How to replace heating batteries for gas welding? How batteries are replaced in gas welding - theory and practice Replacing heating batteries in gas welding.
When building a new house or during a major overhaul of an apartment, it is necessary to resolve the issue of installing new heating elements. Moreover, the problem here is not only in the choice of radiators and pipes through which the coolant will move, but also in the way of combining disparate parts of the structure into one reliably 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 craftsmen are inclined towards gas welding. Why? Let's consider in detail and with examples.
The fastening of heating pipes by gas welding is carried out 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 radiators in the warm season, since during the cold season you will have to turn off the general house heating for at least a few hours, which is unlikely to please the neighbors
For the special strength of the seam, filler material in the form of a wire or rod is used. When the hot metal cools, a monolithic joint is formed.
Advantages and disadvantages of welding pipes
One of the main reasons for the popularity of the gas welding method is the specifics of our heating systems. During circulation, all structural elements are constantly under pressure, deforming the joints.
Therefore, a strong welding seam reliably protects against breakthroughs and helps prevent accidents during short pressure surges and even, which often accompany the start and shutdown of central heating.
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A question that sooner or later arises in front of almost every tenant, whether it is an apartment in an apartment building or your own house in the private sector.
Among the variety of existing types of heating batteries and how to install them, it is difficult to make the right choice without special knowledge and experience in this area.
Therefore, whether the heating batteries will be replaced by gas welding or a threaded method, and what type of radiators to use, it is better to decide together with qualified specialists. There is a high risk of costly property damage if the replacement and installation work is not done well.
Advantages and nuances
Today, the replacement of radiators of heating systems with gas welding is gaining more and more demand. This is easily explained: the resulting weld at the junction of the radiator with the pipe (riser) is much stronger than the welded parts themselves.
Such a connection is able to withstand both strong water hammer and high pressure, under which water is supplied to the heating system in all apartment buildings. Using the gas welding method, problems of leakage and breakdown of connections, as well as wear of its seal can be prevented.
When not to use
The appearance of a neatly cleaned weld is more aesthetically pleasing compared to bulky threaded connection fittings. However, it should be noted that gas welding is more suitable for dwellings with a central heating system. In private homes, batteries much more often need to be cleaned and air removed from the system, so a threaded connection in this case is more optimal than a welding one: it will facilitate the installation process if necessary.
Replacement principle
Gas welding is the process of joining several parts by heating their mating edges and filler material to a melting temperature. The result is a high-strength joint that can withstand significant loads. Gas welding is carried out using special equipment: as a rule, it is an acetylene generator, an oxygen cylinder, gas reducers and a burner.
Execution of works
When performing gas welding work, first you need to obtain the appropriate permit for their implementation, if we are talking about an apartment building. It is also important to make sure the qualifications of the welder who will carry out welding work: he must have the appropriate certificate and a valid fire safety permit.
Main stages
Very wide: bimetallic, most popular, aluminum, panel, cast iron. Each type has its own advantages and disadvantages, and the choice depends on the installation site and operating conditions.
Preparation and assembly
Before starting welding work, it is necessary to prepare the room: isolate the furniture, close the walls and floor from possible damage. It is necessary to drain water from the system, remove the coolant (in other variations). Next, with the help of a grinder, it is necessary to dismantle the spent radiators
After all the preparatory work, you need to assemble a new battery for installation. To do this, the nuts at the joints are sealed with flax, smeared with investment paste and tightly wrapped. A special air bleed valve is installed on top, and an American ball valve with a drive is placed on the side of the pipe connection.
Installation
The installation of a new battery is carried out on special brackets, after which all connections with pipes are adjusted - they are welded, and then the seams are cleaned. It should be borne in mind that gas welding usually produces a connection of pipes not exceeding 100 mm in diameter.
After welding, be sure to check the system for strength and tightness. Replacing radiators with gas welding compared to the threaded method is a longer and more expensive process, which has some disadvantages. But quality, reliability and durability are an indisputable and winning advantage.
More about the differences
Replacing batteries by gas welding differs from the threaded method in several ways. So, in addition to the already mentioned aesthetics and the absence of massive nuts and fittings, gas welding allows you to create very strong connections.
So, in the threaded method, more than 12 seams are created, and in the gas welding method, as a rule, no more than 5. This protects the batteries from breaking through the heating system during pressure surges. The absence of seals also contributes to the durability of the structure.
The welding connection is indispensable, as this is the only way to replace batteries in high-pressure systems: in such cases, the thread simply cannot withstand the load and the pipes break through.
I install heating radiators regardless of the location of the old supply pipes.
