With so much ‘plastic adoption’ going on in the industry, it may come as a surprise to hear that copper press-fit systems are growing in popularity with hydraulic consultants and plumbers all over the country. Justin Felix reports.

Improved on-site safety, enhanced joint performance and finish as well as time-efficient installation are all benefits that make it very clear as to why this joining method is fast gaining ground on our shores.

Growing industry use of ‘press-fit’ technology has been a major trend in Europe for over 25 years; however, Australia has only been using press-fit since Viega introduced the Propress system eight years ago.

Press-fit systems offer the advantage of flame free installations, making soldering a thing of the past. Not only does this make the job site safer by eradicating the risk of fire, it also makes the job quicker, leading to greater productivity and efficiency of labour.

Paul Mooney, Zetco Marketing & Business Development Manager explains that, “The speed of installation is a major benefit of press-fit. There are no hot work permits required on major job sites meaning there is no need to carry oxy and acetylene bottles and its performance is second to none. There have been very few issues on job sites with press-fit which gives the plumbers confidence that it is a proven system. Another reason for the increased adoption comes in the form of accessibility. Press-fit products have grown dramatically with Reece, Plumbers Coop, Samios and others all joining Tradelink with an offer in the market place.”

The dramatic rise of press copper fittings has resulted in them being the number one method for joining copper.

Adam Watson, Plumbing Business Development Manager for Reece says, “We find that a lot of plumbers prefer to use copper, however due to slower installation times they have chosen alternatives. Now that there is a solution for copper that is just as quick as the others it has been taken to kindly.”

Systems are available for gas and water applications, both of which are easily distinguishable via green (water) and yellow (gas) indicators.

“The main difference between water and gas fittings is the o-ring seal.  The seal is the important part in this system. In order to get the highest safety level and durability, different o-rings are used for different applications. Each o-ring has different properties that make it most suitable for the application, for instance EPDM water o-ring has the best hygienic proprieties for drinking water, the gas HNBR o-ring has ceramic particles to hold the seal for a period of time in case of fire and the FKM red o-ring is best suited to deal with higher temperatures,” Adam explains.

In addition to the different coloured O-ring, the gas (yellow o-ring) and high temperature (red o-ring) fittings have markings on the outside of the fitting to identify them.

Mechanical press tools that only require one hand operation make the connection process quick and easy by clamping over the joints and securing them with the press of a button. While simple, Adam explains that there are some things plumbers need to know to ensure a secure connection. Three key factors include:

– the applications
– the installation
– tool maintenance

The applications
Plumbers should always check the manufacturers’ manual to ensure that copper press-fitting is suitable for the application. While copper press-fittings can be used in most applications where you would normally use a standard copper fitting there are some limitations. This is because the press-fitting also contains an o-ring and therefore the o-ring as well as the copper needs to be suitable for the temperature, pressure and medium that is flowing through the pipe.

The installation
To ensure a successful joint, it is critical that all steps in the manufacturers’ installation instructions be followed.

Generally speaking though, the following steps are required to be taken for a successful joint to take place:

– It is important to ensure that the pipe is cut completely square.
– Make sure that the internal and external tube end are free from burrs or sharp edges by using a deburring tool to prevent damage to the o-ring.
– Ensure pipe is inserted up to the tube stop.
– Put a witness mark (Black marker or texta) on the right engagement depth and ensure the pipe is fully engaged when pressing.
– Check all fittings have been pressed (inspection).

Tool Maintenance
There are three things that impact on a successful joint: the fitting, the copper and the tool; therefore it is important that the tool is well maintained and serviced regularly.

It is important to consult with the manufacturer of the fittings to determine which tools they warrant to be used on their system. It is also important to note that the profile of fittings is not the same across the board; for example, B Press and Viega use a 3 point press, whereas the Kempress fitting is a 2 point press.
For a step-by-step visual of the joining process, please see page 52.

With so many benefits provided by copper press-fit systems, let’s take a look at the four available in Australia.

ZETCO

After two years in development, Zetco Valves recently launched its new range of press-fit ball valves in sizes 15mm to 50mm, specifically designed for Australian copper tube sizes.

Zetco Press-fit is a range of ball valves, designed and manufactured with a built-in press connection. This results in fewer joints, less mess and major savings through reduced installation time. The integral connection eliminates the use of additional fittings which means fewer leak points for every valve. The range is manufactured under Zetco’s high standards in Italy. Rigorous design and testing has taken place to ensure that Zetco’s premium quality is evident in this new range.

The gas ball valves are certified by the Australian Gas Association (AGA) to AS 4617 and tested to DVGW VP614. The water valves are WaterMarked by IAPMO R&T Oceana to AS 5830.1. The press-fit ends have been tested to AS3688 and the material composition complies with AS2345.

With the press-fit connections built into the valve, the new range can be used with existing V-profile tools from Viega®, Rothenberger® and KemPress®, offering flexibility while avoiding costly outlay on new tools.

