WhyDoPVC&CPVCPipesOccasionallyFail?

ByDr.DuanePriddy,PlasticFailureLabs,Midland,MI

Preface
PVCandCPVCpipesandfittingsareexcellentproductsandhavebeenusedsuccessfullyfordecades.
ThereisalowfailurerateandtheuseofPVC/CPVCmaterialsoffersignificantadvantagesovermetal
pipingmaterialsincludingeaseofinstallationandverylowfailurerates.Iamnotawareofanyhealth
cautionsregardingtheusageofPVC/CPVCpipesandfittingsotherthantheneedtoinstallthem
properlywithoutusingincompatiblematerialsduringtheinstallation.However,aswithallplumbing
productsincludingmetalpiping,occasionallyapipeorfittingmayfail.Whenafailuredoesoccur,our
experienceindicatesthatmostoftenthefailurecanbelinkedtoimproperinstallationpractices.The
intentofthisarticleistoprovideassistanceregardinginstallationerrorstoavoidandtherebyreducethe
occurrenceofafailureinPVCandCPVCplumbing.Again,letmeemphasizethatbyteachingaboutthe
maincausesofoccasionalfailureofPVCandCPVCpipesandfittings,Iaminnowaysuggestingthat
theseplumbingproductsarelessreliableormorepronetofailurethananyotherplumbingmaterial.
Further,IamoutragedbythemisuseofmyteachingsbysometoattackPVCandCPVCplumbing
productsasbeinginherentlyunsafe.IfIweretobuildahomeformyownfamily,Iwoulduseasmuch
plasticplumbinginmyhomeaspossibletokeepthecoststoaminimumwhileprovidingmyfamilywith
asafelivingenvironment.

MostoftheMainCausesofCPVC/PVCPipeFailureListedBelowareDiscussedinthisArticle
I.
ImproperSystemEngineering/Installation
A. Inadequateprovisionforlinearthermalexpansion
B. ExcessuseofCement
C. InsufficientamountofCement
D. WrongClampsusedorClampstootight
E. Incompatiblefirecaulkused
F. Contactofoutsideofpipewithincompatiblematerial(e.g.,solderflux)

II. ImproperOperation
A. Exposuretofreezingtemperatureswithoutfreezeprotection
B. Overpressurization
C. Pulsatingwaterpressure
D. Useofincompatiblematerialsaroundpipes

III. Contamination
A. Internal
1. Useofcontaminatedantifreeze
2. Contaminantsfrommetalwatersupplypiping;e.g.,antimicrobial(MICinhibitor)linings,
corrosioninhibitors,phthalateplasticizersfrompumpseals/gaskets,refrigeration
systemlubricants
B. External
1. IncompatibleFireCaulk
2. Useofincompatible(blackProset)grommetstosealpipeagainstholeinconcrete

3. Contactwithincompatibleplasticcoatedwires
4. Exposuretohotsolderflux
5. Exposuretohotpolyurethanefoaminsulation

IV. Manufacturingdefects
A. Dirtyextrusiondie
B. Incompleteresinconsolidation
C. Highstressesinpipewallduetorapidcooling

V. ResinDefects
A. Occlusions,charparticles,voids
B. Filler/pigmentnotwelldistributed

IV.AbusebyDistributor
A. Storeinsun
B. Damageduringtransport

Introduction
PVCandCPVCpipesareoneofthemostextensivelyusedplasticpipingmaterials.Themainreasonfor
thegreatsuccessofthesepipesistheirlowcost,extremelylowfailurerate,andrelativeeaseof
installation.However,aswithallpipingmaterials,thereareoccasionalfailures.Occasionalfailuresmay
becausedbyanumberoffactorshoweverimproperinstallationisgenerallythemostcommoncause
whenPVCandCPVCpipesfail.

