Through a preventative maintenance program, F.W. Webb Company found and fixed oil leaks at a New Hampshire power plant that could have caused major problems. Instead of a long shutdown that could have affected electricity customers across New England, F.W. Webb completed repairs during a planned two-week plant closure.
Driven by natural gas, the highly-efficient, clean-burning power plant uses both combustion and steam turbines to serve 745 megawatts of electricity to customers. The power plant engaged Webb’s Process Controls Division to perform preventative maintenance on all of the plant’s motor-operated valves. Webb discovered obscured oil leaks in 44% of the Rotork valves— causing downstream issues related to steam discharge.
Webb identified that heat near the steam generator damaged all the direct-mount electric actuators. The team learned that the plant’s Pakscan™ system had experienced malfunctions since 2019 because of incompatible Pakscan/Siemens cards.
The plant shut down for two weeks to allow Webb’s Rotork Service Technicians to perform the following:
Identify 54 Rotork-operated valves distributed across a 48-acre facility comprised of two generators interconnected via a Pakscan system.
Log all settings, performance, inspection, event, and field failure data for each valve, and merge those data with historical and specification data.
Fix leaks in 24 of the 54 valves.
Although the two-week shutdown was planned, complications compacted the schedule, including a three-day delayed start and a requested weekend reduction in crew size. The plant also required Webb technicians to work 12-hour days. To get the job done, technicians formed two groups of three. One team removed the actuators, while the other rebuilt and prepared them for reinstallation.
The power plant avoided a prolonged shutdown and additional capital expenditures thanks to Webb’s preventative maintenance.
The Rotork actuators now perform to the manufacturer-recommended 20-year lifespan. All valves functioned properly after the plant went back online—and the Pakscan system worked flawlessly too.
Webb’s crews overcame the schedule delay, including actuator rebuilds commencing the second week, to complete the project in 11 days with a 100-percent success rate and without any time lost to injury. The power plant avoided a prolonged shutdown and additional capital expenditures thanks to Webb’s preventative maintenance.
As the coronavirus pandemic flared up around the country, the U.S. Army Corps of Engineers rapidly built alternative care facilities to alleviate strain on local hospitals—and MCAA member contractors and manufacturer/supplier partners were there to help. In Chicago, Ferguson, Bradford White, Laars, and Sloan all provided needed materials in record time, and Helm Group (formerly Mechanical, Inc.) was among those working on the ground nonstop as the HVAC and plumbing contractor for the job. Ferguson; LAARS, a Bradford White Company; and SLOAN are all benefactor sponsors.
While most of the Army Corps facilities were designed to handle non-COVID-19 patients, Chicago’s McCormick Place convention center was planned to care for up to 3,000 people with mild or moderate coronavirus infection, freeing up hospital beds for more severe cases. Patients would be separated in the convention center halls by the level of care they required, spread throughout the facility’s 2.6 million square feet of exhibit space. Construction for the first 500 beds was completed April 3. (As the pandemic spread, the project was scaled back to 1,000 beds, because the state lockdown “flattened the curve”—or slowed the pace of infection—and area hospitals were able to keep up with the cases.)
Plumbing Industry Responds
As construction got underway, a plumbing contractor reached out to Ferguson Enterprises for help sourcing 17 Bradford White, 120-gallon, 54 kW, 208-volt water heaters and five LAARS Heating Systems 200-gallon jacketed and insulated vertical storage tanks to generate and store sufficient hot water for the facility. The first treatment area, with 500 beds, needed water heaters and a storage tank for the staff showers and another heater for showers that met Americans with Disabilities Act standards—all within four days.
“We didn’t know what to expect, when we got the call to help on the COVID-19 Care Center project at McCormick Place,” said Jim Kuenn, director of commercial—Central Midwest, Ferguson Enterprises. “We got involved midday on March 31 and needed to turn around a huge amount of product in just a few days. We reviewed the mechanical schedule and specifications provided to us. It was a daunting task that most of our associates had not seen before. We said ‘yes’ because we wanted to not only help our customer but also the community during this time of need.”
