Self-replacement of heating batteries using gas welding

Heating batteries have to be replaced if a major renovation is carried out in a house or apartment, during which heating devices of a different type are installed. When expanding the area of ​​the room due to the balcony, the radiator is removed from under the window, and a tubular radiator with an increased heating surface area is inserted next to the window opening. In case of accidents at boiler houses and breakdowns of heating networks in winter, the heating system may defrost. Elimination of consequences may involve replacing broken batteries. In any case, the owner of the property needs to buy new radiators, and also decide on the method of installing them. The choice is made between threaded and welded connections of heating system elements. At the same time, most craftsmen believe that replacing heating radiators with gas welding makes it possible to obtain a better and more reliable connection that can withstand a short-term increase in operating pressure in the central heating system at the time of water hammer. The installation of radiators is entrusted to qualified gas welders, so as not to be left without heat in cold weather, and not to flood the apartment in the event of a rupture of a poorly executed weld.

• 2 Algorithm for gas welding work
• 3 How to obtain permits to carry out work?
• 4 Sequence of work when replacing radiators
• 5 What is the cost of replacing batteries?

Why is gas welding better than the threaded method?

I would like to highlight the following features of these works:

• When making threaded connections, fittings, nuts and other bulky structures are used, which do not look very aesthetically pleasing. Carefully welded seams become unnoticeable after painting.
• The strength of the welded joint is high, which eliminates the possibility of a leak in the system.
• Welded fastening is indispensable in heating circuits with high pressure, since the threaded connection simply cannot withstand the load.
• The absence of seals, which are a mandatory element of a threaded connection, eliminates the possibility of a pipeline breakthrough due to their wear.
• The final cost of the work, including the purchase of materials necessary to replace batteries, when using gas welding will be lower than when using the threaded connection method.

Gas welding is inferior to the threaded fastening method in terms of time required for dismantling and installation work. Taking into account all the pros and cons, we can summarize that the threaded fastening when replacing batteries is most suitable for private homes.

Gas welding. Replacement of batteries, heating radiators, pipes.

So, replacing heating radiators with gas welding involves the direct use of gas welding for connections. This is a process that has the following principle: the edges of the metal parts of the heating system to be connected are heated with special equipment. As a result, a metal of incandescent temperature is formed between them. When it cools, a strong, inextricable connection is created between the parts welded together.

Typically gas welding devices will operate as follows:

• Preparing parts for welding.
• Welding work - using different types of welding seam: ceiling, horizontal, vertical.
• If necessary, the applied cooled seam is boiled in supposedly weak spots, and cracks in the parts are welded.
• The seams are cleaned.

Currently, replacing heating batteries by welding is a common method. And any professional can explain why this is so - after all, the nuances that are used in the systems of domestic multi-apartment buildings are important here. Their use is due to the use of a coolant that is under high pressure.

Gas welding equipment

The fact that the heating system is constantly under pressure on each element, as well as the possibility of water hammer, can have a somewhat detrimental effect on other types of connections. If an accident suddenly occurs, it will be more expensive to replace the heating battery in another way - in addition, you will also have to pay for repairs to your neighbors if it comes to an apartment building.

However, the reliability of such a design and its durability cannot be underestimated. After all, the strength of the seam after welding will be even greater than the strength of the batteries themselves! Therefore, it cannot be that a breakthrough in the system will form at the seam site. In addition, replacing heating radiators using welding is also aesthetically beautiful. That is why a method such as gas welding is the most effective.

Regardless of how much it costs to replace a heating radiator with gas welding, this method will have several significant advantages over the threaded method:

• The connections have a more aesthetic appearance - there will be no nuts, fittings or other connecting structures.
• The strength of the connection is simply incredible - so the tightness of the system will not be compromised, even if the nominal pressure increases.
• There are no different sealants that are used for threaded connections. Therefore, there will be no breakthroughs due to the fact that these components wear out at the most inopportune moment.
• Welded connections can be used in circuits that have high pressure - in this case, a threaded connection simply will not withstand the pressure.