PlasticFailureLabsisanindependentforensiclaboratory.Wehavebeenconductingforensicfailure
analysesofplasticpartsforseveralyears.Wehavecarriedouthundredsofforensicfailureanalysis
investigationsofCPVCandPVCpipesandfittingsattherequestofinsurancecompanies,installers,pipe
manufacturers,generalcontractors,condominiumassociations,andprivateowners.Wehavefound
thattheoverwhelming/mostcommoncauseoffailureisimproperinstallationpractices.Sometimes
installationerrorsresultincontamination,althoughthesetwoissuesarenotalwaysrelated.The
combinationofpipesunderstressplustheexposuretoincompatiblematerials,canleadto
environmentalstresscrackingfailureorESC.ThisisespeciallythecasewithCPVCsprinklersystem
pipingifnotadequatelyflushedasrecommendedinNFPA13toremovedebrisandtracechemicals.If
CPVCfiresprinklersystemsarenotflushed,tracechemicalsremaintrappedinsideforperiodsoftime
andmaybecomeabsorbedintotheCPVC.CPVCisaveryductilematerial.However,thecombinationof
prolongedhighstressandabsorptionofcertainhydrocarboncontaminantsmaycauseittoweakenand
developstresscracks(Figure1).

ThemostcommoncausesofoccasionalfailureofPVCandCPVCpipesandfittingsarelistedinTable1.
Alsoincludedinthetablearecommontechniquesthatareusedtodetectthelistedcauses.Thereare
manytoolsavailabletotheforensicscientistbutthemostcommonlyusedtoolsareopticalmicroscopy,
scanningelectronmicroscopy(SEM),Fouriertransforminfraredspectroscopy(FTIR),andgas
chromatographymassspectroscopy(GCMS).

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Figure1.FormationofastresscrackontheinsideofaCPVCfiresprinklerpipeatapointwhereatight
fittingclampwasused.

Table1.Sixmaincausesofoccasionalpipefailureandtestingmethodsgenerallyusedfordiagnoses:
TypeofFailure
RootCauseofFailure
Tests
Improperinstallation
excessivecement
sectioning&inspection

insufficientcement
sectioning&inspection

wrongclampused
siteinspection

clampstoofarapart
siteinspection

clampstootight
outofround/clampmarks

noallowanceforthermalexpansion siteinspection

pipesnotproperlyaligned
siteinspection

shortinsertion
sectioning&inspection

Pipeendnotdeburred
sectioning&inspection

Pipeendnotchamfered
sectioning&inspection

nonsquarepipecuts
sectioning&inspection

wrongantifreezeused*
FTIR

Contamination
Incompatiblethreadsealants
FTIR/GCMS
ChemicalCompatibility Incompatiblethreadcuttingoils
FTIR

Phthalatesfromgaskets/seals
GCMS

IncompatibleMICinhibitor
FTIR/ESIMS/GCMS

Incompatibleantifreeze*
GCMS/FTIR

Productdefects
pipedimensionswrong

resinnotfullyconsolidated
SEM

weakextrusionknitlines

dirtydiecreatingextrusionlines
blacklight

voidsorparticulates
OM/SEM/EDS

residualstressduetorapidcooling
OM

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Resindefects

Improperoperation

Abusebydistributor

resinMWtoolow
fillercontentwrong
additives/pigmentsdispersion
chlorinecontentwrong**

waterhammer
overpressurization
areacontamination
freezing

storeinsun
damageduringhandling/transport
*uniquetofiresprinklerpipes
**uniquetoCPVC

MI
TGA
SEM/EDS
EA

OM/SEM
OM/SEM
GCMS/IR
OM

IR
OM

Key: OM=optical microscopy; IR=infrared microscopy; GC-MS=gas chromatography-mass spectroscopy;

SEM/EDS=scanning electron microscopy/electron dispersive spectroscopy; EA=elemental analysis; DSC=differential
scanning calorimetry; TGA=thermal gravimetric analysis

ImproperInstallation
Excessivecementuse:Aninstallationproblemthatweoccasionallyseeistheuseofexcessivecement.
ThesolventsinthecementthemselvesarereadilyabsorbedintoCPVCandPVC;i.e.,theyreadilyare
absorbedintothewallofthepipeandinsidefittingsocketresultinginsolvation/softeningofthe
material.Figure2showsashortpieceofpipewithafittingoneachendhavingexcesscementpuddled
insidetheshortpieceofpipe.Thesolventsinthecementabsorbedintothepipewallresultingin
softeningofthepipewalltothepointthatthepipewallbecameswollen/softenedandnolongerhad
sufficientstrengthtoholdwaterpressureresultinginblowout.

