Professional Documents
Culture Documents
ByDr.DuanePriddy,PlasticFailureLabs,Midland,MI
Preface
PVCandCPVCpipesandfittingsareexcellentproductsandhavebeenusedsuccessfullyfordecades.
ThereisalowfailurerateandtheuseofPVC/CPVCmaterialsoffersignificantadvantagesovermetal
pipingmaterialsincludingeaseofinstallationandverylowfailurerates.Iamnotawareofanyhealth
cautionsregardingtheusageofPVC/CPVCpipesandfittingsotherthantheneedtoinstallthem
properlywithoutusingincompatiblematerialsduringtheinstallation.However,aswithallplumbing
productsincludingmetalpiping,occasionallyapipeorfittingmayfail.Whenafailuredoesoccur,our
experienceindicatesthatmostoftenthefailurecanbelinkedtoimproperinstallationpractices.The
intentofthisarticleistoprovideassistanceregardinginstallationerrorstoavoidandtherebyreducethe
occurrenceofafailureinPVCandCPVCplumbing.Again,letmeemphasizethatbyteachingaboutthe
maincausesofoccasionalfailureofPVCandCPVCpipesandfittings,Iaminnowaysuggestingthat
theseplumbingproductsarelessreliableormorepronetofailurethananyotherplumbingmaterial.
Further,IamoutragedbythemisuseofmyteachingsbysometoattackPVCandCPVCplumbing
productsasbeinginherentlyunsafe.IfIweretobuildahomeformyownfamily,Iwoulduseasmuch
plasticplumbinginmyhomeaspossibletokeepthecoststoaminimumwhileprovidingmyfamilywith
asafelivingenvironment.
MostoftheMainCausesofCPVC/PVCPipeFailureListedBelowareDiscussedinthisArticle
I.
ImproperSystemEngineering/Installation
A. Inadequateprovisionforlinearthermalexpansion
B. ExcessuseofCement
C. InsufficientamountofCement
D. WrongClampsusedorClampstootight
E. Incompatiblefirecaulkused
F. Contactofoutsideofpipewithincompatiblematerial(e.g.,solderflux)
II. ImproperOperation
A. Exposuretofreezingtemperatureswithoutfreezeprotection
B. Overpressurization
C. Pulsatingwaterpressure
D. Useofincompatiblematerialsaroundpipes
III. Contamination
A. Internal
1. Useofcontaminatedantifreeze
2. Contaminantsfrommetalwatersupplypiping;e.g.,antimicrobial(MICinhibitor)linings,
corrosioninhibitors,phthalateplasticizersfrompumpseals/gaskets,refrigeration
systemlubricants
B. External
1. IncompatibleFireCaulk
2. Useofincompatible(blackProset)grommetstosealpipeagainstholeinconcrete
3. Contactwithincompatibleplasticcoatedwires
4. Exposuretohotsolderflux
5. Exposuretohotpolyurethanefoaminsulation
IV. Manufacturingdefects
A. Dirtyextrusiondie
B. Incompleteresinconsolidation
C. Highstressesinpipewallduetorapidcooling
V. ResinDefects
A. Occlusions,charparticles,voids
B. Filler/pigmentnotwelldistributed
IV.AbusebyDistributor
A. Storeinsun
B. Damageduringtransport
Introduction
PVCandCPVCpipesareoneofthemostextensivelyusedplasticpipingmaterials.Themainreasonfor
thegreatsuccessofthesepipesistheirlowcost,extremelylowfailurerate,andrelativeeaseof
installation.However,aswithallpipingmaterials,thereareoccasionalfailures.Occasionalfailuresmay
becausedbyanumberoffactorshoweverimproperinstallationisgenerallythemostcommoncause
whenPVCandCPVCpipesfail.
