INVESTIGATIVE REPORT OF COPPER PLUMBING FAILURES UNDER CONCRETE SLABS

Prepared for National Association of Home Builders 1201 15th Street, N.W. Washington, D.C. 20005-2800

by

NAHB Research Center 400 Prince Georges Boulevard Upper Marlboro, Maryland 20772

August 1992

TABLE OF CONTENTS PAGE INTRODUCTION

BACKGROUND

...............................................

1
1

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FLORIDA INSTALLATIONS ....................................... METALLURGICAL INVESTIGATION ................................ RESULTS ..................................................... RECOMMENDATIONS ........................................... APPENDIX A
Failure Analysis

3
4
4

APPENDIX B
Soil Tests

INTRODUCTION
Copper piping provides a relatively reliable material under most conditions due to the formation of a protective layer of cuprous oxide that protects it in most environments. However, a recent series of failures of underground copper water supply pipes have been reported near Miami, Florida. All of these failures involve type L copper pipe located under concrete slab-on-grade foundations in a single sub-division. All of the copper plumbing under the slab is encased in a continuous plastic sleeve as required by the state building code. The rationale for the sleeve is to protect the sub-slab copper pipe from aggressive soils, groundwater, and concrete leachate. One builder last reported failures in 20 homes, some of which incurred multiple failures. The plumber who installed the copper supply pipes indicated that a second builder is facing similar problems, although these could not be confirmed. This report contains results of a preliminary investigation of failed plumbing materials retrieved from two homes.

BACKGROUND
Reviews conducted by Waters' and by Myers and Cohen2 suggest the following mechanisms can cause copper corrosion by acting alone or in combination. Abnormally aggressive soils. This is typically due to the presence of soils with elevated sulfate or chloride levels and a capacity to retain moisture. Electrochemical concentration cells created by differences in soil composition. For example, backfill soils with a high oxygen content relative to the supporting soil can cause corrosion of the under side of a pipe.

'Waters, D.M., "Internal and E t r a Copper Corrosion in Domestic Water Services," Proceedings of AWWA xenl Annual Conference, Anaheim, CA, May 1977.

2Myers, J.R., and Cohen, A., "Conditions Contributing to Underground Copper Corrosion," Journal A W A , August 1984.
1

Stray electrical currents. One utility companys experience wt stray AC currents ih

resulting from bonding of the electrical system to the plumbing system suggest that this practice should be stopped in favor of other grounding methods3. Thermal galvanic effects. T i frequently results from contact of hot and cold metal pipes hs causing corrosion of the hot water pipe. Galvanic action due to contact of dissimilar metals. Corrosion fatigue caused by thermal expansion and contraction. This rare type of failure usually occurs with flared joints or where copper passes through a concrete slab.

A review of technical journals and other literature revealed only a few reported incidences of
copper failures in residential building4,5. This may be due to coppers satisfactory performance under most conditions. One study4 conducted for the Washington (DC) Suburban Sanitary Commission indicated an unusual failure mechanism in underground copper pipe. In this situation, one-inch copper pipe had been installed for the water service to homes. The copper was sleeved at sections where it approaches or crosses a sanitary sewer using two-inch or three-inch corrugated plastic drain pipe.
An analysis of three failed water supply pipes showed a series of uniformly spaced cavities. The

spacings of the cavities matched that of the corrugationsin the sleeve. The reports author, based on electron microscope examination results, suggested that a number of corrosion mechanisms were operating. However, it was apparent that the primary mechanism involved small vibrations

in the copper pipe that continually destroyed the protective cuprous oxide cover at each point of

3Guerrera, A.A., Groundingof Electric Circuits to Water Services:One Uiiy Companys Experience,Journal tlt AWWA, February 1980. DeRonja, F.S., Investigation of Failed Copper Water Service Lines, for Washington Suburban Sanitary Commission, April 1990, (unpublished).

a e s . . and 5Woodside, R.D., W t r ,F O , Cornet, I., Corrosion and Other ProbIems in Copper Tubing in Some rcs Southern California Housing T a t , Proceedings of the Third International Congress on Metallic Corrosion, Moscow, 1969.
2

contact with a corrugation. This created a situation where other mechanisms, most likely aggressive water, quickly corroded the copper pipe.