Figure2.Puddlingofexcesscementinsideoffittingranintoadjacentpiperesultinginsofteningand
blowoutofthepipewall.

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However,absorptionofthesolventsinthecementintothetoplayerofplasticinthepipeandfitting
socketisnecessarytoachievegoodbonding.Theorganicsolventsincementsoftenthesurfaceofthe
pipeandfittingsocketallowingthepolymermoleculestointertwinetoformapermanentbond.The
organicsolventsinthecementarevolatileandquicklyevaporatesothattheyareonlyaroundlong
enoughtodotheirintendedjobbutnotlongenoughtocausethepipetoweaken.Theproblemisthat
occasionallyinstallersutilizetoomuchcementresultingindribblesrunningdowntheinsideofvertical
runsofpipe.Wehaveobservedenvironmentalstresscracks(ESC)bothunderneath(Figure3)and
adjacent(Figure4)tocementdribbles.ItisnotknownforcertainexactlywhyESCfailuresofpipes
occasionallyoccurunderneathoradjacenttocementdribbles.Onetheoryisthatthecementisporous
andabsorbstracehydrocarboncontaminantspresentinthewaterandfacilitatestheirabsorptioninto
thewallofthepipe.AnothertheoryoftheESCcrackingofCPVCimmediatelyadjacenttoacement
dribbleisthatthedrying/shrinkageofthecementcreatesadjacentstressesontheinsidesurfaceofthe
wallofthepipe.

Figure3.ESCoftheinsidesurfaceofthewallofthepipeunderneathacementdribble

Figure4.CementdribbleoninsideofCPVCpipewithESCcracksfoundaroundtheperipheryofthe
dribble.

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Whenexcessivecementisusedontheoutsideofpipeitisnotasmuchofaproblemasontheinside.
Thisisbecause,ontheoutside,thevolatileorganicsolventsquicklyevaporate.However,ontheinside
ofthepipe,theorganicsolventsaretrappedallowingmoreexposuretimeoftheinsidewallofthepipe
tothesolvent.Byapplyingtheexcesscementtotheendofthepipe,butnotthefitting,whenthepipe
isinsertedintothefitting,theexcesscementispusheddowntheoutsideofthepipeforcingtheexcess
totheoutsideofthepipe.Ifexcesscementisappliedtotheinsideofthefitting,theexcessendsup
remainingtrappedinsidethefittingandeitherpuddlesinsidethefittingorelserunsdowntheinsideof
thepipe(Figure4).Itisgenerallyquiteeasytospotwhetherafittingwasassembledusingasufficient
amountofcementbysimpleexaminationofthecementresidueinthecrevicebetweenthefittingand
thepipeasshowninFigure5.

Figure5.Photosshowingtheexternalappearanceofabad(left)andagood(right)joints.

Insufficientcementuse:Sufficientcementmustbeappliedtoendupwithcompletecoverageofthe
endofthepipeandtheinsideofthefittingsothatacontinuousbondisformedbetweenthepipeand
fittingsurfaces.Ifinsufficientcementisused,voidsmayforminthebondbetweenthepipeandfitting.
Thepresenceofthevoidsresultsinaweakenedassemblywhichmayresultinwaterleakingfromthe
joint.Note:Wehavedevelopedatechniquetonondestructivelyexaminefittingstodetermineifvoids
existbetweenthepipeandfittingorifcompletebondinghastakenplace.Ifdesired,oneofourforensic
engineerscantraveltoasiteandanalyzesuspectfittingassembliestodetermineifvoidsarepresentin
thebondedjoints.