PlasticFailureLabsisanindependentforensiclaboratory.Wehavebeenconductingforensicfailure
analysesofplasticpartsforseveralyears.Wehavecarriedouthundredsofforensicfailureanalysis
investigationsofCPVCandPVCpipesandfittingsattherequestofinsurancecompanies,installers,pipe
manufacturers,generalcontractors,condominiumassociations,andprivateowners.Wehavefound
thattheoverwhelming/mostcommoncauseoffailureisimproperinstallationpractices.Sometimes
installationerrorsresultincontamination,althoughthesetwoissuesarenotalwaysrelated.The
combinationofpipesunderstressplustheexposuretoincompatiblematerials,canleadto
environmentalstresscrackingfailureorESC.ThisisespeciallythecasewithCPVCsprinklersystem
pipingifnotadequatelyflushedasrecommendedinNFPA13toremovedebrisandtracechemicals.If
CPVCfiresprinklersystemsarenotflushed,tracechemicalsremaintrappedinsideforperiodsoftime
andmaybecomeabsorbedintotheCPVC.CPVCisaveryductilematerial.However,thecombinationof
prolongedhighstressandabsorptionofcertainhydrocarboncontaminantsmaycauseittoweakenand
developstresscracks(Figure1).
ThemostcommoncausesofoccasionalfailureofPVCandCPVCpipesandfittingsarelistedinTable1.
Alsoincludedinthetablearecommontechniquesthatareusedtodetectthelistedcauses.Thereare
manytoolsavailabletotheforensicscientistbutthemostcommonlyusedtoolsareopticalmicroscopy,
scanningelectronmicroscopy(SEM),Fouriertransforminfraredspectroscopy(FTIR),andgas
chromatographymassspectroscopy(GCMS).
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Figure1.FormationofastresscrackontheinsideofaCPVCfiresprinklerpipeatapointwhereatight
fittingclampwasused.
Table1.Sixmaincausesofoccasionalpipefailureandtestingmethodsgenerallyusedfordiagnoses:
TypeofFailure
RootCauseofFailure
Tests
Improperinstallation
excessivecement
sectioning&inspection
insufficientcement
sectioning&inspection
wrongclampused
siteinspection
clampstoofarapart
siteinspection
clampstootight
outofround/clampmarks
noallowanceforthermalexpansion siteinspection
pipesnotproperlyaligned
siteinspection
shortinsertion
sectioning&inspection
Pipeendnotdeburred
sectioning&inspection
Pipeendnotchamfered
sectioning&inspection
nonsquarepipecuts
sectioning&inspection
wrongantifreezeused*
FTIR
Contamination
Incompatiblethreadsealants
FTIR/GCMS
ChemicalCompatibility Incompatiblethreadcuttingoils
FTIR
Phthalatesfromgaskets/seals
GCMS
IncompatibleMICinhibitor
FTIR/ESIMS/GCMS
Incompatibleantifreeze*
GCMS/FTIR
Productdefects
pipedimensionswrong
resinnotfullyconsolidated
SEM
weakextrusionknitlines
dirtydiecreatingextrusionlines
blacklight
voidsorparticulates
OM/SEM/EDS
residualstressduetorapidcooling
OM
Page3of16
Resindefects
Improperoperation
Abusebydistributor
resinMWtoolow
fillercontentwrong
additives/pigmentsdispersion
chlorinecontentwrong**
waterhammer
overpressurization
areacontamination
freezing
storeinsun
damageduringhandling/transport
*uniquetofiresprinklerpipes
**uniquetoCPVC
MI
TGA
SEM/EDS
EA
OM/SEM
OM/SEM
GCMS/IR
OM
IR
OM
ImproperInstallation
Excessivecementuse:Aninstallationproblemthatweoccasionallyseeistheuseofexcessivecement.
ThesolventsinthecementthemselvesarereadilyabsorbedintoCPVCandPVC;i.e.,theyreadilyare
absorbedintothewallofthepipeandinsidefittingsocketresultinginsolvation/softeningofthe
material.Figure2showsashortpieceofpipewithafittingoneachendhavingexcesscementpuddled
insidetheshortpieceofpipe.Thesolventsinthecementabsorbedintothepipewallresultingin
softeningofthepipewalltothepointthatthepipewallbecameswollen/softenedandnolongerhad
sufficientstrengthtoholdwaterpressureresultinginblowout.
