High-Performance Polymers for. Plumbing

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1 High-Performance Polymers for Plumbing

2 Performance You Can Trust Solvay offers the industry s broadest selection of high-performance polymers for water-handling systems. Radel PPSU Acudel mod. PPSU Udel PSU Solef PVDF Amodel PPA Ixef PARA Ryton PPS Polidan PEX

3 For more than 20 years, Solvay has supplied high-performance polymers that can cost-effectively outperform brass and copper in pipes, fittings, valves, manifolds, flexible hoses, water meters and others, used in pressurized hot water systems. Better than Metal Corrosion free No heavy metals No scale build-up Superior thermal insulation More design freedom Lower environnmental footprint than metals Reliable Performance Over 20 years in pressurized systems Resistance to hot chlorinated water Ease of installation Lower overall costs Global agency approvals Our materials finds place in sanitary and heating water applications from cold to hot water or steam, in drinking high purity water or heating chemically agressive water, mixtures, in low or high pressure piping system and for medium-term to very long-term applications (5 to 50 years). Dedicated Global Support At Solvay, we place a high value on helping our customers succeed. That s why we have a dedicated global network of marketing, sales and technical support staff who understands the unique requirements of this industry. Our highly experienced staff is eager to help you with material selection, product and application development, MoldFlow process modeling, finite element analysis and product testing. Plus, we can assist with design, processing and assembly techniques. We understand the importance of reliable support and work hard to earn your confidence in us as your preferred materials supplier. High-Performance Polymers for Plumbing / 3

4 Designing With Plastics Engineers can find it challenging to work with polymers, especially if most of their experience has been with metals. If you re new to plastics, you must take the time to understand their unique nature, their properties and testing methods. This will help you to properly evaluate and understand how to use a particular material. Unlike metals, the mechanical properties of plastics are time and temperature dependent. Engineers must carefully consider how these and other operating conditions such as chemical environment, pressure and mechanical loads will affect the long-term properties that are critical to the application. Plastics Respond Differently to Heat Amorphous thermoplastics Amorphous thermoplastics have a random molecular orientation. Instead of having a defined melting point, they soften over a range which is called the glass transition temperature ( T g ). When using amorphous plastics, the T g should be significantly higher than the operating temperature as they have no useful properties above this point. Semi-crystalline thermoplastics have highly ordered molecules dispersed within regions of random amorphous molecules. This gives them a T g as well as a sharp melting point ( T m ). These materials maintain some useful properties above the T g and are molten above the T m. Modulus High stiffness Tg No useful stiffness Cross-linking can be induced in materials that are normally thermoplastics to improve heat resistance. The permanent connections that are chemically formed between molecular chains also enhance mechanical properties and chemical resistance. Temperature Semi-crystalline thermoplastics High stiffness Modulus Tg Moderate stiffness Tm No useful stiffness Temperature 4 \ High-Performance Polymers for Plumbing

5 Effects of Stress Over Time Creep is the tendency of a material to deform when stress is applied over a long period of time. It can have a significant effect on the long-term performance of a plastic component, especially when operating under high stress or high heat. Creep testing measures strain as a function of time at a constant temperature and constant load. The slope of the curve is the creep deformation rate of the material. As shown in the figure below, even though the short-term properties of different plastics may be similar, they can react very differently to applied stress over time. Creep resistance over time Strain [ % ] Plastic 1 Plastic 2 Plastic ,000 1,200 Time [ hours ] Creep-rupture testing is similar to creep testing except that higher stresses are used to determine the time needed to cause failure. Data is plotted log-log to generate creeprupture curves at different temperatures (see figure below). This information can then be extrapolated to predict longterm hydrostatic strength ( LTHS ). Based on LTHS values, engineers can determine appropriate design stresses and safety margins for pressurized plumbing applications. Creep-rupture testing can also help determine limitations due to hydrolytic and oxidative stability. Significant changes in the slope of the creep-rupture line are due to structural changes in the material and indicate that upper limits have been reached. Chemical Resistance Chlorine and chlorine-based products are widely used to disinfect drinking water. At elevated temperatures, these chemicals produce an oxidizing environment that can adversely affect a system s ability to withstand the continuous stress of pressurized water over time. Oxidative resistance varies considerably among polymers. Excessive oxidation can result in part failure due to reduced mechanical properties or weight loss, which can lead to embrittlement, stress cracking or crack propagation. High temperatures can significantly accelerate these effects. Agency Approvals Independent organizations around the world, such as NSF, WRc and KTW, write standards and certify products that come into contact with drinking water. They carefully evaluate plastics under expected end-use conditions to ensure that no substances can be extracted that might cause health concerns. Some agencies perform additional tests to evaluate a material s effect on taste and odor as well as its tendency to support microbiological growth. Solvay voluntarily certifies its plastics on a global basis to help OEMs expedite the approval process required for components used in hot potable water systems. LTHS failure modes 100 Stress [ MPa ] 10 Creep Thermal instability Stress cracking ,000 10, ,000 Time [ hours ] High-Performance Polymers for Plumbing / 5

