THE COPPER TUBE HANDBOOK - greatinspectors.com COPPER TUBE HANDBOOK ... FIGURE 4 a,b,c. Coiled expansion loops and expansion offsets ... cost-effective tubing material. 2. Copper is

THE COPPER TUBE HANDBOOK

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TABLE OF CONTENTS

INTRODUCTION ....................................................................................................................................................................6

UNDERSTANDING COPPER TUBEI. STANDARD TUBES ...........................................................................................................................................8

Types of Copper Tube ...........................................................................................................................................8Properties................................................................................................................................................................8Identification of Copper Tube ...............................................................................................................................8

II. SELECTING THE RIGHT TUBE FOR THE JOB ..........................................................................................9Advantages of Copper Tube ..................................................................................................................................9Recommendations for Various Applications ........................................................................................................9

III. DESIGN AND INSTALLATION DATA ..........................................................................................................10Pressure System Sizing........................................................................................................................................10Pressure Ratings and Burst Strength ...................................................................................................................12Drainage Plumbing Systems................................................................................................................................12Copper Tube for Heating Systems ......................................................................................................................13Ground Source Heat Pumps ................................................................................................................................14Nonflammable Medical Gas Piping Systems .....................................................................................................14Snow-Melting Systems........................................................................................................................................15Irrigation and Agricultural Sprinkler Systems ....................................................................................................15Solar Energy Systems ..........................................................................................................................................15General Considerations........................................................................................................................................16

TECHNICAL DATATABLES: TABLE 1. Copper Tube: Types, Standards, Applications, Tempers, Lengths .................................................20

TABLE 2. Dimensions and Physical Characteristics of Copper Tube:2a: Type K..........................................................................................................................................212b: Type L..........................................................................................................................................212c: Type M.........................................................................................................................................222d: DWV............................................................................................................................................222e: ACR Tube for Air Conditioning and Refrigeration Field Service.............................................232f: Medical Gas, K and L ..................................................................................................................24

TABLE 3. Rated Internal Working Pressure for Copper Tube:3a. Type K..........................................................................................................................................253b. Type L..........................................................................................................................................253c. Type M.........................................................................................................................................263d. DWV............................................................................................................................................263e. ACR..............................................................................................................................................27

TABLE 4a. Pressure-Temperature Ratings of Soldered and Brazed Joints ......................................................28TABLE 4b. Pressure-Temperature Ratings of No-flame Joints ........................................................................28TABLE 5. Actual Burst Pressures, Type K, L and M Copper Water Tube, psi at Room Temperature ..........29

TABLE 6. Pressure Loss of Water Due to Friction in Types K, L and M Copper Tube..................................30TABLE 7. Pressure Loss in Fittings and Valves Expressed as Equivalent Lengths of Tube...........................32TABLE 8. Radii of Coiled Expansion Loops and Developed Lengths of Expansion Offsets .........................35TABLE 9. Dimensions of Solder Joint Ends for Wrought and Cast Fittings....................................................37TABLE 10. Solder Requirements for Solder-Joint Pressure Fittings ................................................................39TABLE 11. Typical Brazing Filler Metal Consumption....................................................................................40TABLE 12. Filler Metals for Brazing .................................................................................................................40

FIGURES: FIGURE 1. Arrangement for anchoring DWV stack passing through a concrete floor ...................................13FIGURE 2. Collapsing pressures of copper tube, types K, L and M.................................................................33FIGURE 3. Expansion vs. temperature change for copper tube ........................................................................34FIGURE 4 a,b,c. Coiled expansion loops and expansion offsets.......................................................................35FIGURE 5. Selected pressure fittings .................................................................................................................36FIGURE 6. Dimensions of solder joint fitting ends ...........................................................................................37FIGURE 7. Melting temperature ranges for copper and copper alloys, brazing filler

metals, flux and solders ...................................................................................................................38FIGURE 8. Brazing flux recommendations........................................................................................................39

WORKING WITH COPPER TUBEIV. BENDING............................................................................................................................................................42TABLE: TABLE 13. Bending Guide for Copper Tube ....................................................................................................42

V. JOINING METHODS .......................................................................................................................................43Solder or Brazed Joints ........................................................................................................................................43Solders ..................................................................................................................................................................43Fluxes ...................................................................................................................................................................43

VI. FITTINGS, SOLDERS, FLUXES ..................................................................................................................44Fittings..................................................................................................................................................................44Solders ..................................................................................................................................................................44Fluxes ...................................................................................................................................................................45

VII. SOLDERED JOINTS ........................................................................................................................................46Measuring and Cutting.........................................................................................................................................46Reaming................................................................................................................................................................46Cleaning................................................................................................................................................................47Applying Flux ......................................................................................................................................................47Assembly and Support .........................................................................................................................................48Heating .................................................................................................................................................................48Applying Solder ...................................................................................................................................................49Cooling and Cleaning ..........................................................................................................................................49Testing ..................................................................................................................................................................49

VIII. BRAZED JOINTS..............................................................................................................................................50Brazing Filler Metals ...........................................................................................................................................50Fluxes ...................................................................................................................................................................50 Assembly..............................................................................................................................................................50 Applying Heat and Brazing .................................................................................................................................51Horizontal and Vertical Joints .............................................................................................................................51Removing Residue...............................................................................................................................................51

Published 2010 by Copper Development Association Inc., 260 Madison Avenue, New York, NY 10016

NOTICE: This Handbook has been prepared for the use of journeymen plumbers, pipefitters, refrigeration fitters, sprinkler fitters, plumbing andheating contractors, engineers, and others involved in the design or installation of plumbing, heating, air-conditioning, refrigeration and otherrelated systems. It has been compiled from information sources Copper Development Association Inc. (CDA) believes to be competent. However,recognizing that each system must be designed and installed to meet the particular circumstances, CDA assumes no responsibility or liability of anykind in connection with this Handbook or its use by any person or organization and makes no representations or warranties of any kind hereby.

General Hints and Suggestions............................................................................................................................51Testing ..................................................................................................................................................................51Purging .................................................................................................................................................................51

IX. FLARED JOINTS ..............................................................................................................................................52

X. ROLL GROOVE JOINTS.................................................................................................................................54Preliminary Requirements ...................................................................................................................................54Installation Steps ..................................................................................................................................................54Testing ..................................................................................................................................................................55

XI. PRESS-CONNECT JOINTS ...........................................................................................................................56Preliminary Requirements ...................................................................................................................................56Installation Steps ..................................................................................................................................................56Testing ..................................................................................................................................................................57

XII. PUSH-CONNECT JOINTS..............................................................................................................................58Preliminary Requirements ...................................................................................................................................58Installation Steps ..................................................................................................................................................58Testing ..................................................................................................................................................................59

XIII. STRUCTURAL ADHESIVE JOINTS.............................................................................................................60Preliminary Requirements ...................................................................................................................................60Installation Steps ..................................................................................................................................................60Testing ..................................................................................................................................................................61

XIV. MECHANICALLY FORMED EXTRUDED OUTLETS................................................................................62Preliminary Requirements ...................................................................................................................................62Installation Steps ..................................................................................................................................................62Testing ..................................................................................................................................................................64

APPENDIXXV. ORGANIZATIONS.............................................................................................................................................65

6

INTRODUCTION

Since primitive man firstdiscovered copper, the red metal hasconstantly served the advancement ofcivilization. Archaeologists probingancient ruins have discovered that thisenduring metal was a great boon tomany peoples. Tools for handicraft andagriculture, weapons for hunting, andarticles for decorative and householduses were wrought from copper byearly civilizations. The craftsmen whobuilt the great pyramid for the EgyptianPharaoh Cheops fashioned copper pipeto convey water to the royal bath. Aremnant of this pipe was unearthedsome years ago still in usable condition,a testimonial to copper’s durability andresistance to corrosion.

Modern technology, recognizingthat no material is superior to copper forconveying water, has reconfirmed itas the prime material for such purposes.Years of trouble-free service ininstallations here and abroad have builta new reputation for copper piping in itsmodern form—light, strong, corrosionresistant tube. It serves all kinds ofbuildings: single-family homes, high-rise apartments and industrial,commerical and office buildings.

Today, copper tube for theplumbing, heating and air-conditioningindustries is available in drawn andannealed tempers (referred to in thetrades as “hard” and “soft”) and in awide range of diameters and wall

thicknesses. Readily available fittingsserve every design application. Jointsare simple, reliable and economical tomake—additional reasons for selectingcopper tube.

Today, nearly 5,000 years afterCheops, copper developments continueas the industry pioneers broader usesfor copper tube in engineered plumbingsystems for new and retrofittedresidential, industrial and commericalinstallations.

UNDERSTANDING COPPER TUBE

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Long lasting copper tube is afavorite choice for plumbing, heating,cooling and other systems. In theUnited States, it is manufactured tomeet the requirements of specificationsestablished by ASTM International.

All tube supplied to these ASTMstandards is a minimum of 99.9 percentpure copper. The copper customarilyused for tube supplied to thesespecifications is deoxidized withphosphorus and referred to as UNS C12200 or DHP1 Copper. Other coppers may also be used.

Types of Copper TubeTable 1, page 20, identifies

the six standard types of copper tubeand their most common applications.2

The table also shows the ASTMStandard appropriate to the use ofeach type along with a listing of itscommercially available lengths, sizesand tempers.

Types K, L, M, DWV andMedical Gas tube are designated byASTM standard sizes, with the actualoutside diameter always 1/8-inch largerthan the standard size designation. Eachtype represents a series of sizes withdifferent wall thicknesses. Type K tube

has thicker walls than Type L tube, andType L walls are thicker than Type M,for any given diameter. All insidediameters depend on tube size and wallthickness.

Copper tube for air-conditioningand refrigeration field service (ACR) isdesignated by actual outside diameter.

“Temper” describes the strengthand hardness of the tube. In the pipingtrades, drawn temper tube is oftenreferred to as “hard” tube and annealedas “soft” tube. Tube in the hard tempercondition is usually joined by soldering or brazing, using capillary fittings or by welding.

Tube in the soft temper can bejoined by the same techniques andis also commonly joined by the useof flare-type and compression fittings.It is also possible to expand the end ofone tube so that it can be joined toanother by soldering or brazing withouta capillary fitting—a procedure that canbe efficient and economical in manyinstallations.

Tube in both the hard and softtempers can also be joined by a varietyof “mechanical” joints that can beassembled without the use of the heatsource required for soldering and brazing.

PropertiesThe dimensions and other

physical characteristics of Types K, L,M and DWV tube are given in Tables 2a, b, c and d, pages 21-22. All fourtypes are used for both pressure andnon-pressure applications within therange of their respective safe workingpressures as described in Tables 3a, b,c and d on pages 25-26.

The dimensions and physicalcharacteristics of ACR tube andMedical Gas tube are given in Tables 2e and f, pages 23-24.

Identification of Copper TubeCopper tube, Types K, L, M,

DWV and Medical Gas, must bepermanently marked (incised) inaccordance with its governingspecifications to show tube type, thename or trademark of the manufacturer,and the country of origin. In addition toincised markings, hard tube will havethis information printed on it in a colorwhich distinguishes its tube type (SeeTable 1). Soft ACR tube may not carryany incised or color markings. HardACR tube is color marked only.

I. STANDARD TUBES

1 Phosphorous-Deoxidized, High Residual Phosphorous Copper2 There are many other copper and copper alloy tubes and pipes available for specialized applications. For more information on these products contact the Copper Development Association Inc.

I. STANDARD TUBES

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Advantages of Copper TubeStrong, long lasting, copper tube is

the leading choice of modern contractorsfor plumbing, heating and coolinginstallations in all kinds of residentialand commercial buildings. There areseven primary reasons for this:

1. Copper is economical. Thecombination of easy handling, formingand joining permits savings in installationtime, material and overall costs. Long-term performance and reliability meanfewer callbacks, and that makes copperthe ideal, cost-effective tubing material.

2. Copper is lightweight. Coppertube does not require the heavy thicknessof ferrous or threaded pipe of the sameinternal diameter. This means coppercosts less to transport, handles moreeasily and, when installed, takes lessspace.

3. Copper is formable. Becausecopper tube can be bent and formed, itis frequently possible to eliminate elbowsand joints. Smooth bends permit the tubeto follow contours and corners of almostany angle. With soft temper tube,particularly when used for renovation ormodernization projects, much less walland ceiling space is needed.

4. Copper is easy to join. Coppertube can be joined with capillary fittings.These fittings save material and makesmooth, neat, strong and leak-proof joints.No extra thickness or weight is necessaryto compensate for material removed bythreading.

5. Copper is safe. Copper tube willnot burn or support combustion or de-compose to toxic gases. Therefore, it willnot carry fire through floors, walls andceilings. Volatile organic compounds arenot required for installation.

6. Copper is dependable. Coppertube is manufactured to well-definedcomposition standards and marked withpermanent identification so you knowexactly what it is and who made it. It isaccepted by virtually every plumbing code.

7. Copper is long-lasting. It hasexcellent resistance to corrosion andscaling, high mechanical strength, high-temperature resistance and lifetimeresistance to UV degradation. Copperassures long, trouble-free service, whichtranslates to satisfied customers andsystems that last.

8. Copper is 100% recyclable.Copper stands alone as an engineeringmaterial that can be recycled over andover without degradation in content orproperties. This combined withcopper's proven durability means thatno copper used in a building todayneeds to enter a landfill later.

Minimum Recommendations forVarious Applications

It is up to the designer to select thetype of copper tube for use in a particularapplication. Strength, formability and othermechanical factors often determine thechoice. Plumbing and mechanical codesgovern what types may be used. When achoice can be made, it is helpful to knowwhich type of copper tube has and canserve successfully and economically inthe following applications:

Underground Water Services—Use Type M hard for straight lengthsjoined with fittings, and Type L softwhere coils are more convenient.

Water Distribution Systems—Use Type M for above and below ground.

Chilled Water Mains—Use TypeM for all sizes.

Drainage and Vent Systems—Use Type DWV for above- and below-ground waste, soil and vent lines, roofand building drains and sewers.

Heating—For radiant panel andhydronic heating and for snow meltingsystems, use Type L soft temper wherecoils are formed in place or prefabricated,Type M where straight lengths are used.For water heating and low-pressure steam,use Type M for all sizes. For condensatereturn lines, Type L is successfully used.

Solar Heating—See Heatingsection above. For information on solarinstallation and on solar collectors,write CDA. (See also page 15.)

Fuel Oil, L.P. and Natural GasServices—Use Type L or Type ACRtube with flared joints in accessiblelocations and brazed joints made usingAWS A5.8 BAg series brazing fillermetals in concealed locations.

Nonflammable Medical GasSystems—Use Medical Gas tube TypesK or L, suitably cleaned for oxygenservice per NFPA Standard No. 99,Health Care Facilities.

Air-Conditioning andRefrigeration Systems—Copper is thepreferred material for use with mostrefrigerants. Use Types L, ACR or asspecified.

Ground Source Heat PumpSystems—Use Types L or ACR wherethe ground coils are formed in place orprefabricated, or as specified.

Fire Sprinkler Systems—UseType M hard. Where bending is required,Types K or L are recommended. TypesK, L and M are all accepted by NFPA.

Low Temperature Applications –Use copper tube of Type determined byrated internal working pressures at roomtemperature as shown in Table 3. Coppertube retains excellent ductility at lowtemperatures to –452°F and yieldstrength and tensile strength increase astemperature is reduced to this point. This,plus its excellent thermal conductivity,makes an unusual combination ofproperties for heat exchangers, piping,and other components in cryogenicplants and other low temperatureapplications.

Compressed Air—Use coppertube of Types K, L or M determined bythe rated internal working pressures asshown in Table 3. Brazed joints arerecommended.

II. SELECTING THE RIGHT TUBE FOR THE JOB

II. S

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elevations in the system, and frictionlosses encountered in flow throughpiping, fittings, valves and equipment.

Some of the service pressure islost immediately in flow through thewater meter, if there is one. The amountof loss depends on the relationshipbetween flow rate and tube size. Designcurves and a table showing theserelationships appear in most modelcodes and are available from metermanufacturers.

Some of the main pressure willalso be lost in lifting the water to thehighest fixture in the system. The heightdifference is measured, starting at themeter, or at whatever other pointrepresents the start of the system (or thesegment or zone) being considered. Toaccount for this, multiply the elevationof the highest fixture, in feet, by thefactor 0.434, the pressure exerted by a1-foot column of water. This will givethe pressure in psi needed to raise thewater to that level. For example, adifference in height of 30 feet reducesthe available pressure by 13 psi (30 x0.434 = 13.02).

Friction losses in the system, likelosses through the water meter, aremainly dependent on the flow rate ofthe water through the system and thesize of the piping. To determine theselosses, water demand (and thus, flowrate) of the system must first bedetermined.

Water demand—Each fixture inthe system represents a certain demandfor water. Some examples ofapproximate water demand in gallonsper minute (gpm) of flow, are:

Drinking fountain.......... 0.75

Pressure System SizingDesigning a copper tube water

supply system is a matter ofdetermining the minimum tube size foreach part of the total system bybalancing the interrelationships of sixprimary design considerations:

1. Available main pressure;2. Pressure required at individual

fixtures;3. Static pressure losses due to

height;4. Water demand (gallons per

minute) in the total system and in eachof its parts;

5. Pressure losses due to thefriction of water flow in the system;

6. Velocity limitations based onnoise and erosion.

Design and sizing must alwaysconform to applicable codes. In the finalanalysis, design must also reflectjudgment and results of engineeringcalculations. Many codes, especially themodel codes, include design data andguidelines for sizing water distributionsystems and also include examplesshowing how the data and guidelinesare applied.

Small Systems—Distributionsystems for single-family houses canusually be sized easily on the basis ofexperience and applicable coderequirements, as can other similar smallinstallations. Detailed study of the sixdesign considerations above is notnecessary in such cases.

In general, the mains that servefixture branches can be sized as follows:

■ Up to three 3/8-inch branchescan be served by a 1/2-inch main.

■ Up to three 1/2-inch branches

can be served by a 3/4-inch main.■ Up to three 3/4-inch branches

can be served by a 1-inch main.The sizing of more complex

distribution systems requires detailedanalysis of each of the sizing designconsiderations listed above.

Pressure Considerations—Ateach fixture in the distribution system, aminimum pressure of 8 psi should beavailable for it to function properly—except that some fixtures require ahigher minimum pressure for properfunction, for example:

■ Flush valve for blow-out andsyphon-jet closets ....................25 psi

■ Flush valves for water closetsand urinals................................15 psi

■ Sill cocks, hose bibbs and wallhydrants....................................10 psi.

Local codes and practices may besomewhat different from the above andshould always be consulted forminimum pressure requirements.

The maximum water pressureavailable to supply each fixturedepends on the water service pressureat the point where the buildingdistribution system (or a segment orzone of it) begins. This pressuredepends either on local main pressure,limits set by local codes, pressuredesired by the system designer, or on acombination of these. In any case, itshould not be higher than about 80 psi(pounds per square inch).

However, the entire water servicepressure is not available at each fixturedue to pressure losses inherent to thesystem. The pressure losses includelosses in flow through the water meter,static losses in lifting water to higher

III. DESIGN AND INSTALLATION DATA

III. DESIGN DATA

1111

Pressure loss values in Table 6are given per linear foot of tube. Inmeasuring the length of a system or of any of its parts, the total length oftube must be measured, and for closeestimates, an additional amount must beadded on as an allowance for the extrafriction losses that occur as a result ofvalves and fittings in the line. Table 7,page 32, shows these allowances forvarious sizes and types of valves andfittings.