In addition to the quality of installation, I also pay great attention to the aesthetics of the overall appearance of the connection.
I don't use old pieces of pipe, welded elbows and welded threads...only whole pipe that I bend and thread.
I use a "roller" pipe bender, which guarantees a small radius and perfectly even pipe bend, regardless of the quality of the pipe being bent.
For packing taps and installing "American" I use an anaerobic sealant (guaranteed for the entire service life of the connection without corrosion).
In those cases where the installation of taps is done on linen with paste, I make notches, which guarantees the fixation of the linen and prevents it from being squeezed out.
When welding pipes, I use pipe sockets... based on the requirement
Guaranteed weld-free welding the first time. (especially relevant in cases where it is not possible to pressurize the system)
Only high-quality and original materials and components, time-tested.
Guarantee of Quality and Aesthetic appearance of all performed works.
and... Good mood for the entire service life of heating radiators :)
pipe bending: comparison of the bends of a roller pipe bender and a hydraulic one + bends with different bending radii ... standard and small, which I use in my work
packaging materials: only high-quality anaerobic Loctite sealants and investment materials... Vibra-Tite paste + Geb linen
notching: additional guarantee against extrusion of flax when winding up and assembling threaded connections
socket welding: guaranteed high-quality welding joint, regardless of the conditions and convenience of welding, recommended by SNiP
Quality and original materials and components: FAR, RB, GEB, Loctite, Vibro-Tite, Fischer
Replacement of heating radiators with gas welding
Installation, installation of one heating radiator with a turnkey pipe bender - from 10.000 rubles
This bag includes ... dismantling of the old radiator and all the necessary preparatory and installation work: measurements, threading, packing of taps, pipe bending.
As a rule, there is a partial replacement of the riser from the floor to the middle of the riser, above the mounting sleeve, including the complete replacement of the horizontal supply pipes. This allows you to achieve horizontal and parallel accuracy in the location of the supply pipes in relation to the radiator and the wall. As a result, it allows you to place the radiator as expected, regardless of the location (height) of the lower and upper horizontal supply pipes.
Since I use a pipe bender, therefore, only the pipe itself is purchased, which I bend myself and cut threads only in the right places for installing cranes at the place of work ... and all this (except for the pipe itself) is already included in the price of installing a radiator !! !
Steel tubular and other non-standard design radiators Zender, Arboniya, bay window, niches and other non-standard types of connection - from 12.000 rubles
Remove the convector (old radiator) and straighten the heating riser - 6.000 rubles
Approximate time to complete work with gas welding -
from about 3 days (it all depends on the complexity and number of radiators)First and second day: check-in and preparatory work for assembling new radiators, fixing brackets and hanging radiators (if possible), measuring, bending and cutting pipes, threading and packing taps - the most complete preparation before the final stage of pipe welding.
The third day: shutdown and draining of water for the final final stage of work - overcooking of supply pipes.
As a rule, the last stage of welding (taking into account the adjustment) takes approximately 1.5 - 2 hours for each radiator.
Overcooking of water supply risers with gas welding
Overcooking of one water supply riser in a straight line (galvanized) - from 15.000 rubles .
Estimated time to complete gas welding work - approximately 3 days (depending on complexity)
First and second day: check-in and preparatory work ... preparation of whips of risers with welding of new bends, bending of pipes for shifting risers (if necessary) and packing of cranes.
The third day: in the morning, turning off and draining the water for the final, final stage of work ... overcooking the risers.
As a rule, whatever there is an admixture, both water risers (cold and hot) are turned off simultaneously ... the time for overcooking two water risers at the same time is approximately 2 hours
Working with frozen pipes
Replacement, installation of one heating radiator with pipe freezing, without turning off the heating risers
Lead time for pipe freezing- from about 3 days (it all depends on the complexity and number of radiators)
It all depends on the complexity of execution ... how many radiators to replace, how many days of work, taking into account the stages and preparatory work + the installation itself.
As a rule, the work takes place in several stages:
1. The most difficult ... is freezing the riser and dismantling the old convector with a temporary jumper device to restore circulation through the heating riser.
2. Assembling a new radiator and hanging it in the right place, followed by taking measurements and preparing the necessary blanks for the supply pipes.
3. The final stage ... re-freezing the riser, with fitting and final connection of a new heating radiator.
PS. The final price of the work is determined by me only after reviewing the photographs with measurements and understanding the task!
Inspection with a thermal imager
Examination and identification of heat losses using a thermal imager, which allows you to visually see all the defects in the adjoining walls, window openings
the degree of heating of heating radiators and other cold bridges - 5.000 rubles
PS. in case of ordering replacement of heating radiators, examination with a thermal imager ... FREE OF CHARGE!!!
