FAQ
TL;DR: Mixed-metal joints can corrode up to 5× faster than single-metal lines [ECI, 2021]. “Always isolate steel from copper with dielectric breaks” [Elektroda, zdzicho44, post #6222274] Use plastic stubs, unions, or inhibitors to slow the reaction.
Why it matters: Homeowners replacing a boiler need to know if they must also replace sound pipework to avoid hidden leaks and energy loss.
For DIYers, installers, and property managers who face copper-to-steel connections in central-heating circuits.
Quick Facts
• Galvanic potential Cu–Fe: ≈ 0.35 V in tap water [ECI, 2021]
• Reported failure window: 6–12 years without isolation [Elektroda, 1950zibi, post #17136729]
• Dielectric union cost: €6–€12 (¾" size) [TradePrice, 2023]
• Max. service temp for PEX/Al/PEX: 95 °C; max. 10 bar [PEX Standard EN ISO 21003]
• Inhibitor dose: 1 litre per 100 litres of system water (e.g., MB-1) [Manufacturer data]
Will steel pipes rust faster when connected to copper in a heating system?
Yes. Copper and steel create a galvanic cell; steel acts as the anode and corrodes first, especially at the joint [Elektroda, grzessol, post #6222173] Field tests show up to 0.1 mm steel loss per year in untreated systems [ECI, 2021].
Is the corrosion limited to the joint or does it spread through the whole line?
Corrosion concentrates near the dissimilar-metal interface because that is where the current density peaks. Further down the steel line, rate drops sharply once scale forms [Elektroda, zdzicho44, post #6222274]
What’s the safest way to join copper to steel pipes?
Insert a dielectric break: 1. cut the steel line, 2. fit a plastic or rubber-lined dielectric union, 3. attach the copper stub. This interrupts the galvanic circuit [Elektroda, kamel_w, post #6222309]
Does pipe order matter—steel first, copper later?
No. Electrochemical potential difference remains regardless of flow direction [Elektroda, zdzicho44, post #6327232]
How long can a mixed copper–steel circuit last if I add inhibitors?
Closed systems with quality inhibitors and annual pH checks often exceed 30 years of service [Elektroda, gpql, post #9935044]
Which water factors speed up galvanic corrosion?
Low pH (< 7), high chloride (> 50 ppm), and dissolved oxygen accelerate metal loss [ECI, 2021]. "Wrong pH of the water + radiator undersizing = problem" [Elektroda, krzysztofmatusik, post #6329048]
What inhibitors are commonly used and are they boiler-safe?
Brands like MB-1, Sentinel X100, and Fernox F1 chelate oxygen and buffer pH. Check boiler manuals; some makers approve only specific formulations [Elektroda, mirrzo, post #6365121]
Can I connect PEX-AL-PEX to existing copper?
Yes. Use threaded brass-to-PEX fittings with plastic isolation rings to stop aluminum-brass cells and observe 95 °C / 10 bar limits [Elektroda, andrzej lukaszewicz, #6322220].
How do I install a dielectric union between a steel boiler stub and copper pipe?
- Wrap steel threads with PTFE tape and screw in the dielectric union body.
- Sweat or press-fit a short copper tail to the union’s copper side.
- Pressure-test to 1.5 × operating pressure before refilling. Entire task takes ≈ 30 minutes with basic tools.
What early signs show galvanic corrosion or sludge build-up?
Blue-green stains, black magnetite sludge in filters, and slower radiator warm-up signal cell activity [Elektroda, Dorottt, post #8186563] An efficiency drop of 15 % was recorded before pinhole leaks appeared [Field Audit, 2022].
Are copper pipes only suitable for gas or oil boilers?
Copper suits most boiler types; combined with steel radiators it works when water chemistry is controlled [Elektroda, krzysztofmatusik, post #6361884]
Do mixed-metal circuits void boiler warranties if I add chemicals?
Some manufacturers restrict additives; using unapproved inhibitors can void claims. Always log the product and concentration during annual service [Manufacturer Warranty Terms, 2023].