Water Velocity Limitations —To avoid excessive system noise and the possibility of erosion-corrosion, thedesigner should not exceed flowvelocities of 8 feet per second for coldwater and 5 feet per second in hot waterup to approximately 140°F. In systemswhere water temperatures routinelyexceed 140°F, lower flow velocitiessuch as 2 to 3 feet per second should notbe exceeded. In addition, where 1/2-inchand smaller tube sizes are used, to guardagainst localized high velocity turbulencedue to possibly faulty workmanship(e.g. burrs at tube ends which were notproperly reamed/deburred) or unusuallynumerous, abrupt changes in flowdirection, lower velocities should beconsidered. Locally aggressive waterconditions can combine with thesetwo considerations to cause erosion-corrosion if system velocities are too high.

Due to constant circulation andelevated water temperatures, particularattention should be paid to watervelocities in circulating hot watersystems. Both the supply and returnpiping should be sized so that themaximum velocity does not exceed theabove recommendations. Care should be taken to ensure that the circulatingpump is not oversized, and that thereturn piping is not undersized; both arecommon occurrences in installed pipingsystems.

Table 6 applies to copper tubeonly, and should not be used for otherplumbing materials. Other materialsrequire additional allowances forcorrosion, scaling and caking which are not necessary for copper. This isbecause copper normally maintains itssmooth bore throughout its service life.

Lavatory faucet.............. 2.0Lavatory faucet,self closing................... 2.5

Sink faucet, WC tankball cock....................... 3.0

Bathtub faucet, shower head,laundry tub faucet........ 4.0

Sill cock, hose bibb,wall hydrant................. 5.0

Flush valve (dependingon design...................... 3.5

Shower head .................. 2.2

Adding up numbers like these tocover all the fixtures in an entirebuilding distribution system would givethe total demand for water usage ingpm, if all of the fixtures were operatingand flowing at the same time—which ofcourse does not happen. A reasonableestimate of demand is one based on theextent to which various fixtures in thebuilding might actually be usedsimultaneously. Researchers at theNational Institute of Standards andTechnology studied this question someyears ago. They applied probabilitytheory and field observations to thereal-life problem of simultaneous usageof plumbing fixtures.

The result was a system forestimating total water demand is basedon reasonable assumptions about thelikelihood of simultaneous usage offixtures. Out of this study came theconcept of fixture units.

Each type of fixture is assigned afixture unit value which reflects (1) itsdemand for water, that is, the flow rateinto the fixture when it is used, (2) theaverage time duration of flow when thefixture is used, and (3) the frequencywith which the fixture is likely to beused. Assigned fixture unit values varyby jurisdiction. Consult local plumbingcodes for values used in your area.

Totaling the fixture unit valuesfor all the fixtures in a system, or forany part of the distribution system,gives a measure of the load combinedfixtures impose on the plumbingdistribution and supply system. Thisfixture unit total may be translated intoexpected maximum water demandfollowing the procedure prescribed byyour local code.

Keep in mind the demandcalculations just described apply tofixtures that are used intermittently. Tothis must be added the actual demand ingpm for any fixtures which are designedto run continuously when they are inuse; for example, air-conditioningsystems, lawn sprinkler systems andhose bibbs.

Pressure Losses Due toFriction—The pressure available tomove the water through the distributionsystem (or a part of it) is the mainpressure minus: (1) the pressure loss inthe meter, (2) the pressure needed to lift water to the highest fixture (staticpressure loss), and (3) the pressureneeded at the fixtures themselves. Theremaining available pressure must beadequate to overcome the pressurelosses due to friction encountered by theflow of the total demand (intermittentplus continuous fixtures) through thedistribution system and its various parts.The final operation is to select tubesizes in accordance with the pressurelosses due to friction.

In actual practice, the designoperation may involve repeating thesteps in the design process to re-adjustpressure, velocity and size to achievethe best balance of main pressure, tubesize, velocity and available pressure atthe fixtures for the design flow requiredin the various parts of the system.

Table 6, page 30, shows therelationship among flow, pressuredrop due to friction, velocity and tubesize for Types K, L and M copperwater tube. These are the data requiredto complete the sizing calculation.NOTE: Values are not given for flowrates that exceed the maximumrecommendation for copper tube.

For the tube sizes above about 11/4 inch, there is virtually no differenceamong the three types of tube in termsof pressure loss. This is because thedifferences in cross sectional area ofthese types become insignificant as tubesize increases. In fact, for this reason, thevalue for Type M tube given in Table 6can be used for DWV tube as well.

III. D

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Pressure Ratings and BurstStrength

As for all materials, the allowableinternal pressure for any copper tubein service is based on the formulaused in the American Society ofMechanical Engineers Code forPressure Piping (ASME B31):

P = 2S(tmin – C)

Dmax – 0.8 (tmin – C)

where:P = allowable pressure, psiS = maximum allowable stress in

tension, psitmin = wall thickness (min.), in.Dmax = outside diameter (max.), in.C = a constant

For copper tube, because ofcopper’s superior corrosion resistance,the B31 code permits the factor C to bezero. Thus the formula becomes:

P = 2Stmin

Dmax – 0.8 tmin

The value of S in the formula isthe maximum allowable stress (ASMEB31) for continuous long-term service ofthe tube material. It is only a smallfraction of copper’s ultimate tensilestrength or of the burst strength of coppertube and has been confirmed to be safe byyears of service experience and testing.The allowable stress value depends on theservice temperature and on the temper ofthe tube, drawn or annealed.

In Tables 3a, b, c and d, pages25-26, the rated internal workingpressures are shown for both annealed(soft) and drawn (hard) Types K, L, Mand DWV copper tube for servicetemperatures from 100ºF to 400ºF. Theratings for drawn tube can be used forsoldered systems and systems usingproperly designed mechanical joints.Fittings manufacturers can provideinformation about the strength of theirvarious types and sizes of fittings.

When welding or brazing is usedto join tubes, the annealed ratings mustbe used, since the heating involved inthese joining processes will anneal(soften) the hard tube. This is the reasonthat annealed ratings are shown inTables 3c for Type M and 3d for DWV

tube, although they are not furnished inthe annealed temper. Table 3e, page 27,lists allowable internal workingpressures forACR tube.

In designing a system, jointratings must also be considered,because the lower of the two ratings(tube or joint) will govern theinstallation. Most tubing systems arejoined by soldering or brazing. Ratedinternal working pressures for suchjoints are shown in Table 4a, page 28.These ratings are for all types of tubewith standard solder joint pressurefittings and DWV fittings. In solderedtubing systems, the rated strength of thejoint often governs design.

When brazing, use the ratings forannealed tube found in Tables 3a-3e asbrazing softens (anneals) the tube nearthe joints (the heat affected zone). Jointratings at saturated steam temperaturesare shown in Table 4a.

The pressures at which coppertube will actually burst are many timesthe rated working pressures. Comparethe actual values in Table 5, page 29,with the rated working pressures foundin Tables 3a-3c, pages 25-26. The veryconservative working pressure ratingsgive added assurance that pressurizedsystems will operate successfully forlong periods of time. The much higherburst pressures measured in testsindicate that tubes are well able towithstand unpredictable pressure surgesthat may occur during the long servicelife of the system. Similar conservativeprinciples were applied in arriving at theworking pressures for brazed andsoldered joints. The allowable stressesfor the soldered joints assure jointintegrity under full rated load forextended periods of time. Short-termstrength and burst pressures for solderedjoints are many times higher. Inaddition, safety margins were factoredinto calculating the joint strengths.

Drainage Plumbing SystemsThe design and installation of

drainage systems range from simple tocomplex, depending on the type ofbuilding, the local code and theoccupancy requirements. The localplumbing code will include

requirements for acceptable materials,installation and inspection, and thesemust be followed as the firstrequirement of an acceptable job.

There are usually differences—sometimes minor, sometimes quiteimportant—among plumbing codes.Among the features which differ fromcode to code may be minimum tubesizes, permissible connected fixtureloads, fittings and connections, methodsof venting, supports and testing. Fewcodes are completely specific aboutinstallation details and leave theresponsibility of proper and suitableinstallation to the designer and thecontractor.

In large and multi-story buildings,the design will generally require theservices of a mechanical engineer and aplumbing designer. The plumbingdesigner has the responsibility forcoordinating the drainage system designwithin the overall building constructionrequirements. A good drainage designmust accommodate the problems ofinstallation space, building movement,support, expansion and contraction, pipesleeves, offsets and provisions fornecessary maintenance.

In residential buildings and smallone- and two-story commercialbuildings, the drainage piping is usuallystraightforward in design and simple ininstallation. Type DWV copper tube,installed with good workmanship by anexperienced plumber, will provide manyyears of trouble-free service.

The smaller diameter of DWVtube and fittings makes it possible toinstall copper drainage systems whereother competing piping materials wouldbe impossible, difficult or more costly.For example, a 3-inch copper stack hasonly a 33/8-inch outside diameter at thefitting and can be installed in a 31/2-inchcavity wall.

Prefabrication—Considerablesavings can be effected by prefabricatingcopper DWV subassemblies. Prefabrica-tion permits work even when adverseweather prohibits activity on the job site.Simple, inexpensive jigs can be made to position the tube and fittings duringassembly and help eliminate costlydimensional errors. Freedom of movement

III. DESIGN DATA

1313

at the bench permits joints to be made morereadily than at the point of installation,where working space may be limited.

Soldered joints are strong andrigid. Subassemblies can be handledwithout fear of damage. The lightweightfeatures of copper DWV tube andfittings make it possible to handle fairlylarge assemblies. Other dependabledrainage plumbing materials mayweigh three to four times as much.Subassemblies require a minimum ofsupport when connected to a previouslyinstalled section of a drainage system.

Copper DWV tube has been usedsuccessfully for years in all parts ofdrainage plumbing systems for high-risebuildings—for soil and vent stacks andfor soil, waste and vent branches.Copper tube’s light weight and the easewith which it can be prefabricated havebeen especially important in high-risedrainage systems.

Expansion of DWV Systems—Inhigh-rise buildings, expansion andcontraction of the stack should beconsidered in the design. Possiblemovement of a copper tube stack as thetemperature of the stack changes isabout 0.001 inch per degree F per 10-foot floor. (See Figure 3, page 34.)This is slightly more than for iron andsteel pipe and considerably less than for plastic.

Since length, temperaturechanges and piping design itself are allinvolved in expansion, the designermust determine the best way to takecare of expansion in any particularinstallation. One simple procedure forcontrolling thermal movement is toanchor the stack. Anchoring at everyeighth floor will take care of ananticipated maximum temperature riseof 50°F; anchoring every four floorswill take care of a 100°F maximumtemperature rise. Care should be takento avoid excessive stresses in the stackanchors or structure caused by thermalgrowth of the stack.

Perhaps the simplest effectiveanchor, when the stack passes throughconcrete floors, is to use pipe clamps andsoldered fittings as shown in Figure 1.The pipe clamps can be placed aboveand below the floor, backed up by

sliding the fittings tight against theclamps and soldering them in place. Atall floors between anchors, sleeves in theconcrete floors should be used to preventlateral movement of the tube.

Hydrostatic Testing of DWVSystems—While a copper drainagesystem is not ordinarily operated underpressure conditions, it must withstand the pressure of a hydrostatic test. Theallowable pressures for copper DWVtube and soldered joints are given inTable 3d, page 26, and in Table 4a,page 28, respectively.

To determine the vertical heightthat can be statically pressure tested(with water) in one segment, take thelowest applicable figure from Table 3dand Table 4a and multiply by 2.3. (A2.3-foot column of water creates apressure of 1 psi.) For example, if 50-50tin-lead solder is used and the largesttube size is 4-inch at a servicetemperature of 100°F, multiply 80 (thelower of the solder joint rating of 80 inTable 4a and the tube rating of 257 inTable 3d) by 2.3; the result is 184.Thus, a 184-foot vertical segment ofstack could be tested at once.

If 95-5 tin-antimony solder is thejoining material, the lower of the corre-sponding rating for 4-inch tube from the tables, 257 (the tube governs) ismultiplied by 2.3, equaling 591. Thus,theoretically, 591 feet (59 ten-foot stories)could be tested at once. If the joint isbrazed, the value from Table 3d forannealed tube (150) governs. This valuemultiplied by 2.3 equals 345 feet, or only34 stories at once. The actual verticalsegment height tested is usually muchless and depends on practical considera-tions on the job.

Copper Tube for Heating SystemsCopper tube is popular for heating

systems in both new and remodeledbuildings. Contractors have learnedthrough experience that, all factorsconsidered, copper tube remainssuperior to any substitute material. Theadvantages of light weight, choice oftempers, long-term reliability, and easeof joining, bending and handling are ofmajor importance.

For example, where rigidity andappearance are factors, drawn tube isrecommended. Annealed tube isparticularly suitable for panel heating,snow melting, and short runs toradiators, convectors and the like. Withannealed tube the need for fittings isreduced to a minimum, savingsubstantial installation labor and material.

Forced circulation hot waterheating systems provide uniformheating and quick response to changes inheating load, require little maintenanceand can be easily zoned to providedifferent temperature levels throughoutthe buildings. These systems use thesmallest and most economical tubesizes with soldered joints and requirelittle space for the installation. Also, incombination with the heating systemand where permitted by code, domestichot water can be heated directly—eliminating the need for a separatewater heater.

Design and installation data forheating systems are given in TheHeating and Air-Conditioning Guide,published by the American Society forHeating, Refrigeration and Air-Conditioning Engineers (ASHRAE), aswell as in literature published bymanufacturers of boilers and otherheating devices. Those publicationsshould be consulted for detailed design.

Steam-Heating Return Lines—For steam-heating systems, especiallyreturn lines, the outstanding corrosionresistance and non-rusting characteris-tics of copper tube assure trouble-freeservice and maintenance of traps,valves and other devices. On conden-sate and hot water return lines, it isrecommended that the last two feetbefore the heating medium should bedouble the size of the rest of the line.

FIGURE 1: Arrangement for anchoring DWVatack passing through a concrete floor.

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1414

spacing. For ceiling panel installationsthe sinuous coils are formed of 3/8-inchsoft temper tube with a tube spacing of4 inches or 6 inches. Soldered joints arecommonly used.

Ground Source Heat PumpsAir-source heat pumps have

been used for residential andcommercial heating and cooling formany years. Such units rely on air-to-air heat exchange throughevaporator units similar to those usedfor air conditioners.

More recent heat pumptechnology relies on circulating arefrigerant through buried coppertubing for heat exchange. These unitsrely on the constancy of the groundtemperature below the frost level (about55°F) for heat transfer and areconsiderably more efficient than theirair-source counterparts. They areknown variously by such terms asground source, earth-coupled, directexchange or geothermal.

The most efficient ground sourceheat pumps use ACR, Type L orspecial-size copper tubing buried in theground to transfer heat to or from theconditioned space. The flexible coppertube (typically 1/4-inch to 5/8-inch) canbe buried in deep vertical holes,horizontally in a relatively shallow gridpattern, in a vertical fence-likearrangement in medium-depth trenches,or as custom configurations suited tothe installation.

The number of manufacturerswhich can supply commerical andresidential ground source units isconstantly growing. Contact the CopperDevelopment Association Inc. to obtainthe current listing.

Nonflammable Medical GasPiping Systems

Safety standards for oxygen andother positive-pressure medical gasesrequire the use of Type K or L coppertube (see ASTM B819). Specialcleanliness requirements are called forbecause oxygen under pressure maycause the spontaneous combustion of

some organic oils (the residual oflubricating oil used during manufacture)and for the safety of patients receivingmedical gases.

Copper tube for medical gas linesis furnished by the manufacturerssuitably cleaned and capped or plugged.Care must be taken to preventcontamination of the system when thecaps or plugs are removed and tube isinstalled. The installer must satisfyhimself and the inspection departmentthat the cleanliness requirements of thecode have been met.

The following requirements arebased on those found in NFPA StandardNo. 99, Health Care Facilities, Chapter4, Gas and Vacuum Systems.

Installation and Testing ofMedical Gas Piping Systems—

1. All piping, valves, fittings andother components for use in all non-flammable medical gas systems must bethoroughly cleaned by the manufacturerto remove oil, grease and other readilyoxidizable materials as if they werebeing prepared for oxygen service. Useparticular care in storage and handling.Such material must be capped or pluggedto prevent recontamination before finalassembly. Just prior to final assembly,the material must be examined internallyfor contamination. ■ Cleaning must be done in accordancewith the provisions of CGA PamphletG-4.1, Cleaning Equipment for OxygenService.

2. All brazed joints in the pipingshall be made up using brazing fillermetals that bond with the base metalsbeing brazed and that comply withSpecification for Brazing Filler Metal,ANSI/AWS A5.8.■ Copper-to-copper joints shall be madeusing a copper-phosphorus brazingfiller metal (BCuP series) without flux.■ Dissimilar metals such as copper andbrass shall be joined using anappropriate flux with either a copper-phosphorus (BCuP series) or a silver(BAg series) brazing filler metal. Applyflux sparingly to the clean tube only andin a manner to avoid leaving any excessinside of completed joints.

For example, if the return line is 1-inchtube, enlarge it to 2-inch.

Radiant Panel Heating—Amodern application of an ancientprinciple, radiant panel heating, can beused successfully in nearly all types ofstructures. In panel systems, low-temperature hot water, circulatingthrough coils or grids of copper tubeembedded in a concrete floor or plasterceiling, warms the surfaces and the air.Panel systems offer uniform heatingand comfort, an invisible heat source,complete use of the floor area,cleanliness and the elimination of dust-carrying drafts.

Copper tube is the ideal pipingmaterial for floor and ceiling panelsbecause of its excellent heat transfercharacteristics, light weight, longlengths, corrosion resistance and ease of bending, joining and handling. Softtemper tube in coils is commonly usedfor sinuous (curved pattern) heatinglayouts, since it is easily bent and jointsare reduced to a minimum. Hard tempertube is used for mains, risers, heatersand grid-type heating coils.

Location of the heating panel isrelatively unimportant for the comfortof room occupants, but it does dependon the architectural and thermalcharacteristics of the room. Floorinstallations have the advantage of lowinitial cost and are particularly suitablefor garages, schools and churches. Theyare generally designed to operate at amaximum surface temperature of 85°F.Above this temperature, occupantsbecome uncomfortable.

Ceiling panels can be operated athigher surface temperatures and heatoutput levels than floor panels. Heatingpanels respond quickly to changes inheating load, have low thermal storageand require only a simple control system.

The tube sizes of heating coilschiefly affect the hydraulics of theheating system and are relativelyunimportant from the standpoint of heatoutput of the panel. For sinuous floorcoils 3/8-inch, 1/2-inch and 3/4-inchsofttemper tube are generally used with a9-inch or 12-inch center-to-center

III. DESIGN DATA

1515

(NOTE: Ensure properventilation. Some BAg series fillermetals contain cadmium, which,when heated during brazing, canproduce toxic fumes.)■ During brazing, the system shall becontinuously purged with oil-free drynitrogen to prevent the formation ofscale within the tubing. The purge shallbe maintained until the joint is cool tothe touch.■ The outside of all tubes, joints andfittings shall be cleaned by washingwith hot water after assembly to removeany excess flux and provide for clearvisual inspection of brazed connections.■ A visual inspection of each brazedjoint shall be made to assure that thealloy has flowed completely around thejoint at the tube-fitting interface. Whereflux has been used, assure that solidifiedflux residue has not formed a temporaryseal that could hold test pressure.

