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The Couta Group 117A Miller Street, Epping, VIC 3076 Tel:1300 735 180
Installation Guidelines
Page 2 of 18
Water Pex™ Piping Systems Installation Guidelines
‘The Couta Group’ Water Pex Piping System Installation Guidelines
This manual contains recommended installation instructions for Water Pex™ piping systems. Failure to
observe these installation instructions may result in substandard performance of the system. The Couta
Group Pty Ltd expressly disclaim any responsibility or liability for substandard performance resulting from
failure to comply with the installation instructions
1. Water Pex™ Pipe Description
The Water Pex™ piping system is available in 2 differing structures. These include:
a. Pex/Al/Pex
This is a five layered macro-composite construction and is the latest innovation for water applications. The
inside layer is made of cross-linked polyethylene (PEX). This is bonded to an overlapped welded aluminium
layer which in turn is bonded to an outside cross-linked polyethylene PEX layer. The middle layer is 100%
oxygen tight and all layers are extruded in one step.
Water Pex™ Pex-Al-Pex pipe combines the benefits of both metal and plastic pipes. The inline welded
aluminium tube is absolutely safe against oxygen penetration. It compensates for the snap-back forces
and the linear expansion caused by temperature changes. The basis of the system is simple, safe and fast
pipe installation: simply bend by hand, cut to length, ream and bevel, join together, crimp, done.
This structure provides the pipe with the advantages of metal and plastic while avoiding their weaknesses,
and brings the following benefits to plumbing –
• it is lower in cost when compared to conventional copper or gal systems
• it is lightweight, bendable and does not need to be welded
• installation times are significantly reduced, saving labour costs
• the product is hygienic, non toxic and smooth
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Water Pex™ Piping Systems Installation Guidelines
• low on going maintenance requirements
b. Pex-b Multi-Purpose
The pex-b piping is a lower cost general purpose piping system for water only.
The inner layer of the pipe is constructed from pex-b material. Bonded to the pipe is an outer coloured
layer that provides the product with increased UV resistance making it suitable for external applications.
This piping system is available in a range of colours to make installation quick and easy and comply with
National regulations. The available colours include:
a. Black Multi-purpose water pipe
b. Blue Cold water
c. Red Hot Water
d. Lilac Recycled water
e. Green Rain water
Both systems have been independently tested and certified to demonstrate that they meet the
requirements of the required Australian Standards The systems have also been tested to demonstrate
compliance with AS4020 Testing of products for use in contact with drinking water. In addition the
manufacturing facilities are independently certified to ISO 9001.
c. The Facts – The Differences Between Pe-X A and Pe-X B
In today’s market, there are many misconceptions about the different types of PE-X pipe available. Some
manufacturers will attempt to convince you that their type is the best. But what are the facts?
PE-X pipe is made from High Density Poly-Ethylene (HDPE). PE-X is the short term for Cross-linked (hence,
“X”) Poly-Ethylene (PE). The cross-linking process improves the chemical and temperature performance
ratings of the polymer and provides flexibility and additional strength.
All PE-X is divided into 3 main types: A, B and C. It is a misconception to think that one type is better than
the other simply because it’s an A, B, or C type. These letters are used to identify the manufacturing
process and have nothing to do with quality of performance ratings. All PE-X systems manufactured by
reputable companies are made to meet the same international performance standards. Whether it is
PE-X A, B or C, all products must meet and be certified to the same Australian and International Standards
-AS4176, AS2493 and ISO21003.
PEX-A tubing is produced using the Peroxide (or, “Engel”) method, named after the inventor Tomas Engel.
During the manufacturing process, free radicals are created when HDPE polymer is melted and cross-links
between molecules occur at temperatures that exceed the decomposition temperature of the polymer.
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Water Pex™ Piping Systems Installation Guidelines
PEX-B is made using a "Silane" or "Moisture Cure" method of cross-linking where links between the
molecules of the HDPE form after the extrusion process by use of a catalyst and exposure of the pipe to
hot water. This type of PEX is the most common and is manufactured by a large number of companies
including Foshan Rifeng Corporation – the makers of Water Pex.
PEX-C is manufactured using the “Electronic Irradiation” method of cross-linking, also known as "Cold"
cross-linking. Here, cross-linking of the molecules is done after the process of extrusion by exposing the
pipe to an electron radiation beam. The radiation emitted breaks the existing links between molecules of
the polymer and facilitates the cross-linking process.
The most common forms of PE-X used in Australia are PE-X A and PE-X B.
PE-X A has a requirement for the degree of cross linking to be greater than 70% whereas for PE-X B the
requirement is greater than 65%. Why the difference?
