FORZA GLOBAL Forzaplas system Instruction Manual

Forzaplas system

Specifications

Manufacturer: FORZA GLOBAL
Product: FORZA PE-Xa PIPING Systems
Systems: FORZAPLAS, FORZA HDPE/AL/PEX GAS, FORZA
PE-Xa BRASS CRIMP
Applications: Hot and Cold Water, Potable Water,
Rainwater, Recycled Water
Material: Cross-linked high-density
polyethylene
Color Coding: BLACK (Potable Water), RED (Potable
Water), GREEN (Rainwater), LILAC (Recycled Water)
Features: Flexibility, Impact Resistance, Quiet
Water Delivery, Lead-Free System

Installation Guide

Tools Required

• Expander Tools for leak-proof joints

Installation Steps

1. Prepare the pipes and fittings.
2. Ensure the pipe ends are clean and free from debris.
3. Insert the pipe into the fitting until fully seated.
4. Use the expander tool to create a secure joint.
5. Repeat for all connections.

Warranty

The FORZAPLAS Plumbing System (excluding tooling) is warranted
for 25 years when installed by a licensed plumber in accordance
with AS 3500 of the National Plumbing Code Parts 1, 4 and 5 and
established installation practices.

Australian Standards Compliance

The FORZAPLAS Plumbing System is certified by Approval Mark
International to Australian Standards and complies with Australian
and New Zealand Standards AS/NZ 2492:2007 for Pipe (Lic.No.74616)
and AS/NZS 2537.2:2011 for fittings (Lic. No. 74797).

FAQ

Q: Can FORZA PE-Xa PIPING Systems be used for both domestic and

commercial applications?

A: Yes, FORZA is suitable for both domestic and commercial
applications.

Q: What is the warranty period for the FORZAPLAS Plumbing

System?

A: The system is warranted for 25 years when installed by a
licensed plumber according to specified standards.

SPECIFICATIONS & INSTALLATION GUIDE
ANOTHER QUALITY PRODUCT BY
FORZA GLOBAL

FORZA GLOBAL are the manufacturers and distributors of FORZA PE-Xa PIPING Systems which includes the LeadFree FORZAPLAS system for potable water, rainwater and recycled water.

FORZA GLOBAL also manufacture and distribute FORZA HDPE/AL/PEX GAS System, FORZA PE-Xa BRASS CRIMP system. This manual provides specification and installation information for the FORZAPLAS system for Hot and Cold Water.

A LEAD-FREE SYSTEM.

The FORZAPLAS system is a unique expansion jointing system which relies on the elastic memory of the PE-Xa pipe and sleeves. A FORZAPLAS expansion sleeve is fitted over the pipe end; both the pipe and expansion sleeve are expanded using the expander tool, the FORZAPLAS fitting is then pushed into the pipe with expansion sleeve. The memory effect of the FORZAPLAS will then complete the joint. All products are manufactured to strict quality controls and comply with Australian Standards, are watermarked approved and fully warranted for 25 years. The superior material properties of FORZA PE-Xa are ideal for hot and cold water installations. The system is hygienic, lead-free and non-toxic, providing clean and clear potable water without the inherent problems of conventional plumbing system which include chlorine, corrosion and scale.

Colour coded pipe is available in BLACK and RED for potable water, GREEN for harvested rainwater and LILAC for recycled water. FORZA is suitable for domestic and commercial applications.
FORZA cross linked high-density polyethylene offering flexibility and impact resistance. With a smooth bore design the result is quiet delivery of water minimizing water hammer and noise attributed to fluctuations in hydraulic pressure.
The FORZAPLAS Plumbing System joint can be made without the need for flame, heat, solder, or solvents.