Figure2.Puddlingofexcesscementinsideoffittingranintoadjacentpiperesultinginsofteningand
blowoutofthepipewall.
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However,absorptionofthesolventsinthecementintothetoplayerofplasticinthepipeandfitting
socketisnecessarytoachievegoodbonding.Theorganicsolventsincementsoftenthesurfaceofthe
pipeandfittingsocketallowingthepolymermoleculestointertwinetoformapermanentbond.The
organicsolventsinthecementarevolatileandquicklyevaporatesothattheyareonlyaroundlong
enoughtodotheirintendedjobbutnotlongenoughtocausethepipetoweaken.Theproblemisthat
occasionallyinstallersutilizetoomuchcementresultingindribblesrunningdowntheinsideofvertical
runsofpipe.Wehaveobservedenvironmentalstresscracks(ESC)bothunderneath(Figure3)and
adjacent(Figure4)tocementdribbles.ItisnotknownforcertainexactlywhyESCfailuresofpipes
occasionallyoccurunderneathoradjacenttocementdribbles.Onetheoryisthatthecementisporous
andabsorbstracehydrocarboncontaminantspresentinthewaterandfacilitatestheirabsorptioninto
thewallofthepipe.AnothertheoryoftheESCcrackingofCPVCimmediatelyadjacenttoacement
dribbleisthatthedrying/shrinkageofthecementcreatesadjacentstressesontheinsidesurfaceofthe
wallofthepipe.
Figure3.ESCoftheinsidesurfaceofthewallofthepipeunderneathacementdribble
Figure4.CementdribbleoninsideofCPVCpipewithESCcracksfoundaroundtheperipheryofthe
dribble.
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Whenexcessivecementisusedontheoutsideofpipeitisnotasmuchofaproblemasontheinside.
Thisisbecause,ontheoutside,thevolatileorganicsolventsquicklyevaporate.However,ontheinside
ofthepipe,theorganicsolventsaretrappedallowingmoreexposuretimeoftheinsidewallofthepipe
tothesolvent.Byapplyingtheexcesscementtotheendofthepipe,butnotthefitting,whenthepipe
isinsertedintothefitting,theexcesscementispusheddowntheoutsideofthepipeforcingtheexcess
totheoutsideofthepipe.Ifexcesscementisappliedtotheinsideofthefitting,theexcessendsup
remainingtrappedinsidethefittingandeitherpuddlesinsidethefittingorelserunsdowntheinsideof
thepipe(Figure4).Itisgenerallyquiteeasytospotwhetherafittingwasassembledusingasufficient
amountofcementbysimpleexaminationofthecementresidueinthecrevicebetweenthefittingand
thepipeasshowninFigure5.
Figure5.Photosshowingtheexternalappearanceofabad(left)andagood(right)joints.
Insufficientcementuse:Sufficientcementmustbeappliedtoendupwithcompletecoverageofthe
endofthepipeandtheinsideofthefittingsothatacontinuousbondisformedbetweenthepipeand
fittingsurfaces.Ifinsufficientcementisused,voidsmayforminthebondbetweenthepipeandfitting.
Thepresenceofthevoidsresultsinaweakenedassemblywhichmayresultinwaterleakingfromthe
joint.Note:Wehavedevelopedatechniquetonondestructivelyexaminefittingstodetermineifvoids
existbetweenthepipeandfittingorifcompletebondinghastakenplace.Ifdesired,oneofourforensic
engineerscantraveltoasiteandanalyzesuspectfittingassembliestodetermineifvoidsarepresentin
thebondedjoints.
CharlottePipe&FoundrysPVC/CPVCinstallationmanual*recommendsthefollowingprocedurefor
cementapplication:
Applyaheavy,evencoatofcementtotheoutsidepipeend.Applyamediumcoattothefitting
socket.Applyasecondcementapplicationonthepipeend.Itisimportanttoinsuresufficient
penetrationofthesolventcementintothepipeandfittingsurface(s)bywipingthecementwith
thedauberuntilthepipemarkingshavebeenremovedfromthepipesurface.Usually35
rotationsaroundthepipewiththedauberaresufficienttoachievepropersoftening.