6 Get the Performance You Need Sulfone Polymers Radel PPSU Radel PPSU has the highest LTHS of any sulfone polymer, making it well-suited for components operating in chlorinated water under high pressure (up to 10 bars) and temperatures up to 95 C. Radel PPSU offers high fatigue resistance, excellent chemical resistance and very high impact strength. Acudel modified PPSU Acudel compounds are proprietary formulations that fill the cost-performance gap between PPSU and PSU. They provide toughness and chemical resistance along with hydrolytic and dimensional stability for plumbing systems with less demanding pressure and temperature requirements. Udel PSU Udel PSU exhibits low creep, good toughness and excellent dimensional stability in hot water and steam. These attributes combine with proven resistance to oxidative aging to make it a cost-effective material for applications requiring continuous exposure to hot chlorinated water. Fluoropolymers Solef PVDF Solef PVDF provides outstanding resistance to chemicals, UV light and fatigue, along with exceptional barrier properties, scratch resistance and ease of processing. High LTHS values make it well-suited for fittings used in multilayer piping systems that operate under high pressure and temperatures up to 95 C. Solef PVDF combines a unique set of properties required for the design of sleeve for sliding sleeve fittings. Special extrusion grades can be coextruded to produce pipes with barrier or protective layer against oxidative chemicals. High-Performance Polyamides Amodel PPA Amodel PPA is a family of high-performance polyamides suitable for applications with intermittent exposure to hot chlorinated water. It delivers a number of performance advantages over conventional polyamides, including low sensitivity to hydrolysis, higher operating temperatures, lower moisture absorption, better dimensional stability and superior resistance to creep and fatigue. Ixef PARA Ixef PARA is a high-performance polyamide suitable for applications with exposure to cold chlorinated water. Compared to conventional polyamides, it exhibits higher mechanical performances, lower moisture absorption, better dimensional stability, and a smooth, high-quality surface finish. Polyphenylene Sulfide Ryton PPS Ryton PPS offers excellent chemical and thermal oxidative resistance at elevated temperatures. It provides exceptional dimensional stability as it has low to no moisture absorption, and can withstand prolonged exposure to water up to 140 C. Cross-Linkable Compounds Polidan PEX Polidan PEX is a family of silane cross-linkable polyethylene compounds used in monolayer and multilayer piping systems. They offer outstanding flexibility and strength from below freezing up to 95 C and are highly resistant to creep, chemical attack, and crack formation and propagation. Specialty grades for thermal welding, in-situ or self cross-linking, UV protection and industrial applications are available. 6 \ High-Performance Polymers for Plumbing

7 Radel PPSU Acudel modified PPSU Udel PSU Solef PVDF Amodel PPA Ixef PARA Ryton PPS Polidan PEX Fittings body and components Manifolds Pipes Faucets parts Flexible hoses Protective pipe linings Water meters Boiler parts Ball valves High-Performance Polymers for Plumbing / 7