The chemical structure of PE-X A has a lower crystallinity due to the manufacturing method. This results in
the piping having a lower density and lower strength and hence PE-X A needs to have a higher degree of
cross linking to meet the required in use performance standards. PE-X B has a molecular structure with a
higher crystallinity. In comparison to PE=X A, this results in PE-X B product having a higher surface
hardness, better scratch resistance, higher thermo stability, higher rigidity, harder body, better resistance
to chlorine solutions and a higher burst strength.
The wall thickness of PE-X A systems is normally greater than PE-X B because it has a lower burst strength
and hence requires the greater thickness to cope with the same operating pressures. As a result of the
thicker wall of PE-X A pipe, it will generally have a lower SDR and hence a lower flow rate. PE-X B has a
superior flow rate in comparison to PE-X A.
Yes PE-X A is more flexible than PE-X B but BOTH types of PE-X have the same minimum bending radius. As
all piping exposed to the sun must be lagged, claims of better UV resistance for PE-X A are irrelevant.
When it all boils down to the bottom line, both PE-X A and PE-X B MUST meet the same minimum
performance requirements as specified in Building Codes and Australian Standards.
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Water Pex™ Piping Systems Installation Guidelines
2. System Design and Application Classifications
a. The basic Water Pex™ Pex-Al-Pex and Pex b Multi-Purpose piping system components can be used in
the areas of plumbing, under floor heating & radiator heating.
Materials Applications Service
temperatures
Maximum working
pressure
PEX/AL/PEX
Hot & cold water supply,
under floor heating, radiator
heating etc.
-40º~+95º
PN14 = 14 bar
PEX-B
Hold & cold water supply,
under floor heating, fire
protection, radiation heating
-40º~+90º
16mm - PN16
20mm - PN12.5
25mm - PN12.5
32mm - PN12.5
b. Typical Burst Pressures of Pex-AL-Pex & Pex-b Piping
At 25 Deg C Room temp Pex-AL-Pex:
- 16mm pipe = 7.6 Mpa
- 20mm pipe = 5.8 Mpa
- 25mm pipe = 5.2 Mpa
At 25 Deg C Room temp Pex b:
- 16mm pipe = 6.2 Mpa
- 20mm pipe = 4.8 Mpa
c. Minimum distance between pipe fixings
As per AS3500.5:2012 Table 2.14.4, the spacing of brackets for cold and heated water is as follows:
Nominal Pipe Size
DN
Maximum Spacing of Brackets and Clips (m)
Horizontal or
graded pipes Vertical pipes
16 0.60 1.20
20 0.70 1.40
25 0.75 1.50
32 0.85 1.70
40 0.90 1.80
50 1.05 2.1
63 1.10 2.2
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Water Pex™ Piping Systems Installation Guidelines
d. SDR Values for Water Pex Pex-b Piping
SDR values are commonly referred to for single layer pex piping systems for water. They are not relevant
for multilayer pex/al/pex piping systems.
The SDR values of Water Pex single layer Pex-b piping is shown in the following table.
DN Size Maximum Outside
Diameter
Minimum Wall
Thickness
Wall Thickness
Tolerance
SDR Value
16mm x 2.0 16.3 2.0 2.0 – 2.3 9
20mm x 2.0 20.3 1.9 1.9 – 2.2 11
25mm x 2.5 25.3 2.3 2.3 – 2.7 11
32mm x 3.0 32.3 2.9 2.9 – 3.3 11
e. R Values of Couta Group Lagged Water Pipe
The R values of the Couta Group Pex/Al/Pex lagged pipe for our pipe is as follows:
Pipe Nominal Size R Value
16mm 1.57
20mm 1.50
25mm 1.44
AS 3500.5 specifies minimum R values for thermal insulation of piping for various regions throughout
Australia. Climate region C covers Victoria and Tasmania and has the highest requirements with a
minimum R rating of 1.0 specified. The R value required in other Australian regions is lower than 1.0
Couta Group lagged water pipe safely complies with R value requirements.
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Water Pex™ Piping Systems Installation Guidelines
3. Introduction to Water Pex™ Fittings and Tools
Water Pex is a complete system that has been independently tested for compliance to Australian
Plumbing and Building Codes. The system is comprised of both Water Pex™ pipe & fittings.
The Couta Group provides a wide range of fittings in the Water Pex range to ensure installation is as
simple as possible. Water Pex™ fittings are forged from DR brass to ensure that they are suitable and
approved for use with potable water systems.
