Trade Safety Lesson PlanDay 1 of 5 • Exploratory Trade Safety & Career Pathways 30-Minute Fast-Track Vocational Lesson Plan • Grade 9 Orientation Focus Materials PPE • Tools • Jr Year Co-Op Safety Competency Identify OSHA 10 standards for eye, foot, and ear protection; demonstrate cut-resistant glove grading. Tool Mastery Distinguish pipe wrenches from adjustable wrenches; inspect jaws, heel jaws, and safety knurls. Career Horizon Explore paid Co-Op starting January of junior year ($18–$24/hr with 80%+ attendance), debt-free apprenticeship, and licensing. 30-Minute Tactical Timeline 00–05 Min The Hook: "Plumbers Protect the Health of the Nation" Display slides 1–2. Contrast waterborne illness history with modern sanitation infrastructure. Reveal starting apprentice wages and high school Co-Op opportunities starting January of junior year. 05–15 Min Safety Briefing & PPE Station Pass-Around Slides 3–4. Pass ANSI Z87.1 safety glasses, Level 4 cut gloves, and channel-lock pliers. Practice proper stance: pull towards yourself, never push a pipe wrench. 15–25 Min Hands-On Tool Handling & Bench Ergonomics Rotation Students rotate in shop pairs through bench stations to handle 10" pipe wrenches, Channellock pliers, and rotary tubing cutters. Practice setting wrench jaws, testing tooth grip on pipe nipples, and maintaining a balanced pulling stance. 25–30 Min Career Horizon Reality Check: Junior Co-Op & Verbal Debrief Highlight the CTE pathway: Sophomore shop → Junior Co-Op starting January ($18–$24/hr alternating weeks for students with 80%+ attendance) → Senior full Co-Op → Journeyman ($85k+). Conduct verbal wrap-up questions. Benchtop Prep Required 1 pair ANSI Z87.1 glasses per student 6 straight pipe wrenches (10" or 12") & pipe nipples 6 slip-joint tongue-and-groove pliers (Channellock) Sample cut-resistant Kevlar glove demo Co-Op Eligibility Focus Remind freshmen that Co-Op placement starting January of Grade 11 requires an 80%+ attendance record and passing OSHA 10 credentials. Co-Op hours count directly toward their State Journeyman apprenticeship work requirements. Flow Masters Exploratory Series • Lesson 1 Teacher Facilitation Plan CTE Chapter 74 & High School Co-Op Aligned
Trade Safety SlidesFreshman Plumbing Exploratory • Day 1 30-Minute Fast Track Trade Safety, Tools & The Modern Plumber Plumbers protect the health of our nation. Discover the science of sanitation, hand tool mechanics, and paid high school Co-Op opportunities. Protecting Public Health Hand Tool Leverage Junior Co-Op (January) The True Purpose of the Trade Plumbers Protect the Health of the Nation 1. Pure, Safe Drinking Water Plumbers install pressurized copper and PEX lines that deliver clean water to every tap. 2. Disease Prevention Clean plumbing eradicated cholera, dysentery, and typhoid—saving millions of lives! 3. Sanitary Waste Removal DWV pipes whisk waste away instantly, while P-trap seals block toxic methane gases. 4. Hospital Life-Support Lines Plumbers braze medical gas lines carrying pure oxygen and suction directly to ICU beds. Official Trade Motto: Plumbers Protect the Health of the Nation Essential First Responders The CTE Career Horizon Paid Co-Op & Debt-Free Trade Earnings Starting Jan • Grade 11 High School Co-Op Work every other week on a real plumbing service or construction truck. Earn money during high school hours! $18 - $24/hr Logs Apprentice Hours Early Post-Graduation Full Apprenticeship Advance to registered apprentice with local contractors or UA union. Zero college debt, full medical and retirement. $25 - $38/hr Scheduled Annual Raises By Age 23–25 Licensed Journeyman Lead commercial jobs, pull municipal permits, or launch your own fleet. Reciprocal licensing across states. $85,000 - $125k+ High Demand • Recession Proof Co-Op Qualification: 80%+ school attendance, passing grades, and OSHA 10 certification. Earn While You Learn Shop Safety Standard Jobsite Personal Protective Equipment (PPE) ANSI Z87.1 Eye Protection Must be worn 100% of the time in the shop. Shields against flying copper burrs, chemical solvent splashes, and torch slag. Cut-Resistant Work Gloves ANSI Cut Level A3 or higher. Protects fingers from razor-sharp freshly cut copper tubing, reamer blades, and steel burrs. Steel-Toe / Composite Boots ASTM rated footwear prevents crushing injuries from dropped cast iron hubs, heavy copper coils, and pipe stands. Ventilation & Hearing Exhaust fans must operate during PVC solvent cementing. Ear protection required when reciprocating saws or chop saws run.