Pipes connected by welding look aesthetically pleasing

I would like to highlight the following features of these works:

• When making threaded connections, fittings, nuts and other bulky structures are used, which do not look very aesthetically pleasing. Carefully welded seams become unnoticeable after painting.
• The strength of the welded joint is high, which eliminates the possibility of a leak in the system.
• Welded fastening is indispensable in heating circuits with high pressure, since the threaded connection simply cannot withstand the load.
• The absence of seals, which are a mandatory element of a threaded connection, eliminates the possibility of a pipeline breakthrough due to their wear.
• The final cost of the work, including the purchase of materials necessary to replace batteries, when using gas welding will be lower than when using the threaded connection method.

Gas welding is inferior to the threaded fastening method in terms of time required for dismantling and installation work. Taking into account all the pros and cons, we can summarize that the threaded fastening when replacing batteries is most suitable for private homes.

Due to all the advantages of welding, many consumers prefer this option when replacing batteries. Welding heating batteries has the following advantages:

• Neat appearance; after painting, the weld seam remains almost invisible.
• A high degree of reliability, provided that the welding work is carried out by a specialist, the seam is characterized by high strength and durability. It is important to note that the weld can provide the system with much greater reliability than any other modern connection, such as a fitting.

Read more: How to calculate a pump for a heating system

Thanks to the availability of modern welding equipment, the specialists working in our company are able to install batteries in the shortest possible time.

The emergence of new proposals on the heating equipment market prompts the population to think about replacing old batteries with new heating radiators

In order to carry out the replacement, it is important to correctly determine how the heating radiators will be installed. There are many options by which the work can be done, but the most effective is to use gas welding

This is due to the fact that replacing batteries with gas welding has many advantages such as:

• Increased reliability. Provided that the work is completed by a highly qualified craftsman, the resulting seam will be reliable, thanks to which it can serve ideally for many years. In addition, the weld seam will not require additional attention, as is observed when performing installation using pre-mounted joints. This is due to the fact that the connection point does not have an additional seal, which, as a rule, is not durable in operation.
• Neat appearance. After the welding work is completely completed, the seam remains almost invisible, so it does not spoil the external design of the room and can remain in the open.

Only an experienced technician should be trusted to install heating radiators, since the efficiency and economy of the heating system will depend on the quality of the work performed. The craftsmen of our company are able to install radiators using gas welding efficiently and accurately.

Welding is a special process in which molten metal is poured between the edges of parts heated to a certain temperature. It is important to note that the edges are heated to a temperature required by the technology and the characteristics of the material itself.

Gas welding work is carried out to weld metal parts of various shapes; in addition, welding is used to eliminate defects from a metal surface, regardless of its shape and size.

Gas welding work to replace batteries consists of:

• preparatory part;
• welding (applying a seam);
• eliminating cracks and cavities from the surface of a metal part;
• smoothing seams (if necessary).

Only specially trained specialists are allowed to perform gas welding work, since only they are able to weld metal surfaces together as correctly and efficiently as possible.

As already noted, with the help of gas welding it is possible to install heating radiators with the highest quality and reliability. The main explanation for this is that the metal edges of the pipe and radiator are connected by molten metal, which is formed as a result of melting the filler wire. Using gas welding, you can easily and most importantly quickly connect steel pipes to a radiator, the outer diameter of which does not exceed 100 millimeters.

Gas welding of heating system elements in a home, apartment, commercial or industrial facility is a process in which the edges of metal parts are joined at high temperatures using special equipment.

Advantages of gas welding when replacing heating:

• you can weld pipes and heating devices of different sizes and shapes;
• a high-quality weld seam is superior in strength to the parts being connected;
• such connections can withstand high pressure and water hammer;
• if the technology is followed, there is no possibility of a breakthrough along the seam and depressurization;
• the melting speed is simply regulated by changing the angle of the flame;
• the seams made are almost invisible (unlike threaded connections);
• All types of radiators are available for welding: steel, aluminum, cast iron, bimetallic;
• gas heating heating is possible in the absence of electricity (relevant when installing batteries in an apartment in a new building);
• There is no need for a seal, wear of which is the most common cause of leaks.

