CORZAN® CPVC Expert Repipes Air Conditioning in Record Time

This case study is brought to you by the CORZAN® CPVC Marketing Department

(800) 899-5756 | [email protected]

A HEATED SITUATION

Air conditioning and Arizona go hand in hand, except when an owner neglects preventive maintenance for decades.

The new owner of a 240-unit Phoenix apartment complex plagued by unreliable A/C due to persistent HVAC leaks had a big problem on his hands.

All he wanted was a cost-effective replacement of the existing piping system, to code, by early June, which was in less than three months’ time — while maintaining 100% occupancy of a complex with a 2% vacancy rate.

All he needed were three things before the heat of an Arizona summer became excruciating:

1. the right repiping contractor
2. the right piping material
3. the right supplier support

Under its previous ownership, preventive maintenance was virtually nonexistent for the 10-building complex’s HVAC infrastructure. The steel system in each building — two chillers that switch to boilers in the winter — dated back to 1976. Leaks had been “remedied” with compression fittings, bicycle inner tubes, and pipe clamps. The fan coils were degraded and clearly failing. A complete repipe from the mechanical room to the fan coil units for all 240 apartments and the laundry facilities were long overdue.

The City of Phoenix had previously received complaints from tenants who had lost patience with the system defects, and fines had been levied upon the preceding owner. Furthermore, in Arizona, owners are responsible for housing tenants in a hotel when the unconditioned temperature exceeds 90 degrees, which comes early in Phoenix, so taking the system completely offline for the recipe wasn’t an option.

TACKLING AN UNADDRESSED PROBLEM

This was the situation Alex Ganev and Kelly Babb of Arizona Integrity Plumbing walked into. Arizona Integrity Plumbing, The Repipe Expert™ in multifamily structures with a particular affinity for Corzan® CPVC piping systems, knew that a Schedule 80 Corzan CPVC system was the only solution in a full-occupancy scenario where the old system had to run parallel while the repiping took place. “We had to get these people some A/C and fast,” Babb said. “Traditional pipe joining methods would never work for this type of project.”

Besides installing a complete boiler/ chilled water supply and return system for each unit with 6-inch Schedule 80 Corzan CPVC, the project scope included isolation valves at each fan coil unit for the supply and return, to accommodate and encourage ongoing preventive maintenance in the future. Also included were balancing valves and air relief valves on each rooftop supply and return.

Leveraging the expertise of Integrity Plumbing’s senior techs, test stacks of the two-story structure were created to validate the piping route that could bypass the ceilings.

Using a threaded pipe material would have made the project unfeasible from the standpoint of both time and materials. Knowing full well that in repipes there are always unforeseen factors lurking behind the drywall and in the sections buried underground, the complex was divided into two zones.

The existing system had no isolation valves so the crew had to dry pipe to the fan coils zone by zone, building a valve assembly inside each fan coil unit and expeditiously disconnecting the old copper for an entire zone (120 units) in one day, before they could even think about getting the water turned on to begin the process of providing A/C to each individual unit. Only then could Babb’s cross-trained crews turn over 12-16 apartments per day installing, repairing drywall and getting ready for inspection, using specialty tools to cut pipe onsite in the apartments.

TRAINED AND READY TO GO

The job could not have gone to a better-prepared repiping contractor. Long ago trained and certified as a Corzan CPVC installer by Lubrizol, Babb knew that onsite fabrication of Corzan CPVC pipe required only handheld tools for cutting and preparing the pipe and fittings for the simple solvent cement joining process.

A diligent trainer of his own crews, Babb could reinforce the importance of following the simple Corzan CPVC installation steps every time. He even dedicates one crew specifically to pipe cutting, cleaning, and prepping. That’s because of:

• The critical nature of the chamfering and deburring step. Corzan CPVC pros know that it’s essential to slightly bevel and ream the outside and the inside of the pipe to remove burrs and CPVC shavings so that it can be eased into the socket without pushing the solvent cement into the joint. In fact Arizona Integrity Plumbing’s crews use a custom deburring tool connected to their power tools to ensure this step is not missed.
• The importance of quarter-turning the pipe into the fitting to evenly spread the solvent holding it in place, preventing pipe pushout and ensuring a solid bond.
• Allow joint to set for two hours and complete pressure testing to 190 psi.