FLORIDA INSTALLATIONS
The plumbing installations were similar in each of the homes under investigation in Florida. All of the homes are built on concrete slab-on-grade foundations. A polybutylene water service runs from the public supply up to the foundation. All of the remaining water supply plumbing is copper. Sub-slab water supply pipes are type L copper enclosed in a continuous plastic sleeve. There are no joints in the sleeve below the slab. The sleeve terminates just above the floor slab. The joint between the sleeve and copper is typically caulked at some point during construction with a commercial caulking compound. Because the fit between the 3/4-inch I D sleeve and the 1/2-inch copper is tight, the copper is .. frequently lubricated prior to sliding it through the sleeve. Dishwashing liquids and other commercially available soaps are used as the lubricants, although specific soaps were 'not identified.

METALLURGICAL INVESTIGATION
Research Center staff did not have the opportunity to observe any of the failures directly since they were repaired as soon as they were detected. None-the-less, two samples of failed pipe retained by the builder were obtained and analyzed for possible causes of failure. The first set of samples was forwarded to the Copper Development Association (CDA) in Greenwich, Connecticut. The second set was analyzed by Forensic Metallurgy Associates

(FMA), a private forensics service in Springfield, Virginia. Follow-up tests were conducted by

FMA on three soil samples taken from the area near the reported failures: one sample of fill
material that is used to surround the sub-slab plumbing, and two samples of native soil. Results of each analysis are included in the Appendix.

RESULTS
Results of the independent laboratory investigations were similar. Both concluded that the corrosion was due to contact between the copper pipe and an aggressive solution, possibly containing chloride and sulfate ions. Potential sources of the water for the solution include groundwater or surface water that entered the sleeve during construction or condensate that accumulated after construction. Soil test results indicated that all three samples had a pH of 8.1 and contained carbonate minerals. The presence of moisture, an alkaline pH, and carbonate minerals will cause corrosion

of copper. Sulfate and chloride ions in solution can also cause corrosion of copper. However,
neither of these were present in appreciable amounts in the soil.

RECOMMENDATIONS
It is apparent that the protective sleeve serves as a collection point for water that combines with aggressive minerals in the soils, leading to corrosion that creates a failure in the copper. Where local experience indicates that a sleeve is necessary with copper pipes, it may be appropriate to use an alternative pipe material or to install the sleeve with the following recommendations: The sleeve should be one continuous section. Joints should be avoided, but if used, they should be watertight. The sleeve should be capped at its ends until the copper is installed to prevent water from entering during construction. Flexible couplings or caulking may be used to close the gap between the copper and the sleeve. The sleeve and copper should be free of soil particles and other foreign substances that could combine with condensate or moisture from other sources and attack the copper.

Further investigation should be considered to identify the extent of these types of failures and to collect additional data that could more firmly support these recommendations. Additional investigation should also address whether the benefits of sleeving the copper outweigh the potential problems the sleeve may cause. For example, in well-drained soils, it may be possible to install the sub-slab copper directly in the soil.