PVC Lecture Lesson PlanDay 2 of 5 • Exploratory Lecture PVC DWV Systems & Prep Mechanics 30-Minute Structured Lecture & Bench Demonstration • Guided Notes & Dry-Fit Format Interactive Lecture & Bench Demo DWV Engineering Deliver structured lecture on gravity flow physics, 1/4" per foot slope, and P-trap atmospheric sewer barriers. Chemical Weld Theory Explain solvent dissolution vs adhesion, purple primer etching, and OSHA 1910.94 fume ventilation codes. Live Bench Demo Model 90° square shear cutting, inner deburring, 15° outer chamfering, and dry-fit witness alignment. 30-Minute Lecture & Demonstration Agenda 00–08 Min Lecture Part 1: Gravity Drainage, Slope & The P-Trap Present Slides 1–2. Explain how wastewater moves without mechanical pumps. Detail why 1/4" per foot slope is code mandated (2 ft/sec self-cleaning velocity). Illustrate the P-trap water seal blocking toxic methane and sewer pathogens. Students record notes in Section 1. 08–16 Min Lecture Part 2: Solvent Fusion Chemistry & OSHA Fume Standards Present Slides 3–4. Teach the chemistry: THF and cyclohexanone solvents melt polymer chains together. Explain why this is cohesion (molecular weld), not glue (surface adhesion). Deliver the safety mandate: volatile organic compounds (VOCs) require powered exhaust hoods, which is why today's lab is 100% dry-fit. 16–22 Min Live Instructor Bench Modeling: The Mechanics of Prep Gather students around the instructor bench. Model making a 90° square cut with ratcheting shears. Show how an unchamfered edge scrapes against the hub wall. Demonstrate filing the 15° outer chamfer, reaming the bore, and creating a pencil witness mark. 22–30 Min Student Dry-Fit Handling & Lecture Note Wrap-Up Students handle pre-cut 1.5" PVC samples and DWV fittings at benches to observe chamfers and verify 1/3 to 2/3 socket interference. Complete remaining lecture note fields and review key takeaways. Demonstration Materials at Front Bench Cutaway transparent PVC P-trap showing standing water seal 1 length of 1.5" Schedule 40 PVC pipe 1 ratcheting PVC pipe shears & 1 half-round bastard file 1 PVC 90° DWV elbow with alignment witness markings Closed, empty demo cans of primer & cement (visual props only) Key Lecture Emphasis Points Stress that plumbers are building sanitation engineers: improper DWV piping literally sickens building occupants. Reiterate that craftsmanship lives in the mechanical cut and chamfer—bad prep causes 80% of jobsite leaks.
PVC Lecture SlidesFreshman Plumbing Exploratory • Day 2 Lecture 30-Minute Fast Track PVC DWV Systems & The Mechanics of Dry-Fit Prep Vocational lecture on drain-waste-vent engineering, gravity slope physics, solvent fusion molecular theory, and OSHA chemical safety. Module 1: DWV Physics Module 2: Fusion Chemistry Module 3: OSHA Fume Rules Lecture Module 1 • Sanitation Engineering How DWV Systems Protect Public Health Core Principle 1 Gravity Slope Physics Waste pipes must pitch exactly 1/4" per foot. At this angle, water flows at 2 feet per second—fast enough to carry solids without outrunning them. Too steep = water leaves solids behind! Core Principle 2 Atmospheric Venting Like placing your finger over a straw, drainage stops without air. Vent pipes extend out through the roof to equalize air pressure in the drainage tree. Prevents hydraulic vacuum suction Core Principle 3 The P-Trap Water Seal Every plumbing fixture has a dip holding 2" to 4" of standing clean water. This creates an airtight physical liquid plug blocking toxic sewer gas. Blocks methane & deadly pathogens Record Module 1 key terms in your Guided Lecture Reference Sheet. Health of the Nation Standard Lecture Module 2 • Chemical Science Molecular Welding: Why It Is NOT "Glue" Glue (Surface Adhesion) Glue is a sticky middleman between two separate parts. The plastic itself never changes. Under water hammer or physical shock, the glue film breaks and leaks. Ordinary glue is illegal in modern plumbing codes! Solvent Fusion (Cohesion) Active solvents (THF & cyclohexanone) melt the polymer glaze. When pressed together, the plastic chains physically intertwine. As solvents evaporate, the joint becomes ONE solid piece! Purple primer is required by code so inspectors can verify etching! Key Trade Rule: Always twist 1/4-turn upon insertion, and hold 30s to prevent tapered pushback. Molecular Polymer Weld Lecture Module 3 • Safety & Craftsmanship OSHA Ventilation Codes & The 15° Chamfer OSHA Fume Safety Mandate Primer and cement emit volatile organic compounds (VOCs). Without powered exhaust booths, vapor inhalation causes dizziness, headaches, and respiratory inflammation. Vocational Safety Rule: We never open chemical cans in an unventilated shop. Today is 100% dry-fit! Why Mechanical Prep Is 80%