2

SPECIFICATIONS
· Pipe made from Peroxide-cross linked polyethylene (PE-Xa) · Used for Hot and Cold Water Services · Thermal Conductivity :0.35 W/m.K · Roughness: 0.007mm · Maximum Temperature: 95 Deg C · Short-term Temperature in case of HWS malfunction : 100 Deg · Fittings are made from PPSU and C46500 Lead-Free Brass. · Pipe Dimension : 16 to 20 · Suitable for both Wet and Dry construction · Approval Mark International Product Certification to Australian Standards

TM
GLOBAL
World Force In Plumbing Systems

EXPANDER TOOLS
FORZAPLAS systems tools have been designed to ensure a leak proof joint on FORZAPLAS fittings. The expander tools have been manufactured with the highest quality material and designed to give long term trouble free service.
WARRANTY
The FORZAPLAS Plumbing System (excluding tooling) is warranted for 25 years when installed by a licensed plumber in accordance with AS 3500 of the National Plumbing Code Parts 1, 4 and 5 and established installation practices.
AUSTRALIAN STANDARDS COMPLIANCE
The FORZAPLAS Plumbing System is certified by Approval Mark International to Australian Standards and complies with Australian and New Zealand Standards AS/NZ 2492:2007 for Pipe (Lic.No.74616) and AS/NZS 2537.2:2011 for fittings (Lic. No. 74797).

3

TEST PROCEURES FOR WATERMARK COMPLIANCE
Listed below are the characteristics that are being tested for as well as the code from which the method for testing is followed: · Slow crack growth – ISO 13479 · Long term stability – ISO 1167 or as 1462.6 · Thermal stability ­ ISO/TR 10837 · Resistance to weathering ­ ISO 14531-1 · Longitudinal reversion ­ ISO 2505 · Hydrostatic strength ­ ISO 1167 or AS 1462.6 · Elongation at break – ISO 6259-1, ISO 6259-3 · Effect on water- AS 4020 · Opacity- ISO 7686 · Diameter and wall thickness – AS/NZS 1462.1 · Degree of cross linking – ISO 10147
4

PRESSURE LOSS TABLES FOR PN20 PE-Xa PIPE

PEAk F LOw R ATE QS (L/S) .01 TO .50
0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50

COLD WATER AT 25°C

16mm x 2.2 HEAD LOSS
(k PA/m)
0.3465 1.1650 2.3930 4.0077 5.9950 8.3490 11.0620 14.1295
–
–

20mm x 2.8 HEAD LOSS
(k PA/m)
0.1242 0.4141 0.8455 1.4090 2.1001 2.9143 3.8498 4.9036 6.0756 7.3633

25mm x 3.5 HEAD LOSS
(k PA/m)
–
0.1430 0.2905 0.4822 0.7160 0.9908 1.3053 1.6589 2.0510 2.4808

TM
GLOBAL
World Force In Plumbing Systems
32mm x 4.4 HEAD LOSS
(k PA/m)
0.0430 0.0866 0.1430 0.2122 0.2927 0.3846 0.4879 0.6018 0.7266

PEAk F LOw R ATE QS (L/S) .01 TO .50
0.05 0.10 0.15 0.20 0.25
0.30 0.35 0.40 0.45 0.50

HOT WATER AT 60°C

16mm x 2.2 HEAD LOSS
(k PA/m)
0.2913 1.0002 2.0803 3.5175 5.3030 7.4321 9.9026 12.7115
–
–

20mm x 2.8 HEAD LOSS
(k PA/m)
0.0135 0.3520 0.7270 1.2222 1.8343
2.5605 3.3998 4.3509 5.4121 6.5836

25mm x 3.5 HEAD LOSS
(k PA/m)
0.0358 0.1205 0.2475 0.4140 0.6185
0.8685 1.1392 1.4535 1.8038 2.1891

32mm x 4.4 HEAD LOSS
(k PA/m)
0.0106 0.0357 0.0731 0.1218 0.1814
0.2515 0.3318 0.4223 0.5228 0.6329

5

ApprovalMark International hereby grants:
FORZA Global Pty Ltd
2/8 Barclay Road Derrimut, 3030 AUSTRALIA
WaterMark Certificate of Conformity ­ WMCS 2016
Evaluated to:
AS/NZS 2492:2007 – Cross-linked polyethylene (PE-X) pipes for pressure applications
The WaterMark licensee shall comply with all the terms and conditions as stipulated by the governance of the operating rules of WaterMark, and shall comply with standard requirement at all times including when standard is amended. The WaterMark license only covers the product which is identified in the product schedule.
This certificate is issued by a JAS-ANZ accredited certification body. The ABCB and JAS-ANZ do not in any way warrant, guarantee or represent that the product the subject of this Certificate conforms to the WaterMark Certification Scheme Rules, nor accepts any liability arising out of the use of the product. The ABCB disclaims to the extent permitted by law, all liability (including negligence) for claims of losses, expenses, damages and costs arising as a result of the use of the product(s) referred to in this certificate. * This certificate may only be reproduced in its entirety.