While the factory could not supply the heaters in the timeframe required, one of Bradford White’s consigned inventory warehouses in Atlanta, GA, had a sufficient number in stock. The heaters were delivered within 17 hours of ordering. The plumbing contractor and sales representatives credit their long history and experience with Bradford White, along with a vast local and national distribution network, as crucial to overcoming the logistical challenges.
In addition to the water heaters themselves, conversion kits were flown by next-day air from Bradford White’s Middleville, MI, manufacturing facility.
A Team Effort
Those on the scene were impressed to see representatives from every trade working side by side with representatives from the Federal Emergency Management Agency (FEMA) and construction managers coordinating efforts. They would gather together throughout the day to reassess, resulting in constant coordination with FEMA.
“It was impressive to see everyone working together to get this project done quickly,” said Brian Helm, Helm Group (formerly Mechanical, Inc.) CEO and MCAA president. “You need to remember that this was the earliest stages of COVID-19 in the U.S., when we really didn’t know how the virus spread and what the mortality rate was. The trades saw it as their mission to get this facility built, and that’s exactly what they did.”
Helm Group (formerly Mechanical, Inc.) rapidly installed ductwork for the Chicago field hospital, recognizing that good ventilation is key to protecting against transmission of COVID-19.
Helm pointed out that the 500 people working in the space had to remember to stay at least 6′ apart at all times. “The biggest challenge was that all the trades were learning how to do their jobs while staying apart,” noted Helm. “For people’s entire careers, it was always the opposite—help someone out, watch out for the other guy, lift with a buddy, etc.”
As each stage of work was completed, FEMA required testing to make sure that everything worked, so the contractors coordinated with the International Brotherhood of Electrical Workers (IBEW) and others. Challenges arose, but the plumbing crews succeeded in providing enough hot water to service 3,000 beds. Some described themselves as proud to be able to respond during a time of crisis and noted that plumbing is essential to public health.
Ferguson Enterprises, Bradford White, Laars, and Sloan all provided needed materials in record time to contractors like Helm Group (formerly Mechanical, Inc.) to stand up a field hospital in Chicago’s McCormick Place convention center in just 4 days. Photo courtesy of Ferguson.
“The Ferguson team in Chicago stepped up to the challenge, rolled up their sleeves, and worked 24/7 to make it happen,” Kuenn stated. The tight deadlines were met because, Kuenn said, “everyone—from contractors like Helm Group (formerly Mechanical, Inc.) to various vendors—found a way to say ‘yes.’ I get prideful chills from what was accomplished.”
Bradford White supplied water heaters for several major field hospitals, including Javits Convention Center in New York City and McCormick Place, according to Mark Taylor, executive vice president and general manager at Bradford White.
“We are extremely proud of the work being done by our reps, as well as our wholesaler and contractor customers, who are making sure that medical facilities have the hot water they need to combat the COVID-19 pandemic,” said Taylor. “Hot water is critical for cleaning, sanitizing, and hygienic purposes, and it’s important for us to do our part to support the health care workers on the front lines.
“In Michigan, where our water heaters are produced, we reached out to Gov. Gretchen Whitmer and offered to provide products for any temporary field hospitals in the state of Michigan that need water heaters to help address the pandemic. Michigan is one of the states hit particularly hard by COVID-19,” Taylor noted.
Todd Young, vice president of commercial, Ferguson Enterprises, noted the crisis has undoubtedly changed the way everyone lives and works. “We’ve implemented new processes in order to help our customers and communities during this time,” he said.
“To support local hospitals and pop-up facilities across the country, we’ve organized a new response and product procurement system to handle the many inquiries coming in—because it’s the right thing to do,” Young explained. “From delivering jobsite trailers and emergency water heaters to providing products for field hospitals at facilities like CenturyLink Field and Sleep Train Arena, we’re working with a variety of essential businesses in different industries to help our communities push forward … and we’re happy to do it.”
Hygiene Is High Priority
Sloan provided touch-free commercial restroom products to the McCormick Place convention center to facilitate hygiene-friendly handwashing without the risk of cross-contamination.