APPENDIX A Failure Analysis

COPPER TUBE/FITTING SPECIMEN MULTICON SOUTHEAST, INC. DAVIE, FLORIDA

COPPER WATER TUBE/FITTING SPECIMEN MULTICON SOUTHEAST, INC. DAVIE, FLORIDA

Background In August 1991, Mr. A.G. Kireta, Regional Manager for the Copper Development Association (CDA) in the eastern states submitted a copper water tube/fitting specimen to the CDA office in Greenwich, Connecticut for laboratory examination. The specimen consisted of a 29.1-inch length of 0.5-inch diameter (nominal size) Type L copper water tube with a copper coupling soldered to one end which was, in turn, soldered to a 197.5-inch length of Type L capper water tube. It had been removed from a domestic water line, under-the-slab, at an unidentified residence constructed by Multicon Southeast, Inc., Davie, Florida. According to the information furnished, the specimen was representative of other, under-the-slab, tubes which had developed leaks in time periods ranging from six months to four years. It was also reported that all of the leaking copper tube/fitting sections had been located inside polyethylene tubes/sleeves (i.e., in accordance with state codes). Results Examination of the outside surface of the specimen revealed several areas of severe pitting attack (e.g.,see the encircled areas in Figure 1). The corrosion-induced pits contained porous reddish-brown cuprous oxide (Cu2O)which was typically overlaid with some green colored copper corrosion products (Figure 2). Stereomicroscopic examination revealed that one of the corrosioninduced pits had propagated through the tube wall (i.e., see encircled area on the third tube section from the top in Figure 1). It was clearly evident that the nearly-microscopic pinholetype perforation had initiated on the outside surface of the tube. Energy dispersive spectroscopy (EDS) and microchemical analysis (MCA) revealed that the green colored copper corrosion products associatedwith the pitting attack contained major quantities of copper, minor amounts of chloride and sulfur (as sulfate), semiminor quantities of calcium and trace amounts of silicon. The green colored copper corrosion products consisted primarily of copper chloride(s) and copper sulfate.

Figure 1

SECTIONS SHOWING THE REPRESENTATIVE OUTSIDE SURFACE OF THE UNDER-THE-SLAB COPPER WATER TUBE/FITTING SPECIMEN FROM DAVIE, FLORIDA

Several areas of localized pitting attack existed on the outside surface (e.g., see encircled areas). One of these corrosion-induced pits had propagated through the tube wall (i.e., see encircled area on the third tube section from the top)

(Magnification:

0.6X)

Where pitting attack had not taken place on t h e o u t s i d e surface, there was no significant deterioration by the external environment. Basically, the copper in these essentiallyunaffected areas was covered with a protective tarnish film of reddish-browncuprous oxide. At: several locations, the cuprous oxide was overlaid with a thin friable layer of somewhat looselyadherent green colored copper corrosion products (e.g., see the second tube section from the top in Figure 1) which appeared to have been deposited on the outside surface by the evaporation of water which had been transported from pit sites. The total specimen was subsequently sectioned lengthwise in order to examine the inside surface. Examination of the inside surface revealed no significant deterioration by the water conveyed. In general, the inside surfaces of the tubes and fitting were covered with a protective tarnish film of reddish-brown cuprous oxide. Although some green colored copper corrosion products existed on the waterside surface, no major pitting attack had occurred to the underlying copper. It was clearly evident that these longitudinallyoriented corrosion products were soldering flux-related. For example, green colored copper corrosion products were observed to be associated with an 11-inch long sticky petrolatum-base soldering flux-run which existed at one location on the inside surface. Where pitting attack had not taken place on the outside surface, micrometer caliper measurements revealed that the tubes on the specimen still satisfied the wall thickness requirements of American Society for Testing and Materials (ASTM) Standard Specification B88 for Seamless Copper Water Tube. The wall thicknesses varied between 0.036 and 0.037-inch which is typical for 0.5-inch diameter Type L copper water tube. Similarly, the coupling still satisfied the wall thickness requirements of American National Standard ANSI B16.22-1980 for Wrought Copper and Copper Alloy Solder Joint Pressure Fittings. Based upon examination of the specimen submitted for laboratory investigation, it can be concluded that the cause of the pinholetype perforation through the tube wall was corrosion-induced pitting attack which had initiated on the outside surface. Although some soldering flux-initiated corrosion had taken place, there was no significant deterioration on the waterside.

Figure 2

HIGHER MAGNIFICATION VIEW SHOWING REPRESENTATIVE CORROSION-INDUCED PIT SITES ON THE OUTSIDE SURFACE OF THE SLEEVED SPECIMEN FROM DAVIE, FLORIDA

The corrosion-induced pits on the outside surface contained porous reddish-brown cuprous oxide which was typically overlaid with some green colored copper corrosion products.

