PE-X piping has revolutionised the way potable water can be delivered but with such a vast array of products on the market – how do you decide which system to use? Plumbing Connection takes a closer look at the market and the products available.

PE-X pipe systems are somewhat of a modern plumbing phenomenon. In just over 15 years they have captured ~70% of the residential hot/cold water supply market from copper and come out on top of the plastic wars; earning vastly more market share than polybutylene (PB).

With that being said – PE-X and its choice of fittings make for quite a complex decision that many plumbers don’t know enough about – and that can ultimately mean a risk to their business.

There are many considerations to make before you specify or install a PE-X system and although a cursory glance may give you the impression that they are all the same – it’s certainly not that simple.

“With such a vast array of PE-X piping and associated fittings on the market, plumbers can be a bit overwhelmed when it comes to choosing the right product for the job”, says Glenn Bines of Reliance Worldwide.

We understand that you could use metallic products, polybutylene and polypropylene (PP-R) for the delivery of hot and cold potable water but for the purpose of this review we are focussing on PE-X and its suitability for potable water plumbing applications.

This market review provides a broad range of useful things you need to know about PE-X pipe, fittings, tools and system warranties and where to go for more information.

TYPES OF PE-X
In the 1930s scientists first began experimenting with High Density Polyethylene (HDPE) with the aim of producing a more robust pipe than standard polyethylene.

Over time that has been achieved by way of a process of cross-linking the polymer structure with bonds. This cross-linked method became commonly referred to as XLPE or PE-X.

In Australia, PE-X pipe supplied to our market is either categorised as PE-X-A, PE-X-B or PE-X-C.

PE-X-A is produced by the peroxide (Engel) method which takes slightly longer to manufacture, while PE-X-B is known as the silane or ‘moisture cure’ method.

“When extruding PE-X B, if you took the pipe off the machine and left it to sit in the open air, it would take many months to eventually achieve the necessary level of cross linking,” says Glenn.

“We take the pipe after it is coiled and put it into a humidified environment at about 95°C and compress those months’ worth of cross linking into four hours time.”

“The advantages of the cross linking method for PE-X-B is that it’s quick, clean, economical and allows for the pigment to be run throughout the entire wall of the pipe.”

Alan Whittle, Consultant to Iplex Pipelines, explains that PE-X-C is produced by a physical cross linking process instead of chemical agents.

“Firstly, polyethylene pipe is extruded in the normal manner and then exposed to electron beam or gamma radiation under controlled conditions. Whilst the extrusion process is very simple, to manufacture PE-X-C it is necessary to have access to an expensive radiation source,” says Alan.

After installation, all three products have similar properties; however, you can identify PE-X-B by the colour dye running fully through the wall of the pipe, while in most cases the PE-X-A product is white on the inside with the colour pigment only showing on the outside layer. PE-X-C features a natural (translucent) core with a black jacket.

JOINING METHODS
There are three methods of connecting PE-X, all of which involve mechanical fittings.

“Recent developments in copper systems have seen the introduction of crimp joints; however, traditionally you could buy any copper fitting and braze it on to copper tube. You can’t do the same with PE-X. The pipes, joining methods and tools are all system specific so if you buy a pipe from one manufacturer, you have to buy everything from the manufacturer,” says Glenn.

Do not mix and match pipes and fittings from different manufacturers as you will immediately void your warranty which can prove to be a very expensive exercise should something go wrong.

Fittings and tools have evolved and become system specific with varying internal diameters of pipe so even if two products look identical, they probably aren’t. Two Australian manufacturers have developed approved adaptor fittings to help overcome this.

The joining methods are all tested to the same Standard; therefore, it comes down to personal choice and pipes used when deciding which joint is right for you.

Crimp
This is one of the most commonly used joining methods for PE-X as it is has gained confidence in a lot of plumbers and is readily available. This method uses a smaller diameter fitting that can be pushed inside the tubing before being crimped. Hand tools and battery operated tools are both available and different manufacturers will use different jaw sizes, so plumbers will need to use tools specified by manufacturers.

To-do list
– Ensure a square cut of the pipe (90 degrees)
– Fully insert the fitting
– Apply the tool (hand tool or battery operated)
– Check with a go/no go gauge. If it goes over you have done it right, if it interferes, you haven’t.

Slide
This type of joining system is achieved by placing a sleeve over the end of the tubing before expanding the tubing until a fitting can be pushed in. The pipe shrinks back onto the fitting.

“The sleeve should not be inside the expansion area when the pipe end is being expanded. Only polymer sleeves are suitable for polymer fittings. Brass sleeves should not be used in combination with polymer fittings,” says Christoph Schrader, Technical Manager at REHAU.

To-do list (As suggested by REHAU)
1. Cut:
Cut the pipe square using a pipe cutter and slide the sleeve onto the pipe.
2. Expand:
Expand the pipe end once, rotate the expander head by approximately 30º and expand it a second time.
3. Insert and Compress:
Insert the fitting in the expanded pipe end and use a manual or battery operated tool to push the sleeve fully up to the fitting collar.

