Polybutylene Water Pipes Part-1 Of 2

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The Article Provides In-Depth Information About Polybutylene Water Pipes.   Al’s Plumbing, Heating & A/C in Plano, Texas provides maintenance & repairs for all brands of Central A/C, Gas & Electric Furnace, and Heat Pumps.    Additionally, we sell and install new HVAC Systems from American Standard (same company as Trane), Ameristar (same company as American Standard) and Coleman HVAC (same company as York HVAC).

Al’s also provides full-service plumbing maintenance, repairs and replacements for every plumbing component in your home.  Al’s sells and installs Rheem Professional Series gas & electric water heaters, and tankless water heaters.  Al’s is near your home in Plano, TX; Allen, TX; and Frisco, TX.  We service all homes in southern Collin and Denton Counties with no additional travel charge.

Call Al’s today to discuss any concerns or problems you have with your HVAC System or Plumbing.  We will arrange an appointment at your convenience and offer 24/7 Emergency Service.

As with most industries — plumbing products evolve over time.  In most cases, the new products are less expensive to make and /or easier to install.  In both cases, they reduce the cost to add plumbing to a home.  Additionally, there are many instances where the new product is superior to what it replaced.

For Example: When PVC (white plastic) sewer lines were invented — they became a new industry standard.  Not only are they less expensive to make than cast iron sewer pipes — they are much easier to install.  They also outlast cast iron by as much as triple the lifespan.

One Of The Worst Plumbing Product Failures In U.S. History Was

Polybutylene Water Pipes

Image Source: YouTube Embedded Video

Click On The White Arrow In The Center Of The Image To View A YouTube Video Describing Polybutylene Water Pipe Failures

Polybutylene (PB) Water Pipes History In The U.S.

Polybutylene water pipes were installed in up to 10 million newly built U.S. homes between 1978–1995.  Most PB pipes’ homes are in the sunbelt. 35% of the homes built in the southern U.S. had PB pipes when new. **  PB was also used in the Mid Atlantic and Northwest Pacific states.  At least 6 million homes were built on-site by home builders.   Texas home builders who installed PB pipes in some new homes included; U.S. Home, Fox & Jacobs,  David Weekly Homes, Monarch Homes, and General Homes. **  Additionally, 3 million mobile or modular homes were manufactured with PB from 1976 –1996.

** Source: Texas Monthly Nov. 1990, Page 62

The Primary Manufacturers Of Polybutylene Water Pipes Were:

• U.S. Brass Corporation — Brand Name: Qest (pronounced “quest”).  It’s identified with “Qest-C-PB 2110” stamped on the pipe.  You can see this brand of pipe in the image just above.

• Vanguard Plastics — Brand Name: Vanguard Thermoguard.   It’s identified with: “Vanguard Plastics” stamped on the pipe.

Early PB pipe installations used hard plastic (Acetal Resin) fittings to make connections.  These fittings were the same gray color as the pipe. 

• Though flexible, PB pipe was supposed to be installed in straight pieces.

• Where the direction of the pipe changed — a fitting was to be used.

• Fittings were inserted into the flexible PB pipe, then a clamp was added to hold the PB pipe tight to the fitting.

• After a short time — many fittings began to show discoloration, others began to crack, and others failed completely.  The failure was due to oxidation (becoming brittle) due to chlorine in the water.

• The majority of leaks in PB pipes started occurring between 10-15 years of age.

Copy The Link Below Into Your Browser To See An Acetal Resin Fitting: 

https://www.google.com/search?q=Acetal+Resin+Fitting+used+With+PB+Water+Pipe&sxsrf=ACYBGNTUUf12-Sy84ZtRRYosEqerJc1crg:1582055316149&source=lnms&tbm=isch&sa=X&ved=2ahUKEwjA8oip79vnAhVP7qwKHYmQAEIQ_AUoAnoECA0QBA&biw=1097&bih=554#imgrc=R76VJdAfFOIXZM

Leaks in PB pipes systems began occurring in the early 1980s.  At first, the majority of the leaks occurred at the pipe fittings.  Both the PB pipe and the plastic fittings became brittle due to exposure to the chlorine in the water.  They became brittle on the inside toward the outside. Once the cracks reached the outside of the fitting or pipe — leaks began.  In earlier installations, there were 10-20 plastic fittings from the main water line to each plumbing fixture.  Later PB installations included a new component (a manifold — more on this below) — this often allowed a single piece of pipe from the manifold to the fixture and dramatically reduced the number of fittings used.

