KITEC PIPING Failure And Solutions
Kitec Piping: The Ticking Time Bomb in Your Plumbing System
In the late 1990s and early 2000s, a new type of plumbing system called Kitec gained popularity in homes and buildings across North America. Marketed as a cost-effective and easy-to-install alternative to traditional copper piping, Kitec was widely used in new construction and renovations. However, as the years passed, the inherent flaws in the Kitec system became increasingly apparent, leading to a massive settlement and growing concerns among homeowners and property managers.
The Rise of Kitec Piping
Kitec piping, manufactured by IPEX Inc., was introduced to the North American market in the mid-1990s. The system consisted of flexible, cross-linked polyethylene (PEX) pipes with aluminum layers for added strength and shape retention. These pipes were connected using brass fittings, which were crimped onto the pipe ends to create a watertight seal.
The Kitec plumbing system was marketed as a more affordable and user-friendly alternative to copper piping, boasting features such as flexibility, resistance to freeze-breakage, and faster installation times. These purported benefits made Kitec an attractive choice for builders and contractors looking to streamline their plumbing installations and reduce costs.
Widespread Use and Growing Concerns
Between 1995 and 2007, Kitec piping was installed in an estimated 292,000 homes and buildings across the United States and Canada. The system was particularly popular in regions with colder climates, where its resistance to freeze-breakage was seen as a significant advantage over copper piping.
However, as early as 2005, reports of failures and leaks in Kitec systems began to surface. Homeowners and property managers discovered that the pipes and fittings were prone to premature deterioration, leading to sudden and severe water damage. By 2007, the manufacturer had ceased production of Kitec piping due to mounting concerns over its reliability and safety.
The Kitec Plumbing System Settlement
In 2011, a class action lawsuit was filed against IPEX Inc. and its related entities on behalf of homeowners who had experienced damage due to Kitec plumbing system failures. The lawsuit alleged that the manufacturers were aware of the inherent defects in the Kitec system but failed to adequately warn consumers or recall the products.
In 2013, a settlement was reached in the Kitec class action lawsuit. The settlement established a $125 million fund to compensate affected homeowners for damages related to Kitec pipe failures and to cover the costs of replacing the defective plumbing systems. The deadline for filing claims under the settlement was January 9, 2020.
Understanding the Failure of Kitec Piping
Several factors contribute to the premature failure of Kitec piping systems:
· Galvanic Corrosion: One of the primary causes of Kitec failure is galvanic corrosion, which occurs when the aluminum layer of the pipe comes into contact with the brass fittings. The interaction between these dissimilar metals creates an electrochemical reaction that accelerates corrosion, weakening the joints and leading to leaks and ruptures.
· Zinc Leaching: The brass fittings used in Kitec systems contain high levels of zinc, which can leach out over time due to prolonged exposure to water. As the zinc leaches out, the fittings become brittle and prone to cracking, further compromising the integrity of the plumbing system.
· Installation Handling: The third failure method relates to handling during installation. If the pipe is ever kinked by bending into a tight radius or crushed by weight, the aluminum layer will tear or perforate, and eventually penetrate the inner or outer layer of PEX – or both. Also, the aluminum layer is slightly overlapped to form the circumference, and this overlapped area has been observed to separate repeatedly. Such perforations, tears, and overlap separations can lead to leaks behind walls, in ceilings, concrete hydronic heated floors, heated driveways, and sidewalk slabs, causing damage to foundations and caissons.
· Pressure and Temperature Fluctuations: Kitec piping is less resilient to extreme pressure and temperature changes compared to copper piping. Sudden fluctuations in water pressure or exposure to high temperatures can strain the pipes and fittings, increasing the risk of leaks and ruptures.
Galvanic Corrosion in Kitec Piping
This image illustrates the point of contact between the aluminum layer in Kitec piping and the brass fittings. This interaction between dissimilar metals can lead to galvanic corrosion. See table below.
Zinc Leaching in Kitec Fittings
This image demonstrates the process of zinc leaching in the brass fittings used in Kitec plumbing systems.
Installation Handling Failures in Kitec Piping
This image shows the consequences of improper handling during Kitec pipe installation. Kinking, crushing, or separating the overlapped aluminum layer can cause perforations, tears, and leaks in the PEX material.
Galvanic Corrosion Table
When two dissimilar metals are in contact with each other in the presence of an electrolyte (such as water), galvanic corrosion can occur. The metal higher on the galvanic series (more noble) will act as the cathode, while the metal lower on the series (less noble) will act as the anode and corrode preferentially.
In the galvanic corrosion chart, the metals are arranged vertically according to their nobility. The further apart two metals are on the chart, the greater the difference in their nobility and consequently, the higher the risk of galvanic corrosion when these metals are coupled together. For example, if magnesium (at the bottom of the chart) is in contact with platinum (at the top of the chart), there will be a significant risk of corrosion for the magnesium, as it is much less noble than platinum.