CharlottePipe&FoundrysPVC/CPVCinstallationmanual*recommendsthefollowingprocedurefor
cementapplication:
Applyaheavy,evencoatofcementtotheoutsidepipeend.Applyamediumcoattothefitting
socket.Applyasecondcementapplicationonthepipeend.Itisimportanttoinsuresufficient
penetrationofthesolventcementintothepipeandfittingsurface(s)bywipingthecementwith
thedauberuntilthepipemarkingshavebeenremovedfromthepipesurface.Usually35
rotationsaroundthepipewiththedauberaresufficienttoachievepropersoftening.
Immediatelyinsertthepipeintothefittingsocketcompletelytothestop,whilerotatingthepipe
14turn.

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*note:alwayscheckwiththepipeandfittingmanufacturerforthemostuptodateinstructions,as
writteninstructionsmaybeupdatedfromtimetotime.

Deburring/ChamferofPipeEnds
Whenapipeiscut,itshouldbecutsquareandanyresidue(burrs)thatformsontheendofthepipe
duringthecuttingoperationshouldberemoved.Further,thesharpouteredgeontheendofthepipe
shouldberoundedorchamfered.Theroundededgeallowsthecementplacedontheinsideofthe
fittingsockettobemoreevenlydistributedasthepipeisinsertedintothesocketaswellashelpingto
achievecompleteinsertioneachtime.

IncorrectClampsandContactwithConduit/Wire:Anotherverycommoncauseofoccasionalfailureis
theuseofthewrongtypeofsupportwhichplacesstressonthepipe.AlsobendingconduitsaroundPVC
orCPVCpipecanplacehighlocalizedstressonthePVC/CPVCpipesincontactwiththeconduit.Some
electricalwires,especiallycomputercables,shouldnotbeallowedtocomeintocontactwithPVCor
CPVCpipesbecausetheouterflexiblesheathmaycontainplasticizerswhichcanmigrateintothepipe
resultinginweakeningandfailureofthepipe.Figure6showsaphotographofaCPVCfiresprinklerpipe
installationrevealingcontactofthepipewithelectricalwireandaconduitbothshouldbeavoided.

Figure6.PictureofinstallationshowingdirectcontactofconduitandelectricalwireswithCPVCpipe.

Thermalexpansion:Mostplasticpipeshaveamuchhighercoefficientoflinearthermalexpansion
(CLTE)thannonplasticmaterials.ThehighCLTEofPVC/CPVCpipesmustbecompensatedforduring
installation,especiallyinenvironmentswherelargetemperaturechangesarelikely.Thenormalwayto
allowforthermalexpansionisbyinstallationofexpansionloopsinlongrunsofpipingandtheuseof
loosefittingorrollerhangarsthatallowforslippage.Aqualifiedsystemengineeringprofessionalshould
beconsultedtoensurethatthesystemisproperlyengineeredtoaccommodatethepossible
temperaturefluctuationsencounteredbythesystemandthatproperexpansioncapabilitiesare
incorporatedintothesystem.

Freezing:ThefailureofCPVCfiresprinklerpipesduetofreezingisnotverycommonbecausethe
sprinklerpipesarenormallylocatedintemperedareas.Nonetheless,occasionallyCPVCfiresprinkler
pipesdofreeze.Ifthereisachanceofexposureoffiresprinklerpipestofreezingtemperatures,itis
importanttofillthepipeswithglycerinsolution.Highpurityglycerinandpropyleneglycolsolutionsare

Page7of16

theonlyantifreezesolutionrecognizedasacceptablebytheNFPA(NFPA13:Section7.6.2).Again,a
highlyexperiencedengineeringprofessionalshoulddesignthepipingsystemtoensurethatappropriate
freezeprotectionisincorporatedintothesystem.

DiagnosesofthefailureofCPVCpipesduetofreezingisachallenge.IfCPVCpipesbreakduetoradial
expansionoficeinsideaCPVCpipe(Figure7),diagnosesisquitesimplebecausethepipegenerally
expandscausingthewallthicknesstodecreaseandgooutofspec(Figure8).However,researchersat
theUniversityofIllinoisfoundthatgenerallywhenpipesfreeze,radialexpansionisconstrainedbythe
pipewallforcingtheicetoexpandlongitudinally.Thelinearexpansionoftheicecausesapressure
buildupbetweentheiceplugandtheoutletorinletvalve.Itisthehighpressurethatcausesthefailure.
Thisdiscoveryledthemtoreceiveseveralpatents(US5,730,168,US5,785,072,andUS5,785,073)on
devicesthatprotectpipesfromfailureduetofreezing.