Sloan also joined the effort, providing its touch-free commercial restroom products to the McCormick Place convention center to facilitate hygiene-friendly handwashing without the risk of cross-contamination.
“At Sloan, we understand that the touch-free products we manufacture across the entire commercial restroom play an essential role in the fight against the COVID-19 pandemic,” said Graham Allen, Sloan co-president and CEO. “We are proud to support those in our backyard of Chicago … and anyone in need across the country, and we will continue to do everything in our power to supply sensor-operated products.”
Plumbing requirements at McCormick Place called for over 200 Sloan sensor faucets in handwashing stations, and Sloan partnered with local suppliers to deliver these hygiene-friendly solutions.
Sloan Outfits Yale Gym with Touch-Free Fixtures
In New Haven, CT, Yale’s Payne Whitney Gym was also converted to a temporary field hospital and needed to retrofit its existing manual faucets and flushometers to provide a more sanitary environment for the influx of patients. The facility removed its existing faucets and replaced them with Sloan sensor-operated faucets, while also installing new Sloan sensor flushometers to provide a touch-free experience.
As MMC Contractors embarked on building a large central utility plant for a globally recognized corporation in the lower Midwest, Ferguson’s new virtual design and construction (VDC) department became a pivotal partner, identifying potential pitfalls and offering cost-effective solutions for the job. Ferguson is a sponsor of MCAA’s 2021 Virtual Education Conference.
The new plant presented challenges. The project had a tight schedule, in addition to a design-assist component using large-diameter HDPE to build manifolds for the cooling tower yard. Working with 48″ HDPE is complicated, and several fittings require custom fabrication. Traditional design methods do not always apply. HDPE requires expensive, large-scale fusion equipment and expertise in build strategy.
To produce a viable and cost-effective solution for the piping manifolds, Ferguson presented their new VDC services as design-assist. With their new VDC department, Ferguson is meeting demands by providing MMC with drawings, HDPE manifold fabrication, and an integrated planned delivery to the jobsite.
MMC chose to work with Ferguson because they became an integral part of the team early in the project. Everyone, including preconstruction, project management, engineering, design, and field supervision, quickly realized the value of the VDC services when Ferguson pointed out design conflicts on the contract drawings. Ferguson presented coordinated shop drawings and a BIM model as their recommendation for the build. Additionally, they made calculated recommendations for upgrading pipe sizes and wall thickness because of industry availability of the product.
“Ferguson project management, VDC, and fabrication teams were pivotal in creating a successful build strategy and truly acting as trusted advisors and not just a supplier.”
Brent Townsend, MMC operations manager, said of Ferguson, “I’m very pleased with their commitment to partnership. As a design-build contractor, the investment in the time it takes to plan and collaborate can be staggering. Ferguson project management, VDC, and fabrication teams were pivotal in creating a successful build strategy and truly acting as trusted advisors and not just a supplier. Their VDC capabilities set them apart from their competition. It’s reassuring to have a supplier that can partner at this level.” The partnership between MMC Contractors and Ferguson created the best solution for the client while introducing the industry to Ferguson’s new and expanded capabilities in VDC.
Over a span of 32 hours, a city of about 20,000 people in upstate New York suffered 13 residential water main breaks. After making temporary emergency repairs, the Department of Public Works (DPW) turned to F.W. Webb, which supplied thousands of feet of HDPE pipe within weeks.
After repairing the initial leaks, the City Council authorized emergency funding for the water main replacement project. Knowing that the existing mains were susceptible to additional breaks, the city had to complete the high-priority project quickly and efficiently. Once the DPW provided a short-term fix for the leaks in the existing asbestos cement pipes, they explored an immediate, long-term solution to replace 23,000 linear feet—or more than 4.3 miles—of water main piping. In addition, the city needed the accompanying water main accessories, so the DPW engaged F.W. Webb, a premier distributor of HDPE pipe, to assist in the repair project.
Compared with iron piping, HDPE pipe is much more lightweight and flexible, less expensive, and lasts longer. HDPE pipe is also leakproof and ideal for directional drilling. These factors made it the obvious choice to solve the residential water service crisis.