PVC Guided Lecture NotesDay 2 Lecture Handout PVC DWV & Prep Guided Notes Freshman Plumbing Exploratory • Technical Lecture & Bench Demonstration Reference Name: Date: Period: 1 Lecture Module 1: Drain-Waste-Vent (DWV) Physics Follow Slides & Instructor Gravity Slope Rule Standard code pitch per foot: Target velocity = 2 ft/sec Vent Stack Function Purpose of atmospheric roof vent: Eliminates vacuum glugging P-Trap Water Seal Deadly gas blocked by standing seal: 2" to 4" clean water barrier 2 Lecture Module 2: The Science of Solvent Fusion (Cohesion vs Adhesion) Theory & Chemistry Why It Is NOT Glue: Record how solvent cement chemically alters the plastic molecules compared to ordinary glue: Purple Primer Code Purpose: Why Hold for 30 Seconds: 3 Lecture Module 3: OSHA Fume Safety & Mechanical Prep Rules Safety Standard OSHA 1910.94 Chemical Ventilation Mandate: Why are chemical cans kept closed in our exploratory shop today? The 15° Outer Chamfer Rule: Explain what happens if an unchamfered, square-edged pipe is forced into a fitting hub: 4 Live Bench Demonstration: Observation Checklist Instructor Demo Observed 90° square shear cut verified against square Observed inner bore reaming & 15° outer file bevel Observed dry-fit 1/3–2/3 depth with pencil witness mark Flow Masters Exploratory Series • Lesson 2 Guided Lecture Notes Handout Lecture & Demonstration Endorsement: ___________________
PVC Lecture Master KeyTeacher Reference • Master Lecture Key PVC DWV & Prep Master Key Day 2 Lecture Facilitation, Exemplar Student Notes & Demonstration Rubric Max Score: 100 Pts Standard: ASTM D2855 & OSHA 1910.94 Module 1: DWV Physics Master Solutions 25 Points Slope Pitch: 1/4" per foot (0.25 in/ft; flows at 2 ft/sec self-cleaning velocity). Roof Vent Purpose: Air Pressure Balance Supplies atmospheric air to prevent vacuum siphonage of trap seals. Gas Blocked: Methane / Sewer Gas Liquid water barrier stops toxic, flammable sewer odors and microbes. Module 2: Chemical Fusion Theory Master Solutions 30 Points Why It Is NOT Glue: Glue relies on superficial surface adhesion without altering the parent plastic. Solvent cement dissolves and softens the PVC polymer chains. When pressed together, the chains interlock and fuse into ONE continuous piece of solid plastic upon evaporation (cohesion). Purple Primer: Chemically strips the hard manufacturing glaze and softens socket walls; purple dye allows plumbing code inspectors to verify proper application. 30-Second Hold: DWV fitting sockets have an intentional taper. Freshly dissolved plastic acts as a hydraulic lubricant, pushing the pipe out like a piston unless held firmly. Module 3: OSHA Fume Rules & Chamfering Master Solutions 25 Points OSHA 1910.94 Fume Ventilation Mandate: Active solvents emit toxic volatile organic compounds (VOCs: THF & MEK). In enclosed shops without local mechanical exhaust booths, fumes build rapidly, causing dizziness and lung irritation. Today operates 100% dry-fit to protect student health. The 15° Outer Chamfer Rule: A sharp, square-cut pipe acts like a squeegee blade, scraping joining compound down to the bottom of the hub socket. This creates a dry joint on the socket walls that leaks, and creates a large bead inside the pipe that catches waste and causes recurrent toilet clogs. Module 4: Bench Demonstration Observation Rubric 20 Points Square Cut (7 pts) Student verifies instructor cut is within 1/16" of 90° using a square. Bore Ream & File (7 pts) Student observes inner deburring and uniform 15° outer bevel filed with rasp. Witness Mark (6 pts) Student observes pencil witness line confirming socket depth and radial alignment. Lecture Facilitation Pro-Tip Pass the transparent cutaway P-trap and dry-fit PVC elbow around the lecture room while talking through Slide 2. Having students physically feel the 1/3-to-2/3 interference fit while you explain socket taper makes the engineering theory tangible without needing chemical exposure.