Immediatelyinsertthepipeintothefittingsocketcompletelytothestop,whilerotatingthepipe
14turn.
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*note:alwayscheckwiththepipeandfittingmanufacturerforthemostuptodateinstructions,as
writteninstructionsmaybeupdatedfromtimetotime.
Deburring/ChamferofPipeEnds
Whenapipeiscut,itshouldbecutsquareandanyresidue(burrs)thatformsontheendofthepipe
duringthecuttingoperationshouldberemoved.Further,thesharpouteredgeontheendofthepipe
shouldberoundedorchamfered.Theroundededgeallowsthecementplacedontheinsideofthe
fittingsockettobemoreevenlydistributedasthepipeisinsertedintothesocketaswellashelpingto
achievecompleteinsertioneachtime.
IncorrectClampsandContactwithConduit/Wire:Anotherverycommoncauseofoccasionalfailureis
theuseofthewrongtypeofsupportwhichplacesstressonthepipe.AlsobendingconduitsaroundPVC
orCPVCpipecanplacehighlocalizedstressonthePVC/CPVCpipesincontactwiththeconduit.Some
electricalwires,especiallycomputercables,shouldnotbeallowedtocomeintocontactwithPVCor
CPVCpipesbecausetheouterflexiblesheathmaycontainplasticizerswhichcanmigrateintothepipe
resultinginweakeningandfailureofthepipe.Figure6showsaphotographofaCPVCfiresprinklerpipe
installationrevealingcontactofthepipewithelectricalwireandaconduitbothshouldbeavoided.
Figure6.PictureofinstallationshowingdirectcontactofconduitandelectricalwireswithCPVCpipe.
Thermalexpansion:Mostplasticpipeshaveamuchhighercoefficientoflinearthermalexpansion
(CLTE)thannonplasticmaterials.ThehighCLTEofPVC/CPVCpipesmustbecompensatedforduring
installation,especiallyinenvironmentswherelargetemperaturechangesarelikely.Thenormalwayto
allowforthermalexpansionisbyinstallationofexpansionloopsinlongrunsofpipingandtheuseof
loosefittingorrollerhangarsthatallowforslippage.Aqualifiedsystemengineeringprofessionalshould
beconsultedtoensurethatthesystemisproperlyengineeredtoaccommodatethepossible
temperaturefluctuationsencounteredbythesystemandthatproperexpansioncapabilitiesare
incorporatedintothesystem.
Freezing:ThefailureofCPVCfiresprinklerpipesduetofreezingisnotverycommonbecausethe
sprinklerpipesarenormallylocatedintemperedareas.Nonetheless,occasionallyCPVCfiresprinkler
pipesdofreeze.Ifthereisachanceofexposureoffiresprinklerpipestofreezingtemperatures,itis
importanttofillthepipeswithglycerinsolution.Highpurityglycerinandpropyleneglycolsolutionsare
Page7of16
theonlyantifreezesolutionrecognizedasacceptablebytheNFPA(NFPA13:Section7.6.2).Again,a
highlyexperiencedengineeringprofessionalshoulddesignthepipingsystemtoensurethatappropriate
freezeprotectionisincorporatedintothesystem.
DiagnosesofthefailureofCPVCpipesduetofreezingisachallenge.IfCPVCpipesbreakduetoradial
expansionoficeinsideaCPVCpipe(Figure7),diagnosesisquitesimplebecausethepipegenerally
expandscausingthewallthicknesstodecreaseandgooutofspec(Figure8).However,researchersat
theUniversityofIllinoisfoundthatgenerallywhenpipesfreeze,radialexpansionisconstrainedbythe
pipewallforcingtheicetoexpandlongitudinally.Thelinearexpansionoftheicecausesapressure
buildupbetweentheiceplugandtheoutletorinletvalve.Itisthehighpressurethatcausesthefailure.