The work involved replacing mains in 14 streets serving 400 residences in 120 buildings, many with multiple water service connections. The repairs also included 35 hydrants and 75 mainline gate valves. Webb worked directly with the DPW to source the necessary materials and coordinated with vendors to expedite delivery so work could commence 6 weeks after funds were approved.
Three separate contractors installed the new piping adjacent to the existing mains using open-cut and directional drilling. The DPW kept the old system active until all new piping was pressure-tested and disinfected and installation of the new service connections was complete. Then, the DPW shut down the old water system in sections.
The work also included the installation of four iHydrants. Manufactured by the Clow Valve Company, a McWane, Inc. division, iHydrants allow a municipality to monitor pressure and temperature changes throughout a water system. The iHydrants will provide a safeguard to prevent future disruptions.
The water main replacement was soon completed in all 14 streets. F.W. Webb’s ability to quickly source and supply more than 4 miles of pipe and the accompanying accessories provided the city with the resources to resolve a water supply calamity before it worsened.
John W. Danforth Company installed a new hot water system in a nursing home without incident and with minimal disruption, thanks in part to Ferguson’s expertise in selecting the ideal replacement system. The new system improved overall efficiency for the nursing home and will be easier to maintain than the old system.
Hot Water for Healthy Living
The hot water system of the GreenField Skilled Nursing & Rehabilitation Center is a critical component for protecting and enhancing residents’ health. Efficient hot water supply is essential in the cleaning and disinfection process. The existing water heater system that served the elderly residents in the primary and largest GreenField building was approaching its end of life.
When the system was first designed in 1997, it was oversized for the building’s needs. There was a tank and two heaters for the high-temperature kitchen and laundry system. The lower-temperature shower and sink system had a second tank and two heaters. As GreenField looked to the future, they were concerned about the cost of replacing parts on the old tanks, and they could not afford to be without hot water if the machinery failed.
High-Tech Needs Assessment
Ferguson’s Commercial HVAC, Hydronics, and Water Heating Team worked directly with the facilities manager, Nick Kwasniak, to assess the building’s need. Using new smartflow water technology to measure the flow of water through the pipes, they were able to capture an accurate and reliable reading of the facility’s current hot water usage.
“This data allows us to properly size the water heater they need, instead of using old methods. This impresses facility managers and contractors because they see real data that leads to real cost savings,” said Scott Peggs, Ferguson’s director of commercial business in the Northeast District. Based on the usage data and previous experience, Kwasniak and the Ferguson team chose to update the water heating system to a Lochinvar SHIELD™ water heating system.
In addition to Lochinvar’s 96-percent efficiency and full modulation with 5:1 turndown, the SHIELD system was appealing because its compact size allowed the team to transport the units to the mechanical room easily. Kwasniak said, “The boiler room is deep in the building with no easy access. The new SHIELD tanks were put on a two-wheel appliance dolly and wheeled through the building by a two-person crew. That’s a huge selling point when facing the install of a 500,000 BTU hot water tank.”
Kwasniak had a long-standing relationship with Danforth and Ferguson. He trusted that the team would share his concern about maintaining a hot-water supply throughout the conversion. “Before a job, Ferguson confirms that any needed materials are onsite. Additionally, all replacement material is lined up and ready to go,” said Eric Fularz, Ferguson hydronics product specialist.
New System Improves Efficiency
Ferguson supplied the piping layout and equipment to the facility, and Tim Ruggiero, a plumber with Danforth, installed the system. “Replacing the old system with a modernized version required that the entire boiler room be repiped. We were downsizing from two systems to a more efficient Lochinvar water heater system,” said Ruggiero. “The new integrated and state-of-the-art system pulls the hot water directly to the kitchen and laundry or through a new Powers electronic mixing valve that maintains a safe temperature for the showers and sinks. All the tanks are kept above 140° F. This prevents Legionella bacteria and protects the residents’ health.”
