grinder. But this is not worth doing - you can violate the strength properties of the seam.
- Drain the pipe - wipe it with a damp and then dry cloth.
- Degrease with white spirit.
- Coat with a corrosion-resistant primer in 2 layers.
- Paint with heat-resistant enamel also in 2-3 steps (the lighter and more transparent the paint, the more layers may be needed to mask the black color).
Of course, all painting work should be carried out before connecting the system, on cold pipes. If the batteries were replaced during the heating season, it is necessary to block the access to the coolant and wait for the system to cool completely.
The paint for the elements of the heating system must withstand at least 100 degrees, be resistant to abrasion and not emit toxic substances when heated
You can decorate only pipes or the entire structure complete with a radiator. The color is usually chosen white, silver, bronze or the tone of the walls. But for some interior styles, you can apply a contrasting shade, for example, dark chocolate, glossy black or spectacular red.
You can open the system and fill the circuit with coolant only after the paint has completely dried.
And finally, we propose to study our selection of videos for a visual representation of the specifics of the upcoming work and important nuances that you should know when replacing batteries.
Video recommendations for choosing the optimal time of year for replacing heating appliances:
This video instruction will help you to visually study the process of gas bypass device using filler wire:
The video is an example of a professional installation of heating pipes and batteries using gas welding and a pipe bender:
Replacing radiators with gas welding is a reliable way to protect your home from possible leaks in the heating system and the effects of water shocks.
But for the work to be done efficiently, it is important to entrust it to a specialist with good experience and modern equipment, because an improperly or inaccurately welded seam can lead to an accident in the next heating season.
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