Certificate No. WM 74817 Issued: 1st July 2019 Expires: 1st July 2024

Originally Certified: 1st July 2019 Current Certification: 1st July 2019

John PRASAD
Director
ApprovalMark International Pty Ltd 20/33 Holbeche Road, Arndell Park 2148, Australia www.approvalmark.com

FORZA PIPE PACKAGING
PIPE SIZE 16MM 20MM 25MM 32MM 40MM 50MM
PIPE SIZE 16MM 20MM 25MM 32MM

PIPE SIZE 16MM 20MM 25MM

LILAC 5M LENGTHS, 50M COILS 5M LENGTHS, 50M COILS 5M LENGTHS, 50M COILS

BLACK 5M LENGTHS, 100M COILS 5M LENGTHS, 100M COILS 5M LENGTHS, 50M COILS 5M LENGTHS, 50M COILS
5M LENGTHS 5M LENGTHS
RED 5M LENGTHS, 100M COILS 5M LENGTHS, 100M COILS 5M LENGTHS, 50M COILS 5M LENGTHS, 50M COILS
GREEN 5M LENGTHS, 50M COILS 5M LENGTHS, 50M COILS 5M LENGTHS, 50M COILS

NOM OD
DN 16-16MM DN 20-20MM DN 25-25MM DN 32-32MM DN 40-40MM DN 50-50MM

MEAN OUTSIDE DIA (mm)

MIN

MAx

16.0

16.3

20.0

20.3

25.0

25.3

32.0

32.3

40.0

40.4

50.0

50.5

WALL THICKNESS (mm)

MIN

MAM

2.2

2.6

2.8

3.2

3.6

4.0

4.4

5.0

5.5

6.2

6.9

7.7

PRESSURE RATINGS
Pipes for water applications are classified in terms of the nominal pressure rating (PN) at water service temperature of 20°C. FORZA has a pressure rating of PN20 and a nominal working pressure and pipe material temperature (PMT).

PMT PN 20

20C KPA 2000

60C 1500

70C 1330

6

FORZAPLAS FITTINGS LIST

CODE

SIZE

FPLES16 FPLES20 FPLES25 FPLES32
CODE

DN16 DN20 DN25 DN32
SIZE

FPLE16
FPLE20 FPLE25 FPLE32

DN16 DN20 DN25 DN32

CODE
FPLET16 FPLET20 FPLET25 FPLET32

SIZE
DN16 DN20 DN25 DN32

DESCRIPTION EXPANSION SLEEVES FORZAPLAS EXPANSION SLEEVE 16MM FORZAPLAS EXPANSION SLEEVE 20MM FORZAPLAS EXPANSION SLEEVE 25MM FORZAPLAS EXPANSION SLEEVE 32MM
DESCRIPTION EQUAL ELBOWS FORZAPLAS NO.12 EQUAL ELBOW 16MM FORZAPLAS NO. 12 EQUAL ELBOW 20MM FORZAPLAS NO. 12 EQUAL ELBOW 25MM FORZAPLAS NO. 12 EQUAL ELBOW 32MM
DESCRIPTION EQUAL TEES FORZAPLAS NO. 24 EQUAL TEE 16MM FORZAPLAS NO. 24 EQUAL TEE 20MM FORZAPLAS NO. 24 EQUAL TEE 25MM FORZAPLAS NO. 24 EQUAL TEE 32MM

CODE
FPLRC2016 FPLRC2516 FPLRC2520 FPLRC3225

SIZE
DN20-16 DN25-16 DN25-20 DN32-25

CODE

SIZE

FPLRT201616 FPLRT201620 FPLRT202016 FPLRT252516 FPLRT252516 FPLRT252520 FPLRT323220 FPLRT323225

DN20x16x16 DN20x16x20
DN20x20x16 DN25x25x16 DN25x25x16 DN25x25x20 DN32x32x20 DN32x32x25

