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Well... we gotta leak.

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Tom_133
Tom_133 Member Posts: 984

Sooo, I installed a 4" copper main on a very large building, and because I had a minor lapse in judgement I decided to solder it. No need to say it, I wont do it again. Next time it will be press, or victaulic, or welded, but not soldering over 3" ever again. It's not that we are not capable, just read on.

I pressure tested it and it held the 100lbs like a champ. Then after one winter it sprang a leak. I get it, I understand it, no need to explain why it happens, or what I did wrong I am very sorry and again I wont repeat this mistake.

Now, the question is with a tight space, and 4" fittings, has anyone successfully pulled apart, cleaned, refluxed and soldered successfully? I can get it pretty dry and I wont do this until June so I got all day to repair, but want to get it right. I would be happy to get the right torch head if anyone has suggestions on that as well. Out of the 20+ joints we got one weeper, well two if you include me.

Thanks

Tom

Tom
Montpelier Vt

Comments

  • pecmsg
    pecmsg Member Posts: 7,171

    Pro Press.

    Steve Minnich
  • hot_rod
    hot_rod Member Posts: 27,695
    edited May 13

    on large sizes like that you can pre-tin the tube and fitting. Basically wiping solder around the pipe and fitting first, then assemble.

    If it is no too close to other fittings you could silver solder over the fitting.
    Blockade is a good rod for that use.

    IMG_1532.jpeg
    Bob "hot rod" Rohr
    trainer for Caleffi NA
    Living the hydronic dream
    Alan (California Radiant) Forbes
  • pumpcontrolguy
    pumpcontrolguy Member Posts: 46

    Most of our copper work is in 2-4" and we never sweat anymore unless a property specifically wants it. You need a lot of heat for 4", so we would typically do two torches at once, one on each side. There are fancy round pipe torches, but we never had those.

  • Steamhead
    Steamhead Member Posts: 18,612

    Maybe rent one of those fancy round torches?

    All Steamed Up, Inc.

    Baltimore, MD, USA
    Steam, Vapor & Hot-Water Heating Specialists
    Oil & Gas Burner Service
    Consulting

  • Mad Dog_2
    Mad Dog_2 Member Posts: 8,630

    Without re-soldering it, I would silver braze right over it. As long as you're not going to burn anything next to it, its the fastest, easiest fix here. Mad Dog

    HydronicMike
  • Mad Dog_2
    Mad Dog_2 Member Posts: 8,630
    edited May 13

    Do you have a photo of the joint and situation? What's also great about silver brazing is that you can drill a small hole at 90 degree 6 o clock position and drain any residual standing water. That hole will be the last part you will braze close. Also, you don't need a Large Rosebud tip or Oxy-Acetylene on 4" Copper. A large Turbotorch tip and a Full B Tank and youre good to go. Mad Dog

  • Tom_133
    Tom_133 Member Posts: 984

    no pics yet. But man I appreciate the help. I may just braze it up!

    Tom
    Montpelier Vt
  • Mad Dog_2
    Mad Dog_2 Member Posts: 8,630

    DM me or call if you need any tips. I've been in your shoes many times and silver-brazed up to 12" Pipe. 516-322-2881

    bjohnhy
  • pedmec
    pedmec Member Posts: 1,443

    Cut it out and propress. You wont regret it. When you get done your gonna wonder why you didn't propress it to start.

    And yes, i have taken plenty of sweat fittings apart, cleaned them, and resoldered successfully. But i wouldn't do it anymore because of propress. Propress is just to simple. The problem with large size sweat fittings is sometimes the interference fit is a little to large to hold the solder. If not properly aligned the gap is larger on one side than the other. Tinning definitely helps but its and added process the adds labor. Add that all up and a propress fitting doesn't seem that expensive anymore. Priced right and the customer is paying for it anyway.

    Good luck

  • mattmia2
    mattmia2 Member Posts: 17,177

    the cost of the solder that goes in to a joint that size isn't trivial either.

  • RascalOrnery
    RascalOrnery Member Posts: 145

    What the blazes is 4" copper used for? Water supply for the whole town?

  • mattmia2
    mattmia2 Member Posts: 17,177

    larger commercial building especially if it has a lot of bathrooms with flushometers. most of our campus buildings have 4" supply or more.

    GGross
  • Mad Dog_2
    Mad Dog_2 Member Posts: 8,630
    edited May 13

    This is a callback, correct? You're already in the Red. A 4 inch Press Tool and fittings are big bucks. If you want out of there, for the cost 3 or 4 sticks of Silver Solder and some acetylene, you can move on. Mad Dog

  • EBEBRATT-Ed
    EBEBRATT-Ed Member Posts: 20,371

    Since it lasted a year do you think you could have an expansion issue? How long of a run is it? Subjected to temperature swings?

    If you silver solder or braze it you don't have to pull it apart.

    If you propress your going to need an elbow which may be all you need if you sawzall though the 4" sweat 90 and unsweat and wipe the solder off both ends of the pipe and maybe trim some off as the PP90 is long radius.

    Thats assuming you can move the pipe that much. Otherwise you going to need a 4" coupling or two.

    I had the same situation except it was a 4" main in a insurance building that feed 2 3" lines at the end of the run.