Figure7.PictureoffrozenCPVCpipe.

ThefrozenpipeshowninFigure7wasthawedandthencutlongitudinallyinhalfbysawingthroughthe
pipewall180degreesawayfromthefracturesurface.Simplymeasuringthethicknessofthepipewall
atthefracturesurfaceandcomparingthewallthickness180degreesopposite,revealsalarge
difference(Figure8).Thedifferenceiscausebytheslowtensilestretchandyielding/neckingatthe
pointoffracture.Theyielding/neckingatthepointoffractureresultsinthethinningofthematerialat
thepointoffracture.

Figure8.Wallthicknessatfractureissignificantlysmallerthan180oopposite.

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Pipealignment:Pipesmustbeinstalledwithoutexcessivebendingdeflectionstressesonthepipe.Pipe
manufacturersinstructionsshouldbefollowedregardingthemaximumallowablebendingdeflections
oftheirpipes.Excessivebendingdeflectionmayleadtofailureofboththepipeandthefittingstowhich
thepipesareconnected.ElbowandTeefittingsaresubjecttocreepfailureinthecrotch(Figure9)if
pipesarenotinstalledin90degreealignment.

Figure9.Pipesinstalledoutofalignmentplacinghighstressonthecrotchofanelbowresultingincreep
failure.

Shortinsertion:WhenPVC/CPVCpipesareinsertedintofittingstheyshouldbeinsertedalloftheway
untiltheendofthepipehitsthestop.Iftheyareshortinserted,apocketremainsbetweentheendof
thepipeandthestop.ThisisaplacewhereESCfailuremayoccur.Thegapactsasaplacewhere
contaminantsmayaccumulateandeventuallyESCofthefittingtakeplace.Recentlywewereinvolvedin
diagnosingtherootcauseoffailureoftwolargehydronicheatingsystemshavingtherecirculationloop
constructedusingCPVCpipesandfittings.Fivefittingswerereceivedforforensicanalysis.Allfivefittings
failedinexactlythesameway.Thefailurewasinitiatedinthespacebetweentheendofthepipeand
theinsertionstopinthefitting.ThefailuremodewasESC.Theheatexchangerleakedresultingin
contaminationoftherecirculatedwaterwithrefrigerantlubricantoil(polyolester)whichbecame
concentratedintheshortinsertionspacecausingfailureofthefittingbyESC(Figure10).Werecently
presentedtheresultsofourfailureanalysisattheFailureAnalysisDivisionoftheSocietyofPlastic
EngineersAnnualTechnicalConferenceheldinBoston,May2011.Acopyofthepaperisavailableupon
request.

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ContaminationExterior:CaremustbetakennottoallowPVC/CPVCpipestocontactothermaterials
thatcontainaromaticesterplasticizersandflameretardants.Figures11and12showexamplesof
failureduetocontactofCPVCwithothermaterialsthatcontainnoncompatibleplasticizers.Figure11
wasapiperemovedfromacondominiumwhereaworkersealedalloftheopeningsinwallsusingafire
caulkthatcontainedphthalateplasticizers.AdropofexcessfirecaulkfelldownontoaCPVCfire
sprinklerpipe.GCMSanalysisofthecaulkandthefailedpiperevealedthepresenceofphthalateester
plasticizers.PhthalateestersarehighlyincompatiblewithPVC/CPVCpipes.

Figure10.microscopicviewofthefracturesurfaceofafittingremovedfromahydronincheating
system.Allofthefittingsfailedinexactlythesameway;i.e.,byabsorptionoflubricantoilfromthe
refrigerant(duetoaleakintheheatexchanger)intothepocketbetweentheendofthepipeandthe
pipeinsertionstopmoldedintothefittingsocket.