To minimize the risk of galvanic corrosion, it is best to choose metals that are close together on the galvanic series when designing systems where dissimilar metals may come into contact with each other.
Identifying Kitec Piping in Your Home or Building
If you suspect that your home or building may contain Kitec piping, it is crucial to identify and address the issue promptly. Here are some key characteristics to look for:
· Pipe Markings: Kitec pipes are typically marked with the brand name “KITEC” or “IPEX” along with the pipe size and pressure rating. These markings may be printed directly on the pipe or on a label wrapped around the pipe.
· Pipe Color: Kitec pipes are usually orange or blue in color, with an aluminum layer sandwiched between the inner and outer layers of PEX material.
· Fitting Appearance: Kitec fittings are made of brass and are often stamped with “Kitec” or codes such as “NSF-PW.” The fittings are connected to the pipes using a crimping method, which leaves a distinctive hexagonal or round crimp pattern on the pipe end.
Identifying Kitec: Labelling
Identifying Kitec: Brass Fittings
If you are unsure whether your plumbing system contains Kitec piping, it is advisable to consult with a licensed plumber or home inspector who can assess your system and provide guidance on the best course of action.
Case Studies: The Failure and Ramifications of Kitec Piping
Case Study 1: Dezincification and Corrosion Issues – In numerous homes, particularly those in Nevada. Kitec piping experienced failures due to high acidity in the water. The brass fittings, containing high amounts of zinc, underwent dezincification where zinc leached out weakening the joints and causing leaks. This problem was not limited to the fittings but also affected the pipes themselves. The interaction between the aluminum layer and zinc from the fittings caused corrosion, leading to clogging and bursting of the pipes. These failures were widespread and led to substantial property damage.
Case Study 2: Accelerated Pipe Deterioration – In areas with high water temperatures, Kitec pipes showed accelerated deterioration. The pipes were prone to bursting, especially when exposed to hot chlorinated water, exceeding their design limits. The brass fittings’ high zinc content exacerbated the issue, causing blockages and pipe failures. This systemic problem led to numerous incidents of flooding and significant repair costs. The failures typically began within 8-10 years of installation and increased in frequency over time.
Case Study 3: Legal Actions and Settlements – The widespread issues with Kitec piping led to multiple class action lawsuits in both the United States and Canada. Homeowners reported significant damage due to pipe bursts and leaks. The lawsuits claimed that the manufacturer, IPEX, failed to warn about the pipes’ susceptibility to failure. In 2011, a $125 million settlement was reached to compensate affected homeowners. The settlement covered repairs and replacements of the defective piping systems.
The Importance of Replacing Kitec Piping
Given the well-documented risks associated with Kitec piping, it is essential for homeowners and property managers to take proactive steps to address the issue. If you have confirmed the presence of Kitec in your home or building, consider the following:
· Professional Assessment: Hire a licensed plumber to evaluate the condition of your Kitec system and recommend a replacement plan. In some cases, a complete re-pipe may be necessary to ensure the long-term reliability and safety of your plumbing.
· Timely Replacement: Prioritize the replacement of your Kitec piping to minimize the risk of leaks, water damage, and potential health hazards. Delaying the replacement process can lead to more extensive and costly repairs down the line.
· Insurance Considerations: Contact your insurance provider to discuss coverage for Kitec-related damages and determine if any additional riders or endorsements are necessary to protect your investment.
· Disclosure to Buyers or Tenants: If you are selling a property with Kitec piping, or if you are a landlord with affected units, it is crucial to disclose the presence of the defective plumbing system and any plans for remediation. Failure to disclose this information could result in legal liability.
By addressing the issue of Kitec piping proactively, homeowners and property managers can safeguard their investments, prevent costly water damage, and ensure the safety and well-being of those who live or work in the affected buildings.
Lessons Learned from Kitec
The Kitec piping debacle serves as a sobering reminder of the importance of thorough testing, monitoring, and accountability in the building materials industry. While the promise of cost savings and ease of installation may have driven the initial adoption of Kitec, the long-term consequences have been devastating for countless homeowners and property managers.
As we look to the future, it is crucial that we prioritize the use of proven, reliable materials in our plumbing systems and hold manufacturers accountable for the safety and durability of their products. By staying informed about potential risks, working with qualified professionals, and advocating for stronger industry standards, we can help prevent similar issues from arising and protect the integrity of our homes and buildings.
If you have Kitec piping in your property, remember that you are not alone. With the right knowledge, resources, and support, you can navigate this challenge and ensure the long-term safety and value of your investment. Do not hesitate to seek professional guidance and take action to replace your defective plumbing system – your peace of mind and the well-being of those who depend on your property are well worth the effort.
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