TWISTS AND TURNS

The project was beset by several surprises and obstacles beyond the existing complex logistics, such as:

• New leaks to the old system almost daily as the crew ran pipe parallel while making roof penetrations through the floor joists, causing vibration.
• Discovery of asbestos in the popcorn ceilings of the buildings, adding a $500,000 abatement price tag (not counting labor) to the project in the event the ceilings were disturbed. Leveraging the expertise of their senior techs, test stacks of the two-story structure were created to validate the piping route that could bypass the ceilings altogether.
• Dealing with condensation due to the differential between the ambient temperature and water temperature in the 40s range. “CPVC performs better than anything out there for condensation,” said Babb. “We never noticed any sweating of the pipes, even in the areas we weren’t going to insulate until after we got the A/C online; the metal was dripping like crazy from water temperatures in the 40s.”

Assuring availability of materials, mitigating the effects of Arizona’s heat, and getting through AHJ inspection helped keep the project on track.

Fortunately, getting through inspection was relatively painless. The Authority Having Jurisdiction (AHJ) was already familiar with Schedule 80 CPVC and made themselves available to Arizona Integrity Plumbing throughout the process. They oversaw hydrostatic testing at the ball valve one building at a time and required visibility into the underground trenching in progress.

INVALUABLE SUPPLIER SAFETY NET

Despite achieving the online milestone of June against some steep odds, a project as complicated as this one can go awry quickly without a meaningful supplier support system. For Arizona Integrity Plumbing and their crews, that dedicated support was provided by Lubrizol Piping Systems Consultant and Territory Manager Bob Ard.

In addition to coordinating with Lubrizol’s partner Corzan CPVC piping manufacturer, Ard provided other assistance including:

• Engaging a qualified engineering firm to develop project drawings
• Establishing contacts with branch managers of high-inventory materials suppliers for 24/7 responsiveness
• Providing technical assistance and data where needed

“The drawings and actual site conditions rarely match in a repipe job, so material usage is a big variable. Bob was so committed to making sure we had the education and support we needed no matter what we were up against,” said Babb. 

“He made sure vendors would be available to us on an emergency basis. If he didn’t know the answer to something, he’d find someone who did. Standing by your product like he does is critical to a project’s success.”

“They did a phenomenal job with all of the logistics and heat,” said Ard. As Babb prepares to repipe the complex’s mechanical room itself after air conditioning season, and move on to other multifamily properties for this new owner, this is a partnership that is certain to bear fruit.

Corzan® CPVC
Marketing Department

9911 Brecksville Road
Cleveland, Ohio 44141-3201 USA
888.234.2436 ext. 7393

The information contained herein is reliable based on current information but the advertiser makes no representations, guarantees or warranties,
express or implied, including any implied warranties of merchantability or fitness for a particular purpose, or regarding the completeness, accuracy,
or timeliness of any information. Always consult your pipe and/or fitting manufacturer for current recommendations.

© Lubrizol Advanced Materials, Inc. 2020, all rights reserved. All marks are property of Lubrizol Advanced Materials, a Berkshire Hathaway Company. Printed in U.S.A. November 2020

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While many people wonder when their property may need a repipe, it is not usually the topic of many conversations until the time comes. Usually, a home or property owner finds out they need a repipe when it is an emergency due to a busted or leaking pipe.

While most pipes last 30-50 years on average, there’s no definitive timeline for a pipe’s lifespan. Because they are frequently under pressure and daily use, they can fail at any time.

Because we here at AZIP care about your home and family’s well-being, we have outlined the signs you may experience when a repipe is necessary.

If you are experiencing any of the following, please reach out to us as soon as possible for a free repipe quote!

Old Homes and Pipes

While a home or property pipes’ lifespan will vary depending on multiple factors, it is essential to note that pipes will need replacing every 30-60 years. In many cases, this is the length of time a pipe’s materials begin to corrode through and become severely damaged, leading t catastrophic failure.