Figure11.FailureofCPVCfiresprinklerpipeunderneathfirecaulkthatfellontheexteriorsurfaceof
thepipe.

Page10of16

Figure12showsanexampleofthefailureofaCPVCpotablewaterpipewhereablackgrommet(Proset)
thatwasusedtosealaPVC/CPVCpipepenetrationthroughaconcretefloor.Itwaswellknownthat
ProsetblackgrommetsarenotcompatiblewithPVC/CPVCbecausetheycontainphthalateester
plasticizerssometalfoiltapewasappliedtothepipeasaprophylactictoprotectthepipefromchemical
contaminationbythephthalateesterplasticizersinthegrommet.Metalfoiltapewilllikelynotbe
sufficienttostopphthalateesterplasiticizersfrommigrationfromblackProsetgrommets.Forthepast
fewyears,pipemanufacturershavestronglyrecommendedagainsttheuseofsuchincompatible
grommetsand,asaresult,ProSetnowmanufacturesawhitegrommetwhichiscompatiblewithPVC
andCPVCpipes.

Figure12.FailureofaCPVCpotablewaterpipeduetomigrationofphthalateplasticizerfromgrommet
downmetalfoilprophylacticusedtoprotectthepipe.

SolderfluxisanothermaterialthatmaycontainchemicalsthatareincompatiblewithPVC/CPVC.If
copperpipesarebeingsolderedinthevicinityofPVC/CPVCpipes,hotfluxcanfall,spatter,orvaporize
andcondenseontheoutsidesurfaceofthePVC/CPVCpipescausingESCfailure.

Polyurethanesprayfoam(PUSF)insulationcanbeaproblem.PUSFgeneratesheatasitcures.Iftheheat
istrappedbyathicklayeroffoamagainstthewallofthepipe,theheatcanweakenanddistortthepipe.
Also,eachPUSFmanufacturerhasformulationsthatcontainadditivessuchasfireretardants.Someof
theseformulationsmaynotbecompatiblewithPVC/CPVC.YoushouldconsultwiththePUSF
manufacturerbeforeapplyingPUSFinspaceswhereitmaycontactPVCandCPVCpipesaskingthemif
fortheirassurancesofthechemicalcompatibilityoftheirproductwithplasticpipingmaterials.The
CPVCpipeshowninFigure13iscracked.Examinationofthecracksurfacesintheleakingpipeshownin
Figure13showedESCfailurebymigrationofchemicalsfromtheoutsidesurfaceofthepipe(Figure14).

ContaminationInterior:Someproductsthatareusedinconstructionmaycontainchemicalsthatare
notcompatiblewithPVC/CPVCpipesandfittings.Thereforecaremustbeexercisedduringinstallation
tomakesurethatonlyapprovedmaterials(e.g.,metalpipethreadsealants,cuttingoils,firecaulks,
antifreeze,antibacteriallinedpipes,etc.)areusedduringinstallation.TheLubrizolCorporationisa
globalsupplierofCPVCresincompoundswhichmaintainstheindustry'sonlylistofcompatibleproducts
forusewithpipeandfittingsmadefromLubrizolCPVCcompounds.(see
http://www.lubrizol.com/BuildingSolutions/ChemicalCompatibility.html)

Page11of16

Figure13.CPVCpipeinsidewallcoveredwithPUSF.

Figure14.Closeupviewofthefracturesurfacesshowingdistinctivethumbnailchemicalpenetration
patternsfromtheoutsidewallofthepipe.Blackarrowpointstoleaklocationandredarrowsshow
thumbnailpenetrationzonesthatformaschemicalsmigrateintotheoutsidewallofthepipe.

Infiresprinklersystems,generallysteelpipingisusedtodeliverthewatertotheCPVCportionofthe
system.Therefore,wheninternalcontaminationoftheCPVCpipingdoesoccur,themostlikelysourceof
thecontaminationarethesteelpipes.Thisiswhyitisimportanttothoroughlyflushsteelpipesbefore
theyareconnectedtoCPVCpiping.NFPA13installationinstructionsforfiresprinklersystemsdescribes
properflushingproceduresforsteelpipesandspecifiesthattheentirefiresprinklersystembe
periodicallyflushed.