(Magnification:

2X)

Conclusions
The only viable explanation for the external corrosion was localized areas of moisture/water w h i c h had collected and concentrated inside the polyethylene tube/sleeve. The source of the water was possibly groundwater which had seeped. into the nonmetallic tube. Alternatively, the polyethylene tube may have collected water during construction of the residence. Regardless of the source of the water, aggressive chloride and sulfate ions in the aqueous environment initiated and supported the pitting attack. The source of the chloride ions could have been the groundwater. Alternatively, their source could have been the concrete used to form the slab. Most likely, the source of the sulfate ions was the groundwater.

Recommendations When non-metallic sleeves/tubes must be placed around copper (or other metallic) tubes/fittings, the installation practice must preclude the ingress of moisture/water. For example, the ends of tubes must be appropriately sealed. The tubes/sleeves must also be free of moisture/water when the copper tubes/fittings are inserted. Preferably, copper water tubes/fittings should be placed in underground environments without tubes/sleeves because the use of these shielding devices precludes the use of cathodic protection for corrosion mitigation in those very-rare instances where the soil/groundwater is aggressive to copper. Additional information on the underground corrosion of copper and the cathodic protection technique for mitigating this deterioration is presented in the paper "Conditions Contributing to Underground Copper Corrosion." A copy of this paper is included 'in the Appendix. September 18, 1991 JRM/AC/jm
157/1

METALLURGY ASSOClATES
7503 Maritime Lane

FORENSIC

Springfield, VA 22153
p -

(703)455-4446

INVESTIGATION OF A FAILED COPPER WATER SUPPLY LINE

Prepared for

NAHB National Research Center 400 Prince George's Boulevard Upper Marlboro, MD 20772-8731

by Frank S. DeRonja

April 30, 1992

FMA File No. 203251

Backaround: A copper water supply line under a residential foundation in Davie, Florida, failed as a result of perforation of the copper tube wall after about three years of service. The copper line had been installed within a protective plastic tube sleeve that passed through and underneath the concrete foundation slab. Sections from the failed supply line and a sample of the type of sleeve material used in the installation were furnished to Forensic Metallurgy Associates to identify the possible cause(s) of the copper tube failure. Figure 1 shows a general view of the samples that were received for study.

Specimens Examined:
Q1: Section of failed copper water supply line containing a perforated

wall.
Q2: Section of failed copper water supply line exhibiting corrosion damage.

K1: Sample of plastic tube sleeve.

Examination Results and Observations: Measurements of Specimens Q1 and Q2 revealed that the copper tube satisfies the wall thickness requirements of the American Society for Testing and Materials (ASTM) Standard Specification B88 for 1/2-inch diameter, Type L, seamless copper water tube. Compositional analysis by energy-dispersive x-ray spectrometry (EDS) disclosed that the tube composition is consistent with that set forth in the B88 Standard. Microscopic examinations of Specimens Q1 and Q2 revealed that the external surface lacks a continuous film of protective cuprous oxide (Cu2O) and displays areas of pitting corrosion. One of the corrosion pits on specimen Q1 had completely penetrated the tube wall and formed a pinhole. The inside surface of the specimens is covered with protective cuprous oxide andshows no significant deterioration from the internal environment. Figures 2 and 3 show views of the corrosion-damaged external surface. The location and pattern of the corrosion attack indicate that portions of the copper supply line had been in contact with a liquid. Aqueous solutions containing high contents of oxidizing acids, aerated non-oxidizing acids, ammonia compounds from fertilizer, or oxidizing salts are most destructive to copper because they prevent the formation of or dissolve the protective cuprous oxide film. Pitting is the usual form of 1

corrosive attack of copper when the protective cuprous oxide film has not completely formed or has been dissolved or has been exposed to extraneous surface deposits o f dirt or other foreign substances. Specimens Q1 and Q2 were washed with distilled water to remove superficial surface deposits and then examined with a scanning electron microscope (SEM). Figure 4 shows views of the pinhole failure and a nearby pit on Specimen Q1. Compositional analyses by EDS revealed the pitted areas on both specimens contain chlorine and elements consistent with the presence of sulfate and clay constituents. This indicates that the copper water supply tube was in contact with ground water/soil that had entered the plastic tube protection sleeve. Wet soils and f water with high concentrations o chloride and sulfate ions can be extremely corrosive to copper metal, particularly where the water is entrapped and stagnated. Typical EDS analysis spectra for the compositions of the surface deposits on the specimens are shown in Figures 5 through 7. The microstructure of Specimen Q1 was examined in the pitted area near the pinhole. Figure 8 shows where the metallographic sample was removed from the specimen and Figure 9 shows views of the microstructure. The examination revealed that the corrosion pitting was not related to deficiency in the copper metal material or to stress corrosion cracking of the copper. Examination of the K1 3/4" plastic sleeve revealed that it is an olefin plastic and as such contains no reactive chemical constituents that could be detrimental to copper in physical contact with it.