The primary problems with the PB pipe itself are; stress-fractures,  cracking, and pinholes forming.  These problems were compounded with poor installations — where the pipe was often bent instead of using a fitting.  This put additional stress on the pipe, and made it more likely to begin leaking where it was bent.

Copy The Link Below Into Your Browser To See A Pin-Hole Leak Where PB Pipe Was Bent (instead of using a fitting) to change direction:

https://www.google.com/search?q=pin+holes+in+polybutylene+pipe&sxsrf=ALeKk0123ZMnaAkrod06Zu4cf5jdfSjalg:1602515813283&source=lnms&tbm=isch&sa=X&ved=2ahUKEwjnq7DOrK_sAhVEUK0KHSgNAvQQ_AUoAXoECBYQAw&biw=1280&bih=646#imgrc=R76VJdAfFOIXZM

Identifying Polybutylene Water Pipes In A Home

In most DFW slab-foundation homes — water pipes are installed under the slab.  The pipes come upward through the slab at plumbing fixtures’ locations.   In some cases, water lines may be installed in the attic — and come downward to plumbing fixtures.

Image Source: ShutterStock

This Photo Depicts How Water Pipes Are Typically Installed In New DFW Homes.

Note: The Water Pipes In The Photo Are PEX Flexible Water Pipe.  PEX Is Used In Many New DFW Homes Built Today.  PEX is typically red for hot water lines and blue for cold water.

Places Where You May See Polybutylene Water Pipes:

PB pipes are typically gray.

Under A Sink:  Copy The Link Below Into Your Browser To See A PB Pipe Visible Under A Sink:

https://www.google.com/search?q=polybutylene+pipe+under+sink&sxsrf=ALeKk01IioJMBT5PJy-n3iRNpx2LSuu_-A:1582644628873&source=lnms&tbm=isch&sa=X&ved=2ahUKEwjim6PXgu3nAhUI1qwKHRfQA2YQ_AUoAXoECA0QAw&biw=1097&bih=554#imgrc=DCfqoxJjxcIwJM

At A Toilet:  Copy The Link Below Into Your Browser To See A PB Pipe Visible At A Toilet Connection:

https://www.google.com/search?q=polybutylene+pipe+near+toilet&sxsrf=ALeKk011Svuc3lMMdM7mhYjcgtg64lwI-Q:1582644714525&source=lnms&tbm=isch&sa=X&ved=2ahUKEwiQ4Y6Ag-3nAhUD26wKHQEqCv0Q_AUoAnoECA0QBA&biw=1097&bih=554#imgrc=DGwikOkkAyvF8M

https://www.google.com/search?q=copper+stub+out+from+polybutylene+pipe&source=lnms&tbm=isch&sa=X&ved=2ahUKEwjTrLDRsO3nAhUPWqwK HdxrA2EQ_AUoAnoECA0QBA&biw=1097&bih=554#imgrc=U_UFTsHIyLheyM

Near The Water Heater:  Copy The Link Below Into Your Browser To See A PB Pipe Visible Near A Water Heater (right side of photo):

https://www.google.com/search?q=pb+pipe+connected+to+a+water+heater&sxsrf=ACYBGNTcug9FedIn9Zlf8xAnvULSrwmr0g:1581968033979&source=lnms&tbm=isch&sa=X&ved=2ahUKEwi8-teVqtnnAhUCWa0KHUtrC_MQ_AUoAnoECA0QBA&biw=1097&bih=554#imgrc=snpwQGco9tVSxM

In The Attic:  Copy The Link Below To A PB Installation In An Attic:

https://www.google.com/search?q=pb+pipe+in+attic&tbm=isch&ved=2ahUKEwjMzaDYre3nAhVBZ60KHQpjCBEQ2-cCegQIABAA&oq=pb+pipe+in+attic&gs_l=img.3…29909.34757..34955…0.0..0.63.842.17……0….1..gws-wiz-img…….0i67j0j0i30j0i5i30j0i8i30j0i24.dEiQArEai3g&ei=rWpVXozDJ8HOtQWKxqGIAQ&bih=554&biw=1097#imgrc=BguvHzzjo003uM

