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PolyPlumbDismantling a PolyPlumb jointReduced component fittingsPolyPlumb fittings must not be dismantledfor any reason prior to jointing.Changes have been made to 15mmPolyPlumb couplers, elbows and teesand 22mm PolyPlumb elbows, tees andcouplers (or connectors), which needto be considered when using PolyPlumbspares kits with these fittings, as follows:Step 1: Procedure for using the component packof spares. Dismantling the jointIf it is necessary to remove a joint pipe froma fitting, the cap-nut should be unscrewed andthe pipe with all the socket components presenton the pipe end should be pulled out of the socketof the fitting. The pipe end complete with all thesocket components should be cut off and discarded.A complete component pack of socket spares shouldbe fitted to the socket as described below and pipejointing should be carried out as described.Step 2: Replacement componentsThe component pack (Code: PB95XX) is suppliedas a cap-nut with all the socket componentspresent in the correct order and retained bya retaining cap.Step 3: Preparing componentsCompletely remove the retaining cap, ensuring thatthe socket components remain within the cap-nut.Step 4: Replacing the componentsWithout removing any of the socket componentsfrom the cap-nut, introduce the cap-nut and socketcomponents to the socket of the fitting and tightenup the cap-nut by hand, ensuring that thecomponents enter the socket without snagging.Step 1: Original PolyPlumb fittingsIf the bottom white washer is present in the fittingbelow the grab-ring, then the spares kit can beused as supplied without making any changes.Step 2: New PolyPlumb fittingsIf there is no bottom white washer presentbelow the grab ring with one of the five listedfittings, then this is one of the fittings which hasbeen modified.Before the spares kit is used, the carrier mouldingshould be carefully removed from the cap-nut andthe bottom white washer should be removed anddiscarded without changing the order of any ofthe other components. After this has been done,the spares kit should be offered up to the socketof the fitting, inserting the components into thesocket in the order they are within the kit andthen screwing down the cap-nut onto the outsideof the socket.Retaining CapGrab ringSpacerStep 5: Checking the fittingCarry out a visual check to ensure that all socketcomponents are present in the correct order asshown in the diagram and that the rubber ’O’ ringis lubricated. If in doubt, the ‘O’ ring should bere-lubricated using PolyPlumb silicone lubricant.Step 6: Fitting the jointCarry out pipe jointing as described previously.Retaining Cap Spacer (28mm only)Grab ring“O” ringPipe StiffenerSpacerSpacer WasherPolyPlumb fittings general arrangement10www.polypipe.comPipe Stiffener“O” ring15mm couplers, elbows and tees and 22mm elbows,tees and couplers (or connectors)

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PolyMaxStreamline push-fit plumbingPolyMax is our newest plumbingfitting range, introduced afterextensive research, to meet consumerand installer demand.PolyMax fittings are slim, sleek and attractive,making PolyMax the perfect choice for surfacemounted installations. PolyMax is easilydemounted using our handy release tool. UsePolyMax with Polypipe white polybutyleneflexible pipe, using a Polypipe metal or plasticpipe stiffener. For extra security, choose the newPolypipe sealed stiffener.PolyMax can be used on a wide range of homeimprovement and refit projects, including hotand cold water systems.12www.polypipe.comThe system offers a number of benefits: New white push-fit system, ideal for homeimprovement and refit projects PolyMax fittings are slim, sleek and attractive:ideal for surface mounted applications PolyMax is secure in use but tool demountable Use for most hot and cold water supply orheating applications Use with Polypipe white polybutylene pipesystems or with copper pipe Use Polypipe metal, plastic or sealed stiffeners(15mm and 22mm only)