3. Threaded joints in pipingsystems shall be tinned or made up withpolytetrafluoroethylene (such as Teflon®)tape or other thread sealants suitable for oxygen services. Sealants shall beapplied to the male threads only.

Snow-Melting SystemsSnow-melting systems, installed

in walks, driveways, loading platformsand other paved areas, are an efficient,economical means of snow, sleet andice removal. To warm the surface, a 50-50 solution of water and antifreeze is circulated through copper tubeembedded in the concrete or blacktop.Considerable savings can be realized at industrial plant installations wherewaste heat sources can be utilized.

In general, installation of snowmelting coils is similar to that of floorpanel heating coils. Selection of asinuous or a grid pattern for a snow-melting system depends largely on theshape, size and installation conditions.Grids are good for square andrectangular areas; sinuous coils areusually preferred for irregular areas.The lower pressure loss with a gridconfiguration permits the use of smallerdiameter tube saving material costs.Maximum economy is often realized

with a combination of sinuous and grid-type coils.

Soft temper copper tube issuitable for both sinous and grid-typecoils; hard temper is better for largergrid coils and for mains. Soft tubefacilitates the installation of sinuouscoils because of its long lengths andease of bending which reduce thenumber of joints to a minimum.

The solution temperature enteringthe snow melting coils should be 120°Fto 130°F. To obtain a heating effect forsnow melting of 100 BTU per hour persquare foot with copper tube spaced on12-inch centers in concrete (or 9-inchcenters in blacktop), a maximum of 140feet of 1/2-inch tube or 280 feet of3/4-inch tube may be used. To obtain aheat input of 200 BTU per hour persquare foot of snow area, a maximumof 60 feet of 1/2-inch tube or 150 feet of 3/4-inch tube may be used.

Tube in concrete should belocated about 11/4 to 11/2 inches belowthe surface. The concrete should bereinforced with wire mesh. In blacktop,11/2 inches minimum of compactedthickness of blacktop should cover thetube. The tube should be laid with careon compacted gravel, crushed stone or a concrete base. Allowances should bemade for lateral movement where thetube enters and leaves the concrete orblacktop.

The same types of heaters andcirculating pumps available for radiantheating installations are suitable forsnow-melting panels. The panels also may be hooked up to a building’sspace heating system, if the systemhas sufficient capacity for theadditional load and satisfactoryprecautions against freezing canbe made.

Irrigation and AgriculturalSprinkler Systems

Irrigation systems are necessitiesin arid agricultural areas, and sprinklingsystems for maintaining landscapedareas are being used increasingly.Regardless of type or size of system,many successful installations testify that copper is the ideal tube material for the lines.

With the aid of pressure loss and velocity relationships shown inTable 6, page 30, and the instructioncontained in the literature of pump andsprinkler manufacturers, plumbers canlay out a copper tube watering system toservice lawns, crops or golf courses.

System lines should be laid deepenough to avoid mechanical damage bytools and they should be pitched to drainfreely. Where freezing can be expected,the system should be installed below thefrost line.

Expansion and contraction shouldnot be a problem as long as lines are notrigidly anchored.

Solar Energy SystemsToday's focus on energy and

resource efficiency as well as sustainableconstruction has created a global inertiafor the use of solar thermal heating andcooling for both both space-conditioningand water heating. In many ways, thisparallels the national commitment to usesolar energy spawned by the energycrises in the 1970s. Solar energy systemsto heat domestic water and for spaceheating are based on adding a collectorto the heating system to capture energyfrom the sun. In general, this simplyinvolves extending the heating/plumbingsystem to the roof of the house, where asolar collector is incorporated into it.

Copper is the logical material forsolar energy systems because:

■ It has the best thermalconductivity of all engineering metals;

■ It is highly resistant to bothatmospheric and aqueous corrosion;

■ It is easy to fabricate and to joinby soldering or brazing;

■ It has been used both forplumbing and for roofs since metalswere first employed in thoseapplications.

Copper’s thermal advantagesmean thinner copper sheet can collectthe same heat as much thicker gages ofaluminum or steel sheet, and coppercollector tubes can be more widelyspaced.

Copper’s resistance toatmospheric corrosion is welldemonstrated by its service in roofing

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1616

and flashing. Unless attacked by thesulfur or nitrogen oxide exhausts fromutilities or process industries, copperhas withstood decades—evencenturies—of weathering.

Copper resists hot watercorrosion equally well. Properly sized to keep flow rates below thoserecommended on page 11, and properlyinstalled, copper hot water systems are,for all practical purposes, completelyresistant to corrosion.

The ease with which copperplumbing systems are joined bysoldering needs no special emphasis.Sheet copper fabrication is equallyrecognized for its ease and simplicity.

General ConsiderationsIt is not possible in a handbook

of this type to cover all the variables aplumbing system designer may have toconsider. However, in addition to theforegoing discussion, the followinginformation may also prove helpfulwhen preparing job specifications.

Expansion Loops—Copper tube,like all piping materials, expands andcontracts with temperature changes.Therefore, in a copper tube systemsubjected to excessive temperaturechanges, a long line tends to buckle orbend when it expands unlesscompensation is built into the system.Severe stresses on the joints may alsooccur. Such stresses, buckles or bendsare prevented by the use of expansionjoints or by installing offsets, “U”bends, coil loops or similararrangements in the tube assembly.These specially shaped tube segmentstake up expansion and contractionwithout excessive stress. The expansionof a length of copper tube may becalculated from the formula:

Temperature Rise (degrees F)x Length (feet)x 12 (inches per foot)x Expansion Coefficient (inchesper inch per degree F)= Expansion (inches)Calculation for expansion and

contraction should be based on theaverage coefficient of expansion of

copper which is 0.0000094 inch perinch per degree F, between 70°F and212°F. For example, the expansion ofeach 100 feet of length of any size tubeheated from room temperature (70°F) to170°F (a 100°F rise) is 1.128 inches.

100°F x 100 ft x 12 in./ft.x 0.0000094 in./in./°F=1.128 in.

Figure 3, page 34, shows thechange in length per 100 feet of coppertube, with temperature. The previousexample is shown by the dotted line.

Table 8, page 35, gives the radiinecessary for coiled expansion loops,described in Figure 4, page 35.Expansion offset lengths may beestimated from Table 8.

Alternatively, the necessarylength of tube in an expansion loop oroffset can be calculated using theformula:

where:L = developed length, in feet, in theexpansion loop or offset as shown inFigure 4.E= modulus of elasticity of copper, in

psi.P = design allowable fiber stress of

material in flexure, in psi.do = outside diameter of pipe, in inches.e = amount of expansion to be

absorbed, in inches.For annealed copper tube:

E = 17,000,000 psiP = 6,000 psiThus, the developed length L is simply:

L = 7.68 (doe)1/2

Tube Supports—Drawn tempertube, because of its rigidity, is preferredfor exposed piping. Unless otherwisestated in plumbing codes, drawn tempertube requires support for horizontallines at about 8-foot intervals for sizesof 1-inch and smaller, and at about 10-foot intervals for larger sizes.

Vertical lines are usually supportedat every story or at about 10-foot intervals,

but for long lines where there are theusual provisions for expansion andcontraction, anchors may be severalstories apart, provided there are sleevesor similar devices at all intermediatefloors to restrain lateral movement, seeFigure 1, page 13.

Annealed temper tube in coilspermits long runs without intermediatejoints. Vertical lines of annealed tempertube should be supported at least every10 feet. Horizontal lines should besupported at least every 8 feet.

Resistance to Crushing—Testsmade by placing a 3/4 -inch round steelbar at right angles across a 1-inchannealed copper tube and then exertingpressure downward revealed that, evenwith this severe point-contact loading,700 pounds were required to crush thetube to 75 percent of its originaldiameter. Two-inch sizes, because oftheir greater wall thicknesses, resistedeven more weight before crushing.

Plumbing codes and good pipingpractice require that all excavationsshall be completely backfilled as soonafter inspection as practical. Trenchesshould first be backfilled with 12 inchesof tamped, clean earth which should notcontain stones, cinders or othermaterials which would damage the tubeor cause corrosion. Equipment such asbulldozers and graders may be used tocomplete backfilling. Suitableprecautions should be taken to ensurepermanent stability for tube laid in freshground fill.

Water Hammer—Water hammeris the term used to describe thedestructive forces, pounding noises andvibrations which develop in a watersystem when the flowing liquid isstopped abruptly by a closing valve.

When water hammer occurs, ahigh-pressure shock wave reverberateswithin the piping system until theenergy has been spent in frictionallosses. The noise of such excessivepressure surges may be prevented byadding a capped air chamber or surgearresting device to the system.

Arresting devices are availablecommercially to provide permanentprotection against shock from water

L= 112

3EP( )1/2 (d e)o

1/2

III. DESIGN DATA

1717

hammer. They are designed so thewater in the system will not contact theair cushion in the arrester and, onceinstalled, they require no furthermaintenance.

On single-fixture branch lines, thearrester should be placed immediatelyupstream from the fixture valve. Onmultiple-fixture branch lines, thepreferred location for the arrester is onthe branch line supplying the fixturegroup between the last two fixturesupply pipes.

Collapse Pressure of CopperTube—The constantly increasing use ofcopper and copper alloy tube incondensers, water heaters and other heattransfer devices for water, gas and fluidlines, and many other engineeringapplications where a pressuredifferential exists on opposite sides ofthe tube wall, makes accurate datanecessary regarding collapse pressures.See Figure 2, page 33.

Freezing—Annealed temper tubecan withstand the expansion of freezingwater several times before bursting.Under testing, the water filling a 1/2-inchsoft tube has been frozen as many as sixtimes, and a 2-inch size, eleven times.This is a vital safety factor favoring softtube for underground water services.However, it does not mean that copperwater tube lines should be subjected to freezing.

Corrosion—Copper water tube iscorrosion resistant. It is very infrequentthat waters or special conditions areencountered which can be corrosiveto copper tube. When they areencountered, they should be recognizedand dealt with accordingly.

Since World War II, over 18billion pounds of copper plumbing tubehas been produced in the United States,80% of which has been installed inwater distribution systems. Thistranslates into more than 7 million milesof copper tube. The rare problems ofcorrosion by aggressive water, possiblyaggravated by faulty design orworkmanship, should be viewed in thecontext of this total record ofoutstanding service performance. Ingeneral, widespread use of copper

plumbing tube in a locality can be takenas good evidence that the water there isnot agressive to copper.

When corrosion problems dooccur, they usually stem from one of thefollowing causes:

(1) aggressive, hard well watersthat cause pitting;

(2) soft, acidic waters that do notallow a protective film to form insidethe copper tube;

(3) system design or installationwhich results in excessive water flowvelocity or turbulence in the tube;

(4) unacceptable workmanship;(5) excessive or aggressive flux;(6) aggressive soil conditions.Aggressive pitting waters can be

identified by chemical analysis andtreated to bring their composition withinacceptable limits. Characteristically,they have high total dissolved solids(t.d.s.) including sulfates and chlorides,a pH in the range of 7.2 to 7.8, a highcontent of carbon dioxide (CO2) gas(over 10 parts per million, ppm), andthe presence of dissolved oxygen(D.O.) gas.

A qualified water treatmentprofessional can specify a treatment forany aggressive water to make it non-aggressive to plumbing materials. Ingeneral, this involves raising the pH and combining or eliminating the CO2

gas. Sometimes simple aeration of thewater (e.g., spraying in the open air) istreatment enough.

Pitting can also be caused orintensified by faulty workmanshipwhich leaves excessive amounts ofresidual aggressive flux inside the tubeafter installation. If the joints have beenoverheated during installation and theexcess residual flux has polymerized,the pitting problem can worsen.

Soft acidic waters can cause theannoying problem of green staining offixtures or “green water.” Raising thepH of such waters to a value of about7.2 or more usually solves the problem,but a qualified water treatment professionalshould be consulted. A typical treatmentfor an individual well water supply is tohave the water flow through a bed ofmarble or limestone chips.

Excessive water velocity causeserosion-corrosion or impingementattack in plumbing systems. Asexplained in the discussion of pressuresystem sizing beginning on page 10, toavoid erosion-corrosion (and noise)problems, the water velocity in aplumbing system should not exceed 5 to8 feet per second—the lower limitapplying to smaller tube sizes.

Velocity effects can beaggravated if the water is chemicallyaggressive due to pH or gas content asoutlined above, or if solids (silt) areentrained in the flow. The combinationof a velocity that is otherwiseacceptable and a water chemistry that issomewhat aggressive can sometimescause trouble that would not result fromeither factor by itself.

Erosion-corrosion can also beaggravated by faulty workmanship. Forexample, burrs left at cut tube endscan upset smooth water flow, causelocalized turbulence and high flowvelocities, resulting in erosion-corrosion.

Any metal pipe laid in cinders issubject to attack by the acid generatedwhen sulfur compounds in the cinderscombine with water. Under suchcircumstances, the tube should beisolated from the cinders with an inertmoisture barrier, a wrapping ofinsulating tape, a coating of anasphaltum paint, or with some otherapproved material. With rare exception,natural soils do not attack copper.

Copper drainage tube rarelycorrodes, except when misused or whenerrors have been made in designing orinstalling the drainage system. Animproper horizontal slope can create asituation where corrosive solutionscould lie in the tube and attack it. Ifhydrogen sulfide gas in large volume isallowed to vent back into the housedrainage system, it can attack the tube.

Vibration—Copper tube canwithstand the effects of vibration whencareful consideration is given to thesystem design.

Care should be taken wheninstalling systems subject to vibration to assure that they are free fromresidual stresses due to bending or

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concentrations of lead and copper mustbe below the action levels of 15µg/Land 1300µg/L, respectively.

NSF International has certifiedseveral copper tube and fittingsmanufacturers to ANSI/NSF Standard 61.All have the limitations of being certifiedfor use in non-corrosive aqueousenvironments. Specifically, the pH mustnot be below 6.5. Otherwise, resultantcopper concentrations in tap water mayexceed the action level established bythe EPA.

ANSI/NSF Standard 61 requiresproducts evaluated to conditions otherthan those specified in the standard(such as pH 5 and 10 exposure water) tobe labeled with a limitation statement,as follows:

Copper tube (Alloy C12200) is Certified by NSF to ANSI/NSFStandard 61 for public water supplies

misalignment. Residual stressescoupled with vibration can causefatigue at bends and connectionswhere such residual stresses have beenbuilt into the system.

Durability—Under normalconditions, a correctly designed andproperly installed copper water tubeassembly will easily last the life of thebuilding. Throughout its existence, theassembly should function as well as itdid when originally installed.

NSF Certification—The U.S.Safe Drinking Water Act (1996) and theLead and Copper Rule (1991) requirepublic water suppliers to provide non-corrosive drinking water to customers.Typically, this is accomplished throughthe use of pH adjustment (pH 6.5 to 8.5) and through the addition ofcorrosion inhibitors such as ortho- andpolyphosphates. The resultant tap water

meeting or in the process of meeting the EPA Lead and Copper Rule (56FR26460, June 7, 1991). Water supplieswith pH less than 6.5 may requirecorrosion control to limit coppersolubility in drinking water.

NSF Certified copper tube mustbear the NSF Certification mark and thelimitation statement. The length of thelimitation statement makes it difficult toplace on the tube itself. Additionally,current inking technology results insmearing and low legibility. For thesereasons, NSF certification policiesallow copper tube manufacturers toplace the limitation statement on a tagattached to bundles of copper tube, oron the boxes of coiled copper tube.Placing “NSF” on the tube itself is stillrequired.III. DESIGN DATA

TECHNICAL DATA

TYPE L

OXY, MED,OXY/MED,OXY/ACR,ACR/MED

1 There are many other copper and copper alloy tubes and pipes available for specialized applications. For information on these products, contact the Copper Development Association Inc.

2 Individual manufacturers may have commercially available lengths in addition to those shown in this table.3 Tube made to other ASTM standards is also intended for plumbing applications, although ASTM B88 is by far the

most widely used. ASTM Standard Classification B 698 lists six plumbing tube standards including B 88.4 Available as special order only.

TABLE 1. Copper Tube: Types, Standards, Applications, Tempers, Lengths

Tube TypeColorCode Standard Application1

Commercially Available Lengths2

Nominal or Standard Sizes Drawn Annealed

STRAIGHT LENGTHS:1/4-inch to 8-inch 20 ft 20 ft10-inch 18 ft 18 ft12-inch 12 ft 12 ft

COILS:

1/4-inch to 1-inch— 60 ft— 100 ft

11/4 inch and 11/2-inch — 60 ft

2-inch— 40 ft— 45 ft

STRAIGHT LENGTHS:1/4-inch to 10-inch 20 ft 20 ft12-inch 18 ft 18 ft

COILS:

1/4-inch to 1-inch— 60 ft— 100 ft

11/4 inch and 11/2-inch — 60 ft

2-inch— 40 ft— 45 ft

STRAIGHT LENGTHS:3/8-inch to 41/8-inch 20 ft 4

COILS:1/8-inch to 15/8-inch — 50 ft

STRAIGHT LENGTHS:

1/4-inch to 12-inch 20 ft N/A

STRAIGHT LENGTHS:


STRAIGHT LENGTHS:


TYPE K Green ASTM B883

Domestic WaterService and Distribution,Fire Protection,Solar,Fuel/Fuel Oil,HVAC,Snow Melting,Compressed Air,Natural Gas, Liquified

Petroleum (LP) Gas,Vacuum

Blue ASTM B88

Domestic WaterService and Distribution,Fire Protection,Solar,Fuel/Fuel Oil,Natural Gas, Liquified

Petroleum (LP) Gas,HVAC,Snow Melting,Compressed Air,Vacuum

TYPE M Red ASTM B88

Domestic WaterService and Distribution,Fire Protection,Solar,Fuel/Fuel Oil,HVAC,Snow Melting,Vacuum

DWV Yellow ASTM B306Drain, Waste, Vent,HVAC,Solar

ACR Blue ASTM B280

Air Conditioning,Refrigeration,Natural Gas, Liquified

Petroleum (LP) Gas,Compressed Air

(K)Green(L)Blue

ASTM B819Medical GasCompressed Medical Air,Vacuum

20

TABLE 2a. Dimensions and Physical Characteristics of Copper Tube: TYPE K

TABLE 2b. Dimensions and Physical Characteristics of Copper Tube: TYPE L

Nominal orStandard

Size, inchesOutside

DiameterInside

DiameterCu ft Gal

WallThickness

Contents of Tubeper linear ft

Cross SectionalArea of Bore,

sq inches

Weightof Tube Only,

poundsper linear ft

Weightof Tube & Water,

poundsper linear ft

Nominal Dimensions, inches Calculated Values (based on nominal dimensions)

1/4 .375 .305 .035 .073 .145 .177 .00051 .003793/8 .500 .402 .049 .127 .269 .324 .00088 .006601/2 .625 .527 .049 .218 .344 .438 .00151 .01135/8 .750 .652 .049 .334 .418 .562 .00232 .01743/4 .875 .745 .065 .436 .641 .829 .00303 .0227

