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What causes corrosion on PEX fittings?
PEX fittings are made of brass and are much resistant to corrosion, except in some cases.
In this one, these 20-year age fittings were embedded in mortar behind the tiles, and it's this contact with mortar that caused the corrosion.
Similar fittings of the same age within the same PEX tubing installation and which are simply free from any mortar around them, did not get corroded.
These corroded outlets were found leaking behind the wall tiles and down to the floor below floor tiles,then causing a water infiltration through the slab down to the underneath ceiling of the lower apartment.
In this one, these 20-year age fittings were embedded in mortar behind the tiles, and it's this contact with mortar that caused the corrosion.
Similar fittings of the same age within the same PEX tubing installation and which are simply free from any mortar around them, did not get corroded.
These corroded outlets were found leaking behind the wall tiles and down to the floor below floor tiles,then causing a water infiltration through the slab down to the underneath ceiling of the lower apartment.
How to replace the corroded PEX wall outlets and avoid putting mortar around them:
Step 1: Removing the tiles around the PEX wall fittings
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If you encounter a similar case where the PEX outlet is completely embedded behind the wall tiles...
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...Start by clearing the joint between tiles with a flat screwdriver. Always wear safety goggles when breaking porcelain!
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Continue breaking the wall tile little by little and with your screwdriver kept as oblique as possible (parallel to the wall).
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Patiently get the rid of the first wall tile.
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Now you can see the mortar that was used to fix it.
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Use a flat chisel and a 2 Kg hammer to break the mortar.
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Get the rid of it. Take care not to damage the bath tub or any sanitary fixture depending on your installation.
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Change to a point chisel and start freeing the embedded PEX water outlets from their surrounding plaster:
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Step 2: Removing the corroded PEX compression elbow fittings
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Little by little the embedded elbow emerges.
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Make sure it is freed all around.
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If you need to break a bit of the tiles, use a tile cutter.
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The wall outlet is now ready for the next step.
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Time now to remove the fixing screws of the PEX water outlet:
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Try all screwdrivers you have as the screw heads will be completely corroded.
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Hit them counterclockwise with a flat screwdriver.
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Whenever you can, unscrew them with grip pliers.
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You can consider yourself lucky if you succeed!
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If the screws don't move, simply use a drill to remove their heads !
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Step 3: Pulling the shower PEX tube out of the PEX manifold
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After releasing the PEX tube from the manifold, pull it out using the corroded elbow as a handle.
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Keep pulling steadily alternating your hands.
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The extents of the corrosion are well visible on this PEX connector.
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Now continue removing the screws which did not unscrew. Bend them and cut them with grip pliers:
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Step 4: Pull new PEX tube, fit the PEX elbow connectors
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Do not reuse the same tube. Buy a few meters.
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Introduce the new PEX and push steadily and firmly...
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...until it shows at the other side.
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Use a screwdriver to pull it out towards you.
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Now start by making a U for each outlet using 2 compression elbows.
Using a cutter, make a chamfer prior to introducing the elbow.
Be careful not to damage the seals.
Use one drop of dish-washing liquid as a lubricant.
Using a cutter, make a chamfer prior to introducing the elbow.
Be careful not to damage the seals.
Use one drop of dish-washing liquid as a lubricant.