PolyMaxJointingThere are five vital steps to successfully jointing the PolyMax system.Step 1a: Cutting Polypipe pipeStep 3: Visually check fitting and fitting componentsCheck the pipe is not scored or scratched in anyway and if it is, cut back to a point where there isno damage. Using a Polypipe pipe cutter, cut thepipe squarely using the “K” marks on the pipe asa guide. These marks indicate when the pipe hasbeen inserted into the fitting correctly.Visually check that all components are present,undamaged and free from contamination.LubricantsAll Polypipe fittings are supplied with pre-lubricatedEPDM ‘O’ rings. If any further lubrication is required,only Polypipe silicone lubricant should be used.Substances such as solder flux must not be used.Step 4: Insert pipe fully into fittingInsert pipe into the fitting, ensuring it is insertedto the full socket depth denoted by the next “K”mark on the pipe.Step 1b: Cutting copper pipe for insertionin a PolyMax fittingWherever possible, use a rotational pipe cutterwhen cutting copper pipe. Ensure that all cutends have a rounded lead in, with burrs removed.Never use a hacksaw. You will need to mark theinsertion depth on the pipe as below.Pipe Diameter (mm)10152228Insertion Depth (mm)22354244Step 2: Use of pipe stiffenerInsert a pipe stiffener into the pipe (not requiredwith copper pipe). Polypipe offer three types ofstiffeners for use with PolyMax fittings: metal,plastic and for extra security - a sealed stiffener(15mm and 22mm only). When using a sealedstiffener, the stiffener will be retained in the fittingwhen demounted.Step 5: Check joint securityA quick tug on the pipe will confirm that the pipe isinserted past the grab ring and that a grab ring waspresent in the fitting. It does not however, ensurethat the pipe is fully inserted as this can only beconfirmed by using the depth insertion mark.Demounting a PolyMax jointPolyMax fittings are fully demountable andre-usable. To demount a PolyMax fitting use theraised edge of the demounting tool (FITAID) anddepress the collet squarely towards the fitting andpull the pipe out of the fitting. Care should be takenthat the collet is pushed all the way back to thefitting squarely to avoid scratching or scoring thepipe when it is pulled from the fitting.www.polypipe.com13

PolyFitQuickfix push-fit plumbingPolyFit is our hand demountablewhite, push-fit plumbing system,offering maximum flexibilityand adjustability.PolyFit features a one step jointing operationfor quick and easy installation. PolyFit leadsthe market in speed to fit. If you need to adjusta fitting joint during the installation process,PolyFit fittings can be quickly demounted byhand, or by using our release tool.Use PolyFit with Polypipe white polybutyleneflexible pipe, using a Polypipe metal or plasticpipe stiffener. For extra security, choose the newPolypipe sealed stiffener. PolyFit can be used ona wide range of contract and retrofit projects,including hot and cold water systems, and isparticularly suitable for first fix installations.14www.polypipe.comThe system offers a number of benefits: One step operation for quick and easyinstallation PolyFit is ideal for first fix applicationsor when demountability is important PolyFit is hand or tool demountable formaximum flexibility Use for most hot and cold water supplyor heating applications Use with Polypipe white polybutylenepipe systems or with copper pipe Use Polypipe metal, plastic and sealedstiffeners (15mm and 22mm only)

PolyFitJointingThere are five vital steps to successfully jointing the PolyFit system.Step 1a: Cutting Polypipe pipeCheck the pipe is not scored or scratched in anyway and if it is, cut back to a point where there isno damage. Using a Polypipe pipe cutter, cut thepipe squarely using the “K” marks on the pipe asa guide. These marks indicate when the pipe hasbeen inserted into the fitting correctly.place by a cap nut. All cap-nuts are torqued toensure they cannot unscrew easily. There is noneed to undo cap-nuts and remove any componentsprior to jointing PolyFit fittings.LubricantsAll Polypipe fittings are supplied with pre-lubricatedEPDM ‘O’ rings. If any further lubrication is requiredonly Polypipe silicone lubricant should be used.Substances such as solder flux must not be used.Step 4: Insert pipe fully into fittingInsert pipe into the fitting, ensuring it is insertedto the full socket depth denoted by the next “K”mark on the pipe.Step 1b: Cutting copper pipe for insertionin a PolyFit fittingWherever possible, use a rotational pipe cutterwhen cutting copper pipe. Ensure that all cutends have a rounded lead in, with burrs removed.Never use a hacksaw. You will need to mark theinsertion depth on the pipe as below.Pipe Diameter (mm)10152228Insertion Depth (mm)25354244Step 2: Use of pipe stiffenerInsert a pipe stiffener into the pipe (not requiredwith copper pipe). Polypipe offer three typesof stiffeners for use with PolyFit fittings: metal,plastic and for extra security - a sealed stiffener(15mm and 22mm only). When using a sealedstiffener, the stiffener will be retained in thefitting when demounted.Step 5: Check joint securityA quick tug on the pipe will confirm that the pipeis inserted past the grab ring and that a grab ringwas present in the fitting. It does not howeverensure that the pipe is fully inserted as this can onlybe confirmed by using the depth insertion mark.Demounting a PolyFit jointPolyFit fittings are fully demountable and re-usable.To demount a PolyFit fitting simply depress the colletsquarely towards the fitting and pull the pipe outof the fitting. Care should be taken that the colletis pushed all the way back to the fitting squarelyto avoid scratching or scoring the pipe when it ispulled from the fitting. When systems have beenpressurised the collet is designed to grip into thepipe therefore using a fitting release aid (ProductCode: FITAID) will assist in demounting fittings.Step 3: Visually check fitting and fitting componentsVisually check that all components are present,undamaged and free from contamination. PolyFitfittings contain; a blue bottom washer; an EPDM‘O’ ring; a blue top washer and a collet all held inwww.polypipe.com15