Page12of16

SomeantiMICorantimicrobialliningsinsteelpipesmaycontaintracesofwaterextractiblechemicals
thatarenotcompatiblewithCPVC.Figure15showstheeffectsofwatercontainingvarioustracelevels
ofanamine(didecylmethylamine,acontaminantoftenfoundinABF2)anditsquaternaryammonium
saltformonCPVCtestspecimens.Noticetheextensivecrazinganddiscolorationofthetreatedtest
specimensdownaslowas0.001%or10ppmofamineleadstochemicalattackandweakeningofCPVC.
CurrentlytherearesomeMICinhibitorproductsthathavebeenapprovedbyLubrizolasbeing
compatiblewiththeirBalzemasterCPVCpipes.Thelistcontinuestogrowasadditionalproductsare
testedandapproved.Sinceitisnotastaticlist,wesuggestthatyourefertotheLubrizolwebsiteforthe
mostupdatedlist(seehttp://www.lubrizol.com/BuildingSolutions/ChemicalCompatibility.html).

Figure15.Theeffects(discolorationandcrazing)oftracelevelsofchemicalcontaminantsfromABFII
(amineandammoniumsalt)onstressedCPVCtestspecimens.1=0.1%amineinwater,2=0.01%aminein
water,3=0.001%amineinwater,4=0.1%ammoniumsaltinwater,5=control.

Wewerethefirsttodiscoverandexpressconcern(in2007)aboutthepotentialincompatibilityoftrace
chemicalsthatmaybeextractedfromABF2.ThisdiscoveryhascauseddebatethroughouttheFire
SprinklerIndustry.Recently(3/30/10),FMApprovalscompletedalaboratoryinvestigationoftheissue.
Theyidentifiedextractiblechemicalspresentinsteelpipeshavingantimicrobialliningsandperformed
chemicalcompatibilitytestsoftheextractedchemicalswithCPVC.TheFMApprovalsstudyconcluded
insomecasesdegradationbyreductionofElongationatBreakorTensileStrengthatYieldwas
observedforCPVCspecimensexposedforamaximumof30daystoextractsfromABF/AMScoatedsteel
pipe.Thisfindinghasalsobeenchallengedduetothewayinwhichthechemicalcompatibilitytesting
wasconducted.

InternalContaminationbyRefrigerantLubricantOil
PVCandCPVCpipingisoftenusedtorecirculatethewaterinhydronicheatingsystems.Heatexchanger
leaksareveryrare.However,shouldaleakoccurinaheatexchanger,thewaterintherecirculationloop

Page13of16

maybecomecontaminatedwiththeoillubricantintherefrigerant.BackwhenCFCwasusedasthe
refrigerant,thelubricantwasmineraloil.Whenaleakoccurred,noPVCorCPVCfailureoccurred
becausemineraloiliscompatiblewithbothPVCandCPVC.However,thechangetoHCFCrefrigerants
broughtabouttheneedtochangetoamorepolarlubricantoilbecausemineraloilisnotsolublein
HCFCrefrigerant.MostHCFCrefrigerantsutilizepolyolesteroil(POE)asthelubricant.Unfortunately,
POEoilishighlyincompatiblewithPVC/CPVC(Figure16)andleaksinheatexchangerscancausefailure
ofthePVCorCPVCpipingsystem(Figure10).Thereisaneedforhydronicheatingsystem
manufacturerstodevelopalternativerefrigerantlubricantsthatarecompatiblewithPVCandCPVC.

Figure16.ExposureofaCPVCpipetestringunderstressbecomesbrittleafteronlyafewhoursof
exposuretoPOE.