Despite the fact that welding work requires more effort and time, it is thanks to them that maximum reliability and durability of the installed heating equipment is achieved. For apartment buildings and high-pressure circuits, according to many experts, welding is the only possible option for connecting to a common system.

To install and replace radiators using gas welding, you will need special equipment:

• oxygen balloon;
• acetylene cylinder;
• gas reducer;
• burner device.

A mixture of oxygen and acetylene is used as solder. To increase the strength of the weld, filler wire is recommended, which allows you to obtain a monolithic connection after cooling.

Replacing batteries on a gas welding machine involves performing several successive steps:

1. Turning off the supply and draining the coolant (performed by a representative of the management company).
2. Dismantling old batteries and, if necessary, pipes (cut as smoothly as possible with a grinder).
3. Assembling (packing) a new battery, cleaning and degreasing the surfaces to be connected.
4. Installing the radiator at the mounting location (mounting it on brackets).
5. Installation of taps, valves, air vents (Mayevsky tap).
6. welding of heating pipes and radiators (connection to the system).
7. Checking the quality of seams and cleaning their surface.
8. Coolant supply and leak testing (pressure testing).

Read more: Adjusting the temperature of heating radiators

Algorithm for gas welding work

Gas welding work is carried out according to the following algorithm:

• first, steel parts are prepared for welding by cutting the seam;
• then carry out welding work, choosing the most suitable type of welding seam from the three existing ones - ceiling, horizontal or vertical;
• then carefully inspect the applied and cooled seam in order to identify weak points that need to be welded again to prevent the appearance of microcracks;
• the surface of the weld is cleaned.

Gas welding can be used to connect metal parts, regardless of their size and shape. During the gas welding process, the edges of the joined products melt, onto which a special filler wire is fused. Quality work is achieved using acetylene and oxygen, as well as proven solder.

A set of equipment and consumables for gas welding. There are enough acetylene and oxygen cylinders to install four radiators

The molten metal, cooling, creates a strong and very reliable connection between the parts being welded together. Most often, gas welding is used to fasten steel pipes whose diameter does not exceed 100 mm. A professionally performed replacement of heating batteries by gas welding reduces to zero the likelihood of a heating system breakthrough in welded areas, since the seam due to the fusion of solder is much stronger than the material of the main pipes.

General concepts

So what is this method? During the working process, the edges of the joined elements are heated with a special device, after which they are firmly connected to each other. Only steel pipes with a diameter of no more than 10 cm can be welded using this method. Before making the connection, it is necessary to carry out some preliminary preparation.

Equipment for gas welding.

Advantages

Modern batteries are developed using the latest technologies, thanks to which you can significantly reduce your costs during the heating season and have a warmer room. Therefore, replacing old radiators with new ones plays an important role in the life of every person. The effectiveness of replacement using gas welding is determined by the following factors:

• affordable event price;
• absence of massive and heavy connections;
• aesthetic appearance;
• high strength;
• no additional seals;
• long service life.

Experts consider gas welding to be the most durable and durable method of connecting steel pipelines. It is possible to carry out welding work on metal pipes of non-standard shapes and sizes, which cannot be done with any other type of connection. Only the use of this method guarantees that the system will withstand the high coolant pressure used in multi-storey buildings.

Battery replacement process.

Classification of seams

Welding seams can be of three types:

1. vertical;
2. horizontal;
3. ceiling

Any of them looks quite aesthetically pleasing and is practically invisible to the naked eye. Gas welding does not allow damage along the seam. If you plan to weld radiators yourself, all actions must be precise and careful, since if you handle operating welding equipment carelessly, there is a possibility of damage to other components of the system. Ceiling seams (welding is done from the bottom up) are more expensive than vertical and horizontal ones.