According to Fularz, “Another important change in the system included updating from the old non-condensing heaters to new condensing equipment. When water temperatures returning to the unit were 130° F or below, the unit would condense. And when equipment that is not made to condense does, it can damage the burners, igniter, heat exchanger, and anything else it contacts. The new equipment is made to condense. This is where it gains efficiency, and it is essential that colder temperature water return to it. This required a change in the pipe system.”
The installation was trouble-free, with minimal disruption to the business. “It took roughly two-and-a-half weeks for the job to be complete. Our total downtime was less than four hours,” said Ruggiero. Kwasniak noted, “After the install, no one—from kitchen staff to laundry staff—noticed a difference in supply after running on a quarter less the hot water capacity. And that is a good thing.
“There is no doubt that a year out, we will see significant savings,” Kwasniak continued. “Additionally, improving our energy efficiency was an important concern which we are pleased to address with the new Lochinvar water heater system. Ferguson’s ability to calculate our actual hot water usage greatly reduced our total storage and BTUs from the original design.”
Ruggiero highlighted an additional safety benefit. “Conducting maintenance on the system in the future will be worry-free. In the past, during times of maintenance, the building experienced periods of fluctuation or no flow. With this new system, we can take one system down for maintenance and the other system will continue to provide the residents with a consistent flow of hot water that still meets all state regulation temperatures.”
A Model System
The project was such a success that Kwasniak, Ruggiero, and Ferguson will host the Central New York Society of Healthcare Engineers in February 2020. “We will bring in facility managers, engineers, and design-build professionals to tour the GreenField Skilled Nursing & Rehabilitation Center and see the new system, and Ferguson will have the opportunity to provide training on their services,” said Kwasniak.
Training is essential to Ferguson’s success as an experienced partner. “We find that the more we share our knowledge and expertise, the more comfortable contractors and builders are with the products,” said Cody Genkos, Ferguson heating sales specialist. “Each situation is unique, so the more they know, the more it allows us to work together to find unique solutions. For example, health care engineers have different requirements, even government regulations they must meet during a job.”
Mike Zaremski, Ferguson product specialist, added, “Whenever we conduct training, someone always says, ‘Oh, I wish I knew that before.’ Not only are we helping them improve energy efficiency, by providing training on our equipment, we also help our customers find smart, more efficient ways of maintaining their system.”
“It is unusual to have an expert onsite to explain and demonstrate the science and mechanics in your hot water system,” added Peggs. “Our product experts are onsite or on call with facility managers to help tackle technical issues.”
Danforth and Ferguson are proud to help GreenField Skilled Nursing & Rehabilitation Center maintain its reputation for safety for many years to come through the new and improved hot water system.
Because of the “design-on-the-fly” approach to building a solar panel manufacturing plant, Mollenberg-Betz, Inc., does not always know which products it will need and when, but it does know that F.W. Webb Company will provide just what they need when they do. The two have teamed up to provide engineered process piping solutions throughout the 1.2-million-square-foot SolarCity facility under construction in Buffalo, NY.
“Finding a PVF supplier in the region who could handle our extensive needs for the SolarCity installation was a top priority,” said Brenda McGinnis, purchasing manager at Mollenberg- Betz. “With F.W. Webb we found a partner with the right solutions and customer service approach to execute this complex project successfully.”
SolarCity’s design/build approach prevented Mollenberg-Betz from ordering all products up front or establishing a regular delivery and installation schedule, so F.W. Webb ordered all of the GF inventory specified in the original job takeoff, stored it nearby, and provides it as needed. Here Mollenberg-Betz Foreman Justin Takas (left) inspects the latest delivery of GF pipe with F.W. Webb Industrial Plastics Manager Jim Matthews.
Project Poses Multiple Challenges
At the site of the former Republic Steel complex in South Buffalo, NY, a herculean effort is underway to build the SolarCity manufacturing plant. The sheer size of the $900 million project—with its footprint equivalent to approximately 17 football fields—presents every imaginable type of construction challenge, such as finding enough skilled workers and securing the right materials in manageable amounts. To compound matters, the Buffalo-Niagara area is experiencing an unprecedented commercial construction boom of epic proportions, putting additional pressure on the availability of talent and building supplies.