Thisdiscoveryledthemtoreceiveseveralpatents(US5,730,168,US5,785,072,andUS5,785,073)on
devicesthatprotectpipesfromfailureduetofreezing.
Figure7.PictureoffrozenCPVCpipe.
ThefrozenpipeshowninFigure7wasthawedandthencutlongitudinallyinhalfbysawingthroughthe
pipewall180degreesawayfromthefracturesurface.Simplymeasuringthethicknessofthepipewall
atthefracturesurfaceandcomparingthewallthickness180degreesopposite,revealsalarge
difference(Figure8).Thedifferenceiscausebytheslowtensilestretchandyielding/neckingatthe
pointoffracture.Theyielding/neckingatthepointoffractureresultsinthethinningofthematerialat
thepointoffracture.
Figure8.Wallthicknessatfractureissignificantlysmallerthan180oopposite.
Page8of16
Pipealignment:Pipesmustbeinstalledwithoutexcessivebendingdeflectionstressesonthepipe.Pipe
manufacturersinstructionsshouldbefollowedregardingthemaximumallowablebendingdeflections
oftheirpipes.Excessivebendingdeflectionmayleadtofailureofboththepipeandthefittingstowhich
thepipesareconnected.ElbowandTeefittingsaresubjecttocreepfailureinthecrotch(Figure9)if
pipesarenotinstalledin90degreealignment.
Figure9.Pipesinstalledoutofalignmentplacinghighstressonthecrotchofanelbowresultingincreep
failure.
Shortinsertion:WhenPVC/CPVCpipesareinsertedintofittingstheyshouldbeinsertedalloftheway
untiltheendofthepipehitsthestop.Iftheyareshortinserted,apocketremainsbetweentheendof
thepipeandthestop.ThisisaplacewhereESCfailuremayoccur.Thegapactsasaplacewhere
contaminantsmayaccumulateandeventuallyESCofthefittingtakeplace.Recentlywewereinvolvedin
diagnosingtherootcauseoffailureoftwolargehydronicheatingsystemshavingtherecirculationloop
constructedusingCPVCpipesandfittings.Fivefittingswerereceivedforforensicanalysis.Allfivefittings
failedinexactlythesameway.Thefailurewasinitiatedinthespacebetweentheendofthepipeand
theinsertionstopinthefitting.ThefailuremodewasESC.Theheatexchangerleakedresultingin
contaminationoftherecirculatedwaterwithrefrigerantlubricantoil(polyolester)whichbecame
concentratedintheshortinsertionspacecausingfailureofthefittingbyESC(Figure10).Werecently
presentedtheresultsofourfailureanalysisattheFailureAnalysisDivisionoftheSocietyofPlastic
EngineersAnnualTechnicalConferenceheldinBoston,May2011.Acopyofthepaperisavailableupon
request.
Page9of16
ContaminationExterior:CaremustbetakennottoallowPVC/CPVCpipestocontactothermaterials
thatcontainaromaticesterplasticizersandflameretardants.Figures11and12showexamplesof
failureduetocontactofCPVCwithothermaterialsthatcontainnoncompatibleplasticizers.Figure11
wasapiperemovedfromacondominiumwhereaworkersealedalloftheopeningsinwallsusingafire
caulkthatcontainedphthalateplasticizers.AdropofexcessfirecaulkfelldownontoaCPVCfire
sprinklerpipe.GCMSanalysisofthecaulkandthefailedpiperevealedthepresenceofphthalateester
plasticizers.PhthalateestersarehighlyincompatiblewithPVC/CPVCpipes.
Figure10.microscopicviewofthefracturesurfaceofafittingremovedfromahydronincheating
system.Allofthefittingsfailedinexactlythesameway;i.e.,byabsorptionoflubricantoilfromthe
refrigerant(duetoaleakintheheatexchanger)intothepocketbetweentheendofthepipeandthe
pipeinsertionstopmoldedintothefittingsocket.