How to obtain work permits?

Only professional gas welders who have a document confirming their education in this specialty are allowed to install heating batteries using gas welding. In addition, the welder must have a valid fire safety permit. It is advisable that the specialist has experience (excellent, if many years) in carrying out gas welding work. The quality of the final result is also affected by the equipment used, which must not only be in good working order, but also meet established safety requirements.

Gas welding work is carried out in special clothing, in special glasses with a protective shield that prevents the eyes from catching “bunnies,” as experienced welders say. We must not forget about gloves that protect the skin of the hands from the effects of negative factors.

Mandatory equipment for a gas welder includes protective equipment such as goggles, a shield, and work gloves. All listed items are intended for gas welding work.

Please note that at the moment in apartment buildings there is a ban on carrying out gas welding work without obtaining permission from the authorized bodies. Violators of this legal norm face a significant fine.

Sequence of work when replacing radiators

To dismantle old heating devices, it is necessary to drain the coolant from the heating system. The easiest way to carry out this procedure is in a private house using a tap, the presence of which is provided for at the design stage of an autonomous heating system. In an apartment building, you will need to call a representative of the service organization or management company.

Dismantling an old heating device using a grinder, which is available to every lover of doing repair work with their own hands. In this case, the master works without protective equipment - this cannot be done

After draining the coolant, they begin to dismantle the old batteries. To cut pipes, use a regular grinder. The cut must be neat and straight so that the installation of new heating devices can be carried out without unnecessary difficulties.

Then the new battery is packed, and this procedure can be performed by the apartment owner himself. In this case, you need to stock up on some materials: investment paste, flax, a set of pipe nuts, and an adjustable wrench. The nuts are sealed with flax, coated with paste, and then screwed onto the pipes protruding from the radiator. Then, on the mounting side with the heating system pipes, a ball valve with a squeegee, called an American valve, is installed, as well as a Mayevsky valve.

Assembling a new bimetallic heating radiator from separate sections using nipples with seals

Next, they begin installing the new battery, installing it in place of the old radiator. They begin welding the squeegee screwed into the battery to the heating system. For better coolant circulation, a jumper pipe is welded between the pipes (coming to the battery and leaving it).

A true master of his craft will carefully install a new battery like this. The owners can only paint the replaced sections of pipes, after which no one will even guess about the installation work

As you can see, the process of replacing heating devices is a serious and very responsible matter. Therefore, to carry out work, you should contact the Housing Office department in writing. The owner of the apartment writes a request statement in which he describes the problem and the need to shut off the heating system in an apartment building. Housing office employees will review the application, give permission and agree with the applicant on the date of installation work. Next, you need to wait for the plumber, who will be sent by the Housing Office to the address specified in the application. The plumber will turn off the heating system and carry out all the necessary work. Upon completion of the radiator replacement procedure, the specialist will necessarily test the system in test mode to verify the quality of the service provided to the applicant.

Some housing offices may require documents from which you can find out the technical characteristics of the heating elements being installed. Such documents may include a technical passport, as well as a description of pipes and batteries.

Installation of heating radiators on gas welding: what is needed for this

Sooner or later, owners of both apartments and cottages are faced with the need to replace old pipes and radiators of the heating system. The process of installing new batteries is quite serious and must be approached with the utmost seriousness.

To carry out work to replace batteries, you need to write an application to the housing maintenance office describing the problem and the entire essence of the request. After considering the application, the housing office must review the application and provide a response to the apartment owner. If agreed, a date for the work will be discussed.

In no case should you replace batteries without warning; such amateur activity is fraught with fines, since gas welding is prohibited.

On this day, the central heating throughout the house is turned off - this work can only be carried out by an authorized plumber or another housing office employee.

You can dismantle old batteries yourself, but it is recommended to entrust the installation of new radiators to a certified specialist. If you contact a specialized company that deals with battery replacement, all the documents, from the permit to the registration certificate, can be handled by the company’s employees. True, you have to pay for everything.