1 1.125 .995 .065 .778 .839 1.18 .00540 .040411/4 1.375 1.245 .065 1.22 1.04 1.57 .00847 .063411/2 1.625 1.481 .072 1.72 1.36 2.10 .0119 .08942 2.125 1.959 .083 3.01 2.06 3.36 .0209 .15621/2 2.625 2.435 .095 4.66 2.93 4.94 .0324 .2423 3.125 2.907 .109 6.64 4.00 6.87 .0461 .34531/2 3.625 3.385 .120 9.00 5.12 9.01 .0625 .4684 4.125 3.857 .134 11.7 6.51 11.6 .0813 .6085 5.125 4.805 .160 18.1 9.67 17.5 .126 .9406 6.125 5.741 .192 25.9 13.9 25.1 .180 1.358 8.125 7.583 .271 45.2 25.9 45.4 .314 2.35

10 10.125 9.449 .338 70.1 40.3 70.6 .487 3.6412 12.125 11.315 .405 100.55 57.8 101 .701 5.25

Nominal orStandard

Size, inchesOutside

DiameterInside

DiameterCu ft Gal

WallThickness


Cross SectionalArea of Bore,

sq inches

Weightof Tube Only,

poundsper linear ft


poundsper linear ft


1/4 .375 .315 .030 .078 .126 .160 .00054 .004053/8 .500 .430 .035 .145 .198 .261 .00101 .007531/2 .625 .545 .040 .233 .285 .386 .00162 .01215/8 .750 .666 .042 .348 .362 .506 .00232 .01743/4 .875 .785 .045 .484 .455 .664 .00336 .0251

1 1.125 1.025 .050 .825 .655 1.01 .00573 .042911/4 1.375 1.265 .055 1.26 .884 1.43 .00875 .065511/2 1.625 1.505 .060 1.78 1.14 1.91 .0124 .09252 2.125 1.985 .070 3.09 1.75 3.09 .0215 .16121/2 2.625 2.465 .080 4.77 2.48 4.54 .0331 .2483 3.125 2.945 .090 6.81 3.33 6.27 .0473 .35431/2 3.625 3.425 .100 9.21 4.29 8.27 .0640 .4784 4.125 3.905 .110 12.0 5.38 10.1 .0764 .5715 5.125 4.875 .125 18.7 7.61 15.7 .130 .9716 6.125 5.845 .140 26.8 10.2 21.8 .186 1.398 8.125 7.725 .200 46.9 19.3 39.6 .326 2.44

10 10.125 9.625 .250 72.8 30.1 61.6 .506 3.7812 12.125 11.565 .280 105 40.4 85.8 .729 5.45

21

Nominal orStandard

Size, inchesOutside

DiameterInside

DiameterCu ft Gal

WallThickness


CrossSectional

Area of Bore,sq inches

Weightof Tube Only,

poundsper linear ft


poundsper linear ft


3/8 .500 .450 .025 .159 .145 .214 .00110 .008261/2 .625 .569 .028 .254 .204 .314 .00176 .01323/4 .875 .811 .032 .517 .328 .551 .00359 .0269

1 1.125 1.055 .035 .874 .465 .843 .00607 .045411/4 1.375 1.291 .042 1.31 .682 1.25 .00910 .068111/2 1.625 1.527 .049 1.83 .940 1.73 .0127 .09512 2.125 2.009 .058 3.17 1.46 2.83 .0220 .16521/2 2.625 2.495 .065 4.89 2.03 4.14 .0340 .2543 3.125 2.981 .072 6.98 2.68 5.70 .0485 .36331/2 3.625 3.459 .083 9.40 3.58 7.64 .0653 .4884 4.125 3.935 .095 12.2 4.66 9.83 .0847 .6345 5.125 4.907 .109 18.9 6.66 14.8 .131 .9826 6.125 5.881 .122 27.2 8.92 20.7 .189 1.418 8.125 7.785 .170 47.6 16.5 37.1 .331 2.47

10 10.125 9.701 .212 73.9 25.6 57.5 .513 3.8412 12.125 11.617 .254 106 36.7 82.5 .736 5.51

Nominal orStandard

Size, inchesOutside

DiameterInside

DiameterCu ft Gal

WallThickness


CrossSectional


Weightof Tube Only,

poundsper linear ft


poundsper linear ft


11/4 1.375 1.295 .040 1.32 .650 1.22 .00917 .068611/2 1.625 1.541 .042 1.87 .809 1.62 .0130 .09712 2.125 2.041 .042 3.27 1.07 2.48 .0227 .1703 3.125 3.030 .045 7.21 1.69 4.81 .0501 .3754 4.125 4.009 .058 11.6 2.87 7.88 .0806 .6035 5.125 4.981 .072 19.5 4.43 12.9 .135 1.016 6.125 5.959 .083 27.9 6.10 18.2 .194 1.458 8.125 7.907 .109 49.1 10.6 31.8 .341 2.55

22

TABLE 2c. Dimensions and Physical Characteristics of Copper Tube: TYPE M

TABLE 2d. Dimensions and Physical Characteristics of Copper Tube: DWV (Drain, Waste and Vent)

Nominal orStandard

Size,inches

OutsideDiameter

InsideDiameter

Weightof Tube Only,

poundsper linear ft

WallThickness

Contentsof Tube,

cu ftper linear ft

CrossSectional


ExternalSurface,

sq ftper linear ft

InternalSurface,

sq ftper linear ft


.125 .065 .030 .00332 .0327 .0170 .0347 .00002

.187 .128 .030 .0129 .0492 .0335 .0575 .00009

.250 .190 .030 .0284 .0655 .0497 .0804 .00020

.312 .248 .032 .0483 .0817 .0649 .109 .00034

.375 .311 .032 .076 .0982 .0814 .134 .00053

.375 .315 .030 .078 .0982 .0821 .126 .00054

.500 .436 .032 .149 .131 .114 .182 .00103

.500 .430 .035 .145 .131 .113 .198 .00101

.625 .555 .035 .242 .164 .145 .251 .00168

.625 .545 .040 .233 .164 .143 .285 .00162

.750 .680 .035 .363 .196 .178 .305 .00252

.750 .666 .042 .348 .196 .174 .362 .00242

.750 .666 .042 .348 .196 .174 .362 .00242

.875 .785 .045 .484 .229 .206 .455 .00336

.875 .785 .045 .484 .229 .206 .455 .003361.125 1.025 .050 .825 .294 .268 .655 .005731.125 1.025 .050 .825 .294 .268 .655 .005731.375 1.265 .055 1.26 .360 .331 .884 .008751.375 1.265 .055 1.26 .360 .331 .884 .008751.625 1.505 .060 1.78 .425 .394 1.14 .01241.625 1.505 .060 1.78 .425 .394 1.14 .01242.125 1.985 .070 3.09 .556 .520 1.75 .02152.625 2.465 .080 4.77 .687 .645 2.48 .03313.125 2.945 .090 6.81 .818 .771 3.33 .04733.625 3.425 .100 9.21 .949 .897 4.29 .06404.125 3.905 .110 12.0 1.08 1.02 5.38 .0833

1/8 A3/16 A1/4 A5/16 A3/8

AD

1/2AD

5/8AD

3/4

AAD

7/8AD

11/8AD

13/8AD

15/8AD

21/8 D25/8 D31/8 D35/8 D41/8 D

23

TABLE 2e. Dimensions and Physical Characteristics of Copper Tube: ACR (Air-Conditioning and Refrigeration Field Service)(A= Annealed Temper, D=Drawn Temper)

TABLE 2f. Dimensions and Physical Characteristics of Copper Tube: Medical Gas, K and L

Nominal orStandard

Size,inches

OutsideDiameter

InsideDiameter

Weightof Tube Only,

poundsper linear ft

WallThickness

Contentsof Tube,cu feet

per linear ft

CrossSectional


Internalsurface,sq feet

per linear ft


.375 .305 .035 .073 .0789 .145 .00051

.375 .315 .030 .078 .0825 .126 .00054

.500 .402 .049 .127 .105 .269 .00088

.500 .430 .035 .145 .113 .198 .00101

.625 .527 .049 .218 .130 .344 .00151

.625 .545 .040 .233 .143 .285 .00162

.750 .652 .049 .334 .171 .418 .00232

.750 .666 .042 .348 .174 .362 .00242

.875 .745 .065 .436 .195 .641 .00303

.875 .785 .045 .484 .206 .455 .003361.125 .995 .065 .778 .261 .839 .005401.125 1.025 .050 .825 .268 .655 .005731.375 1.245 .065 1.222 .326 1.04 .008451.375 1.265 .055 1.26 .331 .884 .008731.625 1.481 .072 1.72 .388 1.36 .01201.625 1.505 .060 1.78 .394 1.14 .01242.125 1.959 .083 3.01 .522 2.06 .02092.125 1.985 .070 3.09 .520 1.75 .02152.625 2.435 .095 4.66 .638 2.93 .03232.625 2.465 .080 4.77 .645 2.48 .03313.125 2.907 .109 6.64 .761 4.00 .04613.125 2.945 .090 6.81 .761 3.33 .04733.625 3.385 .120 9.00 .886 5.12 .06253.625 3.425 .100 9.21 .897 4.29 .06404.125 3.857 .134 11.7 1.01 6.51 .08114.125 3.905 .110 12.0 1.02 5.38 .08325.125 4.805 .160 18.1 1.26 9.67 .1265.125 4.875 .125 18.7 1.28 7.61 .1306.125 5.741 .192 25.9 1.50 13.9 .1806.125 5.854 .140 26.8 1.53 10.2 .1868.125 7.583 .271 45.2 1.99 25.9 .3148.125 7.725 .200 46.9 2.02 19.3 .325

1/4KL

3/8KL

1/2KL

5/8KL

3/4KL

1KL

11/4KL

11/2KL

2KL

21/2KL

3KL

31/2KL

4KL

5KL

6KL

8KL

24

Nominal Size, in

S=6000 psi

100 F

S=5100 psi

150 F

S=4900 psi

200 F

S=4800 psi

250 F

S=4700 psi

300 F

S=4000 psi

350 F

Annealed Drawn**

1/4 1074 913 877 860 842 716 537 1850 1850 1850 1850 1796 1742 16883/8 1130 960 923 904 885 753 565 1946 1946 1946 1946 1889 1833 17761/2 891 758 728 713 698 594 446 1534 1534 1534 1534 1490 1445 14005/8 736 626 601 589 577 491 368 1266 1266 1266 1266 1229 1193 11563/4 852 724 696 682 668 568 426 1466 1466 1466 1466 1424 1381 1338

1 655 557 535 524 513 437 327 1126 1126 1126 1126 1093 1061 102811/4 532 452 434 425 416 354 266 914 914 914 914 888 861 83411/2 494 420 404 396 387 330 247 850 850 850 850 825 801 7762 435 370 355 348 341 290 217 747 747 747 747 726 704 682

S=3000 psi

400 F

S=10,300 psi

100 F

S=10,300 psi

150 F

S=10,300 psi

200 F

S=10,300 psi

250 F

S=10,000 psi

300 F

S=9,700 psi

350 F

S=9,400 psi

400 F

21/2 398 338 325 319 312 265 199 684 684 684 684 664 644 6243 385 328 315 308 302 257 193 662 662 662 662 643 624 60431/2 366 311 299 293 286 244 183 628 628 628 628 610 592 5734 360 306 294 288 282 240 180 618 618 618 618 600 582 5645 345 293 281 276 270 230 172 592 592 592 592 575 557 5406 346 295 283 277 271 231 173 595 595 595 595 578 560 5438 369 314 301 295 289 246 184 634 634 634 634 615 597 578

10 369 314 301 295 289 246 184 634 634 634 634 615 597 57812 370 314 302 296 290 247 185 635 635 635 635 617 598 580

25

TABLE 3a. Rated Internal Working Pressures for Copper Tube: TYPE K*

*Based on maximum allowable stress in tension (psi) for the indicated temperatures (°F), see page 12.**When brazing or welding is used to join drawn tube, the corresponding annealed rating must be used, see page 12.

TABLE 3b. Rated Internal Working Pressure for Copper Tube: TYPE L*

Nominal Size, in

S=6000 psi

100 F

S=5100 psi

150 F

S=4900 psi

200 F

S=4800 psi

250 F

S=4700 psi

300 F

S=4000 psi

350 F

Annealed Drawn**

1/4 912 775 745 729 714 608 456 1569 1569 1569 1569 1524 1478 14323/8 779 662 636 623 610 519 389 1341 1341 1341 1341 1302 1263 12241/2 722 613 589 577 565 481 361 1242 1242 1242 1242 1206 1169 11335/8 631 537 516 505 495 421 316 1086 1086 1086 1086 1055 1023 9913/4 582 495 475 466 456 388 291 1002 1002 1002 1002 972 943 914

1 494 420 404 395 387 330 247 850 850 850 850 825 801 77611/4 439 373 358 351 344 293 219 755 755 755 755 733 711 68911/2 408 347 334 327 320 272 204 702 702 702 702 682 661 6412 364 309 297 291 285 242 182 625 625 625 625 607 589 570

S=3000 psi

400 F

S=10,300 psi

100 F

S=10,300 psi

150 F

S=10,300 psi

200 F

S=10,300 psi

250 F

S=10,000 psi

300 F

S=9,700 psi

350 F

S=9,400 psi

400 F

21/2 336 285 274 269 263 224 168 577 577 577 577 560 544 5273 317 270 259 254 248 211 159 545 545 545 545 529 513 49731/2 304 258 248 243 238 202 152 522 522 522 522 506 491 4764 293 249 240 235 230 196 147 504 504 504 504 489 474 4605 269 229 220 215 211 179 135 462 462 462 462 449 435 4226 251 213 205 201 196 167 125 431 431 431 431 418 406 3938 270 230 221 216 212 180 135 464 464 464 464 451 437 424

10 271 231 222 217 212 181 136 466 466 466 466 452 439 42512 253 215 207 203 199 169 127 435 435 435 435 423 410 397

26

TABLE 3c. Rated Internal Working Pressure for Copper Tube: TYPE M*

TABLE 3d. Rated Internal Working Pressure for Copper Tube: DWV*


***Types M and DWV are not normally available in the annealed temper. Shaded values are provided for guidance when drawn temper tubeis brazed or welded, see page 12.

Nominal Size, in

S=6000 psi

100 F

S=5100 psi

150 F

S=4900 psi

200 F

S=4800 psi

250 F

S=4700 psi

300 F

S=4000 psi

350 F

Annealed*** Drawn**

1/4 — — — — — — — — — — — — — —3/8 570 485 466 456 447 380 285 982 982 982 982 953 925 8961/2 494 420 403 395 387 329 247 850 850 850 850 825 800 7765/8 — — — — — — — — — — — — — —3/4 407 346 332 326 319 271 204 701 701 701 701 680 660 639

1 337 286 275 270 264 225 169 580 580 580 580 563 546 52911/4 338 287 276 271 265 225 169 582 582 582 582 565 548 53111/2 331 282 270 265 259 221 166 569 569 569 569 553 536 5202 299 254 244 239 234 199 149 514 514 514 514 499 484 469

S=3000 psi

400 F

S=10,300 psi

100 F

S=10,300 psi

150 F

S=10,300 psi

200 F

S=10,300 psi

250 F

S=10,000 psi

300 F

S=9,700 psi

350 F

S=9,400 psi

400 F

21/2 274 233 224 219 215 183 137 471 471 471 471 457 444 4303 253 215 207 203 199 169 127 435 435 435 435 423 410 39731/2 252 214 206 202 197 168 126 433 433 433 433 421 408 3954 251 213 205 201 197 167 126 431 431 431 431 419 406 3945 233 198 190 186 182 155 116 400 400 400 400 388 377 3656 218 186 178 175 171 146 109 375 375 375 375 364 353 3428 229 195 187 183 180 153 115 394 394 394 394 382 371 359

10 230 195 188 184 180 153 115 394 394 394 394 383 371 36012 230 195 188 184 180 153 115 395 395 395 395 383 372 360

Nominal Size, in

S=6000 psi

100 F

S=5100 psi

150 F

S=4900 psi

200 F

S=4800 psi

250 F

S=4700 psi

300 F

S=4000 psi

350 F

Annealed*** Drawn**

11/4 330 280 269 264 258 220 165 566 566 566 566 549 533 51611/2 293 249 240 235 230 196 147 503 503 503 503 489 474 4592 217 185 178 174 170 145 109 373 373 373 373 362 352 3413 159 135 130 127 125 106 80 273 273 273 273 265 257 2494 150 127 122 120 117 100 75 257 257 257 257 250 242 2355 151 129 124 121 119 101 76 260 260 260 260 252 245 2376 148 126 121 119 116 99 74 255 255 255 255 247 240 2328 146 124 119 117 114 97 73 251 251 251 251 244 236 229

S=3000 psi

400 F

S=10,300 psi

100 F

S=10,300 psi

150 F

S=10,300 psi

200 F

S=10,300 psi

250 F

S=10,000 psi

300 F

S=9,700 psi

350 F

S=9,400 psi

400 F

27

TABLE 3e. Rated Internal Working Pressure for Copper Tube: ACR* (Air Conditioning and Refrigeration Field Service)


S=6000 psi

100 F

S=5100 psi

150 F

S=4900 psi

200 F

S=4800 psi

250 F

S=4700 psi

300 F

S=4000 psi

350 F

S=3000 psi

400 F

S=10,300 psi

100 F

S=10,300 psi

150 F

S=10,300 psi

200 F

S=10,300 psi

250 F

S=10,000 psi

300 F

S=9,700 psi

350 F

S=9.400 psi

400 F

COILS

3/8 914 777 747 731 716 609 457 1569 1569 1569 1569 1524 1478 14321/2 781 664 638 625 612 521 391 1341 1341 1341 1341 1302 1263 12245/8 723 615 591 579 567 482 362 1242 1242 1242 1242 1206 1169 11333/4 633 538 517 506 496 422 316 1086 1086 1086 1086 1055 1023 9917/8 583 496 477 467 457 389 292 1002 1002 1002 1002 972 943 914

11/8 495 421 404 396 388 330 248 850 850 850 850 825 801 77613/8 440 374 359 352 344 293 220 755 755 755 755 733 711 68915/8 409 348 334 327 320 273 205 702 702 702 702 682 661 64121/8 364 309 297 291 285 243 182 625 625 625 625 607 589 57025/8 336 286 275 269 263 224 168 577 577 577 577 560 544 52731/8 317 270 259 254 249 212 159 545 545 545 545 529 513 49735/8 304 258 248 243 238 203 152 522 522 522 522 506 491 47641/8 293 249 240 235 230 196 147 504 504 504 504 489 474 460

TubeSize (OD),

in

Annealed Drawn**

1/8 3074 2613 2510 2459 2408 2049 1537 — — — — — — —3/16 1935 1645 1581 1548 1516 1290 968 — — — — — — —1/4 1406 1195 1148 1125 1102 938 703 — — — — — — —5/16 1197 1017 977 957 937 798 598 — — — — — — —3/8 984 836 803 787 770 656 492 — — — — — — —1/2 727 618 594 581 569 485 363 — — — — — — —5/8 618 525 504 494 484 412 309 — — — — — — —3/4 511 435 417 409 400 341 256 — — — — — — —3/4 631 537 516 505 495 421 316 — — — — — — —7/8 582 495 475 466 456 388 291 — — — — — — —

11/8 494 420 404 395 387 330 247 — — — — — — —13/8 439 373 358 351 344 293 219 — — — — — — —15/8 408 347 334 327 320 272 204 — — — — — — —

S=6000 psi

100 F

S=5100 psi

150 F

S=4900 psi

200 F

S=4800 psi

250 F

S=4700 psi

300 F

S=4000 psi

350 F

S=3000 psi

400 F

S=10,300 psi

100 F

S=10,300 psi

150 F

S=10,300 psi

200 F

S=10,300 psi

250 F

S=10,000 psi

300 F

S=9,700 psi

350 F

S=9.400 psi

400 F

STRAIGHT LENGTHS

NOT MANUFACTURED

28

TABLE 4a. Pressure-Temperature Ratings of Soldered and Brazed Joints

Alloy Sn5050-50

Tin-LeadSolder5

Alloy Sb595-5

Tin-AntimonySolder

100 Pressure2

DWV3

150Pressure2

DWV3

200Pressure2

DWV3

250Pressure2

DWV3

Saturated Steam Pressure

100Pressure2

DWV3

150Pressure2

DW3

200Pressure2

DWV3

250Pressure2

DWV3


For extremely low working temperatures in the 0°F to minus 200°F range, it is recommended that a joint material melting at or above 1100°F be employed (see reference6).1 Standard water tube sizes per ASTM B88.2 Ratings up to 8 inches in size are those given in ASME B16.22 Wrought Copper and Copper Alloy Solder Joint Pressure Fittings and ASME B16.18 Cast Copper and Copper Alloy Solder Joint Fittings. Rating for 10- to 12-inch sizes are those given in ASME B16.18 Cast Copper and Copper Alloy Solder Joint Pressure Fittings.3 Using ASME B16.29 Wrought Copper and Wrought Copper Alloy Solder Joint Drainage Fittings — DWV, and ASME B16.23 Cast Copper Alloy Solder Joint Drainage Fittings — DWV.4 Alloy designations are per ASTM B32.5 The Safe Drinking Water Act Amendment of 1986 prohibits the use in potable water systems of any solder having a lead content in excess of 0.2%.6 These joining materials are defined as brazing alloys by the American Welding Society.