Figure11.FailureofCPVCfiresprinklerpipeunderneathfirecaulkthatfellontheexteriorsurfaceof
thepipe.
Page10of16
Figure12showsanexampleofthefailureofaCPVCpotablewaterpipewhereablackgrommet(Proset)
thatwasusedtosealaPVC/CPVCpipepenetrationthroughaconcretefloor.Itwaswellknownthat
ProsetblackgrommetsarenotcompatiblewithPVC/CPVCbecausetheycontainphthalateester
plasticizerssometalfoiltapewasappliedtothepipeasaprophylactictoprotectthepipefromchemical
contaminationbythephthalateesterplasticizersinthegrommet.Metalfoiltapewilllikelynotbe
sufficienttostopphthalateesterplasiticizersfrommigrationfromblackProsetgrommets.Forthepast
fewyears,pipemanufacturershavestronglyrecommendedagainsttheuseofsuchincompatible
grommetsand,asaresult,ProSetnowmanufacturesawhitegrommetwhichiscompatiblewithPVC
andCPVCpipes.
Figure12.FailureofaCPVCpotablewaterpipeduetomigrationofphthalateplasticizerfromgrommet
downmetalfoilprophylacticusedtoprotectthepipe.
SolderfluxisanothermaterialthatmaycontainchemicalsthatareincompatiblewithPVC/CPVC.If
copperpipesarebeingsolderedinthevicinityofPVC/CPVCpipes,hotfluxcanfall,spatter,orvaporize
andcondenseontheoutsidesurfaceofthePVC/CPVCpipescausingESCfailure.
Polyurethanesprayfoam(PUSF)insulationcanbeaproblem.PUSFgeneratesheatasitcures.Iftheheat
istrappedbyathicklayeroffoamagainstthewallofthepipe,theheatcanweakenanddistortthepipe.
Also,eachPUSFmanufacturerhasformulationsthatcontainadditivessuchasfireretardants.Someof
theseformulationsmaynotbecompatiblewithPVC/CPVC.YoushouldconsultwiththePUSF
manufacturerbeforeapplyingPUSFinspaceswhereitmaycontactPVCandCPVCpipesaskingthemif
fortheirassurancesofthechemicalcompatibilityoftheirproductwithplasticpipingmaterials.The
CPVCpipeshowninFigure13iscracked.Examinationofthecracksurfacesintheleakingpipeshownin
Figure13showedESCfailurebymigrationofchemicalsfromtheoutsidesurfaceofthepipe(Figure14).
ContaminationInterior:Someproductsthatareusedinconstructionmaycontainchemicalsthatare
notcompatiblewithPVC/CPVCpipesandfittings.Thereforecaremustbeexercisedduringinstallation
tomakesurethatonlyapprovedmaterials(e.g.,metalpipethreadsealants,cuttingoils,firecaulks,
antifreeze,antibacteriallinedpipes,etc.)areusedduringinstallation.TheLubrizolCorporationisa
globalsupplierofCPVCresincompoundswhichmaintainstheindustry'sonlylistofcompatibleproducts
forusewithpipeandfittingsmadefromLubrizolCPVCcompounds.(see
http://www.lubrizol.com/BuildingSolutions/ChemicalCompatibility.html)
Page11of16
Figure13.CPVCpipeinsidewallcoveredwithPUSF.
Figure14.Closeupviewofthefracturesurfacesshowingdistinctivethumbnailchemicalpenetration
patternsfromtheoutsidewallofthepipe.Blackarrowpointstoleaklocationandredarrowsshow
thumbnailpenetrationzonesthatformaschemicalsmigrateintotheoutsidewallofthepipe.
Infiresprinklersystems,generallysteelpipingisusedtodeliverthewatertotheCPVCportionofthe
system.Therefore,wheninternalcontaminationoftheCPVCpipingdoesoccur,themostlikelysourceof
thecontaminationarethesteelpipes.Thisiswhyitisimportanttothoroughlyflushsteelpipesbefore
theyareconnectedtoCPVCpiping.NFPA13installationinstructionsforfiresprinklersystemsdescribes
properflushingproceduresforsteelpipesandspecifiesthattheentirefiresprinklersystembe
periodicallyflushed.