PolyFitSelect your Flexible HosesFlexible hoses are a great addition tothe PolyFit product range. This versatilecollection comes in a wide range of lengthand connection end combinations tosuit every need.Many of our flexible hoses include the PolyFitone step joint feature and are quick and easyto install - ideal for use in tricky to reach ortight locations.1 All PolyFit flexible hoses are listed underthe Water Regulations Advisory Scheme Look out for the black thread that is woundinto each hose, which denotes a WRAS qualityproduct. Each EPDM hose is suitable for usein domestic hot and cold water applications All PolyFit flexible hoses which have a tapconnector nut now contain captive rubberseals ensuring that seals are not lost ordamaged on-site2 PolyFit flexible hoses come in a packagingdesign which aids quick and easy productselection and all hoses come in pairs1PolyFit Fitting 15mm and 22mmPolyFit push-fit connections. PolyFit endsare secure in use but also fully demountableand re-usable.23Tap Connection Nut 1/2” and 3/4” These ‘wing nut’ style tap connector nutswill only require hand tightening.3PolyFit Chrome Plated Valve 15mm and 22mmOur compression end connectors use thesame high quality components as the restof the PolyFit push-fit range.4Compression Fitting 15mm and 22mmConnectors incorporating service valves toreduce the number of joints within a system.Incorporates the PolyFit push-fit feature.16www.polypipe.com4

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PolySurePermanent press-fit plumbingPolySure is our radial press-fit system,available in UK sizes, and installedusing specialist crimping tools.PolySure features secure, tamperproof jointingtechnology for a permanent fit.The slim profile fittings are ideal for use in visibleinstallations. An inbuilt location washer ensuresthe crimping tool jaws are correctly positionedfor accurate fitting and a visual socket depthindicator and double ‘O’ ring seal providesenhanced jointing.Use PolySure with Polypipe white or greypolybutylene flexible pipe.PolySure can be used in any hot and cold waterinstallation but is particularly suited to buildingswith high levels of public access traffic, wheresecurity and joint integrity are paramount.The system offers a number of benefits: Supplied in both metal and plastic bodiedsolutions, and offering the same high security The first radial press-fit system in standardUK sizes PolySure is ideal for applications wheresecurity is paramount PolySure offers a permanent, tamper prooffit and the slim profile fittings are ideal forvisible applications Fitted location washer ensures jaws arecorrectly positioned for crimping Visual socket depth indicator and double‘O’ ring seal provide enhanced jointing Use for most hot and cold water supply orheating applications Use with Polypipe white or grey pipe systems18www.polypipe.com