Copper Sweat Lesson PlanDay 3 of 5 • Exploratory Copper Tubing & Sweat Soldering 30-Minute Fast-Track Vocational Lesson Plan • Supply Piping & Capillary Action Focus Materials Type L Copper • Flux • Lead-Free Solder Copper Tube Grades Differentiate Type K (Green/heavy underground), Type L (Blue/interior supply), and Type M (Red/thin branch). Mechanical Prep Master tubing cutter tightening, ream internal constriction ridge, and polish surface to bright virgin metal. Capillary Physics Demonstrate capillary attraction: how liquid solder defies gravity into a 0.003" fluxed fitting cup. 30-Minute Tactical Timeline 00–05 Min The Hook: "The 100-Year Metal" Display Slides 1–2. Show copper's natural antimicrobial properties (kills bacteria in hours) and 400+ PSI burst resistance. Show color-coded stamps: Green (K), Blue (L), Red (M). 05–15 Min Slide Demo: Prep Secrets & Capillary Attraction Slides 3–4. Demonstrate tubing cutter technique (tighten 1/4-turn per revolution; never overtighten). Emphasize reaming: un-reamed burrs create turbulent water flow and pipe erosion. Show flux paste application. 15–25 Min Hands-On Bench Rotation: Copper Cutting & Fitting Prep Each student cuts a 5" length of 1/2" Type L copper tube, reams the interior ridge with cutter reamer, cleans tube end with emery cloth to bright copper, and wires-brushes fitting cup. Apply flux and dry-fit. 25–30 Min Instructor Torch / ProPress Showcase & Exit Check Demonstrate a 10-second sweat joint with propane torch and lead-free solder, followed by a 4-second ProPress hydraulic crimp. Check student prep work. Benchtop Prep (Per Station) 1/2" Type L hard-drawn copper tubing sticks Handheld copper tubing cutters with fold-out reamers Strips of 120-grit emery cloth or maroon Scotch-Brite 1/2" copper wire fitting brushes Water-soluble soldering paste flux & acid brushes Key Safety Precautions Sharp internal burrs: Warn students never to run bare fingers inside freshly cut copper tube. Never touch copper after heating: Copper conducts heat instantly down the tube. Always use pliers. Flow Masters Exploratory Series • Lesson 3 Teacher Facilitation Plan ASTM B88 Standard Specification Aligned
Copper Sweat SlidesFreshman Plumbing Exploratory • Day 3 30-Minute Fast Track Copper Tubing & The Art of Sweat Soldering Explore the gold standard of potable water delivery: tube grades, precision reaming, capillary action, and modern press tools. Types K, L, & M Emery & Wire Prep Capillary Solder Draw Tubing Specifications Reading the Color Code: Types K, L, & M Green Stripe Type K (Thickest) Heavy wall thickness. Approved for underground water services, commercial mains, and severe burial conditions. Heavy Underground / Service Blue Stripe Type L (Standard) Medium wall thickness. The residential and commercial standard for interior potable water supply lines and boiler piping. Interior Supply Standard Red Stripe Type M (Thinnest) Light wall thickness. Used for low-pressure residential branch lines and hydronic baseboard heating loops. Light Residential / Heating Rule: Copper is sized by Nominal Inside Diameter (OD is always 1/8" larger). 100% Recyclable Natural Metal Fabrication Science Reaming: Why Burrs Destroy Piping The Cutter Wheel Ridge As a rotary cutter penetrates copper, it rolls an interior ridge inward, constricting the pipe diameter by up to 15%. Always use the fold-out reamer or pen deburrer to remove this ridge! The Hidden Threat: Erosion Cavitation If left un-reamed, high-velocity water hits the ridge, causing turbulent vortices and microscopic air bubbles that eat pinholes through copper over time. A 10-second reaming pass saves a $10,000 future water damage claim! Step 2 of Prep: Polish tube end and fitting cup with emery cloth to shiny virgin copper. Bright Metal = Leak-Free Joint Physics in the Torch Flame Capillary Action & Flame-Free Pressing Capillary Sweat Solder Liquid solder is sucked into the microscopic 0.003" space between tube and fitting cup by surface tension—even flowing vertically upwards against gravity! Rule: Solder flows toward the hottest point. Heat the fitting, not the pipe! Modern Flame-Free: ProPress Battery-powered hydraulic jaws exert over 7,000 lbs of force, permanently compressing an engineered copper fitting and EPDM O-ring in just 4 seconds. Huge commercial demand: No open flame permits, no hot work fire watch! PPE Reminder: Safety glasses and cut gloves are mandatory at the copper cutting station. Begin Bench Rotation!
