PIPES & FITTINGS
Designing out installation risk in water supply systems
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Water leaks in buildings are often seen as a long-term operational issue, but many stem from decisions made much earlier in the project lifecycle. Here, Steve Bamforth, UK strategic project director at Polypipe Building Services, explains how poor installation can cause leakage and how innovative product design can play a crucial role in reducing risk before a water supply system is even in use
lthough there has been some success in reducing leakage levels in recent years, the volume of water lost through supply systems remains significant.
Government data shows that around 20% of water supply is lost through leaks – a figure that underscores the importance of tackling faults at installation rather than post-commissioning. Leaks create significant costs for contractors in terms of repair work, reputational impact and delays to project timelines. They can also result in higher water bills and frequent maintenance, increasing a building’s operational costs, which are then passed onto occupants. While ageing infrastructure is a key cause of leaks in water supply systems, errors during installation can create several pressure points and significantly increase the risk of disruption, damage and cost.
Pressure points
A key pressure on the quality and robustness of supply systems is the industry-wide shortage of skilled labour which, together with the drive to reduce project timescales, can lead to hurried and faulty installation. Incorrectly connected pipework is one of the most common problems. Joints that haven’t been fully soldered can create faults through which water can seep over time. Similarly, if a threaded joint hasn’t been tightened to the correct torque, it’s likely to loosen, leading to a costly and inconvenient leak.
Poor alignment or inadequately supported joints can also create stress points. Over time, this can cause joints to sag and ultimately crack or break. Ensuring the connection at the joint is correct is essential to the system’s ability to effectively accommodate thermal expansion and contraction. A weak or unstable connection is less able to deal with material changes caused by temperature variations, while fluctuations in water pressure can exacerbate these weaknesses which then result in bursts or leaks.
Using incompatible materials for system joints, such as connecting metal pipes with plastic fittings, can also compromise system integrity. Variances in expansion rates, corrosion, or chemical reactions can all lead to vulnerabilities and leakage across the water supply system. Aside from structural concerns, sub-standard water system installation can also lead to health and safety risks. Water leaks can cause damp, mould growth and structural damage, posing risks to both the building and its occupants. Moreover, hidden leaks, resulting from obscured installation problems, can go undetected for months or even years, steadily causing damage and developing health risks for those living or working in the building. All of this reinforces the need for installation- friendly systems that reduce the scope for human error and support consistent quality on-site.
Engineering out the risk
Manufacturers like Polypipe Building Services have a crucial role to play in helping contractors mitigate installation risk and should take the lead through innovative product design that limits the problems commonly associated with supply system installation. A key example is the integration of a ‘leak before press’ function in press-fit supply systems. This type of feature is becoming increasingly common and has been adopted by several manufacturers to ensure the integrity and reliability of installations. This function enables installers to identify potential leaks before a system is fully commissioned, ensuring that any faults are detected and rectified during installation.
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Some manufacturers have also incorporated visual inspection windows into pipe fittings to enable installers to see inside the joint being pressed and check that the pipe is correctly located. A clear view of what’s going on inside the fitting reduces the risk of misalignment and ensures that the pipe is properly inserted before the joint is pressed. In addition, there are bespoke tools to
improve installation practices and eliminate issues associated with poor fitting. For example, custom deburring tools allow installers to achieve a smooth, burr-free pipe-end after cutting. This is essential for correct fitting and
leak prevention and is a relatively cost-effective way to improve installation. Similarly, pressure test plugs that screw into pipe ends allow installers to pressure-test sections of the system before the full assembly is complete. With installation quality under pressure from labour shortages and fast-track schedules, manufacturers have an opportunity to step up. By designing products that make fault-free installation easier, they can support better on- site outcomes, reduce risk and help contractors deliver systems that last. To find out more about the MecFlow Supply System range:
https://www.polypipe.com/mecflow
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