In A Basement:  Copy The Link Below To A PB Installation In A Basement:

https://www.google.com/search?q=Polybutylene+pipe+in+attic&tbm=isch&ved=2ahUKEwjZmavGr-3nAhWEja0KHYn4Dj4Q2-cCegQIABAA&oq=Polybutylene+pipe+in+attic&gs_l=img.3…1741.1741..2357…0.0..0.81.81.1……0….1..gws-wiz-img.T2ujumrxcZc&ei=oGxVXtnJOYSbtgWJ8bvwAw&bih=554&biw=1097#imgrc=C8MIBIPcgYAAmM

A Polybutylene Water Pipes Installation May Include A Manifold.  Manifold units were added to later PB Pipes installations, to reduce the number of fittings required. 

Copy The Link Below To See A PB Installation With A Manifold:

https://www.google.com/search?q=polybutelene+water+lines+manifold&tbm=isch&ved=2ahUKEwjGxZvNnNnnAhVsg60KHZ_4B6EQ2-cCegQIABAA&oq=polybutelene+water+lines+manifold&gs_l=img.3…31521.40595..41123…6.0..0.68.628.12……0….1..gws-wiz-img.ID-f0yMiPo4&ei=aNxKXsbxE-yGtgWf8Z-ICg&bih=554&biw=1097#imgrc=IcEmCzZ71h7mrM

Polybutylene Water Pipes Timeline

• Late 1960’s — Celanese Corporation (brand: Celcon) and DuPont Corporation (brand: Delrin) developed the polymer Acetal Resin (a form of plastic).  It was to be used in the manufacturing of plastic products.

• Acetal Resin fittings were used in earlier PB pipes installations.     In 1965, a Celanese researcher said: ”Failure usually occurs when chlorine deposits build up on the Acetal Resin.”

• 1970’s — Shell Oil Company became the sole producer of Polybutylene resin.

• 1975  U.S. Brass Corporation designed, manufactured, and began selling PB water pipes systems with polybutylene pipe and acetal resin fittings.

• 1975   U.S. Brass bought polybutylene resin from Shell (for the pipe) and Celcon from Celanese (for the fittings).

• U.S. Brass sold its products under the Qest (pronounced “Quest” brand name.   This brand of PB pipe is stamped with “Qest-C-PB-1210”.

Copy The Link Below To See A Photo Of Qest PB Pipe (pronounced  “Quest”):

https://www.google.com/search?q=qest+polybutylene+pipe&tbm=isch&ved=2ahUKEwiu9-G5l-3nAhWPY60KHcy0AdgQ2-cCegQIABAA&oq=qest+polybutylene+pipe&gs_l=img.3…16482.18079..18430…0.0..0.54.236.5……0….1..gws-wiz-img.53Nh4EYhvqw&ei=XFNVXq7ZB4_HtQXM6YbADQ&bih=554&biw=1097#imgrc=_9xxUiT8G8qwuM

• 1980, Vanguard Plastics in Kansas began producing: PB Pipe & fittings under the brand name: “Vanguard Thermoguard”.  This pipe is stamped with: “Vanguard Plastics”.

Copy The Link Below Into Your Browser To See A Photo Of Vanguard PB Pipe: 

https://www.google.com/search?q=vanguard+pb+pipe+photo&tbm=isch&ved=2ahUKEwixi6axsa_sAhUK0KwKHX9SBCkQ2-cCegQIABAA&oq=vanguard+pb+pipe+photo&gs_lcp=CgNpbWcQA1CWrgJYvrgCYNm6AmgAcAB4AIABSYgBzwKSAQE2mAEAoAEBqgELZ3dzLXdpei1pbWfAAQE&sclient=img&ei=ZniEX7HAHIqgswX_pJHIAg&bih=554&biw=1097#imgrc=_Xbvuy5k7gPTqM

At the beginning, both U.S. Brass and Vanguard manufactured fittings made of Acetal Resin.