Departure, Consultation and Measurements
Departure to the object for inspection, measurements and consultations (at the request of the customer) - 5.000 rubles
PS.Usually, to understand the work, photos with measurements by mail are enough for me and there is no need for a special trip!!!
this service is for those customers who for some reason cannot or do not want to take measurements and it (this service) does not guarantee that I will take on the fulfillment of your order and in any case it is paid separately, regardless of whether I will fulfill your an order or not, as this is primarily a consultation and measurements, according to which in any case I will give you a recommendation and calculation for the selection of radiators, materials and a connection diagram.
Transport and other expenses
Purchase and delivery of pipes and components - from 3.000 rubles. (the components themselves and pipes are paid separately)
Also, this amount includes gas filling (acetylene + oxygen), cleaner + anaerobic sealant, linen with paste and other consumables.
Minimum order:
Due to the technological features of my installation of heating radiators and the need to bring a lot of tools to the site (a whole workshop) + purchase and preparatory work ...minimum order from 3 heating radiators or 33.000 rubles
PS. The final price of the work is determined by me only after viewing the photos with measurements and understanding the task.
We are sure that if you have not yet changed heating radiators, then you have yet to do this, which means that you will need to immediately solve a lot of questions from the category: whether to do it yourself or invite a specialist; what materials to use; what technology to use. Replacing heating batteries with gas welding is the best alternative to old cast-iron radiators that have already worked out their operational life. But, unfortunately, it is often not only them that have to be changed. Many happy owners of apartments in new buildings are dissatisfied with the aesthetic appearance, heat transfer and safety of already installed heating devices.
Replacement of heating batteries with gas welding (from 4 pieces) 4000 rub
Replacement of heating batteries with gas welding (from 2 pieces) 4500
Replacement of heating batteries with gas welding (1 pc) 5000 rub.
Budgeting 0 rub.
Today, a wide variety of materials are freely available, and on the Internet you can find any instructions and, of course, try to replace heating devices yourself. But can you then be sure of the reliability of the result of your work? After all, it is not enough to choose high-quality materials, it is important to thoroughly observe the process technology. Otherwise, after all, you can be left without precious heat at the most inopportune moment - for example, in the midst of winter frosts. So, it is obvious that the installation of radiators using gas welding is a process that requires an exceptionally qualified approach. And, having become acquainted with the technology closer, you can easily verify this.
Replacing heating batteries with gas welding: the essence of the process
Gas welding, in its essence, is the heating of the edges of parts of the structure. In some cases, a filler material is used in the process. The main advantage of the technology is the absence of the need for a source of electrical energy, as well as the high reliability and tightness of the resulting seams. But in order to achieve this effect, you need to know some features. For example, the power of the heat source must be sufficient to carry out a continuous process, and the temperature must also be higher than the temperature of the oxidation of the metal in the gas.It is equally important to choose the right special equipment for welding. You will need to purchase a generator (acetylene or some other gas), as well as an oxygen tank and gas reducers. And, of course, the welding device itself. It can be a torch or a cutter with a set of interchangeable tips. Also, the mandatory list of equipment includes: a rubber sleeve, which is necessary for transferring gas to a tool from cylinders, a fire safety valve.
Replacing heating batteries with gas welding requires that you achieve strong connections, which means that it is necessary to approach the installation of equipment and the choice of welding method as responsibly as possible. You can choose from several existing types of connections, the most popular of which is butt. But if the material used has a thickness of more than 5 mm, then you will already have to choose a Y- or X-shaped cutting of the edges. The most profitable and economical ways of cutting pipes are oxygen, manual and mechanized.
As you already understood, replacing heating radiators with gas welding is a process that requires preliminary study in theory, and then consolidation in practice. But few, of course, want to train on a real object.
If you contact us for help, you can consult on all your questions, as well as get information on the approximate cost of replacing heating radiators.
The final estimate can be compiled by a specialist who will conduct a final assessment of the object personally. And then you will only need to prepare the room for the start of work. To do this, it is better to take out excess furniture, close floor coverings and protect interior details.
Our specialists will do the rest: they will deliver materials and equipment, agree on the merging of central heating risers, and pressure test the system.
If desired, you can also order the transfer of radiators and risers to more convenient places, as well as organize the installation of a boiler in a private house for an autonomous heating solution.
And our company is distinguished by an individual approach to each client. You will be aware of every stage of installation, and your wishes will be taken into account when choosing materials for replacing gas-welded heating batteries. Experts are ready to answer your every question, and the final result will be an effective and reliable solution for heating your home.