8 Sulfone Polymers Radel PPSU, Acudel modified PPSU and Udel PSU Sulfone polymers have successfully replaced brass in pressurized hot water applications for over 20 years. These tough, heat-resistant plastics can be molded to tight tolerances and exhibit low creep under a sustained load at elevated temperatures. This combines with their excellent oxidation resistance to make sulfone polymers a reliable choice for applications that requires long-term continuous exposure to hot chlorinated water. Low Compressive Creep Sulfone polymers have low creep, meaning they exhibit only a slight deformation under a continuously applied load. This allows components made from these materials to maintain a low deformation and reliable seal over time, even at higher temperatures. Key Features Outstanding long-term hydrostatic strength Excellent mechanical instantaneous properties Low tensile and compressive creep Withstand continuous exposure to hot chlorinated water Sulfone polymers for plumbing Grade Radel R-5000 Series Acudel Udel P-1700 Udel GF Series Description Unfilled Unfilled Unfilled Glass fiber reinforced Compression creep deformation at 95 C Deformation [ % ] Acudel, 20 MPa Radel, 20 MPa Acudel, 30 MPa Radel, 30 MPa ,000 10,000 Time [ hours ] 8 \ High-Performance Polymers for Plumbing

9 Exceptional Resistance to Hot Chlorinated Water The micrographs below were taken of fittings made from Radel, Acudel and Udel sulfone polymers that were continuously exposed to hot chlorinated water for 1,600 hours. These test conditions are extremely harsh and are significantly more aggressive than industry standards for PEX piping systems. As shown below, no cracks have formed in any of the sidewalls and no oxidation has occurred on the surface of the fitting made from Radel PPSU. Very little oxidation has occured on the surface of the Acudel modified PPSU fitting, and only a small amount on the surface of the Udel PSU fitting. Radel PPSU at 300x magnification No Oxidation Layer Acudel modified PPSU at 300x magnification 6 μm Oxidation Layer Udel PSU at 300x magnification 22 μm Oxidation Layer Determining Long-Term Hydrostatic Strength When designing a pressurized system, it s important to understand how a material performs when exposed to constant stress in the presence of water. Data from creep-rupture curves generated at various temperatures can be extrapolated to predict a material s LTHS for a given set of conditions. These values are then used to determine design stresses that include appropriate safety margins. Long-term hydrostatic strength 100 Stress [ MPa ] 10 Radel R-5100, 20 C Acudel 22000, 20 C Udel P-1700, 20 C Radel R-5100, 70 C Acudel 22000, 70 C Udel P-1700, 70 C ,000 10, ,000 Time [ hours ] 50-year prediction and lower prediction limits (1) calculated by ISO 9080 method 4 Temperature [ C] Time [Hours] Radel R-5100 Acudel Udel P-1700 Mean [MPa] LPL [MPa] Mean [MPa] LPL [MPa] Mean [MPa] LPL [MPa] , , (1) The stress level at a given time that will not produce failures in 97.5 % of the test samples at 50 years. High-Performance Polymers for Plumbing / 9

10 Fluoropolymers Solef PVDF Solef PVDF is a semi-crystalline, melt-processable fluoropolymer that offers excellent barrier properties, resistance to chemicals and oxidation, exceptional fatigue resistance, and long-term hydrostatic strength. It has been used successfully in domestic water supply applications for nearly 20 years and has an equally impressive track record in the chemical processing, semiconductor, and oil and gas industries. Injection molded Solef 1010 has been used for many years for the fabrication of fittings bodies or manifolds and sleeves for sliding sleeve fittings. Extrusion grade Solef is used in multilayer pipes in combination with polyolefin to provide protection against the oxidative chemicals contained in the water (i.e. chlorine dioxide used for shock disinfection) or as a barrier to several chemicals (i.e. hydrocarbons from a polluted ground). Key Features Excellent resistance to chemicals and hot chlorinated water Outstanding long-term hydrostatic strength Exceptional fatigue resistance Good barrier properties against a broad range of chemicals UV resistance for outdoor applications Smooth surface to prevent biofilm adhesion Resistant to flame propagation Solef PVDF for plumbing Grade Description 1010 Injection molding and extrusion Multilayer extrusion 10 \ High-Performance Polymers for Plumbing