Copper Sweat WorksheetDay 3 Activity Copper Tube & Soldering Prep Freshman Plumbing Exploratory • Grade Identification & Capillary Prep Name: Date: Period: 1 Copper Grade Color Code Identification Match each copper tubing grade with its identifying stripe color and primary trade application. Type K Stripe Color: _________ Wall: Thickest Type L Stripe Color: _________ Wall: Medium Type M Stripe Color: _________ Wall: Thinnest Options for Letters: A. Interior residential potable water standard B. Light-wall heating / branch lines C. Heavy-duty underground water mains 2 Soldering Mechanics & Pipe Prep Science Q1. Why must the interior of a freshly cut copper tube always be reamed? What happens over years of water flow if this step is skipped? Q2. What is the dual purpose of applying soldering paste flux before heating a copper joint? Q3. How does "capillary action" allow molten solder to fill an entire copper fitting cup, even when flowing uphill against gravity? 3 Bench Station Hands-On Inspection Sign-Off Tube cut square without flat spots or oval shape Full reamer deburring pass verified (smooth bore) Polished with emery cloth to bright bare metal Flow Masters Exploratory Series • Lesson 3 Student Worksheet Instructor Bench Approval: ___________________
Copper Sweat Answer KeyTeacher Reference • Answer Key Copper Tube Prep & Solder Key Day 3 Exploratory Evaluation & Bench Inspection Guide Max Score: 100 Pts Standard: ASTM B88 & ASME B16.22 Part 1: Copper Grade Color Code Key 30 Points (10 pts each) Type K Letter C • Green Stripe Thickest wall; approved for underground water services and severe environments. Type L Letter A • Blue Stripe Medium wall; standard for residential and commercial interior potable supply lines. Type M Letter B • Red Stripe Thinnest wall; used for low-pressure residential heating and domestic branch lines. Part 2: Technical Comprehension Key 45 Points (15 pts each) Q1 Expected Answer: Rotary cutters roll an internal constriction ridge inward. If un-reamed, this lip reduces pipe diameter, increases flow velocity, creates severe turbulence, and triggers erosion cavitation (microscopic vortex bubbles that eat pinholes through copper over time). Q2 Expected Answer: Soldering paste flux (1) chemically cleans and dissolves minor residual surface oxides, and (2) forms an airtight protective barrier that prevents rapid re-oxidation of the bare metal when exposed to intense torch heat. Q3 Expected Answer: Capillary attraction is surface tension pulling a liquid into an extremely narrow clearance (approx 0.002"–0.004" between copper tube OD and fitting hub ID). Because molten solder flows toward the hottest point, applying heat to the fitting cup draws solder deep into the joint evenly. Part 3: Bench Station Inspection Rubric 25 Points Square Cut (8 pts) No spiral tracking or egg-shaping; wheel tightened gradually (1/4 turn/rev). Bore Reaming (9 pts) Full internal lip removed; bore is 100% open with no sharp burrs. Emery Polishing (8 pts) Polished 1" from end to bright bare copper; fitting cup wire-brushed. Hot Work & Freshman Exploratory Guidelines Freshmen should practice mechanical prep (cutting, reaming, emery polishing, fluxing, and dry-fitting). Active torch soldering should be conducted as an instructor demonstration or under 1-on-1 direct supervision behind a fire-resistant spark blanket with a 5 lb ABC fire extinguisher within arm's reach. Flow Masters Exploratory Series • Lesson 3 Answer Key Instructor Confidential