Push-fit
Push type fittings involve the tubing being pushed into the fitting and is held in place by a stainless steel grip ring. These fittings do not require any specialised tools, just a square cut on the end of the tubing.

To-do list
– Ensure a square cut of the pipe (90 degrees)
– Check for scratches on the pipe or dirt in the fittings
– Pipe have witness marks on it that indicate the depth of penetration for the fittings so make sure they are reached

TOOLS AND MAINTENANCE
Tools play an important role in the PE-X system and manufacturers will either supply their own tools or recommend tools to suit their fittings. As well as using the right tools, plumbers need to maintain them to ensure they are fit for third party purpose.

“Just about all plumbing tools, regardless of the brand, can benefit from some simple care and servicing to extend their reliability and service life,” explains Paul Greenough, Field Technician at The Energy Network (TEN).

“One of the most common problems is oil leaks which has several prime causes. Tools used near or in dirty, dusty locations should be frequently wiped clean or where possible, blown off with compressed air. All hydraulics’ weep small amounts of oil. Dirt gets attracted to these areas and causes premature scoring of bores and wearing of scraper seals and O-rings.”

“Using tools in or near wet locations causes corrosion in circuit boards and rusting/pitting in cylinder bores. A good measure would be to give the tool a quick wipe and spray with a moisture displacement spray such as WD40 or similar. Water left in the heads can also cause deep pitting and rusting thus causing an oil leak. Water combined with dirt makes a grinding paste that will also score the bores, leading to a more expensive repair,” explains Paul.

Batteries should be kept clean and dry as corrosion on the contacts or internally can be caused by use in wet locations. Again it’s best to dry the battery and wipe it clean as soon as possible.

“Older Ni-cad batteries can suffer from overcharging. It is best to use them until depleted and then charge to full, rather than allowing them to charge for extended periods. Ni-MH and Lithium Ion batteries do not suffer this type of problem. All batteries, whether used or not, will self-discharge over time.

“Certain styles of pressing tool are commonly faced with bent or broken heads caused by the locking pin not being fully inserted and backing out during the pressing cycle. These pins need to be cleaned and lightly oiled with WD40 or similar to ensure that they are engaging and locking properly before use,” explains Paul.

It is recommended that you spend a few minutes every day, or at least once a week, doing some simple cleaning and oiling. This simple procedure can greatly reduce repair costs in the long run. Servicing on a regular basis can also help to catch problems in the early stage. High usage tools may benefit from servicing every six months, or sooner, depending on frequency of use. Plan to at least send your tool in for servicing every year at the very least.

“A service always includes a calibration on the tool which is performed on almost every repair. At TEN, we test the tool when received and after it’s repaired to ensure it is working to its designed values. Mechanical (manual) tools are not calibrated as they rely on human muscle power to operate.”

GENERAL DO’S AND DON’TS WITH PE-X SYSTEMS
Follow the procedures below to ensure you don’t void your warranty.

1. Do not mix and match manufacturer’s products as you will void your warranty
2. Protect the pipe at all times and make sure the pipe and fittings are clean
3. Do pressure test every system on completion of installation
4. Don’t use PE-X to connect solar panels to the storage tank
5. Don’t install PE-X where it will be exposed to direct sunlight, unless verified with the manufacturer
6. Do complete any brazing/soldering before connecting fittings to pipe and quench fitting before fixing pipe
7. Do ensure your PE-X is sleeved when penetrating a slab
8. Do replace any kinked or damaged pipe before testing
9. Do allow for pipe movement/thermal expansion/contraction through studs or frames
10. Check the unsupported radii of the pipe
11. Do use grommets, sleeves or stud clips to overcome Point 7, in accordance through the manufacturer’s instructions
12. Do install clipping to recommended standards
13. Do calibrate your crimp tool on a daily basis
14. Don’t use metallic clips as they can bite into the pipe if it expands

STORY NOTES
As you will appreciate, this subject has required a lot of research and a fairly lengthy explanation – but that’s only half the story.

Over the years we’ve had a number of plumbers ask us for various details about PE-X suppliers and their ranges, as they have likely come across a brand onsite that is not familiar to them.

From our research, we know there are more than a dozen (WaterMark approved) suppliers active in the Australian market.

We’ve tracked them down and in most cases they responded enthusiastically to a number of questions about their ranges, warranties and contact points.

We asked all current WaterMark approved suppliers to participate. Philmac (Secura) and Plumbing Plus (Pex Plus) advised at the time of printing this magazine they were not in a position to supply information. And in spite of repeated requests, we received no response from RooPE-X (Plumber Link) and ForzaPE-X.

If we have left any supplier out, it would only be due to the fact their Certification company didn’t advise us of their WaterMark licence, or if a new brand has hit the market since mid-August.

During our discussion with various suppliers, there was some dissatisfaction with the control of WaterMark approvals in this product area. Once a company gains its WaterMark approval for their fittings, the factory they make it in is subject to an annual onsite audit – that’s one day a year. What happens after that in some instances is conjecture. The grape-vine suggests some fittings are then produced at lesser quality factories but the fittings still carry the original WaterMark identification related to the audited factory – buyer beware! And be doubly-aware of offers for non-WaterMarked stock off the back of a truck.