There are no idle contractors in the Buffalo area. Most are working on the Riverbend Commerce Park project, where the SolarCity facility is under construction, or a host of other large-scale projects transforming Buffalo and stretching construction resources.
Including SolarCity, there are at least eight large-scale commercial projects underway—valued collectively at over $1 billion.
When Mollenberg-Betz was selected to install all the PVF for the high-purity processing, water, chemical, waste, and general purpose process lines in the SolarCity facility, one of the first challenges was to find a capable supplier of engineered plastic piping systems—one who could supply more than inventory.
“Mollenberg-Betz has been in business for over 100 years, and we have diverse expertise and depth. We seek out smart vendors to form cohesive, strategic partnerships with us for the benefit of our customers,” said H. Van Mollenberg, president and CEO of Mollenberg-Betz.
F.W. Webb Offers Solutions
On most days, up to 40 different contractors from various trades are on site at the massive plant, competing for workspace. Constant contact with F.W. Webb ensures that Mollenberg-Betz has adequate inventory and support to stay on track. Pictured from left to right, Kevin Buchanan of GF, Mollenberg-Betz Project Manager Jamie DeWald, and Ryan Warner of GF consult at the SolarCity jobsite.
“F.W. Webb introduced our teams to highly engineered plastic piping products and solutions from Georg Fischer (GF),” McGinnis said. “They went the extra mile with product and installation training, and even further by simplifying MBE/WBE [Minority Business Enterprise and Women’s Business Enterprise] requirements and helping us establish a Class-1000 cleanroom to fabricate high-purity lines.”
“F.W. Webb has brought all its resources to bear on this large, unprecedented project,” said Van Mollenberg. “We have been thoroughly impressed with the company’s depth of expertise and ability and commitment to support us every step of the way.”
Tackling the Unknown
The massive SolarCity project functions essentially as a design-build, or design on the fly, which presents challenges. Without knowing the full scope of the project, Mollenberg-Betz could not order all products and material up front or establish a regular delivery and installation schedule. Working within the confines of this arrangement, the F.W. Webb team front-loaded the project by ordering all of the GF inventory specified in the original job takeoff. Stored at a nearby Webb location, this inventory is available in regular or urgent shipments.
On most days, up to 40 different contractors from various trades, including steel, HVAC, and electrical, maneuver to install their materials in the overhead plenum. The skeletal facility is dotted with lifts, tools, machinery, inventory, and teams of construction personnel. Mollenberg-Betz is in the mix, scrambling for work-space to install the specialized PVF that will become an essential component of the solar panel manufacturing process. Getting squeezed out by a traffic jam of subcontractors can delay installation and make it difficult to determine types and quantity of products needed from day-to-day
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“F.W. Webb has brought all its resources to bear on this large, unprecedented project.”
—H. Van Mollenberg, president and CEO of Mollenberg-Betz
In all circumstances, continuous contact between F.W. Webb and Mollenberg-Betz ensures adequate inventory and support, including facilitation of special and back orders to keep the project moving steadily toward its midyear target completion date.
Cleanroom Operations
Solely responsible for installing all the high-purity process piping at SolarCity, Mollenberg-Betz needed a cleanroom to fabricate the GF pipe for this specialty application. F.W. Webb was instrumental in assisting with setup and training of a Class- 1000 cleanroom at a Mollenberg-Betz location. Fitted with three stages of filtration to remove particles, the 18′ x 25′ cleanroom refreshes air 150 times an hour. Once fabricated and packaged, the pipe is moved to a 40′ storage unit at the construction site to await installation.
Emerging Industry
Light production of solar panels at the SolarCity facility is expected to begin as soon as the project is completed, with full production planned for 2017. Spinoff industries are anticipated, making Buffalo a focal point for the emerging alternative fuel industry. Mollenberg-Betz and F.W. Webb can relish knowing their cohesive partnership contributed to this important undertaking.