PEX Expansion Lesson PlanDay 4 of 5 • Exploratory PEX-A & Cold Expansion Systems 30-Minute Fast-Track Vocational Lesson Plan • Milwaukee M12 ProPEX & Shape Memory Focus Materials PEX-A • ProPEX Rings • M12 Expander Thermal Memory Understand PEX-A cross-linking (Engel method) and how shape memory naturally shrinks expanded tubing. Milwaukee M12 Tool Operate the Milwaukee M12 ProPEX tool with auto-rotating expansion heads to achieve uniform radial stretch. F1960 Inspection Visually verify ASTM F1960 joints: full insertion to shoulder, ring stop orientation, and maximum 1/16" gap. 30-Minute Tactical Timeline 00–05 Min The Hook: "The Pipe That Remembers Its Shape" Display Slides 1–2. Show a kinked piece of PEX-A pipe and hit it with a heat gun to watch it magically return to a round shape. Contrast PEX-A (expansion only) with stiffer PEX-B/C. 05–15 Min Slide Demo: The Milwaukee M12 Auto-Rotating Expander Slides 3–4. Demonstrate the Milwaukee M12 cordless expander. Explain why the expansion head must auto-rotate (prevents internal grooving). Show ProPEX ring positioning with the molded stop lip seated against the pipe edge. 15–25 Min Hands-On Bench Rotation: M12 Expansion & Fitting Insert Students cut 1/2" PEX-A square with shears, slide a 1/2" ProPEX expansion ring onto the end, cycle the Milwaukee M12 tool (4–5 expansions), immediately push the fitting all the way to the shoulder, and hold 5 seconds. Complete Worksheet. 25–30 Min Visual Joint Inspection & Shrink-Back Demonstration Inspect finished student assemblies. Confirm ring stop contacts fitting shoulder with less than 1/16" gap. Compare flow rate: ProPEX full-port vs crimp fitting restriction. Benchtop Prep (Per Station) Coils/sticks of 1/2" Uponor/PEX-A tubing (red & blue) 1/2" ProPEX expansion rings with integrated stop lips 1/2" ASTM F1960 engineered polymer (PPSU) or brass fittings Milwaukee M12 ProPEX Expander Tools with 1/2" heads Milwaukee expansion cone grease / lubricant Crucial Operator Safeguards Never expand PEX-B: Standard PEX-B will crack and split. Only PEX-A (ASTM F876) can be expanded! Speed is key: Once the tool expands the pipe, insert the fitting IMMEDIATELY before memory closes the opening. Flow Masters Exploratory Series • Lesson 4 Teacher Facilitation Plan ASTM F1960 Cold Expansion & Milwaukee M12 Standards
PEX Expansion SlidesFreshman Plumbing Exploratory • Day 4 30-Minute Fast Track PEX-A Tubing & The Milwaukee Expander Harness thermal molecular memory: ProPEX expansion rings, ASTM F1960 full-flow fittings, and the cordless Milwaukee M12 auto-rotating expander. PEX-A Shape Memory Milwaukee M12 Auto-Rotate ASTM F1960 Full Flow Polymer Science PEX-A & The Magic of Thermal Memory Engel Method True PEX-A Flexibility Cross-linked above the melting point (over 85% cross-linking). It is the only PEX pipe flexible enough to expand without cracking. Tightest Bend Radius Shape Recovery Kink Repairable If PEX-A accidentally kinks during rough-in, heating it with a heat gun resets the molecular chains back to a round, perfect pipe! Never Replace Kinked Pipe Zero Restriction Full-Flow Fittings Because the pipe expands, ASTM F1960 fittings match the pipe's internal diameter. Crimp fittings choke water flow by 30%! Max GPM Flow Rate Color Coding: Red = Domestic Hot Water • Blue = Domestic Cold Water Only PEX-A Can Use Expansion! Tool Anatomy & Mechanics The Milwaukee M12 ProPEX Expander The Auto-Rotating Head As the tool cycles, the expansion segments expand, retract, and automatically index a few degrees before the next stroke. Why it rotates: Prevents the head segments from pressing deep vertical grooves into the pipe wall, ensuring a 100% round seal! The ProPEX Ring Stop Edge ProPEX rings feature an integrated molded stop lip. Slide the ring over the pipe until this lip rests squarely against the cut end. No measuring tape or 1/8" gaps required—the built-in stop aligns the ring automatically! Maintenance: Apply a light dab of expander cone grease to the tool cone before each shift. Fast, Clean, Ergonomic Installation Protocol 4 Steps to a Perfect Expansion Joint 01 Square Cut Cut tube squarely at 90° using PEX shears. Clean cut ensures ring sits flat. 02 Slide Ring Slide ProPEX ring until its molded stop edge contacts the cut pipe end. 03 Expand M12 Insert tool head fully. Expand 4 to 6 times until the tool auto-rotates smoothly. 04 Insert & Clamp Push fitting in IMMEDIATELY to the shoulder. Watch memory shrink and clamp!