Zetco Valves warrants that the joint pressed by a Viega®, Rothenberger® or KemPress® V-Profile tool will not leak for a minimum period of 25 years provided it is installed according to the installation instructions provided with every valve. Installation instructions can also be found on the Zetco website.

CONEX >B<PRESS

Conex Bänninger was launched >B< Press in December 2011 to satisfy a growing demand for press-fit systems in Australia.

Conex >B< Press is a versatile press-fitting system for use with hard, half-hard and soft copper tube, providing a secure, long-life, leak-proof joint. They are available in Copper and Red Brass and are suitable for use with copper tube to EN 1057.

>B< Press is installed with a mechanical press tool with a compatible jaw to fit each size of fitting required. When pressure is exerted through the press tool the joint is permanently made and the fitting cannot be dismounted or re-used. >B< profile has the advantage of a 3 Point Press, which includes two mechanical presses either side of the bead and one hydraulic press crimping the o-ring. They claim this provides a more secure joint.

Conex has also developed a unique pressing indicator, a specially designed EPDM o-ring. It has a reduced section in two positions, causing leaks at low pressures when not pressed (from 0.1 to 5.0 bar). When the fitting is pressed, the o-ring material compresses, filling the gaps, securing a leak-free path.

Therefore there is no need to go to full test pressure to check that all fittings have been pressed. This >B< Press feature is available in fittings sized 12-108mm and suitable for hot and cold water applications.

Warranty is 25 year guarantee against faults caused by defective manufacture of the fittings. It does not cover faults arising from incorrect installation. The warranty covers installation with type A and B copper tube conforming to AS1432 but does not cover any faults arising from competitor fittings used on the same installation nor faults caused by damaged >B< Press fittings (through excessive pressure, for example) where competitor fittings created non-compliant conditions.

Conex Bänninger recommends the use of Rothenberger press tools.

VIEGA PROPRESS

Viega Propress offers a high degree of flexibility for gas and drinking water installations. This is guaranteed with multiple components that are suitable for dimensions from DN 15 to DN 100. Each individual component benefits from a unique the Viega Smart Connect-Feature. The Smart Connect feature provides a quick and easy way to identify unpressed-connections during the pressure testing process. If the connection has a leak, the “dry” leakage test will show a visible pressure decrease over the entire pressure range from 2,2 kPa to 300 kPa. If the leakage test is carried out with water, this visibly escapes from the unpressed fittings in the pressure range of 100 kPa to 650 kPa. Another advantage Viega claim with their press connection is a cylindrical pipe insertion. This prevents damage to the sealing element during the assembly process.

All Viega Propress-fittings are hygienically packed and supplied in a bag. Distinctive colour coding on the packaging means mistakes are out of the question. Similarly, coloured dots are also marked on the products: green stands for drinking water and yellow for gas.

Viega’s new ring jaw sets make for a handy addition when working in tight and confined spaces as Robert Hardgrove, Viega’s technical manager/strategic projects in Australia explains.

“We developed the ring jaw sets in response to customer feedback and ongoing research and development.

“We knew these sets would appeal to plumbers and mechanical services companies in particular, as they provide them with greater flexibility – plus they’re ideal for using in confined spaces.”

The ring jaw sets are designed for pressing DN15-DN32 for use with the Picco tool, and DN15-DN50 for use with the Pressgun 4B or Pressgun 5.

The individual ring jaws can be placed around fittings which are very close to surfaces and other obstructions, and then pressed using a clamping jaw fitted to the pressing tool. The combination of a 360° positionable ring jaw, a 180° rotatable tool head and the 180° tool pivoting range during pressing makes virtually any tight spot accessible.

Viega Propress fittings carry a 25-year warranty against defects in material and workmanship from Viega, conditional on being installed by a licensed plumber who follows the instructions!

KEMPRESS

MM Kembla has combined its experience and knowledge of nearly 100 years of Australian copper tube manufacturing with German engineering to produce the KemPress® copper press-fit connection system.

The KemPress fittings have been designed to provide a tight fit when pushed together to allow the rough in to be completed piror to pressing. This ensures you have the right design and tube placement and allows to you to make adjustments, if required, prior to pressing. This is especially beneficial for vertical installations.

The objective of the press process is to deliver a permanent connection while achieving the required pull out strength according to AS3688. The KemPress process presses the lip of the fitting and then compresses the O-ring at the same time.

KemPress has a Watermark licence and is compliant to AS3688 and AS4020. The fittings have undergone a rigorous testing program including: KemPress Watermark Certification of Conformity.

To make life easy for plumbers the KemPress system has been designed to be compatible with other copper press-fit systems. The KemPress tool’s light weight and slim line design makes it easy to handle and has been specifically designed and tested to work with KemPress-fittings. The KemPress tool is available in 2 sizes:

– KPS 15mm – 32mm Copper
– KPL 15mm – 65mm Copper

With a warranty of 25 years, and a design life of over 50 years, KemPress offers plumbers a great product and aims for peace of mind.

All four suppliers provide an extensive range of fittings suitable for both gas and water applications and all are available to view on their respective websites which can be found below.