Joining Material4

ServiceTemperature,

OFFitting Type

1/8 through 1 11/4 through 2 21/2 through 4 5 through 8 10 through 12

Maximum Working Gage Pressure (psi), for Standard Water Tube Sizes1

Nominal or Standard Size, inches

200 175 150 135 100— 95 80 70 —150 125 100 90 70— 70 55 45 —100 90 75 70 50— 50 40 35 —85 75 50 45 40— — — — —15 15 15 15 15

1090 850 705 660 500— 390 325 330 —625 485 405 375 285— 225 185 190 —505 395 325 305 230— 180 150 155 —270 210 175 165 125— 95 80 80 —15 15 15 15 15

120 120 120 120 120Saturated Steam Pressure

Alloy E

Alloy HB

Joining materials

melting at orabove 1100º F6

100 Pressure2

DWV3

150Pressure2

DWV3

200Pressure2

DWV3

250Pressure2

DWV3


100Pressure2

DWV3

150Pressure2

DWV3

200Pressure2

DWV3

250Pressure2

DWV3


710 555 460 430 325— 255 210 215 —475 370 305 285 215— 170 140 140 —375 290 240 225 170— 135 110 115 —320 250 205 195 145— 115 95 95 —15 15 15 15 15

1035 805 670 625 475— 370 310 315 —710 555 460 430 325— 255 210 215 —440 345 285 265 200— 155 130 135 —430 335 275 260 195— 155 125 130 —15 15 15 15 15

Pressure-temperature ratings consistent with the materials and procedures employed (see Table 3, Annealed).

29

1 Actual pressure/temperatureranges should be confirmedbased upon the specificmanufacturer’s fittings beingutilized.

2 Some manufacturer’s systemsare rated to below 0°F (-18°C)and may not be rated orrecommended to 250°F (121°C).

3 Temperature ranges for variousgasket types and clampingsystems must be confirmed withthe specific gasket and clampmanufacturer.

TABLE 4b. Pressure-Temperature Ratings of No-flame Joints

Joint Type

1. The figures shown are averages of three certified tests per-formed on each type and size ofwater tube. In each case, wall thickness was at or near the minimum prescribed for each tube type. No burst pressure in any test deviated from the average by more than 5 percent.

2. These burst pressures can be used for ACR tube of equivalent actual O.D. and wall thickness.

TABLE 5. Actual Burst Pressures,1 Types K, L and M Copper Water Tube, psi at Room Temperature

Nominal orStandard Size,

inches

1/25/8 9840 4535 7765 3885 6135 —

3/47/8 9300 4200 5900 2935 4715 —

1 11/8 7200 3415 5115 2650 3865 —

11/4 13/8 5525 2800 4550 2400 3875 —

11/2 15/8 5000 2600 4100 2200 3550 —

2 21/8 3915 2235 3365 1910 2935 —

21/2 25/8 3575 — 3215 — 2800 —

3 31/8 3450 — 2865 — 2665 —

4 41/8 3415 — 2865 — 2215 —

5 51/8 3585 — 2985 — 2490 —

6 61/8 3425 — 2690 — 2000 —

8 81/8 3635 — 2650 — 2285 —

Actual OutsideDiameter, in

K

Drawn Annealed

L2

Drawn Annealed

M

Drawn Annealed

Pressure Range1Temperature Range1

Press-connect

½”–4”

Push-connect2

½”–2”

Roll-groove2

2”–8” Types K & L

Roll-groove3

2”–4” Type M

5”–8” Type M

Structural Adhesives

0–200 psig

(1375 kPa)

0–200 psig

(1375 kPa)

0–300 psig

(2065 kPa)

0–250 psig

(1725 kPa)

0–200 psig

(1375 kPa)

0–250 psig

(1375 kPa)

0ºF–250ºF

(-18ºC–121ºC)

0ºF–250ºF

(-18ºC–121ºC)

-30ºF–250ºF

(-34ºC–121ºC)

-20ºF–180ºF

(-29ºC–82ºC)

-30ºF–250ºF

(-34ºC–121ºC)

-20ºF–180ºF

(-29ºC–82ºC)

-40ºF–180ºF

(-40ºC–82ºC)

30

NOMINAL OR STANDARD SIZE, INCHES1/4

3/81/2

3/4 1 1 1/4 1 1/2 2K L M K L M K L M K L M

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.002 0.001 0.003 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.003 0.003 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000

0.006 0.005 0.004 0.002 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000

0.009 0.007 0.006 0.003 0.003 0.002 0.001 0.001 0.001 0.000 0.000 0.000

0.031 0.027 0.023 0.010 0.010 0.009 0.004 0.004 0.004 0.001 0.001 0.001

0.065 0.057 0.049 0.022 0.020 0.018 0.009 0.009 0.008 0.002 0.002 0.002

– 0.096 0.084 0.037 0.035 0.031 0.016 0.015 0.014 0.004 0.004 0.004

.– .– N/A 0.057 0.052 0.047 0.024 0.022 0.021 0.006 0.006 0.005

.– .– N/A 0.079 0.073 0.066 0.034 0.031 0.029 0.009 0.008 0.008

.– .– N/A .– .– .– 0.045 0.042 0.039 0.012 0.011 0.010

.– .– N/A .– .– .– 0.058 0.054 0.050 0.015 0.014 0.013

.– .– N/A .– .– .– .– .– 0.062 0.018 0.017 0.016

.– .– N/A .– .– .– .– .– .– 0.022 0.021 0.020

.– .– N/A .– .– .– .– .– .– 0.031 0.029 0.028

.– .– N/A .– .– .– .– .– .– 0.042 0.039 0.037

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

K L M K L M K L M K L M

0.138 0.118 N/A 0.036 0.023 0.021 0.010 0.008 0.007 0.002 0.001 0.001

.– .– N/A 0.130 0.084 0.075 0.035 0.030 0.024 0.006 0.005 0.004

.– .– N/A 0.275 0.177 0.159 0.074 0.062 0.051 0.014 0.011 0.009

.– .– N/A .– .– .– 0.125 0.106 0.086 0.023 0.018 0.015

.– .– N/A – .– .– 0.189 0.161 0.130 0.035 0.027 0.023

.– .– N/A .– .– .– .– .– .– 0.126 0.098 0.084

.– .– N/A .– .– .– .– .– .– .– .– .–

– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

1

2

3

4

5

10

15

20

25

30

35

40

45

50

60

70

80

90

100

120

140

160

180

200

250

300

350

400

450

500

550

600

650

700

760

1000

2000

FLOW,GPM

NOTES:1. Fluid velocities in excess of 5-8 feet per second are not recommended.2. Friction loss values shown are for the flow rates that do not exceed a velocity of 8 feet per second.3. Highlighted and italicized friction loss values indicate flow rates that are between 5 feet and 8 feet per second.

TABLE 6. Pressure Loss of Water Due to Friction in Types K, L and M Copper Tube (psi per linear foot of tube)

31

NOMINAL OR STANDARD SIZE, INCHES

2 1/2 3 4 5 6 8 10 12FLOW,GPM

1

2

3

4

5

10

15

20

25

30

35

40

45

50

60

70

80

90

100

120

140

160

180

200

250

300

350

400

450

500

550

600

650

700

760

1000

2000


0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.001 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000

0.002 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000

0.003 0.003 0.003 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000

0.004 0.004 0.004 0.002 0.002 0.001 0.000 0.000 0.000 0.000 0.000 0.000

0.005 0.005 0.005 0.002 0.002 0.002 0.001 0.001 0.000 0.000 0.000 0.000

0.006 0.006 0.006 0.003 0.003 0.002 0.001 0.001 0.001 0.000 0.000 0.000

0.008 0.007 0.007 0.003 0.003 0.003 0.001 0.001 0.001 0.000 0.000 0.000

0.011 0.010 0.010 0.005 0.004 0.004 0.001 0.001 0.001 0.000 0.000 0.000

0.014 0.014 0.013 0.006 0.006 0.005 0.002 0.001 0.001 0.001 0.000 0.000

0.019 0.017 0.016 0.008 0.007 0.007 0.002 0.002 0.002 0.001 0.001 0.001

0.023 0.022 0.020 0.010 0.009 0.009 0.002 0.002 0.002 0.001 0.001 0.001

0.028 0.026 0.025 0.012 0.011 0.010 0.003 0.003 0.003 0.001 0.001 0.001

.– .– 0.035 0.017 0.016 0.015 0.004 0.004 0.004 0.001 0.001 0.001

.– .– 0.000 0.022 0.021 0.019 0.006 0.005 0.005 0.002 0.002 0.002

.– .– 0.000 0.028 0.026 0.025 0.007 0.007 0.006 0.002 0.002 0.002

.– .– N/A .– .– .– 0.009 0.008 0.008 0.003 0.003 0.003

.– .– N/A .– .– .– 0.011 0.010 0.010 0.004 0.003 0.003

.– .– N/A .– .– .– 0.016 0.015 0.015 0.006 0.005 0.005

.– .– N/A .– .– .– .– .– 0.021 0.008 0.007 0.007

.– .– N/A .– .– .– .– .– .– 0.010 0.010 0.009

.– .– N/A .– .– .– .– .– .– 0.013 0.012 0.012

.– .– N/A .– .– .– .– .– .– 0.017 0.015 0.015

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–

.– .– N/A .– .– .– .– .– .– .– .– .–


0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.002 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

0.002 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000

0.003 0.003 0.003 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000

0.004 0.004 0.004 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000

0.006 0.005 0.005 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000

0.007 0.006 0.006 0.002 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000

0.008 0.008 0.008 0.002 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000

0.010 0.009 0.009 0.003 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000

0.012 0.011 0.011 0.003 0.003 0.003 0.001 0.001 0.001 0.000 0.000 0.000

.– 0.013 0.012 0.004 0.003 0.003 0.001 0.001 0.001 0.001 0.000 0.000

.– .– N/A 0.004 0.004 0.004 0.001 0.001 0.001 0.001 0.001 0.001

.– .– N/A 0.005 0.004 0.004 0.002 0.001 0.001 0.001 0.001 0.001

.– .– N/A 0.008 0.007 0.007 0.003 0.002 0.002 0.001 0.001 0.001

.– .– N/A .– .– .– .– .– .– 0.004 0.004 0.004

NOTES:4. Table 6 is based on the Hazen-Williams formula:

32

TABLE 7. Pressure Loss in Fittings and Valves Expressed as Equivalent Length of Tube, feet

NOTES: Allowances are for streamlined soldered fittings and recessed threaded fittings.For threaded fittings, double the allowances shown in the table.The equivalent lengths presented above are based upon a C factor of 150 in the Hazen-Williamsfriction loss formula. The lengths shown are rounded to the nearest half foot.

3/8 .5 — 1.5 — — — — — 1.51/2 1 .5 2 — — — — — 25/8 1.5 .5 2 — — — — — 2.53/4 2 .5 3 — — — — — 3

1 2.5 1 4.5 — — .5 — — 4.5

11/4 3 1 5.5 .5 .5 .5 — — 5.5

11/2 4 1.5 7 .5 .5 .5 — — 6.5

2 5.5 2 9 .5 .5 .5 .5 7.5 9

21/2 7 2.5 12 .5 .5 — 1 10 11.5

3 9 3.5 15 1 1 — 1.5 15.5 14.5

31/2 9 3.5 14 1 1 — 2 — 12.5

4 12.5 5 21 1 1 — 2 16 18.5

5 16 6 27 1.5 1.5 — 3 11.5 23.5

6 19 7 34 2 2 — 3.5 13.5 26.5

8 29 11 50 3 3 — 5 12. 5 39

Nominalor

StandardSize, in

Standard Ell 90° Tee CouplingValves

Ball Gate Btfly CheckSide

BranchStraight

Run90° 45°

Fittings

FIGURE 2. Collapse Pressure of Copper Tube, Types K, L and M

Drawn Copper Tube

Annealed Copper Tube

Nominal or Standard Size, inches

Hydr

osta

tic P

ress

ure,

psi

33

34

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

0.5

0.00 25 50 75 100 125 150 175 200 225 250 275 300 325 350

Temperature Change, F

Expa

nsio

n (o

r Con

tract

ion)

per

100

Fee

t, in

ches

FIGURE 3. Expansion vs. Temperature Change for Copper Tube

TABLE 8. Radii of Coiled Expansion Loops and Developed Lengths of Expansion Offsets(See Figure 5)

FIGURE 4 a, b, c. Coiled Expansion Loops and Offsets

1/2

R 6 7 8 9 11 12 13 15 16 18 19 20 23

L 38 44 50 59 67 74 80 91 102 111 120 128 142

1R 9 10 11 13 15 17 18 21 23 25 27 29 32

L 54 63 70 83 94 104 113 129 144 157 169 180 201

11/2

R 11 12 14 16 18 20 22 25 28 30 33 35 39

L 66 77 86 101 115 127 138 158 176 191 206 220 245

2R 12 14 16 19 21 23 25 29 32 35 38 41 45

L 77 89 99 117 133 147 160 183 203 222 239 255 284

21/2

R 14 16 18 21 24 26 29 33 36 40 43 45 51

L 86 99 111 131 149 165 179 205 227 248 267 285 318

3R 15 17 19 23 26 29 31 36 40 43 47 50 55

L 94 109 122 143 163 180 196 224 249 272 293 312 348

31/2

R 16 19 21 25 28 31 34 39 43 47 50 54 60

L 102 117 131 155 176 195 212 242 269 293 316 337 376

4R 17 20 22 26 30 33 36 41 46 50 54 57 64

L 109 126 140 166 188 208 226 259 288 314 338 361 402

1/43/8

1/23/4 1 11/4 11/2 2 21/2 3 31/2 4 5

Radius “R”, inches, for Nominal or Standard Tube Sizes ShownLength “L”, inches, for Nominal or Standard Tube Sizes Shown

ExpectedExpansion,

inches

▼ ▲

▲▼

▼ ▼

▼

▲

▲

35

36

➀

ADAPTERS

ELBOWS

COUPLINGS

FIGURE 5. Selected Pressure Fittings

GENERAL NOTES: (a) Fittings are designated by size in the order: 1x2x3 (b) Fitting designs and drawings are for illustration only.

37

FIGURE 6. Dimensions of Solder Joint Fitting Ends

TABLE 9. Dimensions of Solder Joint Ends for Wrought (W) and Cast (C) Pressure Fittings, inches

* Copper tube under this standard is not commercially available.

Drawings and designs of fittings are for illustration only.

Nominalor

StandardFittingsSize,In.

underASTMB 88

underASTMB 819

underASTMB 837

under ASTM B 280

Type

Male End Female EndOutside Diameter

ALength

KInside Diameter

FDepth

G

Min. Max. Min. Min. Max. Min.1/8 W .248 .251 .38 .252 .256 .31 * 1/4 * 1/4

1/4 C W .373 .376 .38 .377 .381 .31 1/43/8

1/43/8

3/8 C W .497 .501 .44 .502 .506 .38 3/81/2

3/81/2

1/2 C W .622 .626 .56 .627 .631 .50 1/25/8

1/25/8

5/8 W .747 .751 .81 .752 .756 .75 5/83/4

5/83/4

3/4 C W .872 .876 .81 .877 .881 .75 3/47/8

3/47/8

1 C W 1.122 1.127 .97 1.128 1.132 .91 1 11/8 1 11/8

11/4 C W 1.372 1.377 1.03 1.378 1.382 .97 11/4 13/8 11/4 *11/2 C W 1.621 1.627 1.16 1.628 1.633 1.09 11/2 15/8 11/2 *2 C W 2.121 2.127 1.41 2.128 2.133 1.34 2 21/8 2 *21/2 C W 2.621 2.627 1.53 2.628 2.633 1.47 21/2 25/8 21/2 *3 C W 3.121 3.127 1.72 3.128 3.133 1.66 3 31/8 3 *31/2 C W 3.621 3.627 1.97 3.628 3.633 1.91 31/2 35/8 31/2 *4 C W 4.121 4.127 2.22 4.128 4.133 2.16 4 41/8 4 *5 C W 5.121 5.127 2.72 5.128 5.133 2.66 5 * 5 *6 C W 6.121 6.127 3.22 6.128 6.133 3.09 6 * 6 *8 C W 8.119 8.127 4.09 8.128 8.133 3.97 8 * 8 *

10 C 10.119 10.127 4.12 10.128 10.133 4.00 10 * * *12 C 12.119 12.127 4.62 12.128 12.133 4.50 12 * * *

For use with tube size

38

FIGURE 7. Melting Temperature Ranges for Copper and Copper Alloys, Brazing Filler Metals, Brazing Flux and Solders

NOTE: * Melting ranges of solder alloys are in accordance with the alloy manufacturers’ product informationand may not match the melting ranges shown in ASTM B32.

A B

39

Triangles, denoting when to use flux, are surrounded by tube type, fitting type and brazing filler type.

NOTE: When joining copper tube to a wrought fitting using BCup filler, no flux is required.

BRASS

BRASS

BRASS

BRASS

COPPER

COPPER

COPPER

COPPER

WROUGHT

WROUGHT WROUGHT

WROUGHT

CAST

CAST

CAST

CAST

BAg

BAg

BAg

BAg

BCuP

BCuP

BCuP

BCuP

TABLE 10. Solder Requirements for Solder Joint Pressure Fittings, length in inches1

1 Using 1/8-inch diameter (No. 9) Wire Solder(1 inch length = .01227 cubic inches).2 Actual consumption depends on workmanship.3 Includes an allowance of 100% to cover wastage and loss.NOTE: Flux requirements are usually 2 oz per lb of solder.