    It was all propress. I didn't install it but I was the one that had to fix the only leak. Had to waste out 1 3" 90 and 2 3" 45s

    You or anyone can have a leak no matter what method you use.

    Victaulic is expensive especially for copper and you will find the fittings are hard to find.

  • mattmia2
    mattmia2 Member Posts: 17,177

    at 4" cast iron probably will not scale enough to restrict the flow so that is also an option.

  • mattmia2
    mattmia2 Member Posts: 17,177

    looks like propress and vitaulic are about the same price once you buy all the clamps although vitaulic is reversable.

  • Tom_133
    Tom_133 Member Posts: 984

    There are 3- 400k boilers lined up feeding a building with a 3" header, they wanted room for future indirects on it so we added the two tees on either side of the closely spaced tees. So there are not that many joints.

    I know we dont discuss pricing, so I wont get to deep into that but press isn't scaring me, I own all the tooling. The stupid insulation cost me a pretty penny and HATE the idea of paying for that again. I am going to go put my eyes on it and will probably consider brazing all the 20 joints.

    These are good customers, so it's possible they dont want a future worry, so it may get pressed and I may just do the labor for free.

    Tom
    Montpelier Vt
  • Mad Dog_2
    Mad Dog_2 Member Posts: 8,630
    edited May 14

    Tom. Have a little faith in yourself. Its highly unlikely you'll have another leak like that from your soldered joints. It would've happened already. Mad Dog

    bjohnhy
  • hot_rod
    hot_rod Member Posts: 27,695

    Oe time I had to solder over some joints on 4" copper in a year old hotel! It was the got piping and I think the expansion/ contraction caused the leaks.

    I used a rosebud tip but with oxygen/ acetylene, which heated very quickly.

    But if you have the press equipment or can borrow the large jaw fro a wholesaler, go that route and be done quickly.

    Bob "hot rod" Rohr
    trainer for Caleffi NA
    Living the hydronic dream
  • Tom_133
    Tom_133 Member Posts: 984

    Thanks again all!

    Tom
    Montpelier Vt
  • Intplm.
    Intplm. Member Posts: 3,065

    If you soldered it first, don't braze it; brazing over soldered joints can open up a whole new can of worms. So, pick your poison. Solder it where it leaks, and solder the entire joint again, or pro-press it.

    One thing I have done in the past after soldering a large joint is to take my smallest turbo torch tip and cap the joint off so it looks factory done. It can look clean and without any runs, and if done right, will show a visually smooth finished joint. One other thing, do not touch all of your other joints. They should be fine.

  • Mad Dog_2
    Mad Dog_2 Member Posts: 8,630

    Just curious? What Can of Worms 🪱 are we talking about silver-brazing over a Soft-soldered joint? Done it many times without an issue. Mad Dog

  • EBEBRATT-Ed
    EBEBRATT-Ed Member Posts: 20,371

    Yeah. I have brazed over solder joints as well with no issue

  • Steve Minnich
    Steve Minnich Member Posts: 2,883

    20 joints? There’s a sure solution and then there are less than sure solutions. If you already have the ProPress tool and the 4” jaw and it’s a good customer, I’d be pressing it every single time. Cutting the insulation carefully should avoid having to bring the insulator back. Just my .02. Brazing 4” needs a lot of heat and added risk.

    Steve Minnich
  • Intplm.
    Intplm. Member Posts: 3,065

    A can of worms, you ask? It stinks, as a can of worms does.

    Sorry, lol, if this metaphor shows my age. I also have brazed over a solder joint, but not one this large of a diameter, and not one with water in it, as this 4" pipe will surely have some residual water in it, which can surely cause a problem.

    @Tom_133 If you do not have the room to propress this repair, try soldering first. If that doesn't work propress the thing and walk away. At this point, only you can measure the difficulty in terms of time and cost. It's like what my doctor might ask. "On a scale of one to ten, how would you rate the pain?"

    I also like the comment from @Steve Minnich above.

  • Tom_133
    Tom_133 Member Posts: 984

    I can get a very high percentage of the water out. That isn't a factor for me.

    If I do the math based on Supplyhouse.com the fittings for the press will be about 3k, so thats a little rough if I can just braze a fitting or two.

    How do people feel about brazing and already soldered joint?

    Tom
    Montpelier Vt
  • Intplm.
    Intplm. Member Posts: 3,065

    Well, if you can get the water out on a large 4" fitting…go for it.

  • Mad Dog_2
    Mad Dog_2 Member Posts: 8,630

    This is how we deal with pooled water. Mad Dog

    mattmia2Intplm.GGrossPC7060
  • EBEBRATT-Ed
    EBEBRATT-Ed Member Posts: 20,371
    edited May 18

    I have braised over leaking solder joints mostly on refrigeration piping.

    If you can get that not to leak water is a piece of cake

    Also, you don't have to cook the entire joint up to temp at the same time. You start in one spot (usually at the top for me) and work your way around.

    Mad Dog_2Intplm.
  • Mad Dog_2
    Mad Dog_2 Member Posts: 8,630

    What's great about Silver-Brazing is that its so plastic in its molten state that you can bridge large gaps and holes. When you are done Silver-Brazing a joint, it is very obvious, visually, if you have a joint that is not going to leak unlike soft solder where you may have a tiny pinhole leak that is naked to the eye. Mad Dog