Conclusions: Based on the above results and observations, the copper water supply line failed prematurely because of external pitting corrosion. The pitting was caused by exposure of the copper tube to highly corrosive water/silt that had entered the plastic tube protection sleeve. Any soap-type lubricant that may have been used to facilitate insertion of the copper tube into the sleeve was probably not a factor in the pitting corrosion. With respect to other types of substances or liquids that may have been used as a "lubricant" or that may have been applied during termite or rodent control, a knowledge of specific ingredients in the substance is necessary to determine if that substance could have been a contributing factor to the pitting corrosion.

Recommendations for Eliminating the Corrosion Problem: Based on the examination results, corrosive water/silt was present within the plastic sleeve and provided the environment for corrosion of the copper tube within the sleeve. Therefore, it appears that the corrosion problem can be eliminated by taking precautions that will prevent the entry of liquids and solids into the plastic tube protection sleeve. The following precautions are recommended:
1) Use a larger diameter sleeving tube so as to eliminate or minimize the need

for a lubricant during insertion of the copper tube into the sleeve. This will ensure that a lubricating substance that might affect the corrosion behavior of the copper tube or might be detrimental to the plastic sleeve is not introduced into the system.
2) Protect the sleeve from accidental entry of soil during installation by capping the sleeve ends.
3)

If sleeve sections must be joined, make the connection with watertight

couplings.
4) Keep the sleeve ends capped until the copper tube is inserted into the sleeve. 5) After insertion of the copper tube into the sleeve, seal the sleeve at each end with a Fernco-type flexible coupling to prevent entry of ground water, rain water or moisture, Ifflexible couplings are not available, seal the ends with an adequate amount of elastic caulking sealant.

6) During replacement of any failed water supply lines, ensure that the sleeve is watertight and that no water is present within the sleeve before insertion of the new replacement copper tube.

Recommendations for Additional Technical Investigation: The conclusions and recommendations derived from the above study should only be considered tentative since the study was based on limited availability of information and samples relating to one water supply line failure. It would be desirable to study another similar type of copper tube failure in the Davie, Florida region to ensure that all logical corrosion variables have been adequately considered. Such a study should begin before repairs are made to the failed supply line and should include the following:

1)

Field 'Inspection and Specimen Selection for Laboratory Analysis

a) Examination of the water suppiy line installation, including testing of the integrity of the plastic protection sleeve and measurements of any electrical ground current flow.
b) Evaluation of the water line failure relative to the location of nearby structures and environmental conditions. c) Selection of appropriate specimens from the failed copper tube, plastic sleeve, subsurface water, subsurface soil, backfill material and concrete foundation slab.

2)

Laboratory Examination and Analysis a) SEM and EDS of the failed copper tube to identify corrosion features and corrosion product residues. b) Microstructural examination of the copper tube metal. c) Analysis of subsurface water, subsurface soil, backfill, and concrete slab to identify specific corrosive substances. d) Compositional analysis of the plastic-tube sleeve material.

Figure 1. General view of samples, as received condition.

Figure 2. Close-up views of Specimen Q1. Bottom photo shows pitting corrosion and the pinhole failure (arrow).
6

Figure 3. Close-up views of Specimen Q2. Bottom photo shows pitting corrosion on the external surface.