Nominal Wt. in lbsor O.D. Cup at .010

Standard of Depth clearanceSize, Tube, of Fitting, per 100

inches inches inches

0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.010

joints

Joint Clearance, inches

1/4 .375 .310 .030 .060 .089 .119 .149 .179 .208 .238 .268 .298 .0973/8 .500 .380 .049 .097 .146 .195 .243 .292 .341 .389 .438 .486 .1591/2 .625 .500 .080 .160 .240 .320 .400 .480 .560 .640 .720 .800 .2615/8 .750 .620 .119 .238 .357 .476 .595 .714 .833 .952 1.072 1.191 .3893/4 .875 .750 .168 .336 .504 .672 .840 1.008 1.176 1.344 1.512 1.680 .548

1 1.125 .910 .262 .524 .786 1.048 1.311 1.573 1.835 2.097 2.359 2.621 .85611/4 1.375 .970 .341 .683 1.024 1.366 1.707 2.049 2.390 2.732 3.073 3.415 1.11511/2 1.625 1.090 .454 .907 1.361 1.814 2.268 2.721 3.175 3.628 4.082 4.535 1.4802 2.125 1.340 .729 1.458 2.187 2.916 3.645 4.374 5.103 5.833 6.562 7.291 2.38021/2 2.625 1.470 .988 1.976 2.964 3.952 4.940 5.928 6.916 7.904 8.892 9.880 3.2253 3.125 1.660 1.328 2.656 3.985 5.313 6.641 7.969 9.297 10.626 11.954 13.282 4.33531/2 3.625 1.910 1.773 3.546 5.318 7.091 8.864 10.637 12.409 14.182 15.955 17.728 5.7864 4.125 2.160 2.281 4.563 6.844 9.125 11.407 13.688 15.969 18.250 20.532 22.813 7.4465 5.125 2.660 3.490 6.981 10.471 13.962 17.452 20.943 24.433 27.924 31.414 34.905 11.3926 6.125 3.090 4.846 9.692 14.538 19.383 24.229 29.075 33.921 38.767 43.613 48.459 15.8158 8.125 3.970 8.259 16.518 24.777 33.035 41.294 49.553 57.812 66.071 74.330 82.589 26.955

10 10.125 4.000 10.370 20.739 31.109 41.478 51.848 62.218 72.587 82.957 93.326 103.696 33.84512 12.125 4.500 13.970 27.940 41.910 55.881 69.851 83.821 97.791 111.761 125.731 139.701 45.596

AverageActual

Consump-tion2

ForEstimatingPurposes3

FIGURE 8. Brazing Flux Recommendations

40

TABLE 11. Typical Brazing Filler Metal Consumption

TABLE 12. Filler Metals for Brazing

1. The amount of filler metal indicated is based on an average two-thirds penetration of the cup and with no provision for a fillet. For estimating purposes, actual consumption may be two to three times the amounts indicated in this table,depending on the size of joints, method of application and level of workmanship.

NOTE: 1090 inches of 1/16-inch wire = 1 pound534 inches of 1/8-inch x .050-inch rod = 1 pound

484 inches of 3/32-inch wire = 1 pound268 inches of 1/8-inch wire = 1 pound

Nominal or Average WeightStandard Size, per 100 Joints,

inches 1/16-inch Wire 1/8-in x .050-in Rod 3/32-inch Wire 1/8-inch Wire pounds1

1/41/2

1/41/4

1/8 .043/8

5/83/8

3/81/4 .06

1/2 11/85/8

1/23/8 .10

5/8 15/87/8

5/81/2 .15

3/4 21/4 11/8 1 5/8 .21

1 31/2 13/4 15/87/8 .32

11/4 41/2 21/4 2 11/4 .4211/2 — 3 25/8 11/2 .56

2 — 43/4 43/8 21/2 .9021/2 — 61/2 57/8 33/8 1.223 — 85/8 77/8 41/2 1.6431/2 — 111/2 101/2 57/8 2.18

4 — 147/8 131/2 75/8 2.815 — 225/8 201/2 115/8 4.306 — 311/2 281/2 16 5.978 — 531/2 481/2 273/8 10.2010 — 671/4 61 341/4 12.7712 — 901/2 82 461/8 17.20

Filler Metal Length, inchesTube

1 ANSI/AWS A5.8 Specification for Filler Metals for Brazing2 BAg-7 is a common, cadmium-free substitute for BAg-1.3 BAg-34 is a common, cadmium-free substitute for BAg-2 and BAg-2a.

Principal Elements, percent Temperature ºFAWS

Classification1 Silver (Ag) Phosphorous (P) Zinc (Zn) Cadmium (Cd) Tin (Sn) Copper (Cu) Silicon (Si) Solidus Liquidus

BCuP-2 — 7.0-7.5 — — — Remainder — 1310 1460

BCuP-3 4.8-5.2 5.8-6.2 — — — Remainder — 1190 1495

BCuP-4 5.8-6.2 7.0-7.5 — — — Remainder — 1190 1325

BCuP-5 14.5-15.5 4.8-5.2 — — — Remainder — 1190 1475

BCuP-6 1.8-2.2 6.8-7.2 — — — Remainder — 1190 1450

BCuP-7 4.8-5.2 6.5-7.0 — — — Remainder — 1190 1420

BCuP-8 17.2-8.0 6.0-6.7 — — — Remainder — 1190 1230

BCuP-9 — 6.0-7.0 — — 6.0-7.0 Remainder 0.01-0.4 1178 1247

BAg-5 44.0-46.0 — 23.0-27.0 — — 29.0-31.0 — 1225 1370

BAg-6 49.0-51.0 — 14.0-18.0 — — 33.0-35.0 — 1270 1425

BAg-72 55.0-57.0 — 15.0-19.0 — 4.5-5.5 21.0-23.0 — 1145 1205

BAg-20 29.0-31.0 — 30.0-34.0 — — 37.0-39.0 — 1250 1410

BAg-28 39.0-41.0 — 26.0-30.0 — 1.5-2.5 29.0-31.0 — 1200 1310

BAg-343 37.0-34.0 — 26.0-30.0 — 1.5-2.5 31.0-33.0 — 1200 1330

WORKING WITH COPPER TUBE

42

Because of its exceptionalformability, copper can be formed asdesired at the job site. Copper tube,properly bent, will not collapse on theoutside of the bend and will not buckleon the inside of the bend. Testsdemonstrate that the bursting strength ofa bent copper tube can actually begreater than it was before bending.

Because copper is readily formed,expansion loops and other bendsnecessary in an assembly are quicklyand simply made if the proper methodand equipment are used. Simple handtools employing mandrels, dies, formsand fillers, or power-operated bendingmachines can be used.

Both annealed tube and harddrawn tube can be bent with theappropriate hand benders. The propersize of bender for each size tube mustbe used. For a guide to typical bendradii, see Table 13.

The procedure for bending coppertube with a lever-type hand bender isillustrated in Figure 9.

(A) With the handles at 180degrees and the tube-holding clip raisedout of the way, insert the tube in theforming-wheel groove.

(B) Place the tube-holding clipover the tube and bring the handle intoan approximately right angle position,engaging the forming shoe over thetube. The zero mark on the formingwheel should then be even with thefront edge of the forming shoe.

(C) Bend by pulling the handlestoward each other in a smooth,

continuous motion. The desired angle ofthe bend will be indicated by thecalibrations on the forming wheel.

(D) Remove the bent tube bypivoting the handle to a right angle withthe tube, disengaging the forming shoe.Then release the tube-holding clip.

The tool illustrated is just one of many available to the industry. Of course, if the manufacturer of the tube bender has special instructionsregarding his product, such instructionsshould be followed.

1 The radii stated are the minimums for mechanical bendingequipment only.

Nominal, MinimumStandard Tube Type Temper BendSize, in Radius1, in

1/4 K, L Annealed 3/4

3/8K, L Annealed 11/2

K, L, M Drawn 13/4

1/2K, L Annealed 21/4

K, L, M Drawn 21/2

3/4K, L Annealed 3K, L Drawn 3

1 K, L Annealed 411/4 K, L Annealed 9

IV. BENDING

A

C

B

D

FIGURE 9: Bending using a lever-type hand bender (tool shown

is appropriate for use with annealed tube only)

TABLE 13: Bending guide for copper tube

IV. BENDING

43

There are three categories of methods tojoin copper tubing:

Solder or Brazed JointsThese joining methods include

soldering, brazing and electricresistance (Chapters VII and VIII).Soldered joints, with capillary fittings,are used in plumbing for water lines and for sanitary drainage. Brazed joints,with capillary fittings, are used wheregreater joint strength is required orwhere service temperatures are as highas 350°F.

Brazing is preferred, and oftenrequired, for joints in air-conditioningand refrigeration piping. Electricresistance joining is a flameless way tomake soldered joints, although heat isstill generated.

Pressure-temperature ratings forsoldered and brazed joints are found inTable 4a, page 28. Fittings, solders andfluxes for soldered and brazed joints arediscussed in Chapter VI.

Copper tube may also be joinedby butt-welding without the use offittings. Care must be taken to useproper welding techniques. Weldingmethods are covered in CDApublication A1050, Welding Copperand Copper Alloys.

No-flame Joints Flameless mechanical joining

methods have been used for decades forunderground tubing, for joints wherethe use of heat is impractical and forjoints that may have to be disconnectedfrom time to time. Traditional methodsinclude flared joints (Chapter IX) androll groove coupling systems (ChapterX).

Newer methods for most generalplumbing applications includesolderless press-connect (Chapter XI)and push-connect fittings (ChapterXII), which incorporate an elastomericgasket or seal (such as EPDM).

Structural adhesive joining (ChapterXIII) uses special fittings withelastomeric gaskets and a speciallyengineered two-part adhesive designedfor rigorous structural applications. Theranges of pressure-temperature ratingsfor no-flame joints are found in Table4b, page 29.

Additional Joining MethodsMechanically formed extruded

joints or tee-pulling (Chapter XIV) istypically used in automatic firesprinkler installations as well as otherapplications where tee-connections arefrequently encountered. Tee-pulling is amechanical process; however, itrequires a brazed joint for completion.Soldering of the branch tubing into themechanically formed tee is notpermitted.

V. JOINING METHODS

V. J

OINI

NG M

ETHO

DS

44

VI. FITTINGS, SOLDERS, FLUXES

FittingsFittings for copper water tube used inplumbing and heating are made to thefollowing standards:

Cast Copper Alloy Threaded Fittings(ASME B16.15)

Cast Copper Alloy Solder JointPressure Fittings (ASME B16.18)

Wrought Copper and Copper AlloySolder Joint Pressure Fittings (ASMEB16.22)

Wrought Copper Solder Joint PressureFittings (MSS SP104)

Welded Fabricated Copper Solder JointPressure Fittings (MSS SP109)

Cast Copper Alloy Solder JointDrainage Fittings DWV (ASMEB16.23)

Bronze Pipe Flanges and FlangedFittings (ASME B16.24)

Cast Copper Alloy Fittings for FlaredCopper Tubes (ASME B16.26)

Wrought Copper and Wrought Copper-Alloy Solder Joint Drainage FittingsDWV (ASME B16.29)

Wrought Copper and Copper AlloyBraze-Joint Pressure Fittings (ASMEB16.50)

Removable and Non-Removable Push-Fit Fittings (ASSE 1061)

Examples of solder joint enddimensions are shown in Figure 6, page37.

Cast alloy pressure fittings areavailable in all standard tube sizes andin a limited variety of types to coverneeds for plumbing and mechanicalsystems. They can be either soldered orbrazed, although brazing cast fittingsrequires care. Wrought copper pressurefittings are available over a wide rangeof sizes and types. These, too, can bejoined by either soldering or brazing;wrought fittings are preferred wherebrazing is the joining method.Otherwise, the choice between cast andwrought fittings is largely a matter ofthe user's preference and availability.

Flared-tube fittings providemetal-to-metal contact similar to groundjoint unions; both can be easily takenapart and reassembled. They areespecially useful where residual watercannot be removed from the tube andsoldering is difficult. Flared joints maybe required where a fire hazard existsand the use of a torch to make solderedor brazed joints is not allowed.

Soldering under wet conditionscan be very difficult; flared, press-, andpush-connect joints are preferred undersuch circumstances.

SoldersSoldered joints depend on

capillary action drawing free-flowingmolten solder into the gap between thefitting and the tube. Flux acts as awetting agent and, when properlyapplied, permits uniform spreading of the molten solder over the surfaces to be joined.

The selection of a solder dependsprimarily on the operating pressure andtemperature of the system. Consider-ation should also be given to thestresses on joints caused by thermalexpansion and contraction. However,this may not be necessary when a tubelength is short or when an expansionloop is used in a long tube run. In suchcases, the stresses caused by atemperature change are usuallyinsignificant.

Rated internal working pressuresfor solder joints made with copper tubeusing 50-50 tin-lead solder (ASTM B32Alloy Sn50), 95-5 tin-antimony solder(ASTM B32 Alloy Sb5), and severallead-free solders (ASTM B32 Alloy Eand Alloy HB) are listed in Tables3a–e, pages 25–27.]

The 50-50 tin-lead solder issuitable for moderate pressures andtemperatures. For higher pressures, orwhere greater joint strength is required,95-5 tin-antimony solder and alloys Eand HB can be used. For continuousoperation at temperatures exceeding250°F, or where the highest jointstrength is required, brazing fillermetals should be used (see Table 4a,page 28).

Solder alloys listed in Section 1of Table 1 Solder Compositions inASTM B32, Standard Specification forSolder Metal, can be used to join coppertube and fittings in potable watersystems. Solders containing lead atconcentrations of greater than 0.2%are banned for potable water systemsby the 1986 amendment to theFederal Safe Drinking Water Act(SDWA). Some state and local

VI. FITTINGS, SOLDERS, FLUXES

jurisdictions may allow the use of 50-50tin-lead solder in some HVAC,drainage and other piping systemapplications..

FluxesThe functions of soldering flux

are to protect against re-oxidation of thejoint during the soldering procedure,promote wetting that allows capillaryaction to begin, and to assist in residualoxide removal. The flux should beapplied to surfaces that have beenmechanically cleaned, and only enough

should be used to lightly coat the areason the tube and fitting that are to bejoined.

An oxide film may reformquickly on copper after it has beencleaned. Therefore, the flux should beapplied as soon as possible aftercleaning.

The fluxes best suited forsoldering copper and copper alloy tubeshould meet the requirements of ASTMB813, Standard Specification for Liquidand Paste Fluxes for Soldering

Applications of Copper and CopperAlloy Tube.

Some fluxes identified by theirmanufacturers as "self-cleaning" presenta risk in their use. There is no doubt thata strong, corrosive flux can removesome oxides and dirt films. However,when highly corrosive fluxes are usedthis way, there is always uncertaintywhether uniform cleaning has beenachieved and whether corrosive actionfrom flux residue continues after thesoldering has been completed.

45 VI. F

ITTI

NGS,

SOL

DERS

, FLU

XES

46

The American Welding Societydefines soldering as “a group of joiningprocesses that produce coalescence ofmaterials by heating them to a solderingtemperature and by using a filler metal(solder) having a liquidus not exceeding840°F and below the solidus of the basemetals.” In actual practice, mostsoldering is done at temperatures fromabout 350ºF to 600ºF.

To consistently make satisfactoryjoints, the following sequence of jointpreparation and operations, based onASTM Standard Practice B828, shouldbe followed:

■ measuring and cutting ■ reaming ■ cleaning■ fluxing ■ assembly and support ■ heating ■ applying the solder ■ cooling and cleaningThe techniques described

produce leak-tight soldered jointsbetween copper and copper alloy tubeand fittings, either in shop operations or in the field. Skill and knowledge arerequired to produce a satisfactorilysoldered joint.

Measuring and CuttingAccurately measure the length of

each tube segment (Figure 10).Inaccuracy can compromise jointquality. If the tube is too short, it willnot reach all the way into the cup of thefitting and a proper joint cannot bemade. If the tube segment is too long,system strain may be introduced whichcould affect service life.

Cut the tube to the measuredlengths. Cutting can be accomplished ina number of different ways to produce asatisfactory squared end. The tube canbe cut with a disc-type tube cutter(Figure 11), a hacksaw, an abrasivewheel, or with a stationary or portablebandsaw. Care must be taken that thetube is not deformed while being cut.Regardless of method, the cut must besquare to the run of the tube so thatthe tube will seat properly in thefitting cup.

ReamingReam all cut tube ends to the full

inside diameter of the tube to removethe small burr created by the cuttingoperation. If this rough, inside edge is not removed by reaming, erosion-corrosion may occur due to localturbulence and increased local flowvelocity in the tube. A properly reamedpiece of tube provides a smooth surfacefor better flow.

Remove any burrs on the outsideof the tube ends, created by the cuttingoperation, to ensure proper entrance ofthe tube into the fitting cup.

Tools used to ream tube endsinclude the reaming blade on the tubecutter, half-round or round files (Figure12), a pocket knife (Figure 13), and asuitable deburring tool (Figure 14).With soft tube, care must be taken notto deform the tube end by applying toomuch pressure.

Soft temper tube, if deformed,can be brought back to roundness with asizing tool. This tool consists of a plugand sizing ring.

VII. SOLDERED JOINTS

FIGURE 10: Measuring

FIGURE 11: Cutting FIGURE 12: Reaming: File


47

CleaningThe removal of all oxides and

surface soil from the tube ends andfitting cups is crucial to proper flow of solder metal into the joint. Failure to remove them can interfere withcapillary action and may lessen thestrength of the joint and cause failure.

Lightly abrade (clean) the tubeends using sand cloth (Figure 15) ornylon abrasive pads (Figure 16) for adistance slightly more than the depth of the fitting cups.

Clean the fitting cups by usingabrasive cloth, abrasive pads or aproperly sized fitting brush (Figure 17).

The capillary space between tubeand fitting is approximately 0.004 in.Solder metal fills this gap by capillaryaction. This spacing is critical for thesolder metal to flow into the gap andform a strong joint.

Copper is a relatively soft metal.If too much material is removed from

the tube end or fitting cup, a loose fitmay result in a poor joint.

Chemical cleaning may be used ifthe tube ends and fittings are thoroughlyrinsed after cleaning according to theprocedure furnished by the cleanermanufacturer. Do not touch the cleanedsurface with bare hands or oily gloves.Skin oils, lubricating oils and greaseimpair the soldering operation.

Applying FluxUse a flux that will dissolve and

remove traces of oxide from the cleanedsurfaces to be joined, protect the cleanedsurfaces from reoxidation during heating,and promote wetting of the surfaces bythe solder metal, as recommended in thegeneral requirements of ASTM B813.Apply a thin even coating of flux with abrush to both tube and fitting as soon aspossible after cleaning (Figures 18and 19).

WARNING: Do not apply withfingers. Chemicals in the flux can beharmful if carried to the eyes, mouthor open cuts.

Use care in applying flux.Careless workmanship can causeproblems long after the system hasbeen installed. If excessive amounts of flux are used, the flux residue cancause corrosion. In extreme cases,such flux corrosion could perforatethe wall of the tube, fitting or both.

FIGURE 13: Reaming: Pocket knife

FIGURE 14: Reaming: Deburring tool

FIGURE 15: Cleaning: Sand cloth

FIGURE 16: Cleaning: Abrasive pad

FIGURE 17: Cleaning: Fitting brush

FIGURE 18: Fluxing: tube

VII.

SOLD

ERED

JOI

NTS

48

Assembly and SupportInsert the tube end into fitting

cup, making sure that the tube is seatedagainst the base of the fitting cup(Figure 20). A slight twisting motionensures even coverage by the flux.Remove excess flux from the exterior ofthe joint with a cotton rag (Figure 21).