The Water Pex fittings have a double o-ring system for added security of jointing as shown below:
A full listing of the fittings range is available at www.waterpex.com.au The list of fittings is regularly
updated so check back periodically to keep up to date with the latest information.
Water Pex Tooling
a. Reamers available
2 styles of reamers are available dependent on user preferences. The reamers perform the function of
rounding the pipe after cutting and beveling the inner lip to allow easy insertion of the fitting for jointing.
Triangular plastic reamers (see below) are frequently used where a small number of joints are needed.
There are 2 sizes of reamer available being GPZ-ZYD16-20 for 16,20,25 mm systems or the
GPZ-ZYD20-32 for 20, 25, 32mm piping.
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Water Pex™ Piping Systems Installation Guidelines
In addition, we offer metal reamers for each individual size of pipe (red handle picture below). The
advantage of this style of reamer is that the handle can be removed and the reamer fitted to a drill for
easy operation. This is particularly useful for larger bore pipe to make the job easy, or for smaller bore
pipe where there are many joints to be prepared. Product codes are as follows:
Product Code Product Description
GPZ-JD-1216 Reamer JD-1216
GPZ-JD-1620 Reamer JD-1620
GPZ-JD-2025 Reamer JD-2025
GPZ-JD-2632 Reamer JD-2632
b. Cutting tools available
Designed for smooth, even cutting, the tool's jaw should fit firmly over the pipe to allow a square,
burr-free cut.
Pipe cutter (GPZ-SC1)
Used for cutting Pex Al Pex pipes 16-32mm.
Pipe cutter (GPZ-QGQ)
Used for cutting Pex Al Pex pipes 40-63mm
c. Pipe bending tools available
The Water Pex piping systems may be bent with a maximum bending radius of 5 times the pipe Outside
Diameter (OD). For example, a length of 20mm pipe can have a bending radius of not less than 100mm (5
x 20 = 100) or a 32mm pipe a bending radius of not less than 160mm (5 x 32 = 160).
A range of internal and external bending springs is available. Product codes are listed below:
Product Code Product Description
GPZ-EXSP-16 16mm External Bending Spring
GPZ-EXSP-20 20mm External Bending Spring
GPZ-EXSP-25 25mm External Bending Spring
GPZ-EXSP-32 32mm External Bending Spring
GPZ-WH-1216 16mm Internal Bending Spring
GPZ-WH-1620 20mm Internal Bending Spring
GPZ-WH-2025 25mm Internal Bending Spring
GPZ-WH-2632 32mm Internal Bending Spring
Page 9 of 18
Water Pex™ Piping Systems Installation Guidelines
In addition it is important to note that Copper tube benders may also be used to successfully bend Water
Pex product. For example an 18mm copper bender can be used for 16mm Water Pex pipe, 20mm copper
bender for 20mm Water Pex pipe, etc.
d. Manual Pressing Tools
The Couta Group supplies a range of high quality but inexpensive manual pressing tools for 16 through to
32mm piping systems. The manual pressing tools come in kit form and include all jaws and reamers
required to get the job done.
The GPZ-SYQ14-20A KIT is commonly purchased by installers working on water systems. The kit is shown below
and includes the pressing tool, reamers and heads for connecting 16 and 20mm pipe.
The GPZ-SYQ14-32A KIT has a lengthened handle to make crimping of 32mm joints easier. The kit includes
heads and reamers from 16 through 32mm and is shown below.
Note: All the jaws for the Water Pex Systems are designated “U”-profile. Spare jaws can be purchased for
both tools as required.
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Water Pex™ Piping Systems Installation Guidelines
4. Set Up and Operating Instructions for Manual Pressing Tools
Both of the Manual Pressing Tool kits are very similar in set up and operation. Both have individual
pressing jaws for each size of pipe to be crimped. The method of changing jaws is the same on both tools.
In addition both tools need to be calibrated prior to use and calibration is performed by the same method
in both cases.
The lengthened manual pressing tool for sizes 16 through 32mm is shown below. Key part names are
identified as follows:
a. Preparation for use
Choose the correct pressing jaws.
The correct jaws must be chosen for the pipe size to be jointed. For 16mm pipe joint, use the 16mm jaws,
etc.
The jaws are engraved on the face to show the sizing for the pipe outer diameter.
Page 11 of 18
Water Pex™ Piping Systems Installation Guidelines
Mount pressing jaw on to clamp
Open the handles of the pressing tool and undo the Jaw screws (part number 3) so that the jaws can be
inserted into the clamp head.
Position the two jaws in the clamp head ensuring that the two jaws are evenly positioned and the
specification number on each half of the two jaws is facing up. Then retighten the screws to fix the jaw.