Page12of16
SomeantiMICorantimicrobialliningsinsteelpipesmaycontaintracesofwaterextractiblechemicals
thatarenotcompatiblewithCPVC.Figure15showstheeffectsofwatercontainingvarioustracelevels
ofanamine(didecylmethylamine,acontaminantoftenfoundinABF2)anditsquaternaryammonium
saltformonCPVCtestspecimens.Noticetheextensivecrazinganddiscolorationofthetreatedtest
specimensdownaslowas0.001%or10ppmofamineleadstochemicalattackandweakeningofCPVC.
CurrentlytherearesomeMICinhibitorproductsthathavebeenapprovedbyLubrizolasbeing
compatiblewiththeirBalzemasterCPVCpipes.Thelistcontinuestogrowasadditionalproductsare
testedandapproved.Sinceitisnotastaticlist,wesuggestthatyourefertotheLubrizolwebsiteforthe
mostupdatedlist(seehttp://www.lubrizol.com/BuildingSolutions/ChemicalCompatibility.html).
Figure15.Theeffects(discolorationandcrazing)oftracelevelsofchemicalcontaminantsfromABFII
(amineandammoniumsalt)onstressedCPVCtestspecimens.1=0.1%amineinwater,2=0.01%aminein
water,3=0.001%amineinwater,4=0.1%ammoniumsaltinwater,5=control.
Wewerethefirsttodiscoverandexpressconcern(in2007)aboutthepotentialincompatibilityoftrace
chemicalsthatmaybeextractedfromABF2.ThisdiscoveryhascauseddebatethroughouttheFire
SprinklerIndustry.Recently(3/30/10),FMApprovalscompletedalaboratoryinvestigationoftheissue.
Theyidentifiedextractiblechemicalspresentinsteelpipeshavingantimicrobialliningsandperformed
chemicalcompatibilitytestsoftheextractedchemicalswithCPVC.TheFMApprovalsstudyconcluded
insomecasesdegradationbyreductionofElongationatBreakorTensileStrengthatYieldwas
observedforCPVCspecimensexposedforamaximumof30daystoextractsfromABF/AMScoatedsteel
pipe.Thisfindinghasalsobeenchallengedduetothewayinwhichthechemicalcompatibilitytesting
wasconducted.
InternalContaminationbyRefrigerantLubricantOil
PVCandCPVCpipingisoftenusedtorecirculatethewaterinhydronicheatingsystems.Heatexchanger
leaksareveryrare.However,shouldaleakoccurinaheatexchanger,thewaterintherecirculationloop
Page13of16
maybecomecontaminatedwiththeoillubricantintherefrigerant.BackwhenCFCwasusedasthe
refrigerant,thelubricantwasmineraloil.Whenaleakoccurred,noPVCorCPVCfailureoccurred
becausemineraloiliscompatiblewithbothPVCandCPVC.However,thechangetoHCFCrefrigerants
broughtabouttheneedtochangetoamorepolarlubricantoilbecausemineraloilisnotsolublein
HCFCrefrigerant.MostHCFCrefrigerantsutilizepolyolesteroil(POE)asthelubricant.Unfortunately,
POEoilishighlyincompatiblewithPVC/CPVC(Figure16)andleaksinheatexchangerscancausefailure
ofthePVCorCPVCpipingsystem(Figure10).Thereisaneedforhydronicheatingsystem
manufacturerstodevelopalternativerefrigerantlubricantsthatarecompatiblewithPVCandCPVC.
Figure16.ExposureofaCPVCpipetestringunderstressbecomesbrittleafteronlyafewhoursof
exposuretoPOE.