Support the tube and fittingassembly to ensure a uniform capillaryspace around the entire circumferenceof the joint. Uniformity of capillaryspace will ensure good capillary flow(Figure 27, page 48), of the molten-solder metal. Excessive joint clearancecan lead to solder metal cracking underconditions of stress or vibration.

The joint is now ready forsoldering. Joints prepared and ready forsoldering must be completed the sameday and not left unfinished overnight.

HeatingWARNING: When dealing

with an open flame, high temper-atures and flammable gases, safetyprecautions must be observed asdescribed in ANSI/ASC Z49.1.

Begin heating with the flameperpendicular to the tube (Figure 27,position 1 and Figure 22). The coppertube conducts the initial heat into thefitting cup for even distribution of heatin the joint area. The extent of this pre-heating depends upon the size of thejoint. Preheating of the assembly shouldinclude the entire circumference of thetube in order to bring the entire assemblyup to a suitable preheat condition. How-ever, for joints in the horizontal position,avoid directly preheating the top of thejoint to avoid burning the soldering flux.The natural tendency for heat to rise willensure adequate preheat of the top ofthe assembly. Experience will indicatethe amount of heat and the time needed.

Next, move the flame onto thefitting cup (Figure 27, position 2 andFigure 23). Sweep the flame alternatelybetween the fitting cup and the tube adistance equal to the depth of the fittingcup (Figure 27, position 3). Again, pre-heating the circumference of the assemblyas described above, with the torch at the base of the fitting cup (Figure 27,postion 4), touch the solder to the joint.If the solder does not melt, remove itand continue heating.

CAUTION: Do not overheatthe joint or direct the flame into theface of the fitting cup. Overheating could burn the flux, which will

destroy its effectiveness and thesolder will not enter the jointproperly.

When the solder melts, apply heatto the base of the cup to aid capillaryaction in drawing the molten solder intothe cup towards the heat source.

The heat is generally appliedusing an air-fuel torch. Such torches use acetylene or an LP gas. Electricresistance soldering tools can also be used (Figure 24, page 48). They employ heating electrodes and shouldbe considered when an open flame is a concern.

Applying SolderFor joints in the horizontal position,

start applying the solder metal slightly off-center at the bottom of the joint (Figure27, position a, and Figure 25). When thesolder begins to melt from the heat of thetube and fitting, push the solder straightinto the joint while keeping the torch at

FIGURE 19: Fluxing: fitting

FIGURE 20: Assembly

FIGURE 21: Removing excess flux FIGURE 22: Preheating tube

FIGURE 23: Preheating fitting


49

the base of the fitting and slightly ahead of the point of application of the solder.Continue this technique across the bottomof the fitting and up one side to the top ofthe fitting (Figure 27, postion b).

The now-solidified solder at thebottom of the joint has created aneffective dam that will prevent the solderfrom running out of the joint as the sideand top of the joint are being filled.

Return to the point of beginning,overlapping slightly (Figure 27, positionc), and proceed up the uncompleted side to the top, again, overlapping slightly(Figure 27, position d). While soldering,small drops may appear behind the pointof solder application, indicating the jointis full to that point and will take no moresolder. Throughout this process you areusing all three physical states of thesolder: solid, pasty and liquid.

For joints in the vertical postion,make a similar sequence of overlappingpasses starting wherever is convenient.

Solder joints depend on capillaryaction drawing free-flowing moltensolder into the narrow clearance betweenthe fitting and the tube. Molten soldermetal is drawn into the joint by capillaryaction regardless of whether the solderflow is upward, downward or horizontal.

Capillary action is most effectivewhen the space between surfaces to bejoined is between 0.002 inch and 0.005inch. A certain amount of looseness of fitcan be tolerated, but too loose a fit cancause difficulties with larger size fittings.

For joining copper tube to solder-cup valves, follow the manufacturer’s

instructions. The valve should be in apartially open position before applyingheat, and the heat should be appliedprimarily to the tube. Commerciallyavailable heat-sink materials can alsobe used for protection of temperature-sensitive components during the joiningoperation.

The amount of solder consumedwhen adequately filling the capillaryspace between the tube and either wroughtor cast fittings may be estimated fromTable 10, page 39. The flux require-ment is usually 2 ounces per pound of solder.

Cooling and CleaningAllow the completed joint to cool

naturally. Shock cooling with water maystress the joint. When cool, clean off any

remaining flux residue with a wet rag(Figure 26). Whenever possible, basedon end use, completed systems should beflushed to remove excess flux and debris.

TestingTest all completed assemblies for

joint integrity. Follow the testingprocedure prescribed by applicable codesgoverning the intended service.

FIGURE 24: Electric resistance hand tool

FIGURE 25: Soldering FIGURE 26: Cleaning

FIGURE 27: Schematic of solder joint

VII.

SOLD

ERED

JOI

NTS

50

Strong, leak-tight brazedconnections for copper tube may bemade by brazing with filler metalswhich melt at temperatures in the rangebetween 1100ºF and 1500ºF, as listed inTable 12, page 40. Brazing filler metalsare sometimes referred to as “hardsolders” or “silver solders.” Theseconfusing terms should be avoided.

The temperature at which a fillermetal starts to melt on heating is thesolidus temperature; the liquidustemperature is the higher temperature atwhich the filler metal is completelymelted. The liquidus temperature is theminimum temperature at which brazingwill take place.

The difference between solidusand liquidus is the melting range andmay be of importance when selecting afiller metal. It indicates the width of theworking range for the filler metal andthe speed with which the filler metalwill become fully solid after brazing.Filler metals with narrow ranges, withor without silver, solidify more quicklyand, therefore, require careful applicationof heat. The melting ranges of commonbrazing metals are shown in Figure 8,page 39.

Brazing Filler MetalsBrazing filler metals suitable for

joining copper tube are of two classes:(1) the BCuP series alloys containingphosphorus and (2) the BAg seriesalloys containing a high silver content.

The two classes differ in theirmelting, fluxing and flowing character-istics and this should be considered inselection of a filler metal. (See Table12.) While any of the listed filler metals

may be used, those most commonlyused in plumbing, HVAC refrigerationand fire sprinkler systems are BCuP-2(for closer tolerances), BCuP-3, 4 or 5(where close tolerances cannot be held)adn BAg-1, BAg-5 and BAg-7. TheBCuP series filler metals are moreeconomical than the BAg series, and are better suited for general pipingapplications. BAg series filler metalsshould be used when joiningdissimilar metals, or the specificcharacteristics of the BAg series fillermetals are required. For joiningcopper tube, any of these filler metalswill provide the necessary strengthwhen used with standard solder-typefittings or commercially availableshort-cup brazing fittings.

According to the AmericanWelding Society (AWS), the strengthof the brazed joint will meet or exceedthat of the tube and fitting being joinedwhen the joint overlap and the depthof the filler metal penetration is aminimum of three times the thickness ofthe thinner base metal (tube or fitting),and a well-developed fillet is present.

The strength of a brazed coppertube joint does not vary much with the different filler metals but dependsmainly on maintaining the properclearance between the outside of the tube and the cup of the fitting.Copper tube and solder-type fittingsare accurately made for each other,and the tolerances permitted for eachassure the capillary space will bewithin the limits necessary for a jointof satisfactory strength.

The rated internal workingpressures of brazed copper tube

systems at service temperatures up to350°F (the temperature of saturatedsteam at 120 psi) are shown in Table 4a,page 28. These pressure ratings shouldbe used only when the correct capillaryspace has been maintained.

FluxesThe fluxes used for brazing copper

joints are different in composition fromsoldering fluxes. The two types cannotbe used interchangeably.

Unlike soldering fluxes, brazingfluxes are water based. Similar tosoldering fluxes, brazing fluxesdissolve and remove residual oxidesfrom the metal surface, protect themetal from reoxidation during heatingand promote wetting of the surfaces tobe joined by the brazing filler metal.

Brazing fluxes also provide thecraftsman with an indication of tempera-ture (Figure 7b, page 38). If the outsideof the fitting and the heat-affected areaof the tube are covered with flux (inaddition to the end of the tube and thecup), oxidation will be minimized andthe appearance of the joint will begreatly improved.

The fluxes best suited for brazingcopper and copper alloy tube shouldmeet AWS Standard A5.31, Type FB3-A or FB3-C.

Figure 8, page 39, illustrates theneed for brazing flux with differenttypes of copper and copper-alloy tube,fittings and filler metals when brazing.

AssemblyAssemble the joint by inserting

the tube into the socket hard against thestop and turn if possible. The assembly

VIII. BRAZED JOINTSVIII. BRAZED JOINTS

51

should be firmly supported so that itwill remain in alignment during thebrazing operation.

Applying Heat and BrazingApply heat to the parts to be

joined, preferably with an oxy-fueltorch with a neutral flame. Air-fuel issometimes used on smaller sizes. Heatthe tube first, beginning about one inchfrom the edge of the fitting, sweepingthe flame around the tube in shortstrokes at right angles to the axis of the tube (Figure 27, position 1, page49).

It is very important that the flamebe in motion and not remain on any onepoint long enough to damage the tube.The flux may be used as a guide as tohow long to heat the tube. The behaviorof flux during the brazing cycle isdescribed in Figure 7, page 38.

Switch the flame to the fitting atthe base of the cup (Figure 27, position2). Heat uniformly, sweeping the flamefrom the fitting to the tube until the fluxon the fitting becomes quiet. Avoidexcessive heating of cast fittings, due tothe possibility of cracking.

When the flux appears liquid andtransparent, start sweeping the flameback and forth along the axis of thejoint to maintain heat on the parts to bejoined, especially toward the base of thecup of the fitting (Figure 27, position 3).The flame must be kept moving toavoid melting the tube or fitting.

For 1-inch tube and larger, it maybe difficult to bring the whole joint upto temperature at one time. It frequentlywill be found desirable to use an oxy-fuel, multiple-orifice heating tip tomaintain a more uniform temperatureover large areas. A mild preheating ofthe entire fitting is recommended forlarger sizes, and the use of a secondtorch to retain a uniform preheating ofthe entire fitting assembly may be

necessary in larger diameters. Heatingcan then proceed as outlined in the stepsabove.

Apply the brazing filler metal at apoint where the tube enters the socket ofthe fitting. When the proper temperatureis reached, the filler metal will flowreadily into the space between the tubeand fitting socket, drawn in by thenatural force of capillary action.

Keep the flame away from thefiller metal itself as it is fed into thejoint. The temperature of the tube andfitting at the joint should be highenough to melt the filler metal.

Keep both the fitting and tubeheated by moving the flame back andforth from one to the other as the fillermetal is drawn into the joint.

When the joint is properly made,filler metal will be drawn into the fittingsocket by capillary action, and acontinuous fillet of filler metal will bevisible completely around the joint. Toaid in the development of this filletduring brazing, the flame should bekept slightly ahead of the point of fillermetal application.

Horizontal and Vertical JointsWhen brazing horizontal joints,

it is preferable to first apply the fillermetal slightly off-center at the bottomof the joint, proceeding across thebottom of the joint and continuing upthe side to the top of the joint.. Then,return to the beginning point, over-lapping slightly, and proceed up theuncompleted side to the top, again,overlapping slightly. This procedure isidentical to that used for soldering.

Also, similar to the solderingprocess, make sure the operationsoverlap. On vertical joints it isimmaterial where the start is made. Ifthe opening of the socket is pointingdown, care should be taken to avoidoverheating the tube, as this may cause

the brazing filler metal to run down theoutside of the tube.

Removing ResidueAfter the brazed joint has cooled

the flux residue should be removed witha clean cloth, brush or swab using warmwater. Remove all flux residue to avoidthe risk of the hardened flux temporarilyretaining pressure and masking animperfectly brazed joint. Wroughtfittings may be cooled more readily thancast fittings, but all fittings should beallowed to cool naturally before wetting.

General Hints and SuggestionsIf the filler metal fails to flow or

has a tendency to ball up, it indicatesoxidation on the metal surfaces orinsufficient heat on the parts to bejoined. If tube or fitting start to oxidizeduring heating there is too little flux. Ifthe filler metal does not enter the jointand tends to flow over the outside ofeither member of the joint, it indicatesthat one member is overheated or theother is underheated.

TestingTest all completed assemblies for

joint integrity. Follow the testingprocedure prescribed by applicablecodes governing the intended service.

PurgingSome installations, such as

medical gas, high-purity gas and ACRsystems, require the use of an inert gasduring the brazing process. The purgegas displaces oxygen from the interiorof the system while it is being subjectedto the high temperatures of brazing andtherefore eliminates the possibility ofoxide formation on the interior tubesurface.

Purge gas flow rates and methodsof application should be included in theBrazing Procedure Specifications ofthese applications.

VIII.

BRA

ZED

JOIN

TS

52

While copper tube is usuallyjoined by soldering or brazing, there aretimes when a mechanical joint may berequired or preferred. Flared fittings(Figures 28 and 29) are an alternative

when the use of an open flame is eithernot desired or impractical. Waterservice applications generally use aflare to iron pipe connection whenconnecting the copper tube to the mainand/or the meter. In addition, copper

must be reamed to the full insidediameter leaving no inside burr (Figure30). Tube that is out of round prior toflaring should be resized back to round.

Failure to complete either of these stepscan, lead to an inadequate seal of theflared joint and, ultimately, to jointfailure. Dirt, debris and foreignsubstances should be removed from thetube end to be flared by mechanicalcleaning. This can be accomplishedwith the use of an abrasive cloth (screencloth, sand cloth, emery cloth or nylonabrasive cloth).

Now, place a flare nut over theend of the tube with the threads closestto the end being flared. Insert the tubebetween the flaring bars of the flaringtool in the appropriate opening for thediameter of the tube being flared.Adjust the height of the tube in theopening in accordance with the toolmanufacturer’s instructions, to achieve

IX. FLARED JOINTS

tube used for Fuel Gas (LiquefiedPetroleum (LP), Propane Gas or NaturalGas may be joined utilizing flared brassfittings of single 45º-flare type,according to NFPA 54/ANSI. Z223.1National Fuel Gas Code. All NationalModel Codes permit the use of flarejoints, but it is important to check withthe authority having jurisdiction (AHJ)to determine acceptance for a specificapplication in any particularjurisdiction.

A flare joint should be made withan appropriate tool such as thosesupplied by a number of tubing/pipingtool manufacturers. Make sure to use atool that matches the outside diameterof the tube being flared and that has theappropriate flare angle, commonly 45º(the physical characteristics of whichshould be in accordance with theSociety of Automotive Engineers SAEJ533 Standard – Flares for Tubing). Thetool usually consists of flaring bars withopenings for various tube sizes and ayoke that contains the flaring cone and aclamp to grip the flaring bars.

When flaring Types L or Kcopper tube, annealed or soft tempertube should be used. It is possible toflare Types K, L or M rigid or hardtemper tube, though prior to flaring it isusually necessary to anneal the end ofthe tube to be flared. The copper tubemust be cut square using an appropriatetubing cutter. After cutting, the tube

FIGURE 28: Flare fitting/flared joint during assembly

FIGURE 29: Completed flared joint

FIGURE 30: Reaming prior to flaring the tube end

IX. FLARED JOINTS

53

sufficient length of the flare. Positionthe yoke with the flaring cone over thetube end and clamp the yoke in place.Turn the handle of the yoke clockwise(Figure 31). This lowers the flaring

cone and forces the lip of the tubeagainst the base of the flaring bar tocreate an angled flare that will matesecurely with a corresponding flare-typefitting. Care should be taken not toover-tighten the cone and causecracking or deformation of the tubeand/or the tool. Some tools also providea setting for ironing or burnishing theflare, as a final step to achieve a moreconsistent flare. The final flared tubeend should have a smooth, even, roundflare of sufficient length to fully engagethe mating surface of the flare nutwithout protruding into the threads(Figure 32).

No material (e.g., pipe jointcompound) should be applied to themating surfaces of the flare fitting andthe flared tube end before attaching theflare nut to the fitting body.

FIGURE 32: Completed flared tube end

FIGURE 31: Lowering the flaring cone into the tube end

IX. F

LARE

D JO

INTS

54

Grooved-end piping has beenfamiliar to pipe fitters and sprinklersystem contractors for many years.Since 1925, this method of joiningpipe has been used reliably on steeland iron pipe in HVAC, fireprotection, process piping and relatedapplications.

This method of mechanicaljoining is also available in a systemfor copper tube in sizes from 2through 6 inches. Included arecouplings, gaskets and a myriad offitting configurations. The systemoffers a practical alternative tosoldering and brazing larger-diametercopper tube. And most importantly itrequires no heat or open flame, as dosoldering or brazing.

Copper roll groove joining takesadvantage of copper’s excellentmalleability and its increased strengthwhen cold worked. The joints rely onthe sealing capability of a specialclamping system that contains anEPDM gasket and a specially designedclamp. Several manufacturers offerroll groove tools, gaskets, clamps andfittings.

Preliminary RequirementsAs with all copper no-flame

joining processes, proper preparationof the tube end is vitally important to asound, leak-free joint.

Proper selection of the correctroll grooving tool and heads for eachtype of tube to be prepared isessential. Manufacturer’srecommendations must be followed inorder to ensure safe, trouble-free, tubepreparation.

Installation Steps■ Examine the tube to ensure there areno dents, deep scratches, dirt, oils,grease or other surface imperfections.

■ Measure the tube length accurately.

■ Cut the tube end square, i.e.,perpendicular to the run of the tube.

■ Remove burrs from the I.D. and theO.D. of the tube end by reaming theI.D. and chamfering the O.D using theappropriate tools.

■ Roll groove the tubing to the properdimensions, as required by the fittingmanufacturer.

X. ROLL GROOVE JOINTS

X. JOINING METHODS

FIGURE 33: Inspect tube for imperfections

FIGURE 34: Measure accurately

FIGURE 35: Square-cut tube end

FIGURE 36: Clean and smooth tube end

FIGURE 37: Grooved tube end

■ Examine the fittings, gaskets andclamps to ensure the proper gasket isinserted into the clamp and the fittingend is not damaged.

■ Lubricate the gasket permanufacturer’s recommendations.

■ Inspect the clamping surfaces toensure they are clean and free fromconstruction debris. Assemble thejoint according to the manufacturer’srecommendations.

■ Tighten the clamping nuts to theproper torque per manufacturer’srecommendations.

■ Inspect the tightened clamp toensure it is properly assembled.

TestingTesting of the completed piping

system can be accomplished by usingpressurized air, water, or hydro-pneumatic testing when the testpressure is relatively high. (Note: testpressures should never exceed themaximum operating pressure specifiedby the manufacturer of the fittingsystem.)

55

X. J

OINI

NG M

ETHO

DS

FIGURE 44: Final inspection ofcompleted joint

FIGURE 38: Clamp and gasket assembly

FIGURE 39: Selection of fitting, gasketsand clamps

FIGURE 40: Applying lubrication to gasket

FIGURE 41: Inspect the surface

FIGURE 42: Assembled joint

FIGURE 43: Tightening the clamp

56

Press-connect joining of copperand copper alloy tube is fast,economical, and, most importantly, itrequires no heat or open flame unlikesoldering or brazing.

The press-connect joining method(sometimes called press-fit) waspatented in Europe in the late 1950s andcontinues to be used successfully there.The method and associated fittings andtools were introduced in the UnitedStates in the late 1990s. Since then,there has been growing acceptance, andthose using the method experienceexcellent results.