Copy The Link Below Into Your Browser To See A PB Water Pipes System With Fittings Made Of Acetal Resin: 

https://www.google.com/search?q=Acetal+Resin+Fitting+used+With+PB+Water+Pipe&sxsrf=ACYBGNTUUf12-Sy84ZtRRYosEqerJc1crg:1582055316149&source=lnms&tbm=isch&sa=X&ved=2ahUKEwjA8oip79vnAhVP7qwKHYmQAEIQ_AUoAnoECA0QBA&biw=1097&bih=554#imgrc=R76VJdAfFOIXZM

• U.S. Brass officials said they were not aware of the chlorine-degradation problems with Celcon brand resin because Celanese did not tell them.  In 1965, a Celanese researcher said: ”Failure usually occurs when chlorine deposits build up on the Acetal Resin.”

• U.S. Brass stopped making plastic fittings.  Fittings were then made of brass or copper.

• U.S. Brass redesigned PB pipe systems to utilize a ”manifold’.   This dramatically reduced the number of fittings used.
• The manifold is a single, large, easily accessible fitting for all the tubing in the home.    Some fittings were still used — to accommodate direction changes for the pipe.

Copy The Link Below Into Your Browser To See A PB Water Pipes installation Without A Manifold:

https://www.google.com/search?q=polybutelene+water+lines+manifold&tbm=isch&ved=2ahUKEwjGxZvNnNnnAhVsg60KHZ_4B6EQ2-cCegQIABAA&oq=polybutelene+water+lines+manifold&gs_l=img.3…31521.40595..41123…6.0..0.68.628.12……0….1..gws-wiz-img.ID-f0yMiPo4&ei=aNxKXsbxE-yGtgWf8Z-ICg&bih=554&biw=1097#imgrc=z41f_cCQ1N6FPM

Copy The Link Below Into Your Browser To See A PB Water Pipes installation WITH A Manifold:

https://www.google.com/search?q=polybutelene+water+lines+manifold&tbm=isch&ved=2ahUKEwjGxZvNnNnnAhVsg60KHZ_4B6EQ2-cCegQIABAA&oq=polybutelene+water+lines+manifold&gs_l=img.3…31521.40595..41123…6.0..0.68.628.12……0….1..gws-wiz-img.ID-f0yMiPo4&ei=aNxKXsbxE-yGtgWf8Z-ICg&bih=554&biw=1097#imgrc=z41f_cCQ1N6FPM&imgdii=MpjQQJnt3bCnhM

• In 1986, Celanese stopped selling Acetal Resin to be used with plumbing fittings.

• In 1988, U.S. Brass commissioned a study of Celanese (brand Celon) fittings by an engineering consultant. 
• The study concluded that Celanese had to know, at early as 1975, that chlorinated water was harmful to Celcon. 

• PB pipe is rated for: Up to 0.2 Parts Per Million chlorine (PPM)
• U.S. water supplies are capped at 0.4 Parts Per Million chlorine (PPM) by the EPA. 
• Donald E. Duvall of L.J. Broutman and Associates Ltd. wrote: “By 1976, Celanese research showed that Celcon begins to deteriorate dramatically in water containing as little as 0.5 Parts Per Million chlorine (PPM).” 
• Some areas of the U.S. may have lower levels of chlorine.  This might explain why some PB pipe systems have not failed yet.

• Mid-1987 Houston’s Moriarty & Associates filed a lawsuit against; General Homes Corporation (a home builder), U.S. Brass, Shell, and Celanese.
• The suit was filed on behalf of about 100 homeowners alleging their plumbing systems were failing and leaking.
• Moriarty’s research led him to believe there was a vast potential for polybutylene plumbing litigation.

• 1988, U.S. Brass (with assistance from Shell and Celanese) established an 800 number to respond to consumer complaints about leaking plumbing.  It was known as the: “Qest Repair Line”.
• 1990 Celanese stopped selling Acetal Resin (brand name Celcon) — for use in plumbing products.   Note: Acetal Resin continues to be used in other plastic products (not including plumbing).

• On Dec 30, 1990 — CBS “60 Minutes” Aired: Season 23-Episode 16 “The Greatest Thing Since Sliced Bread” with correspondent Ed Bradley.
• This episode exposed polybutylene water pipe installations’ failures to the nation.

• 1991 Shell, Celanese, and DuPont took over the (U.S. Brass) toll-free number and renamed it the “Plumbing Claims Group” (PCG).