PipeDefects
ThemanufacturingprocessofCPVCpipeishighlyregulatedwithnumerousrequiredtestsand
standards.PlasticpipeismanufacturedbyextrusionofmoltenPVC/CPVCresinthroughacirculardie
withamandrelheldinplacewiththinmetalvanes(oftenreferredtoasaspider).Whilepassing
throughthedie,themoltenPVCorCPVCresinformulationisslicedbythemandrelvanesbutthenfuses
backtogetheragaintoproduceasolidpipe.Afterthedie,thepipeiscooledusingacombinationofair
andwaterundercontrolledconditionssothatthepipedoesnotendupwithfrozeninstresseswhich
canaffectthemechanicalstrengthandchemicalresistanceofthepipe.Pipedefects,includingresidual
stress,canresultiftheextrusionandcoolingprocessesarenotproperlyoptimized.Pipesthatcontain
highlevelsoffrozeninstressesarelikecoiledspringslookingforopportunitiestorelievethestress.
Stressreliefcanbeachievedinseveralways.Oneisbycrazingwhichmanifestsitselfbytheformationof
hundredsoftinymicrocracksinthepipewall.Apipethathasundergoneextensivecrazinginthepipe
wallisshowninFigure17.Extrusionlines(causedbyadirtydie)createweakpointsinthepipewallthat
aremoresusceptibletochemicalattackresultinginfailurebyESC.Thismodeoffailureisindicatedby
thepresenceofperfectlystraightparallelcracksrunningdowntheinsidepipewall(Figure18).Pipes
havingthesemanufacturingdefectsaremoresusceptibletofailurewhenexposedtowatercontaining
chemicalsthatareincompatiblewiththepipesandfittings.
Page14of16
Figure17.Extensivesurfacecrazingofoutsidepipewall.
Figure18.Weakextrusionlines(likelycausedbydirtydie)ontheinsidesurfaceofaCPVCsprinkler
systempiperesultingintheformationofparallelstraightcracksuponexposuretowatercontaining
contaminants.
ForensicFailureAnalysisProcess
PVC/CPVCpipesandfittingsareexcellentproductsandhavebeenusedsuccessfullyfordecades.There
isalowfailurerateandtheuseofPVC/CPVCmaterialsoffersignificantadvantageoversteelpiping
Page15of16
materials.IamnotawareofanyhealthcautionsregardingtheusageofPVC/CPVCpipesandfittings
otherthantheneedtoinstallthemproperlywithoutusingincompatiblematerialsduringthe
installation.IfyouarehavingacrackingproblemwithPVCorCPVCpipes,PlasticFailureLabscananalyze
thepipesand/ortheinstallationanddiagnosetherootcauseoftheproblem.Wearealsohighly
experiencedprovidingexpertwitnessservicesshouldthepipefailureleadtolitigation.
Ourgoalistodiagnosethecauseoffailureefficientlyandquickly.Ingeneral,wecarryoutalaboratory
examinationofthepipesincludingmeasurementofpipedimensions,examinationofthepipesurfaces
forphysicaldamage,examinationofthepipesurfacesforthepresenceofcontaminants,examinationof
thecrackfracturesurfacesusingopticalordigitalmicroscopy,andASTMtestingofthepipes.
_____________________________________________________________________________
DuanePriddy,Sr.isthefounderandCEOofPlasticFailureLabs.Thecompanyisaleadingproviderofplastic
consulting,expertwitness,andplasticfailureanalysisservices.PriortostartingPlasticFailureLabs,DrPriddywasa
PrincipalScientistforDowPlasticswherehewasinvolvedinhelpingsolveproblemswithplasticmanufactureand
plasticfailureforover30years.PartiallyduetoDr.PriddyspioneeringforensicinvestigationsofPVC/CPVCfailure,
hewasrecentlyawardedFellowoftheSocietyofPlasticEngineers.PleasefeelfreetocontactDr.Priddyanytime
byphone(989.385.2355)oremailatpriddy@plasticfailure.com.
Disclaimer:Whiletheinformationpresentedinthisdocumentisbelievedtobereliable,noguarantee,warranty,is
made,intended,orimpliedastothecorrectnessorsufficiencyofanyinformationprovidedherein.Ifyouhave
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