CODE

SIZE

FPLS16 FPLS20

DN16 DN20

DESCRIPTION REDUCING COUPLING FORZAPLAS NO.1 REDUCING COUPLING 20MM X 16MM FORZAPLAS NO.1 REDUCING COUPLING 25MM X 16MM FORZAPLAS NO.1 REDUCING COUPLING 25MM X 20MM FORZAPLAS NO.1 REDUCING COUPLING 32MM X 25MM
DESCRIPTION REDUCING TEES FORZAPLAS NO. 27 REDUCING TEE 20MM x 16MM x 16MM FORZAPLAS NO. 26 REDUCING TEE 20MM x 16MM x 20MM FORZAPLAS NO. 25 REDUCING TEE 20MM x 20MM x 16M FORZAPLAS NO. 25 REDUCING TEE 25MM x 25MM x 16M FORZAPLAS NO. 25 REDUCING TEE 25MM x 25MM x 16M FORZAPLAS NO. 25 REDUCING TEE 25MM x 25MM x 20M FORZAPLAS NO. 25 REDUCING TEE 32MM x 32MM x 20M FORZAPLAS NO. 25 REDUCING TEE 32MM x 32MM x 20M
DESCRIPTION STOPPERS
FORZAPLAS NO. 61 STOPPER 16MM FORZAPLAS NO. 61 STOPPER 20MM

8

FORZAPLAS FITTINGS LIST

CODE

SIZE

FPLFSC1615 FPLFSC2020

DN16MM x 1/2″ DN20MM x 3/4″

DESCRIPTION FEMALE STRAIGHT CONNECTOR FORZAPLAS NO. 2 STRAIGHT CONNECTOR 16MM x 1/2″ BSPF DR. FORZAPLAS NO. 2 STRAIGHT CONNECTOR 20MM x 3/4″ BSPF DR.

CODE

SIZE

FPLMSC1615 FPLMSC2020 FPLMSC2515 FPLMSC2520
FPLMSC2525 FPLMSC3225

DN16MM x 1/2″ DN20MM x 3/4″ DN25MM x 1/2″ DN25MM x 3/4″ DN25MM x 1″ DN32MM x 1″

DESCRIPTION MALE STRAIGHT CONNECTOR FORZAPLAS NO. 3 STRAIGHT CONNECTOR 16MM x 1/2″ BSPM DR. FORZAPLAS NO. 3 STRAIGHT CONNECTOR 20MM x 3/4″ BSPM DR. FORZAPLAS NO. 3 STRAIGHT CONNECTOR 25MM x 1/2″ BSPM DR. FORZAPLAS NO. 3 STRAIGHT CONNECTOR 25MM x 3/4″ BSPM DR. FORZAPLAS NO. 3 STRAIGHT CONNECTOR 25MM x 1″ BSPM DR. FORZAPLAS NO. 3 STRAIGHT CONNECTOR 32MM x 1″ BSPM DR.

CODE

SIZE

FPLME1615 FPLME2015

DN16MM x 1/2″ DN20MM x 1/2″

DESCRIPTION MALE ELBOW FORZAPLAS NO. 13 ELBOW 16MM x 1/2″ BSPM DR. FORZAPLAS NO. 13 ELBOW 20MM x 1/2″ BSPM DR.

CODE
FPSC16 FPSC20 FPSC25 FPSC32

SIZE
DN16 DN20 DN25 DN32

DESCRIPTION STRAIGHT COUPLING FORZAPLAS NO. 1 STRAIGHT COUPLING 16MM FORZAPLAS NO. 1 STRAIGHT COUPLING 20MM FORZAPLAS NO. 1 STRAIGHT COUPLING 25MM FORZAPLAS NO. 1 STRAIGHT COUPLING 32MM

CODE

SIZE

FPLSTC1615 FPLSTC2020

DN16MM x 1/2″ DN20MM x 3/4″

DESCRIPTION STRAIGHT TAP CONNECTOR FORZAPLAS NO. 62 STRAIGHT TAP CONNECTOR 16MM x 1/2″ BSPF DR. FORZAPLAS NO. 62 STRAIGHT TAP CONNECTOR 20MM x 3/4″ BSPF DR.