PipeDefects
ThemanufacturingprocessofCPVCpipeishighlyregulatedwithnumerousrequiredtestsand
standards.PlasticpipeismanufacturedbyextrusionofmoltenPVC/CPVCresinthroughacirculardie
withamandrelheldinplacewiththinmetalvanes(oftenreferredtoasaspider).Whilepassing
throughthedie,themoltenPVCorCPVCresinformulationisslicedbythemandrelvanesbutthenfuses
backtogetheragaintoproduceasolidpipe.Afterthedie,thepipeiscooledusingacombinationofair
andwaterundercontrolledconditionssothatthepipedoesnotendupwithfrozeninstresseswhich
canaffectthemechanicalstrengthandchemicalresistanceofthepipe.Pipedefects,includingresidual
stress,canresultiftheextrusionandcoolingprocessesarenotproperlyoptimized.Pipesthatcontain
highlevelsoffrozeninstressesarelikecoiledspringslookingforopportunitiestorelievethestress.
Stressreliefcanbeachievedinseveralways.Oneisbycrazingwhichmanifestsitselfbytheformationof
hundredsoftinymicrocracksinthepipewall.Apipethathasundergoneextensivecrazinginthepipe
wallisshowninFigure17.Extrusionlines(causedbyadirtydie)createweakpointsinthepipewallthat
aremoresusceptibletochemicalattackresultinginfailurebyESC.Thismodeoffailureisindicatedby
thepresenceofperfectlystraightparallelcracksrunningdowntheinsidepipewall(Figure18).Pipes
havingthesemanufacturingdefectsaremoresusceptibletofailurewhenexposedtowatercontaining
chemicalsthatareincompatiblewiththepipesandfittings.

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Figure17.Extensivesurfacecrazingofoutsidepipewall.

Figure18.Weakextrusionlines(likelycausedbydirtydie)ontheinsidesurfaceofaCPVCsprinkler
systempiperesultingintheformationofparallelstraightcracksuponexposuretowatercontaining
contaminants.

ForensicFailureAnalysisProcess
PVC/CPVCpipesandfittingsareexcellentproductsandhavebeenusedsuccessfullyfordecades.There
isalowfailurerateandtheuseofPVC/CPVCmaterialsoffersignificantadvantageoversteelpiping

Page15of16

materials.IamnotawareofanyhealthcautionsregardingtheusageofPVC/CPVCpipesandfittings
otherthantheneedtoinstallthemproperlywithoutusingincompatiblematerialsduringthe
installation.IfyouarehavingacrackingproblemwithPVCorCPVCpipes,PlasticFailureLabscananalyze
thepipesand/ortheinstallationanddiagnosetherootcauseoftheproblem.Wearealsohighly
experiencedprovidingexpertwitnessservicesshouldthepipefailureleadtolitigation.

Ourgoalistodiagnosethecauseoffailureefficientlyandquickly.Ingeneral,wecarryoutalaboratory
examinationofthepipesincludingmeasurementofpipedimensions,examinationofthepipesurfaces
forphysicaldamage,examinationofthepipesurfacesforthepresenceofcontaminants,examinationof
thecrackfracturesurfacesusingopticalordigitalmicroscopy,andASTMtestingofthepipes.
_____________________________________________________________________________
DuanePriddy,Sr.isthefounderandCEOofPlasticFailureLabs.Thecompanyisaleadingproviderofplastic
consulting,expertwitness,andplasticfailureanalysisservices.PriortostartingPlasticFailureLabs,DrPriddywasa
PrincipalScientistforDowPlasticswherehewasinvolvedinhelpingsolveproblemswithplasticmanufactureand
plasticfailureforover30years.PartiallyduetoDr.PriddyspioneeringforensicinvestigationsofPVC/CPVCfailure,
hewasrecentlyawardedFellowoftheSocietyofPlasticEngineers.PleasefeelfreetocontactDr.Priddyanytime
byphone(989.385.2355)oremailatpriddy@plasticfailure.com.

Disclaimer:Whiletheinformationpresentedinthisdocumentisbelievedtobereliable,noguarantee,warranty,is
made,intended,orimpliedastothecorrectnessorsufficiencyofanyinformationprovidedherein.Ifyouhave
informationthatyoubelievecontradictsanyoftheopinionsexpressedinthisarticle,Iwelcomeyourcriticalinput.
Ireservetherighttoeditandmodifytheopinionsexpressedinthisarticleasfurtherinformationandcriticalinput
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