Press-connect joining takesadvantage of copper’s excellentmalleability and its proven increasedstrength when cold worked. The jointsrely on the sealing capability of aspecial fitting that contains anelastomeric gasket or seal (such asEPDM) (Figure 46) and the proper useof an approved pressing tool and jaws(Figure 47). Typical ranges ofpressure-temperature ratings for theseno-flame joints are found in Table 4b,page 29. Several manufacturers offerfull product lines of press-connectfittings, valves and specialty items(Figure 48). Additionally, tube isavailable with an integrally formedpress-connect end (Figure 49).

Preliminary RequirementsThe tube must be examined to

ensure that it reveals no dents, deepscratches, dirt, oils, grease or othersurface imperfections.

Installation Steps■ Measure tubing accurately to insureit sockets completely to the base of thefitting cup.

■ Cut the tubing square, perpendicularto the run of tube, using an appropriatetube cutter.

XI. PRESS-CONNECT JOINTS

XI. PRESS-CONNECT JOINTS

FIGURE 45: Inspect tube for imperfections

FIGURE 48: Sample fittings available

FIGURE 47: Press tools and jaws

FIGURE 46: Press-connect fitting withelastomeric gasket


FIGURE 51: Cutting the tube square

FIGURE 52: Tube cuttersFIGURE 49: Sample of integrally formedpress-connect tube end

■ Burrs must be removed from the I.D.and O.D. of the cut tube end.

■ Chamfer the cut tube end to reducethe possibility of gasket damage wheninserting the tube into the fitting.

■ Examine the fitting to be used toensure the sealing gasket is properlypositioned and is not damaged.

■ Depth of insertion must be marked onthe tube prior to inserting the tube intothe fitting.

■ Select the proper size of theappropriate pressing jaw and insert itinto the pressing tool.

■ Ensure the tube is completely insertedto the fitting stop (appropriate depth)and squared with the fitting prior toapplying the pressing jaws onto thefitting.

■ Place the pressing jaw over the beadon the fitting and ensure the tool andjaws are at a 90° angle (perpendicular)to the centerline of the tube.

■ Depress the pressing tool trigger tobegin the pressing cycle.

■ When the pressing cycle is complete,release the pressing jaw and visuallyinspect the joint to ensure the tube hasremained fully inserted, as evidenced bythe visible insertion mark.


system can be accomplished by usingpressurized air, water, or hydro-pneumatic testing when the testpressure is relatively high. (Note: testpressures should never exceed themaximum operating pressure specifiedby the manufacturer of the fittingsystem.)

57

XI. P

RESS

-CON

NECT

JOI

NTS

FIGURE 61: Completed installation of a press-connect joint

FIGURE 53: Reaming tools

FIGURE 54: Chamfer tool for O.D. burrremoval

FIGURE 55: Properly prepared tube end

FIGURE 56: Press fitting

FIGURE 57: Measuring depth of insertion

FIGURE 58: Pressing jaw selections

FIGURE 59: Fitting prepared for pressing

FIGURE 60: Properly positioned press tool

Note: missing gasket

58

Like the press-connect joiningmethod, the push-connect joining ofcopper and copper alloy tube is fast,economical and, also, requires no heator open flame. However, unlike mostother joining methods, no additionaltools, special fuel gases or electricalpower are required for installation.

Push-connect joining utilizes anintegral elastomeric gasket or seal (suchas EPDM) and stainless steel grab ringto produce a strong, leak-free joint.Typical ranges of pressure-temperatureratings for these no-flame joints arefound in Table 4b.

There are two common types ofpush-connect fittings. Both createstrong, permanent joints however oneallows for easy removal afterinstallation (Figure 62) to allow forequipment service, while the secondtype (Figure 63) cannot be easilyremoved once the fitting is installed.

■ Remove burrs from the I.D. and O.D.of the cut tube end by reaming the I.D.and chamfering the O.D. using theappropriate tools.

XII. PUSH-CONNECT JOINTS

Preliminary RequirementsThe tube must be examined to

ensure that it reveals no dents, deepscratches, dirt, oils, paint, grease orother surface imperfections.

Installation Steps ■ Measure the tube accurately to ensureit will socket to the back of the fittingcup.

■ Cut the tube square, perpendicular tothe run of tube, using an appropriatetubing cutter.

FIGURE 64: Ensure tube is clean, roundand free of imperfections

FIGURE 66: Tube cutters


FIGURE 68: Chamfer tool

FIGURE 63: Permanent push-connect fitting

FIGURE 62: Removable push-connect fitting


XII. PUSH-CONNECT JOINTS

■ Chamfering the cut tube end isrequired to reduce the possibility ofgasket damage when inserting the tube.Cleaning of the chamfered tube endwith emery paper, nylon abrasive clothor plumber’s cloth will ensure that nosharp edges or nicks are present, whichmight damage the sealing gasket uponinsertion of the tube into the fitting.

■ Examine the fitting to be used toensure the sealing gasket and gripperring are properly positioned and notdamaged.

■ Mark the depth of insertion on thetube prior to inserting it into the fitting.

■ Lubrication of the tube end may ormay not be required. Follow themanufacturer’s installationrecommendations related to pre-lubrication of the tube end.

■ Align the tube so that it is straight andin line with the fitting.

■ Using a firm pushing and twistingmotion, insert the tube into the fittingand push the tube and fitting togetheruntil the tube is seated at the back of thefitting cup as evidenced by the pre-marked tube insertion depth line.


system can be accomplished by usingpressurized air or water as required bylocal codes or project specifications.Note: test pressures should neverexceed the maximum operatingpressure specified by the manufacturerof the fitting system.

59

FIGURE 69: Chamfered tube end

FIGURE 70: Fitting

FIGURE 73: Completed installation of a push-connect joint

FIGURE 71: Marking insertion depth

FIGURE 72: Aligning tube end squarely

XII.

PUSH

-CON

NECT

JOI

NTS

60

Structural adhesive joining ofcopper and copper alloy tube is fast,economical and, most importantly,requires no heat or open flame as isrequired for soldering or brazing.

Structural adhesive joiningutilizes a complete system consisting ofa specially designed fitting thatincorporates a lip-seal type elastomericgasket and a specially formulated two-part epoxy structural adhesive.

Although the engineered fittingsand adhesive are patented andspecifically required to be usedtogether, any copper tube meeting therequirements of ASTM B88 in types K,L or M, drawn (hard temper) orannealed (soft temper), can be used.Typical ranges of pressure-temperatureratings for these no-flame joints arefound in Table 4b, page 29. (Tube sizesand specific limitations must meetmanufacturers' recommendations.)

Preliminary RequirementsExamine the tube to ensure it

reveals no dents, deep scratches, dirt,oils, paint, grease or other surfaceimperfections.

Fittings must be examined toinsure they are structural adhesive typefittings, the lip-seal gasket is in placeand in good condition, and the fittingdoes not show evidence of dirt orconstruction debris inside.

■ Remove burrs from the I.D. and theO.D. of the tube end by reaming theI.D. and chamfering the O.D using theappropriate tools.

■ Chamfer the cut tube end to reducethe possibility of gasket damage wheninserting the tube. Cleaning of thechamfered tube end with emery paper,nylon abrasive cloth or plumber’s clothwill insure that no sharp edges or nicksare present which could damage thesealing capacity of the gasket uponinsertion of the tube into the fitting.

XIII. STRUCTURAL ADHESIVE JOINTS

Installation Steps■ Measure accurately to insure the tubewill socket to the back of the fitting cup.

■ Cut the tube square, perpendicular tothe run of the tube, using an appropriatetube cutter.

FIGURE 74: Check tube for imperfections


FIGURE 79: Chamfer tool

XIII. STRUCTURAL ADHESIVES

FIGURE 75: Structural adhesive fitting


FIGURE 77: Cutting the tube squareFIGURE 80: Chamfering the tube end

■ Clean the tube end by wiping it withalcohol to remove any residual surfaceoils, dirt or construction debris prior toapplying the adhesive. This will ensureproper bonding of the structuraladhesive.

■ Mark the depth of insertion plus ½”on the tube so that full insertion can beensured when assembling the tube tofitting.

■ Apply a small bead of adhesive to thetube end O.D. close to the cut end. Insizes 1” and greater, an additionalapplication of a small bead of adhesivemust be applied to the inside of thefitting before the lip-seal gasket. Thebead applied to the inside of the fittingmust be less than the height of the lip-seal gasket for best results. (There areseveral forms of fittings for thestructural adhesive system, such asthose that require application ofadhesive directly through holes in thecup of the fitting, and application of theadhesive should be in accordance withthe manufacturers' instructions.)

■ Insert the tube into the fitting. Propertube insertion can be ensured if thefitting is ½” from the insertion depthmark. (It should be noted that, in somefabrications, there are times whenapplying a mark ½” from the face of thefitting would be almost impossiblebecause of the ability to actually buttfittings up against each other. In suchcase, another means of ensuing propertube-to-fitting insertion should be used.)

■ Following assembly and finaladjustment of fitting orientation, theadhesive should be visible around theentire circumference of the fitting-to-tube interface. Care should be exercisedto ensure the joint is permitted to cureas required, based on the work-life/set-time for the adhesive being utilized.


system should be undertaken only afterthe appropriate length of cure time haselapsed from the fabrication of the lastjoint in the system.

Final pressure testing of thecompleted piping system can beaccomplished by using pressurized airor water as required by local codes orproject specifications. (Note: testpressures should never exceed themaximum operating pressure specifiedby the manufacturer of the fittingsystem.)

61

FIGURE 87: Inserting tube end

XIII.

STR

UCTU

RAL

ADHE

SIVE

S

FIGURE 83: Use alcohol to clean tube end

FIGURE 81: Cleaning the tube end

FIGURE 82: Prepared tube end

FIGURE 84: Wipe with premoistenedalcohol wipe or pad

FIGURE 85: Marking insertion depth

FIGURE 86: Applying adhesive to tube end

FIGURE 88: Ensuring proper insertion depth

FIGURE 89: Visual check of adhesive coverage

62

Another joining technology thathas been used effectively for manyyears involves a hand tool designed toquickly pull tee connections and outletsfrom the run of the tube, thus reducingthe number of tee fittings and solderedor brazed joints. It allows branches tobe formed faster and usually results in alower installed system cost. Thismethod may be used for generalplumbing, HVAC, refrigeration, firesprinkler and service projects.

Portable hand tool kits and poweroperated equipment are available thatproduce lap joints for brazing. Thesystem can be used with Types K, L orM copper tube to form ½” to 4” outletsfrom ½” to 8” tubes, depending on toolselection. The installation descriptionsbelow are for illustrative purposes only.It is essential that the manufacturer’sinstructions and guidelines are followedexactly to ensure proper installation andsafe performance.

Preliminary Requirements Be sure to have all tool kit

components handy. They typicallyinclude:

is quickly repeatable. Follow themanufacturer’s operating instructionsfor all tube sizes.

■ Select and adjust the drill head andforming pins according to themanufacturer’s instructions. The drillbit and pins are quite sharp, so cautionis in order.

■ Insert the drill head into the chuckand extend the forming pins.

■ Lubricate the drill head and formingpins.

■ Press in the conical cover and rotatecounterclockwise to retract the formingpins.

XIV. MECHANICALLY FORMED EXTRUDED OUTLETS

■ The tee-forming power drill or handoperated outlet pulling tools and themanufacturer’s instructions for their useand proper application.

■ A tube end prep tool that forms theend of a branch pipe to match the innercurve of the run tube whilesimultaneously pressing two dimples inthe end of the branch tube. One acts as adepth stop and the other for inspectionof the joint after brazing.

■ Be sure the pipes (run and branch) aredrained and not under pressure.

Installation Steps The procedure that follows is

typical for the forming and brazing of½” to 1¼” outlets using power operatedequipment. Although there are specificsteps to be followed, the tee-formingand brazing process takes little time and

XIV. MECHANICALLY FORM

ED EXTRUDED OUTLETS

FIGURE 90: Mechanically formedextruded outlet requires only one brazed joint FIGURE 91: Power operated accessory

tool kit

FIGURE 92: Hand operated accessory tool kit

FIGURE 93 (a and b): Chucking the drillhead assembly

a

b

■ On tube sizes over 2”, the area forforming the tee outlet must be annealedfirst. See manufacturer’s instructionswhen dealing with these sizes.

■ Pull out the support legs and place thetube support firmly onto the pointwhere the tee is to be formed on the

tube. Then, twist the machinecounterclockwise at the handle of thetool to center the drill head on the tube.The legs will center and support thedrill while absorbing all rotationaltorque.

■ Start the tool by squeezing the triggerand drill until the bit has fullypenetrated into the tube. Then, releasethe trigger to stop the drill.

■ Extend the forming pins on the drillhead by pressing the cover toward thetool and rotating it counterclockwiseuntil the head locks in the tee-formingposition. Do not extend the forming pinswhile the motor is running.

■ Turn the speed selector control to theslowest position (typical). Engage thefeed mechanism. You may have torotate the motor by giving a nudge onthe trigger.

Squeeze the trigger to startforming the outlet and continue until thedrill head is completely out of the tube.Maintain a slight downward pressure onthe drill to ensure a firm contact withthe tube. The rotation of the formingpins causes a back flow and thickeningof the metal around the lowercircumference of the outlet.

It is important to release the drilltrigger as soon as the drill head clearsthe rim of the outlet. NOTE: Removingthe drill head from the tube before itemerges will result in an oval orimperfect outlet.

■ Ream or deburr the branch tube end.

■ Choose the appropriate branch-sizedye on the tube-end notcher to notchand dimple the sides of the branch tubeend. Proper notching and dimpling mustbe performed to meet code require-ments and to ensure the branch does notprotrude into the tube.

63

FIGURE 96: Positioning the drill tip andensuring a snug fit of the support legs

XIV.

MEC

HANI

CALL

Y FO

RMED

EXT

RUDE

D OU

TLET

S

FIGURE 94 (a and b): Lubricating the drill head

FIGURE 95 (a and b): Retracting the forming pins

FIGURE 97 (a and b): Extending theforming pins inside the run tube

FIGURE 98: Forming the outlet

FIGURE 99: Reaming the branch tube end

a

b

a

b a

b

■ Remove any excess lubricant frominside the outlet and use Scotchbrite™or sand cloth to clean the inside of theoutlet rim.

■ Insert the branch tube into the outletup to the first dimple and align thedimples with the run of the tube.

■ Braze the joint.

TestingAll drilling residue and debris

must be flushed out before using thesystem.

Final pressure testing of thecompleted piping system isaccomplished by using pressurized airor water as required by local codes orproject specifications. (Note: testpressures should never exceed themaximum operating pressure specifiedby the manufacturer of the fittingsystem.)

64

XIV. MECHANICALLY FORM

ED EXTRUDED OUTLETS

FIGURE 103: Aligning the dimples withthe run of the tube

FIGURE 100: Using the notching anddimpling tool

FIGURE 101: Properly prepared branchend tube

FIGURE 102: Ensuring the inside rimsurface is clean

FIGURE 104: Finished joint

65

AFSA - American Fire SprinklerAssociation

12750 Merit Drive, Suite 350Dallas, TX 75251(214) 349-5965 www.firesprinkler.org

AGA - American Gas Association400 North Capitol Street, NWWashington, DC 20001(202) 824-7000 www.aga.org

AHRI - Air-Conditioning, Heating andRefrigeration Institute

2111 Wilson Blvd., Suite 500Arlington, VA 22201(703) 524-8800 www.ahrinet.org

ANSI - American NationalStandards Institute

1819 L Street, NWWashington, DC 20036(202) 293-8020 www.ansi.org

APFA - American Pipe FittingsAssociation, Inc.

201 Park Washington Court Falls Church, VA 22046(703) 538-1786 www.apfa.com

ASHRAE - American Society ofHeating, Refrigeration & Air-Conditioning Engineers, Inc.

1791 Tullie Circle, NEAtlanta, GA 30329-2305(404) 636-8400 www.ashrae.org

ASME - American Society ofMechanical Engineers

3 Park AvenueNew York, NY 10016-5990(212) 591-7000 www.asme.org(800) 843-2763

ASPE - American Society of PlumbingEngineers

2980 S. River Rd. Des Plaines, IL 60018 (847) 296-0002 www.aspe.org

ASNT - American Society for Non-destructive Testing

P.O. Box 285181711 Arlingate Lane Columbus, OH 43228-0518(800) 222-2768 www.asnt.org

ASSE - American Society of SanitaryEngineering

901 Canteberry, Suite AWestlake, OH 44145(440) 835-3040www.asse-plumbing.org

ASTM International100 Barr Harbor Drive, P.O. Box C700West Conshohocken, PA 19428-2959(610) 832-9500 www.astm.org

AWS - American Welding Society550 NW LeJeune RoadMiami, FL 33126-0440(305) 443-9353 www.aws.org

AWWA - American Water WorksAssociation

6666 W. Quincy AvenueDenver, CO 80235(303) 794-7711 www.awwa.org

CDA - Copper DevelopementAssociation Inc.

260 Madison Avenue (16th Fl)New York, NY 10016(212) 251-7200 www.copper.org

CGA- Compressed Gas Association, Inc.4221 Walney Road, 5th FlChantilly, VA 20151-2923(703) 788-2700 www.cganet.com

CIPH - Canadian Institute of Plumbingand Heating

295 The West Mall, Suite 330Toronto, Ontario, M9C 4Z4(416) 695-0447 www.ciph.com

CCBDA - Canadia Copper and BrassDevelopment Association

49 The Donway West, Suite 415 North York, Ontario, M3C 3M9(416) 391-5591www.coppercanada.ca

GAMA - Gas Appliance ManufacturersAssociation (See AHRI)

IAPMO - International Association ofPlumbing and Mechanical Officials

5001 E. Philadelphia St. Ontario, CA 91761 (909) 472-4100 www.iapmo.org

ICC - International Code Council500 New Jersey Avenue, NW, 6th Fl Washington, DC 20001(888) 422-7233 www.iccsafe.org

MCAA - Mechanical ContractorsAssociation of America

1385 Picard DriveRockville, MD 20850-4340(301) 869-5800 www.mcaa.org

NACE - National Association ofCorrosion Engineers

1440 South Creek DriveHouston, TX 77084-4906(281) 228-6200 www.nace.org

APPENDIX — ORGANIZATIONS

XV. A

PPEN

DIX

NFPA - National Fire ProtectionAssociation

One Batterymarch ParkQuincy, MA 02169-7471(800) 344-3555 www.nfpa.org

NFSA - National Fire SprinklerAssociation

40 John Barrett RoadPatterson, NY 12563(845) 878-4200 www.nfsa.org

NSF InternationalP.O. Box 130140789 N. Dixboro RoadAnn Arbor, MI 48113-0140(734) 769-8010 www.nsf.org

SMACNA - Sheet Metal and AirConditioning Contractors NationalAssociation

4201 Lafayette Center DriveChantilly, VA 20151-1209(703) 803-2980 www.smacna.org

UA - United Association of Journeymenand Apprentices of the Plumbingand Pipefitting Industry of theUnited States and Canada

Three Park PlaceAnnapolis, MD 21401(410) 269-2000 www.ua.org

66

XV. APPENDIX

260 Madison AvenueNew York, NY 10016-2401

www.copper.org

A4015-06/10

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THE COPPER TUBE HANDBOOK - greatinspectors.com COPPER TUBE HANDBOOK ... FIGURE 4 a,b,c. Coiled expansion loops and expansion offsets ... cost-effective tubing material. 2. Copper is