9

FORZAPLAS FITTINGS LIST

CODE

SIZE

FPLBLARA200 FPLBLARA300

200MM 300MM

DESCRIPTION LAUNDRY BREECHES FORZAPLAS BATH/LAUNDRY ASSEMBLY RIGHT ANGLE 200MM DR.
FORZAPLAS BATH/LAUNDRY ASSEMBLY RIGHT ANGLE 300MM DR.

CODE
FPLSARA150 FPLSARA200

SIZE
150MM 200MM

DESCRIPTION STRAIGHT COUPLING FORZAPLAS SHOWER ASSEMBLY RIGHT ANGLE 150MM DR. FORZAPLAS SHOWER ASSEMBLY RIGHT ANGLE 200MM DR.

CODE

SIZE

FPLWF1615 FPLWF2020

DN16×1/2″MI DN20×3/4″MI

DESCRIPTION FEMALE LUGGED ELBOW FORZAPLAS NO. 15BP LUGGED ELBOW 16MM x 1/2″ BSPF DR. FORZAPLAS NO. 15BP LUGGED ELBOW 20MM x 3/4″ BSPF DR.

CODE

SIZE

FPLWM161565

DN16×1/2″MI-65

FPLWM161590 DN16×1/2″MI-90

FPLWM1615200 DN16×1/2″MI-200

FPLWM201595 DN20×1/2″MI-95

FPLWM2015200 DN20×1/2″MI-200 FPLWM2020200 DN20×3/4″MI-200

DESCRIPTION MALE LUGGED ELBOW FORZAPLAS NO.19BP LUGGED ELBOW 16MM X 1/2″ BSP MALE 65MM LONG DR. FORZAPLAS NO.19BP LUGGED ELBOW 16MM X 1/2″ BSP MALE 90MM LONG DR. FORZAPLAS NO.19BP LUGGED ELBOW 16MM X 1/2″ BSP MALE 200MM LONG DR. FORZAPLAS NO.19BP LUGGED ELBOW
20MM X 1/2″ BSP MALE 95MM LONG FORZAPLAS NO.19BP LUGGED ELBOW 20MM X 1/2″ BSP MALE 200MM LONG DR. FORZAPLAS NO.19BP LUGGED ELBOW 20MM X 3/4″ BSP MALE 200MM LONG DR.
10

ApprovalMark International hereby grants:

Forza Global Pty Ltd
2/8 Barclay Road Derrimut, VIC 3030 AUSTRALIA
WaterMark Certificate of Conformity ­ WMCS 2016
Evaluated to:
AS/NZS 2537.2:2011 ­ Mechanical jointing fittings for use with crosslinked polyethylene (PE-X) for pressure applications ­ Plastics piping systems for hot and cold water installations ­ Crosslinked polyethylene (PE-X) ­ Fittings (ISO 15875-3:2003, MOD)
The WaterMark licensee shall comply with all the terms and conditions as stipulated by the governance of the operating rules of WaterMark, and shall comply with standard requirement at all times including when standard is amended. The WaterMark license only covers the product which is identified in the product schedule.

This certificate is issued by a JAS-ANZ accredited certification body. The ABCB and JAS-ANZ do not in any way warrant, guarantee or represent that the product the subject of this Certificate conforms to the WaterMark Certification Scheme Rules, nor accepts any liability arising out of the use of the product. The ABCB disclaims to the extent permitted by law, all liability (including negligence) for claims of losses, expenses, damages and costs arising as a result of the use of the product(s) referred to in this certificate. * This certificate may only be reproduced in its entirety.
Certificate No. WM 74615

Issued: 22nd July 2020 Expires: 16th July 2023

Originally Certified: 16th July 2015 Current Certification: 22nd July 2020

John PRASAD
Director
ApprovalMark International Pty Ltd 20/33 Holbeche Road, Arndell Park 2148, Australia www.approvalmark.com

FORZAPLAS INSTALLATION INSTRUCTIONS
The following instructions explain the correct installation procedure for FORZAPLAS fittings in conjunction with FORZA PEX PN20 pipe.
Ensure you have the correct FORZAPLAS fittings, FORZA PEX PN20 pipe and Expansion tool with the correct expansion head is ready.

With a set of pipe cutters /shears

1

cut the pipe at 90° ensuring the pipe

is square on the end.

2

Pick up the expansion sleeve and ensure the correct size for the FORZA PEX pipe.