SHARKBITE, AN AUSSIE-MADE EXPORT SUCCESS
After discussions with a range of manufacturers, it quickly became evident that crimp fittings can’t be made economically in this country; however, push fittings can and Sharkbite is a prime example of a successful Australian Made product.

SharkBite™ fittings and pipe are manufactured in Melbourne, in Reliance Worldwide’s state of the art facilities. A walk through the manufacturing facility demonstrates stringent quality control and advanced manufacturing procedures. Glenn Bines assured us that they had not cleaned up the place especially for our visit.

The production process is fully automated with minimal human interaction involved. Reliance Worldwide produce a staggering 100,000 fittings per day and are exporting 1.5 million units to the United States every month.

The Australian push-fit market is quite small but in the United States you cannot have varying outside diameters so products like the SharkBite can be used to join a wide range of materials.

SharkBite is quick and easy to install making it one of the most efficient plumbing systems available.

A HANDY PE-X TOOL
In the winter issue of Plumbing Connection we featured a nifty tool that can save you lots of time and effort when you need to shut the water off right now.

In the last issue of Plumbing Connection we featured a nifty tool that can save you lots of time and effort when you need to shut the water off right now.

This Plumtool Pex Squeeze tool offers a quick solution when you need to shut the water off NOW! With the Plumtool Pex squeeze tool you don’t waste time trying to find shut off valves that may or may not exist and you can shut down a leak or burst pipe in one area without having to shut a whole building or factory.

The squeeze tool allows you to shut off supply on hot or cold PE-X lines up to 20mm diameter, quickly and efficiently. The supplier claims that no permanent damage will result from squeezing the PE-X, as it will return to shape when the squeeze tool is removed and water pressure is restored.

Available at leading plumbing wholesalers. Trade inquiries 0498 800 055

IMPORTANT TECHNICAL NOTE
Plastic piping contamination at service station risks

Polymer (plastic) pipes are a flexible, durable and cost effective alternative to copper pipes; however, their vulnerability to chemicals such as petroleum, oil, liquid fuels and other solvents means special care must be taken when installing drinking water facilities at service stations or other similar facilities.

Plastic piping materials installed in ground heavily contaminated with petroleum can allow petrol and other contaminants to seep into the drinking water they are carrying, even if compliant with Australian Standard 4020 Testing of products for use in contact with drinking water (AS 4020).

Materials used in plastic piping include polyvinyl chloride (PVC), polyethylene (PE) and polypropylene (PP).

How contamination occurs
Although polymer pipes are watertight, plastic is made from similar chemicals to petroleum, enabling petroleum and similar chemicals to slowly seep into the water being carried.

Despite best practices to control spills, it is almost impossible to prevent the ground of a service station from pollution from petroleum products. This creates the potential for the contamination of drinking water in polymer piping that is in contact with the polluted ground.

Contamination of the water supply is not always immediately detectable. It is linked to how heavily the site is polluted and the length of time water remains stationary in the pipe.

Service stations built using copper pipes do not incur the contamination issue in their drinking water supply lines; however, it is an emerging problem at newer sites using approved plastic pipes.

While it is a requirement of the Plumbing Code of Australia that installations avoid the likelihood of contaminating drinking water, the Deemed-to-Satisfy provision that all materials in contact with drinking water must comply with AS 4020 does not make the distinction regarding the special circumstances surrounding service stations and similarly polluted sites.

The problem is not limited to water outlets at service stations, with reports of contamination occurring to the water in plastic pipes at properties located nearby via spread from ground seepage. An example of this contamination occurred when an entire industry estate was affected by a leading petroleum pipeline that went undetected for a number of years, according to the Victorian Department of Health (DOH).

Health risks
Ingestion of petroleum can result in coughing, nausea, vomiting and diarrhoea. In high concentrations it can lead to heart attack, convulsion or coma and in extreme cases, death. Children younger than five years old are the most at risk of health issues following exposure to contaminated water.

Contamination detection
Pipes that are regularly flushed by day-to-day use may not deliver water with a detectable odour. However, when left overnight or for long periods of time, the first flush of water delivered may have a very strong odour and provide an indication that the ground is contaminated.

DOH has received a number of reports where service station customers have filled drinking water bottles at publicly accessible taps, such as those near bowers, and complained of the smell of petrol in water.

Action plumbers can take
It is important that plumbers are mindful of the link between plastic water pipes and petroleum contamination when working at service stations or like properties, as well as surrounding properties where the possibility for contamination exists.

Use your expertise to avoid the contamination of drinking water. Where there is a risk of petrol contamination into the ground, use copper pipes for drinking water pipe work. If copper piping is not possible, practitioners should advise the site operators of the public health risks and erect ‘do not drink’ signs on all publicly accessible water outlets.

This article was originated by the Victorian Department of Health and first appeared in the Plumbing Industry Commission’s, The Registered Plumber newsletter.

PE-X SUPPLIERS AND PRODUCT RANGES