• 1991 The Uniform Plumbing Code removed PB pipes systems as an acceptable water distribution material.

• March 1993 “Good Morning America” reported approximately 500 calls a month were coming into the PCG toll-free number.

• Sept. 1993  The first nationwide Polybutylene Plumbing Class Action Lawsuit was filed (Robert Beeman vs. Shell Oil Company).

• October 1994  The Beeman settlement was settled for $750 billion.

• 1995 — Shell and Celanese added another $100 million to the settlement fund — for a total of $850 million.

• 1995 — Another $100 million was added to the settlement fund — for a total of $950 million.

• 1996 — Shell Oil Company stopped selling Polybutylene resin.

• By June, 1998 nearly 60% of the fund had been spent for only 220,000+ replumbs.  Approximately 10 million homes were built with PB plumbing.

• A month after the Global Settlement Was Approved — Shell and Hoechst Celanese added another $150 million to the settlement fund — for a total of $1.1 Billion.

• In 2017 another Class Action Lawsuit was filed. (Hurt vs. Shell Oil).

• JUDGMENT: This complaint is dismissed with prejudice.  Signed by Judge D. P. Marshall Jr. on 7/6/2018.

• Note: “Dismissal With Prejudice” is a final judgment.  The case may not be pursued again.

Source:  https://www.rand.org/content/dam/rand/pubs/monograph_reports/MR969/MR969.ch14.pdf

Source: Chttps://www.chicagotribune.com/news/ct-xpm-1986-11-13-8603250425-story.html

SUMMARY

FITTINGS:

There appears to be agreement that Acetal Resin fittings often fail due to damage due to exposure to chlorine. 

There appears to be agreement that improper installation of Acetal Resin Fittings may have contributed to their failure.  

There is no way to know which fittings were installed in a home.  Most of the PB water lines systems are hidden behind walls. 

PB PIPE:

We have presented samples of pinholes, cracks or ruptures In PB pipe. 

Because PB pipe was flexible, some installers bent the pipe — when a fitting was required for a direction change.   

We’ve noted that U.S. tap water can have chlorine levels up to double what PB can tolerate.

Ample evidence shows that PB pipe will eventually fail due to exposure to chlorine. 

How long PB Pipe lasts may partially be attributed to the amount of chlorine in the tap water and / or water pressure.

We’ll Leave You To Draw Your Own Conclusions About PB Water Pipes Systems.

** 6 Source: https://www.pbpsa.com/uploads/files/resources/pbpsa-pb1-faq-en-2.pdf   Page 3 (of 17) in the report.

**7 Source:  https://www.cdc.gov/healthywater/drinking/public/chlorine-disinfection.html

**8 Source:  https://www.japantimes.co.jp/news/2016/12/22/national/chlorine-level-1600-times-normal-found-drinking-water-served-infants-nursery/#.XkQhIDJKiUk

**9 Source: https://qz.com/619014/chinas-tap-water-could-be-a-major-breeding-ground-for-superbugs/

**10 Source: https://greentumble.com/10-countries-with-the-best-quality-tap-water/

**11 Source: https://www.pbpsa.com/polybutylene-faq

**12 Source: https://inspectapedia.com/plumbing/PB_Piping.php

**13 Source: http://www.ashireporter.org/HomeInspection/Articles/Take-Another-Look-at-Polybutylene-Plumbing/955

The Article Was Part-1 Of 2

About Polybutylene Water Pipes

Al’s Plumbing, Heating & A/C in Plano, Texas provides maintenance & repairs for all brands of Central A/C, Gas & Electric Furnace, and Heat Pumps.    Additionally we sell and install new HVAC Systems from American Standard (same company as Trane), Ameristar (same company as American Standard) and Coleman HVAC (same company as York HVAC).

Al’s also provides full-service plumbing maintenance, repairs and replacements for every plumbing component in your home.  Al’s sells and installs Rheem Professional Series gas & electric water heaters, and tankless water heaters.  Al’s is near your home in Plano, TX; Allen, TX; and Frisco, TX.  We service all homes in southern Collin and Denton Counties with no additional travel charge.

Call Al’s today to discuss any concerns or problems you have with your HVAC System or Plumbing.  We will arrange an appointment at your convenience and offer 24/7 Emergency Service.

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