If your home was built before the 1970s or through the early 1990s, your pipes might be made of galvanized steel or polybutylene. While these materials were considered safe and effective previously, newer materials are often more safe and non-toxic.

Leaking Pipes or Visible Corrosion

This may be an obvious statement, but leaking pipes should be replaced immediately.

When they are not, they can lead to an immense amount of water damage in your home if they freeze over and burst

It’s also important to remember that if one pipe experiences a leak or corrosion, other pipes in your home may be right behind them as they are likely to be made of the same materials.

Low Water Pressure

While low water pressure can be due to multiple reasons, it is most likely caused by sediment build-up or corrosion that has lead to micro leaks. This, in turn, results in water being unable to frow freely through your pipes, causing increased water pressure due to blockages.

Water Discoloration

Another significant way to know if you need a home repipe is water discoloration!

If you turn on your water and see any color other than clear, it’s time to look into a repipe! Sediment build-up and corrosion can cause water to turn yellow, orange, or brown in some cases.

Consider that these elements can end up in your drinking and bathing water, which could cause long term health effects.

This is especially common after not using water for a few days or when on vacation. Note, if this occurs when using hot-water and not cold, it may be related to your hot water heater and not your pipes.

How Much Does It Cost to Repipe A House?

The cost of repiping a house depends on many factors, including the house’s size, the materials used during your repipe, and any unknown factors that may arise.

Because we often get asked this question by homeowners who want to know when they need a repipe, we provide free quotes on all repiping services at Arizona Integrity Plumbing to let you know the up-front, no-hassle cost of our services. In addition, unlike other repiping companies, our specialists do more than repipe your home or property – we also repair all dry-wall cut-outs adjacent to your pipes!

A good rule of thumb is to remember that the cost to repipe a house falls within the range of 0.40c – $2.20 per linear foot but can add long-term value to your home, especially if you plan to re-sell it!

Experiencing Any of These Issues In Your Home or Property?

Now that you know the signs to look for when wondering if you need a repipe, If you are experiencing any of these issues, please call us immediately at Arizona Integrity Plumbing!

We are available to help you with any questions about the repipe process and what it entails.

Our video below is also a great resource to help you understand the fundamentals of a repipe.

A repipe is when all the old, worn-down plumbing lines in your home or business are replaced with new, more efficient plumbing lines. This is usually necessary for older buildings that have faulty plumbing, are in constant need of plumbing repairs, have Polybutylene, lead, Galvanized, or Kitec pipes, or are getting ready for a remodel.

What is involved in repiping a home or business?

A repipe with The Repipe Expert™ includes:

1. Replacing all water lines in the home or business to each plumbing fixture
2. New hose connections
3. New valves under sinks and toilets
4. New supply lines

A repipe does not include:

1. Replacement of the water main
2. Replacement of the main sewer line
3. Fixing or replacing drain lines, including pipes in your walls, vents, and underground
4. Leaking or broken fixtures on your showers, tubs, sinks, toilets, or water heaters

If you need more than just a repipe or are interested in any of the services that are not generally included, you can always ask The Repipe Expert™ to provide an estimate for those services as well! We’d be happy to give you a free quote!

What steps are involved in getting a repipe?

There are a few steps involved in repiping a home or business, including:
1. Have your home inspected by The Repipe Expert™
2. Our plumbers come to your home or business to repipe
3. A city inspector ensures the job is up to code
4. We will close up the holes and making it look like they were never there

Read below for more details about what is involved in repiping your home or business:

Step 1: Have Your Home Inspected by The Repipe Expert™

Start the process by giving The Repipe Expert™ a call at (800) 899-5756. We’ll come by to inspect your home, business, or property, explain any issues we notice and give you a free quote.

Step 2: Our experienced plumbers come to your home or business to repipe

The second step includes a team of Repipe Experts coming to your home or business to get the repiping done. We bring all the tools, materials, and expertise to Do the Job Right.