Figure 4. SEM views of Specimen Q1. The top photo shows the pinhole as viewed from the external surface; the bottom photo shows a corrosion pit near the pinhole.
8

EG&G O r t e c System 5000 Spectrum P l o t t i n g Program Printplot VOZ.05

Sample ID: Copper line w i t h p i n h o l e , i n hole

Energy Range: 0 Preset:

20 keV 1 0 eV/ch H i Res

100 Sec. Seconds

L i v e Time

Real T i m e : 309.52
60% Deadtime

L i v e Time:

100.00

Sec.

30307 Counts/Second
Acquisition

Acquisition d a t e : 09-Apr-91

t ime : 09:30:00

EG&G O r t e c S y s t e m 5000 Spectrum P l o t t i n g P r o g r a m

Printplot V02.05

Sample IC: Copper line w i t h pin h o l e , blocky solid

Energy Range: 0

20 keV 10 eV/ch Hi Res

100
Sec.

Preset: Live T i m e
Real T i m e :
1041.06

Seconds Live Time:

100.00

Sec.

81% Deadtime

40794 Counts/Second

Acquisition d a t e : 04-Apr-91

Acquisition time: 09:45:18

EG&G Ortec System 5000 Spectrum Plotting Program Printplot V O Z . 0 5

Sample ID: Copper line no hole, pre-hole a r e a

Energy Range:

20 kev 10 eV/ch Hi Res

100
Sec.

Preset: L i v e Time

Seconds Live Time: 100.00

Sec.

Heal T i m e : 325.70
69% Deadtime
Acquisition date:

27955 Counts/Second
09-Apr-91

Acquisition time: 11:02:50

Figure 8. Views of Specimen Q1 after removal of the metallographic sample. The arrows designate t h e pinhole failure.

Figure 9. Microstructure o Specimen Q1 at a corrosion f pit near the pinhole failure,

APPENDIX B

Soil Tests

METALLURGY ASSOCIATES
7503 Maritime Lane
Springfield, VA 22753
(703)455-4446

FORENSIC

INVESTIGATION OF A FAILED COPPER WATER SUPPLY LINE

Prepared for
NAHB National Research Center 400 Prince Georges Boulevard Upper Marlboro, MD 20772-8731

by Frank S. DeRonja July 22, 1992

FMA File No. 203251

Backaround:
A water supply line under a residential foundation in Davie, Florida, failed shortly after installation as a result of perforation of the copper tube wall. The failed line had been sleeved with a protective plastic tube that passed through and underneath the concrete foundation slab. Forensic Metallurgy Associates conducted laboratory examinations and tests on samples of the failed line and reported those findings in a previously submitted report dated April 30, 1992.

The technical investigation was subsequently expanded to include analyses of typical soils in the construction area. This report summarizes the results of the soil analyses.

Specimens Analyzed:
K2: Sample of soil, labeled "#1 Fill"
K3: Sample of soil, labeled "#2 Native"

K4: Sample of soil, labeled "#3 Native,

Hawke's Bluff, Lot 2, Block 13"

Examination Results and Observations: The K2 through K4 soil samples were evaluated to determine their potential for causing corrosion of copper water pipe. Measurements were made of the conductance of a water extract of each soil (a measure of the amount of soluble salts present in the soil), the pH of the water extract, and the neutralization equivalent relative to pH 7.0. Water extracts of the soils were also analyzed for the presence of chloride and sulfate ions.

All three soil samples were found to have a pH of 8.1. This pH was well buffered in the presence of excess soil; it fell rapidly to 7 when the soil was removed from the liquid by filtration. The presence of carbonate minerals in the soils was confirmed by the generation of carbon dioxide gas when the samples were treated with acid. No appreciable amounts of either chloride or sulfate were found in any of the three extracts. The results of electrical conductance measurements and the neutralization equivalent determinations are presented in Table 1.
The combination of an alkaline pH and carbonate minerals in moist soil will cause corrosion of copper metal in contact with the soil. Copper metal etches slowly in an
1

Specimen
K2 (fill) K3 (native)

Conductivity
108 mmoh

Neutralization Equivalent (total alkalinity to pH 7.0) 732.3 mg CaC03 per kg soil

1077.5

118 mmohs
114 mmohs

K4 (native)

1007.5