Slide the ForzaPlas expansion sleeve

3

over the pipe ensuring the lugs are flush with the end of the pipe. Pipe is

now ready to be expanded.

Choose the correct size expander head

for the pipe being expanded. Pictured is

the 20mm head suitable for 20mm pipe.

4

Gently, insert the expander head into the

end of the pipe.

12

FORZAPLAS INSTALLATION INSTRUCTIONS

Press and hold the trigger on the

expander tool, the expander head will

5

begin to splay and expand the end of the pipe. The expansion tool comes with

built-in auto rotation. Ensure you hold

the pipe whilst expanding. Let the tool

complete its cycle, do not stop and start.

Repeat 6 rotations for 16mm and 8

6

rotations for 20mm until snug against the expander head. Remove tool from

pipe end.

Due to the memory of pipe and sleeve,

7

have the fitting ready before expanding.

Immediately push the correct sized fitting into the expanded pipe end.

Push fitting into pipe until it reaches the

8

shoulder of the fitting. If the fitting is loose inside the pipe, over- expansion

may take much longer to contract.

13

9

Hold the pipe in place for 5-8 seconds.

At completion of installation a pressure

test must be carried out in accordance

10

with AS/NZS 3500 and or any other

requirements specified by local

authorities.

14

FORZAPLAS INSTALLATION INSTRUCTIONS
Forza Pipe Cutters
ForzaPlas Expander Heads Available in 16 and 20mm ForzaPlas Expansion Tool
15

Forza Pex pipe and FORZAPLAS fittings are guaranteed against manufacturing defects for a period of 25 YEARS when installed and used in accordance of the Australian Plumbing code and or the LOCAL or STATE Authority and when installed by a licensed PLUMBER.

25

Forza Pex pipe complies with the standards set out in AS/NZS 2492:2007 Cross Linked polyethylene (PE-X) pipes for pressure applications.
Licence No. WM 74817

FORZAPLAS fittings comply to the standards as set out in AS/NZS 2537.2:2011 – Mechanical jointed for use with cross linked polyethylene pipe (XLPE) for hot and cold applications.
Licence No. WM 74797

a product by

Confidential

This Certificate of Currency has been issued by Allianz Australia Insurance Limited and confirms that on the Date of Issue the Policy is current for the Period of Insurance and Limit of Liability as shown herein. This Certificate of Currency is issued as a matter of information only and confers no rights upon its holder.
This Certificate of Currency does not form part of the terms and conditions of the Policy and does not amend, extend, replace or alter the terms, conditions, definitions, limitations and exceptions noted therein.
This Certificate of Currency is provided as a summary only of the cover provided and is current only at the Date of Issue. The Policy may be subsequently altered or cancelled in accordance with its terms after the Date of Issue of this notice without further notice to the holder of this notice.
Certain words used in this document and the Policy have special meanings. The Definitions section of the Policy document contains such terms. Please read the Policy wording, the Schedule and any other documents that form part of the Policy for the terms and conditions of cover.

NAMED INSURED: POLICY NUMBER: PERIOD OF INSURANCE: LIMIT OF LIABILITY:
POLICY WORDING: GEOGRAPHICAL LIMITS:

Forza Global Pty Ltd 22-0127810-LCP 22nd January 2022 to 4pm 22nd January 2023 $50,000,000 per Occurrence or per Occurrence and in the aggregate (as applicable), in accordance with the Policy terms and conditions Steadfast General & Products Liability Policy POL255BA/SF 02/21 Anywhere in the world (subject to limitations of the Policy)

Kailin Gianikouris Senior Liability Underwriter ­ Tailored Lines
Date of Issue: Issued on 2nd February 2022 for and on behalf of Allianz Australia Insurance Limited

CLASSIFICATION: CONFIDENTIAL

TM
GLOBAL
World Force In Plumbing Systems
FORZA GLOBAL PTy LTD ABN 42 161 669 549 ACN 161 669 549 2/8 BARCLAY ROAD, DERRIMUT, VIC 3030
T: (03) 8348 5704 F: (03) 9923 6324 www. FORZAGLOBAL.COm.AU

References

• Forza Global - World Force in Plumbing Systems
• lic.no
• Approval Mark International | Just another WordPress site
• Approval Mark International | Just another WordPress site

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