PolySureJointingThere are seven steps to completing a joint which uses PolySure fittings.Each step is covered in detail here.Unlike the other plumbing systems, the PolySuresystem requires some specialist pressing toolswhich can be purchased directly from Polypipeor via the manufacturer’s stockists. Polypiperecommends using REMS’ pressing equipmentwho have a reputation for manufacturingdurable products that can stand up to today’ssite conditions. For full details of products,instructions, servicing requirements andwarranties please visit: www.rems.deThe chamfering tools are available in eitherindividual tools or as a block of four dependenton the installers preference, however all workin the same way.The chamfer tool spigot should be inserted downthe bore of the pipe until contact is made withthe blades.Step 1: Cutting Polypipe pipeCheck the pipe is not scored or scratched in anyway and if it is, cut back to a point where thereis no damage. Using a Polypipe pipe cutter, cut thepipe squarely using the “K” marks on the pipe asa guide. These marks indicate when the pipe hasbeen inserted into the fitting correctly. It isessential that pipes are cut squarely as this mayaffect chamfering (see step 2).Step 2: Chamfering the pipe s PolySure fittings use press-fit technology whichAseals on the pipe bore, it is necessary to provide aninternal lead on the pipe end so the square edgeof the pipe does not damage the ‘O’ ring seals.The chamfer tool should be twisted gently toprovide a lead in. Any debris should be removedfrom the pipe end and the chamfer tool. Check thatthe pipe has been cleanly chamfered around thefull diameter of the pipe.If not repeat step 2, if so proceed to step 3.Step 3: Visually check fitting and fitting componentsVisually check that all components are present,undamaged and free from contamination.On push-fit fittings this lead in is provided bythe pipe stiffener. Polypipe offer specific pipechamfering tools for our pipes and these mustalways be used.www.polypipe.com19

PolySureLubricantsManual pressing toolAll Polypipe fittings are supplied withpre-lubricated EPDM ‘O’ rings. If any furtherlubrication is required only Polypipe siliconelubricant should be used. Substances such assolder flux must not be used.Secure the jaw in the tool by firstly removingthe locking pins from the Eco Press, lining upthe holes in the Eco Press with those in the jawand re-inserting the locking pins.Step 4: Insert pipe into fittingPolypipe pipes have a visual indicator to assistthe installer in jointing pipes and fittings together.The chamfered Polypipe pipe should be insertedinto the PolySure fitting and pushed in until pipecan be seen through the hole in the stainless steelpressing sleeve. When this has been done thejoint is ready for pressing.Battery operated pressing toolStep 5: Preparing the pressing toolsThere are three types of pressing toolrecommended for jointing PolySure fittings.The REMS Eco Press is a manual pressing toolwhich can be used on 10mm, 15mm and 22mmjoints only but provides the installer with alightweight, low cost entry pressing tool whichcan be used in most situations.Alternatively the battery operated tools (minior standard versions) can be used where a highvolume of joints needs to be made in a shortspace of time. The battery operated tools mustbe used for 28mm fittings.The 10mm, 15mm and 22mm Polypipe THpressing jaws have been designed to fit boththe manual and standard battery operatedpressing tools. The mini pressing jaws are onlycompatible with mini pressing gun and can notbe used with the manual or standard batteryoperated guns. All jaws are specifically designedto press PolySure press-fit fittings and shouldonly be used for these fittings. Likewise no otherpressing jaws should be used for PolySure fittings.20www.polypipe.comTo insert a Polypipe TH jaw into the batteryoperated gun, press the release catch on thelocking pin on the gun. Slide the jaw into thegun, aligning the centre hole in the jaw with thelocking pin, and push the locking pin back intoposition until locked. Once the jaws are lockedin the respective machine the pressing tools arenow ready to complete the joint process.

PolySureStep 6: Securing the jointBattery operated pressing toolWhether using the manual or battery operatedpress gun, the jaws are located onto the fittingin exactly the same manner. Do a final check toensure that the pipe is still inserted fully into thefitting, then using the white washer as a locationpoint fix the jaws over the fitting in theun-pressed condition.The trigger can now be pressed on the tool tostart the pressing process. Keep the triggerdepressed until the jaws have closed completelyand the pressing machine clicks to denote theend of the process.NOTE: Once the process is underway it must becompleted before the s

2 www.polypipe.com 03 Introduction Plumbing & Heating Pipes & Fittings 05 Fittings 06 Plumbing & heating pipe 07 Pipe stiffeners PolyPlumb 09 Jointing and dismantling PolyMax 13 Jointing and demounting PolyFit 15 Jointing and demounting 16 Flexible Hoses PolySure 19 Jointing System Installation 22 Introduction 22 Service conditions 23 Application information 25 Connections to