It is important to pay attention to the jaw direction ensuring that the centre of the pressing hole
is adjacent to the jaw opening direction
Check the Calibration of the Tool
Try to close the clamp without a fitting or pipe in place. The appropriate Trial-Clamping-Force
required to fully close the clamp jaws should be about 20Kg. This will require firm pressure to
close the jaws and handles fully. If closing the handles requires only light pressure then the clamp
will need adjustment before use, please refer to next step for how to adjust.
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Water Pex™ Piping Systems Installation Guidelines
Adjustment of the Crimping Force of the Manual Tool
Open the clamp and loosen the "locking screw"(part No. 1) anti-clockwise for about 3 turns.
If the Trial-Clamping-Force was too loose, you should turn the "calibration screw" (name No. 2) clock-wise
for about 1/4 turn. If the Trial-Clamping-Force is too great, then you should turn the "calibration screw"
anti-clockwise. You should repeat this process until the Trial-Clamping-Force is around 20kg – requires
firm force to close.
Note: The calibration screw should not be touched again when the Trial-Clamping-Force reaches 20Kg,
the clamp should be immediately locked using the locking screw.
Close the clamp and tighten the ‘locking screw’.
With the preliminary adjustment of the tool now complete, it is important to confirm that the crimping is
sufficient by completing a joint using the required sized pipe and fitting and testing with a gauging tool
supplied in the tool kit. The gauging tool is pictured below.
The gauge should slip over the grooves in the sleeve of the crimped fitting without touching the sides. If
the tool scrapes the stainless steel sleeve, needs force, or simply will not go over the crimped sleeve then
the fitting has not been fully crimped. In these cases the tool must be recalibrated and the joint
re-crimped.
Page 13 of 18
Water Pex™ Piping Systems Installation Guidelines
b. Manual Tools – Cautionary Notes for Operation
It is not necessary to use lengthened handles when pressing fittings no bigger than 25mm.Lengthened
handles are necessary for pressing fittings 32mm.
When pressing fittings, the contact points on right and left handles (see main part name No. 10 and 11)
must contact.
Adjustment should be made on following occasions:
o 1st use of the tool
o Every time heads are changed
o Every 60 crimps
o Each day prior to use
o The closed clamp handles can be opened freely with little or no force
The clamp should be maintained periodically by cleaning and adding lubrication oil to pins
(key part No. 3, 5,6,7). As a minimum this should be done once every month.
After adjustment, the nominal operating force applied for crimping the fittings is shown in the following
table:
Specification 16mm 20mm 25mm 32mm
Operation
Force(Kg)
20 32 40 45
5. Installation Procedure for Water Pex™ System
The requirements for the installation of Water systems are mandated by local authorities and AS3500
the Plumbing and Drainage Standard which has been adopted to varying degrees by State Authorities.
AS/NZS 3500 Plumbing and drainage standard is comprised of a number of parts as outlined below:
- 3500.0 Part 0: Glossary of terms (this Standard)
- 3500.1 Part 1: Water services
- 3500.2 Part 2: Sanitary plumbing and drainage systems
- 3500.3 Part 3: Stormwater drainage systems
- 3500.4 Part 4: Heated water services.
- 3500.5 Part 5: Domestic installations
The Standard is primarily intended for the general water industry and for use in the interpretation of
terminology used in the various parts of the Plumbing and drainage series of Standards and covers water
supply from the reticulation main into the premises, including hot water service systems, sanitary
Page 14 of 18
Water Pex™ Piping Systems Installation Guidelines
fixtures, drainage and their associated water and waste fittings, pipe systems and associated
components.
Water Pex systems comply with all requirements of these standards.
It is important for installers of potable water systems to also note that water piping systems (pipe and
fittings jointed) must also comply with AS 4020 - Testing of products for use in contact with drinking
water.
a. Pipe preparation
Cut the pipe to the required length ensuring that the cut is square (perpendicular to the length). Use the
GPZ-SC1 cutter or equivalent for 16 through to 32mm pipe. The GPZ-QGQ cutter is easiest when working
with larger bore piping systems
It is important that you check that the pipe end profile has been cut square as shown below.
b. Rounding and beveling
The reamer tools have the dual purpose of “rounding” the pipe after cutting and then beveling the inner
lip of the pipe to allow easy insertion of the fitting to prevent damage of the o-ring during insertion into
the pipe.
Using either the plastic or metal reamer, insert the correct
sized reamer into the pipe, turning as you go. This will round
the pipe. Push the reamer down and continue to turn so
that the reamer bevels the inner lip of the pipe. You should
see pex swarf being generated at the shoulder of the reamer.