11 Solef PVDF offers outstanding long-term hydrostatic strength The lower prediction limits extrapolated to 50 years are 25 MPa at 20 C and 10 MPa at 80 C. 100 Stress [ MPa ] ,000 10, ,000 Time [ hours ] Solef PVDF, 20 C Solef PVDF, 80 C Excellent Chemical Resistance and Barrier Properties The presence of fluorine monomer and the high crystallinity of Solef PVDF make it extremely resistant to a broad range of chemicals. These attributes also give the material outstanding barrier properties against water vapor, oxygen and hydrocarbons like methane, which helps preserve the integrity of closed systems. Water permeability Permeability [ cc mm /m 2 atm day ] 100,000 10,000 1,000 PVC PVDF Temperature [ C ] Methane permeability Permeability [ cc mm /m 2 atm day ] 10,000 1, HDPE PVC PA 11 PVDF Temperature [ C ] Oxygen permeability Permeability [ cc mm /m 2 atm day ] 10,000 1, HDPE PVC PVDF Temperature [ C ] High-Performance Polymers for Plumbing / 11

12 High-Performance Polyamides Amodel PPA Amodel PPA outperforms standard polyamides in terms of thermal and hydrolysis resistance. Compared to conventional polyamides, it exhibits: Lower moisture absorption Higher hydrolysis resistance even in hot chlorinated water Improved dimensional stability Higher resistance to creep and fatigue Amodel DW-11xx series have been especially developed for plumbing applications. Those grades are DW approved for contact with potable water and exhibit an improved hydrolysis resistance. They are suitable for applications requiring intermittent contact to hot chlorinated water. Drinking water approved grades Grade DW-1130 BK938 DW-1140 BK938 DW-1150 BK938 Description 30 % glass fiber reinforced 40 % glass fiber reinforced 50 % glass fiber reinforced Typical applications Condensing and electrical boiler components Manifolds and faucets components Hot/cold water meter and heat meters Regulation valves Retention of tensile strength after 1,000 hours in water at different temperatures Tensile strength retention [%] Aging time in water [hrs] DW-1150 BK C DW-1150 BK C DW-1150 BK C Fatigue resistance after aging in water at 120 C 1 Hz, tensile, R = 0,01 Applied stress [MPa] ,000 10, ,000 Cycles at break DW-1150 BK938 No weldline, 0 hrs DW-1150 BK938 No weldline, after 500 hrs at 120 C in water DW-1150 BK938 With weldline, 0 hrs DW-1150 BK938 With weldline, after 500 hrs at 120 C in water Ixef PARA Ixef PARA shows an exceptional combination of high stiffness and strength, excellent creep resistance, easy processing, together with low shrinkage, low warpage, and low water pick-up. Even with 50 % glass fiber reinforcement, Ixef PARA provides a smooth, high-quality surface finish. This makes it an excellent candidate for applications where aesthetics are important. Drinking water approved grades Grade DW-1022 BK000 DW-1022 NT000 Typical applications Cold water meters Faucet components Fixations and brackets Description 50 % glass fiber reinforced, black 50 % glass fiber reinforced, natural 12 \ High-Performance Polymers for Plumbing

13 Polyphenylene Sulfide Ryton PPS Ryton PPS compounds for injection molding or extrusion provide excellent chemical resistance along with exceptional dimensional in water thanks to their low water pick-up. Their very low viscosity allows Ryton PPS to be injected in thin-walled parts. Ryton PPS compounds can bear temperatures above 95 C and up to 220 C in extreme cases. Typical applications Hot water and heat meters Condensing and electrical boiler components Water pumps Faucets parts Solar panel heat collectors Chlorinated water resistance (ASTM F2023) Ring tensile strength [MPa] hours 600 hours 1,400 hours 2,000 hours R-4-220BL R-4-270BL XE5430BL XE5500BL High-Performance Polymers for Plumbing / 13