With every job, we carefully reveal only the pipes that need to be worked on, leaving the rest of your home untouched. We also take extra precautions to protect your floors with tarps, and we use plastic to keep any dust contained. Our goal is to protect your home and enable you to continue to occupy it. 

Step 3: A city inspector ensures the job is done to code

Before we finish the job, we go through the proper channels to inspect the new pipes in your home or business.

Step 4: We finish the job by closing up the holes and making it look like we were never there

Lastly, we take the time to mud, texture, and paint the area of the cuts – restoring the areas to look brand new. Many companies will only fix the pipes, and you’ll have to hire another company to patch up any cuts they had to make. At Arizona Integrity Plumbing, we make sure we leave your home looking better than we found it.

How long does repiping a house take?

When determining how long it takes to repipe a house or business, it depends on the amount of work that needs to be completed. Homes can be repiped in about a week, but larger projects that include multiple homes, multi-family homes, or large businesses can take longer. When you get an inspection and quote from The Repipe Expert™, we will be able to give you an estimate on the length of time required to complete the project.

How much does repiping a house cost?

The cost of repiping a house or business depends on the amount of work that needs to be completed, but the average cost for repiping a home is usually between $4,000 to $15,000.

Get A Free Repiping Quote

If you’re ready to get a free quote from The Repipe Expert™, give us a call today at (800) 899-5756 or send us a message here!

Looking for more information on the different types of plumbing pipes and their uses? Contact one of our plumbers today in your service area!

Ever wondered what lies behind your walls and below your floors? Pipes do! And they help our domiciles function with everyday tasks.

Today in this brief article , we will cover the types of Plumbing Pipes and their uses. In general, there are five different types of plumbing pipe materials. 

The most common types of pipes used in todays repipes are PVC, Rigid Copper Piping, or PEX Piping.

Whether you’re purchasing a new home or repairing pipes in your current home, it’s beneficial to understand the different types of pipes used for plumbing and what the pros and cons are of each.

Polyvinyl Chloride Pipe (PVC)

PVC, which stands for polyvinyl chloride, is typically a thick white pipe that is used for drains, vents, waste lines and sewage applications. In general, the thickness of PVC pipes depends on their use and where they will be used. One of the pros of using PVC pipes is that they are light and easy to configure.

PVC Piping Cost: At the time of this article PVC piping costs $4 – $8 per linear foot depending on the 

Rigid Copper Pipe

We’ve all heard of copper pipping as it is the most widely used type of piping, known for its durability and long lasting corrosion resistant attributes. 

Copper piping is used mainly to supply water as copper naturally kills viruses and bacteria, unlike other types of piping materials. 

One of the downfalls of using copper piping however is that it must be soldered together and can require additional fittings at junction points. This leads to increase costs in many cases due to the additional work that is required for fitment.

Copper Pipe Pricing: At the time of this article copper piping costs $2 – $8 per linear foot depending on the 

Cross-linked Polyethylene Piping (PEX)

Cross-linked Polyethylene, or more commonly referred to as PEX piping, is a flexible plastic tubing that is commonly used to replace both hot and cold water supply lines.

It became a popular alternative to other types of tubing because it doesn’t leave traces of rust or corrosion over time. PEX piping is also preferred because it is flexible and small, enabling plumbers to easily maneuver the pipes around corners and in small spaces when needed.  

Unlike many other pipes, PEX pipes are color coded to signify the temperature of water going through the pipes, including red for hot water, blue for cold water and white for either hot or cold water. 

PEX Piping Cost: At the time of this article PEX piping costs $1.50 – $3.50 per linear foot depending on the 

Stainless Steel Pipes

Stainless steel pipes are another durable and long lasting piping alternative. This type of piping is mostly used near costal areas that are subject to high-humidity and increased corrosion. 

Stainless steel pipes are available in a variety of hardness and flexibility but make use of special couplings. In addition these pipes use steel alloy that contains nickel to harden their durability. 

Stainless Steel Piping Cost: At the time of this article Stainless Steel piping varied too much to provide a clear indication of its pricing.