Continue to ream for 3-4 turns.
Page 15 of 18
Water Pex™ Piping Systems Installation Guidelines
It is important that you check that the pipe has been rounded by the
reamer and has been beveled smoothly. Also ensure that the swarf
has been removed from the pipe to ensure that it does not interfere
with crimping of the joint.
c. Creating Pipe Bends
Bending of the pipe may be accomplished by hand, with an internal or external bending spring or copper
tube benders. Bending springs are available within our range of products.
It is very important to note that the minimum bending radius for pipe is 5 x D where D is the nominal
outside diameter of the pipe.
If you want to bend the pipe by hand then this is possible although not the recommended method. A
bending spring is preferred.
If bending the pipe by hand it is recommended that you keep your hands 40cm (16 inches) apart during
the bending process. Create the bend slowly taking care not to kink the pipe or exceed the minimum bend
requirements.
If bending with an internal bending spring, insert the bending spring inside the pipe remembering to leave
a minimum of 2 inches of the spring extruding from the pipe – this is necessary so that you are able to
easily remove the spring after creating the bend. Create the bend ensuring that the bending radius is not
less than 5 x the outer diameter of the pipe. Remove the bending spring when completed.
Where an external bending spring is to be used to create the bend, insert the pipe into the bending spring
and move the spring so that it centres on the point at which you require a bend. Create the bend ensuring
that the bending radius is not less than 5 x the outer diameter of the pipe. Remove the bending spring
when completed.
Page 16 of 18
Water Pex™ Piping Systems Installation Guidelines
d. Connecting Pipe and Fittings – Sizes 16 through 32mm
Check the fitting and pipe - the pipe end should be rounded and beveled as previously described and the
size of the fitting and pipe to be joined must be identical. e.g. 20mm fitting joined to 20mm pipe.
Push the pipe straight on to the fitting (do not “screw/turn” the pipe on to the fitting) until the pipe shows
fully past the witness mark of the sleeve as shown below.
The joint is now prepared for crimping.
Warning: The Couta Group disclaim any responsibility or liability failures due to the use of any
unauthorized tools or mixing and matching the pipe and/or fittings with Couta Group systems.
Ensure that your crimping tool has been adjusted as recommended. Verification/calibration of the tool is
required:
o At the 1st use of the tool
o Every time heads are changed
o Every 60 crimps
o Each day prior to use
o The closed clamp handles can be opened freely with little or no force
IMPORTANT NOTICE:
The Couta Group markets and sells a range of Gas and Water piping systems. Such systems comprise
both pipe and fittings. Our components and systems are certified by SAI Global to the required
Australian Standards required in Australian Building and Plumbing Codes. The certifications apply to
genuine Couta Group products.
The Water Pex piping has not been tested, certified or guaranteed for use in combination with the
product of ANY other company/brand. Similarly for our fittings.
It is CRITICAL that you note that using Water Pex™ pipe or fittings in combination with other
suppliers’ pipe or fittings or use of incorrect tools or other components may cause leakage or other
defects in the system and voids any warranties applicable to the complete Water Pex system. Users
should consult the Couta Group if in doubt as to suitable fittings or tools for any installation.
Page 17 of 18
Water Pex™ Piping Systems Installation Guidelines
Ensure that the correct sized jaw has been fitted to the tool.
Position the jaws so that the face of the jaw abuts the plastic isolating ring as shown below.
Fully close the handles of the crimping tool until the handles lock into their final position. Open the
handles and remove the pressing tool from the fitting. Check the crimp using the gauging tool and if ok
the jointing is complete. The crimped joint will look similar to the following.
The Couta Group has tested and approved the use of Novopress, Klauke, Rothenberger and REMS
battery tools for effective crimping of these larger joints. Jaws are to be U profile. Other brands of
crimping tool have not been fully tested with our systems.
These Installation Guidelines outline common installation situations. If Users meet any new case or have
any questions on the above guidelines, please do not hesitate to contact The Couta Group by phoning
1300 761 916 or via email on [email protected]
Page 18 of 18
Water Pex™ Piping Systems Installation Guidelines
6. Testing and Commissioning of The Installed Water Pex Service
Testing and commissioning of a water service shall be in accordance with Clauses 2.24.2 and 2.24.3 of
AS/NZS 3500.5:2012
After testing has been completed, all fittings should be visually checked for leakage. Results of testing
MUST be recorded on a test report or job sheet. The report must include name of job site and location of
test, date, time, test parameters and testing results. The test report must be attached to the job file for
later reference if required.