14 Cross-Linkable Compounds Polidan PEX Polidan PEX is a family of silane cross-linkable polyethylene compounds. This means that permanent connections, known as cross-links, are chemically formed between molecular chains to create a three-dimensional structure. As a result, cross-linked polyethylene (PEX ) has better thermal stability, mechanical properties and resistance to chemical attack than thermoplastic polyolefins. Monolayer and multilayer PEX pipes made from Polidan compounds are flexible and have excellent strength from below freezing up to 95 C. PEX piping systems are quieter than rigid metal piping systems and require fewer fittings, making them easier and less costly to install. Outperform Thermoplastic Polyolefins Improved resistance to oxidative aging Higher strength at elevated temperatures Better chemical and chlorine resistance Higher heat resistance Improved low-temperature impact strength Superior resistance to crack propagation Better abrasion resistance Special grades for high and very high flexibility Over the past 30 years, this unique combination of properties has allowed Polidan PEX to successfully replace metal in piping materials used in pressurized hot water plumbing systems, service lines and hydronic radiant heating systems. Special grades of Polidan PEX have been especially designed to substitute EPDM, silicone or PVC in pressure braided flexible hoses or shower low pressure hoses. Polidan PEX compounds are globally approved for use with hot potable water and are certified by KTW, NSF and WRc. 14 \ High-Performance Polymers for Plumbing

15 Polidan PEX for plumbing Density MFR190/5 Grade ASTM D 792, g/cm 3 ISO 1133, g/10 min Melt Process T/A-HF Extrusion T/A-LX Extrusion T/A Extrusion T/A-SP Extrusion TUX Extrusion & injection molding T/A-LV Extrusion SI Injection molding PNT 0553/ Extrusion PNT 0856/ Extrusion PNT 0555/ Extrusion Creep behavior at 80 C 6 5 Stress [ MPa ] Strain [ % ] Polidan PEX 10 hours 100 hours 1,000 hours High-density polyethylene 10 hours 100 hours 1,000 hours Long-term hydrostatic pressure tests Temperature [ C] Conditioning Medium ISO Standard Requirements for PEX Pipes Hydrostatic Stress [MPa] Time of Stress [Hours] Hydrostatic Stress [MPa] Performance of Pipes Made from Polidan PEX Time of Stress [Hours] 20 Air or water > 1, Air or water > 19, Air or water 4.4 1, > 40, Air 2.5 8, > 16,000 Pipes made from Polidan PEX perform at a slightly higher level than the standard specified in ISO for PEX pipe used in hot and cold water piping systems. All data on Polidan PEXb grades are obtained on material in combination with 5 % of the corresponding catalyst. High-Performance Polymers for Plumbing / 15

16 Specialty Polymers Worldwide Headquarters Viale Lombardia, Bollate (MI), Italy Americas Headquarters 4500 McGinnis Ferry Road Alpharetta, GA 30005, USA Asia Headquarters Building 7, No, 899, Zuchongzhi Road Zhangjiang Hi-Tech Park Shanghai, , China Safety Data Sheets (SDS) are available by ing us or contacting your sales representative. Always consult the appropriate SDS before using any of our products. Neither Solvay Specialty Polymers nor any of its affiliates makes any warranty, express or implied, including merchantability or fitness for use, or accepts any liability in connection with this product, related information or its use. Some applications of which Solvay s products may be proposed to be used are regulated or restricted by applicable laws and regulations or by national or international standards and in some cases by Solvay s recommendation, including applications of food/feed, water treatment, medical, pharmaceuticals, and personal care. Only products designated as part of the Solviva family of biomaterials may be considered as candidates for use in implantable medical devices. The user alone must finally determine suitability of any information or products for any contemplated use in compliance with applicable law, the manner of use and whether any patents are infringed. The information and the products are for use by technically skilled persons at their own discretion and risk and does not relate to the use of this product in combination with any other substance or any other process. This is not a license under any patent or other proprietary right. All trademarks and registered trademarks are property of the companies that comprise the Solvay Group or their respective owners. 2015, Solvay Specialty Polymers. All rights reserved. D 02/2009 R 05/2015 Version 3.0 Brochure design by ahlersheinel.com