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Installation GuideBLUE904 TM PEX MUNICIPALWATER SERVICE TUBINGW A T E RS E R V I C ET U B I N GWe Build Tough Products for Tough Environments

Blue904 TM Installation Guide1TABLE OF CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Certifications & Listings . . . . . . . . . . . . . . . . . . . . . . . . . . .2Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Handling & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Trenching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Excavating and Preparing the Trench . . . . . . . . . . . . . . . . . .4Depth of Trench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4The Bottom of the Trench . . . . . . . . . . . . . . . . . . . . . . . . . .5Trench Backfill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Contaminated Soils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6PEX Tubing Thermal Expansion . . . . . . . . . . . . . . . . . . . . . .6Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Underground Location . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Above Ground Installation . . . . . . . . . . . . . . . . . . . . . . . . .7Freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Concrete Slabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Repairs Below Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Electrical Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Cutting and Joining PEX . . . . . . . . . . . . . . . . . . . . . . . . . .9Gooseneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Head Loss Charts . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11C904Standard 14 & 61CSA B137.5ASTM F876ASTM F877ASTM F2023

Blue904 TM Installation GuideBlue904 TM Installation Guide2BLUE904 PEX TUBING SYSTEMSMarkingsBlue904 PEX tubing is marked at 5 ft. intervals with thefollowing information:IntroductionIPEX’s Blue904 PEX Municipal Water service tubing has uniquefeatures and performance characteristics as describedin this guide that make it the leading alternative to coppertubing. IPEX Blue904 conforms to CTS OD dimensions,allowing common compression fittings to be used.This booklet provides municipal system installers andinspectors with IPEX recommendations for handling, installingand testing Blue904 PEX. Following the recommendationscontained in this booklet will lead to a professional installationand will ensure maximum life for the water system.StandardsPEX TubingPEX Tubing3AWWAASTMCSANSFC904F876F877F2023B137.514 & 61Certifications & ListingsCanadian Standards Association Blue904 PEX tubing carries third party certification toCSA B137.5.American Water Works Association Blue904 meets AWWA C904. Blue904 Made in Canada IPEX “Nominal pipe size” SDR 9 CTS 160 psi @ 23 C / 73.4 F 100 psi @ 82 C / 180 F 80 psi @ 93 C / 200 F Potable Tubing AWWA C904, ASTM F876 / F877 / F 2023, CSA B137.5,NSF 14 & 61 Manufacturing date and machine number Footage mark every five feet starting with zero at thebeginning of the coilHANDLING & STORAGEBlue904 PEX tubing is supplied in convenient lightweight coilsinside cardboard boxes. PEX should be stored indoors to keepcoils clean prior to installation and to protect product andpackaging from the elements.Blue904 PEX is designed to withstand limited exposure toultraviolet light but should not be exposed to sunlight for morethan 60 days.National Sanitation FoundationBlue904 PEX may be lifted by hand, easily uncoiled andshaped by hand to create changes in direction. Blue904 PEX tubing is NSF certified toNSF Standards 14 & 61.Uncoilers are available to assist in dispensing PEX tubing onthe job site.American Society for Testing and Materials Blue904 PEX tubing carries third party certification toASTM F876, F877, F2023.

4Blue904 TM Installation GuideTRENCHINGSafetyTrenches can be dangerous places. The contractor isresponsible for ensuring that all applicable regulations havebeen observed and that the protection of the workers and thegeneral public is provided.Excavating and Preparing the TrenchThe drawings and bid documents will specify the correct lineand grade to be established by the trenching operation. Asidefrom these engineering considerations, good bedding practicesmake sense for all types of pipes and tubing.The width of the top of the trench will be determined by localconditions. But in the pipe zone the trench width should bekept to a practical minimum.Keep the three basic operations close together: digging, pipelaying and backfilling. The shortest practical stretch of opentrench reduces the possibility of problems associated withwater, frozen ground, impact damage, flotation, and traffic.Depth of TrenchFor water distribution and transmission lines, pipe should beburied so that the top of the pipe is at least 6 inches(150mm) below the deepest recorded penetration of frost.Where surface loads will be encountered and where frost isnot a problem, the minimum height of cover over the crown ofthe pipe is 12 inches (300mm). Before vehicles pass over theline of the pipe under shallow cover, make sure backfill hasbeen completed and compacted to at least 95% standardproctor density.Blue904 TM Installation Guide5The Bottom of the TrenchThe objective of bedding is to provide a continuous support forthe pipe at the required line and grade. Frozen material shouldnot be used to support or bed the pipe. At least 4 inches(100mm) of Class I or Class II bedding material should beplaced under the pipe if rocky conditions exist. The beddingmay or may not be compacted, but in any event ensure thatthe entire pipe is evenly supported by the bedding. Where thetrench bottom is unstable (organic material, or “quick” sand orsimilar material) the trench bottom should be over-excavatedand brought back to grade with approved material.Trench BackfillWhen backfilling the trench use Class I or Class II fill for thefirst 6 inches above the top of the tubing. Ensure there are nolarge rocks (1-1/2" or larger) against the tubing. Where it is nototherwise specified the initial backfill may consist of the nativematerial in the trench provided it is free from large stones, notfrozen, and free of debris or other organic materials. Thepurpose of the initial backfill is to protect the pipe from thefinal backfill.