Ferguson Offers Guidelines for a Smooth Transition to Lead-Free Products
The Reduction of Lead in Drinking Water Act (U.S. Public Law 111- 380) goes into effect nationwide on January 4, 2014. It reduces the allowable lead content of all products that come in contact with drinking water or water for human consumption. Beginning in January, no one can install or sell products that are not deemed lead free for water systems designated for human consumption, including cooking.
If you ignore the new law, you could be facing significant financial issues. Most notably, after January 4, 2014, there is no outlet for products that do not meet the lead law criteria. How the law will be applied to ongoing jobs—those that began before the new requirements went into effect—remains an open question. Some states have already enacted new requirements. Differences exist in the interpretation of which products fall within the scope of the law. States and localities must abide by the federal law but can be more stringent in their own regulations.
Because this legislation creates challenges and opportunities for both contractors and distributors, Ferguson offers these tips to help contractors check their readiness and prepare to comply with the new legislation.
1. Educate yourself and your associates as soon as possible. Talk to your legal counsel. “Lead free” is defined as having not more than a weighted average of .25% lead when used with respect to the wetted surfaces of pipes, pipe fittings, plumbing fittings, and fixtures. The U.S. Environmental Protection Agency (EPA) will oversee the new law. The EPA has not issued any official guidelines to date and is not likely to do so until after the law goes into effect. A draft list of frequently-asked questions (FAQs) is available; it is expected that the FAQs will be finalized and distributed within a few months. See the bottom of this article for education resources.
2. Inspect your existing stock immediately. Look in fabrication shops, jobsite trailers, storerooms, etc., for products that are not lead free and that are used exclusively in potable water. Items to inspect include but are not limited to lavatory faucets, kitchen faucets, brass supplies and stops, brass fittings, cast copper fittings, potable-only backflow products, and low-pressure brass/bronze valves. Anything not installed prior to January 4, 2014, that is used only in potable water cannot be returned to most manufacturers and will essentially be scrap. Some products that contain lead today can be used in other, nonpotable applications (e.g., brass/bronze valves) and will continue to be available in 2014. Work with your distributors and manufacturers now, before it is too late.
3. Talk to local plumbing inspectors about jobs in progress. Enforcement of the law will most likely be the responsibility of local plumbing inspectors. It is important to understand how they will treat jobs in progress. The law is clear about installation after the January 4, 2014, deadline, but what about the units, floors, and sections that are completed in 2013? Will completed portions of the project need to pass inspection prior to the end of the year, or does the whole project need to be lead free? So far, the EPA has been silent about inspection and is upholding the January 4, 2014, cutoff date for sales and installation.
4. Meet with your distributors. Discuss open projects, as there may be availability issues in late 2013 for both compliant and noncompliant products. Jointly decide on transition plans. Most lead-free products have a higher cost and sales price. Review open bids for future projects and consider whether rebidding is needed. Consider whether distributors have any material stocked for you for current projects. Working together minimizes risks for both parties.
5. Learn to identify the difference between lead-free and noncompliant products. There are no standards in place; marking and identification vary from product to product and manufacturer to manufacturer. Many valve manufacturers are changing the color of the handles and attaching tags to the valves. Warning labels are beginning to appear on noncompliant products. Most products that are certified have NSF 61 Annex G or NSF 372 certification on the packaging or the product itself. Talking with your distributors and significant manufacturer partners will help.
6. Understand the differences among lead-free products. Different manufacturers replaced the lead with different metal alloys. Lead-free products may have some subtle installation differences. Discuss the products with your distributors and manufacturers’ representatives. Consider obtaining samples of low-lead solder, flux, and valve components to see how they react differently from other products. Some products now require more heat and therefore more installation time. Estimators and field personnel will need education about the new product requirements.
7. Communicate, communicate, and communicate! This law is tough for the entire industry and we are all trying to limit risks. Working together at every stage, from vendor to installer, we can help each other through this transition.
Education Resources
Ferguson’s No-Lead Law Resource Center, online at www.ferguson.com/leadfree, provides an overview and links to the text of the federal Reduction of Lead in Drinking Water Act.