Blue904 TM Installation Guide6Blue904 TM Installation GuideINSTALLATIONDamageKinked, buckled, gouged or otherwise damaged tubing shallnot be used. Remove and replace any damaged sections.Contaminated SoilsBlue904 is not to be installed in soils which may becontaminated with hydro carbons, chemicals, or any othersubstance which may permeate the pipe and contaminatethe water supply.PEX Tubing Thermal ExpansionBendsPEX tubing may be shaped by hand to a minimum radius of 6times the outside diameter of the tubing. External bend supportsor sleeves may be required to maintain desired position and shape.Blue904 PEX TubingI.D.Underground LocationTo locate buried Blue904, a tracer wire (or other detectionmeans) must be installed in the trench during installation.Above Ground InstallationThe linear expansion rate for PEX tubing is 1.1 inches per100 feet of pipe per 10 F change in temperature. Toaccommodate for the expansion/contraction, snake the tubingalong the bottom of the trench.Nominal Size7Min. Bend 2292511.62541.312.0305Note: When using pipe in coils and bending against the coildirection, the minimum bending radius is 3 times the radiusgiven above. (e.g. 3/4" CTS pipe 3 x 4.5" 13.5")Note: To avoid kinking, care should be taken when bending thetubing in sub zero temperatures. For bending in cold temperatures,use a minimum bend radius of 2 times that listed in the chart.If Blue904 is to be installed above ground, UV protection (i.e.conduit) is required.FreezingIf Blue904 service pipe freezes, it can be thawed using a hotair gun. Do not use open flame. Do not allow the temperatureof the tubing to go above 93ºC.Concrete SlabsBlue904 PEX tubing can penetrate concrete slabs, thoughlocal regulatory bodies may require sleeves at the penetrationpoint. Consult local inspection staff. Tubing subject tomechanical damage must be protected with plastic sleevescomplying with local requirements.Repairs Below GradeRepairs to PEX tubing below grade may be done using repaircouplings. Couplings must then be permanently protectedusing polyethylene heat shrink sleeves or other approvedprotective wrap. The sleeve should be a minimum of2 inches longer than the body of the repair coupling orextend 2 inches beyond the couplings to secure the repair.

8Blue904 TM Installation GuideBlue904 TM Installation GuideCONNECTIONSElectrical GroundingPEX water service tubing may not be used to ground anelectrical system.A separate grounding rod or plate should be used —check with the local authority.Inspection and TestingPEX water service tubing shall be inspected to confirmcompliance with manufacturer’s installation instructions andwith local code regulations.Upon installation, the entire water system shall be pressuretested, preferably in sections, to the local requirements toensure a leak free system.FlushingThe system must be thoroughly flushed after installation. If thetesting is done in subfreezing weather, all of the PEX linesshould be drained after the successful completion of the tests,until the construction project has been completed.9FittingsBlue904 is copper tube size SDR 9; this allows standardAWWA C800 compression valves and fittings to be used.An insert/liner is inserted in the end of the tube and thenthe brass fitting is installed as per the manufacturers’recommended instructions.Cutting and Joining PEX1. Cut the pipe square. A plastic pipe cutter should be used.Ensure that the stainless steel cutting blade is sharp andin good condition.2. Insert the stainless steel PEX liner / insert to the end ofthe tubing and install standard CTS brass compressionvalves/fitting as per manufacturers’ instructions. (Stainlesssteel inserts provide PEX with the structural integritynecessary for use with compression fittings).GooseneckAt the connection between Blue904 pipe and the water main,Blue904 should leave the main at 10 to 20 degrees abovehorizontal compared to the traditional 45 degrees required withcopper service line. This protects against future settlementaround the main which causes stress at the connection. 10º to 20º45º