PEX Expansion WorksheetDay 4 Activity PEX-A Cold Expansion Lab Freshman Plumbing Exploratory • Milwaukee M12 ProPEX Joining & Inspection Name: Date: Period: 1 PEX-A Characteristics & Thermal Memory Q1. Why can only PEX-A (manufactured via the Engel method) be expanded, while attempting to expand PEX-B will crack the pipe? Q2. What is "thermal shape memory," and how does it allow a kinked piece of PEX-A tubing to be repaired on the jobsite? 2 Milwaukee M12 Tool Operation & ProPEX Ring Alignment Q3. Why does the Milwaukee M12 expander head automatically rotate between expansion cycles? What defect would occur if it stayed in one fixed position? Q4. How does the molded stop edge (lip) on a ProPEX expansion ring ensure proper positioning on the pipe end? 3 Bench Station Hands-On Expansion Verification Sign-Off 90° square shear cut with ProPEX ring stop seated M12 tool auto-rotation verified across 4–6 cycles Fitting seated to shoulder with ≤ 1/16" gap to ring Flow Masters Exploratory Series • Lesson 4 Student Worksheet Instructor Bench Approval: ___________________
PEX Expansion Answer KeyTeacher Reference • Answer Key PEX-A Expansion Lab Key Day 4 Exploratory Evaluation & Milwaukee M12 Inspection Guide Max Score: 100 Pts Standard: ASTM F1960 & F876 (PEX-A) Part 1: PEX-A Characteristics & Thermal Memory Key 30 Points (15 pts each) Q1 Expected Answer: PEX-A is cross-linked during the extrusion manufacturing process while the polymer is in an amorphous, molten state (the Engel method), resulting in a cross-linking density exceeding 85%. This grants PEX-A extreme molecular elasticity. PEX-B is cross-linked after extrusion via moisture curing, making its polymer matrix rigid and crystalline; expanding PEX-B tears the polymer chains, causing cracks, stress fractures, and leaks. Q2 Expected Answer: Thermal shape memory is the physical ability of cross-linked polyethylene molecules to return to their original manufactured cylindrical form when energy (heat or time) is applied. If a plumber kinks PEX-A during a tight bend, applying gentle heat from an electric heat gun (approx 260°F–300°F until the tubing turns clear) resets the molecular matrix back to round with zero loss of pressure rating. Part 2: Milwaukee M12 Expander & ProPEX Mechanics Key 45 Points Q3 Expected Answer (25 pts): The Milwaukee M12 expansion head utilizes an internal cam that automatically indexes (rotates a few degrees) on every stroke cycle. This prevents the head segments from pressing repeated, concentrated vertical grooves or ridges into the inner ID wall of the PEX tubing. Grooves create leak paths past the fitting barbs. Auto-rotation ensures a perfectly smooth, 360-degree radial expansion. Q4 Expected Answer (20 pts): The ProPEX ring features an integrated molded stop lip along its back edge. When slid onto the tube end, the lip acts as a positive mechanical physical stop against the freshly sheared pipe face. This prevents the ring from sliding too deep down the pipe or cocking at an angle during the high-force expansion cycle, eliminating the need for manual ruler measurements. Part 3: Bench Station Inspection Rubric 25 Points Square Shear & Ring Fit (8 pts) Clean 90° cut; ring seated flush against the stop edge with no slant. Tool Operation (9 pts) Milwaukee M12 head inserted full depth; auto-rotation verified across 4–6 expansions. Fitting Insertion Gap (8 pts) Fitting inserted immediately; gap between ring edge and fitting shoulder ≤ 1/16" (1 mm). Milwaukee M12 Tool Care for Exploratory Shops Remind students that the expansion cone must be kept clean and lightly lubricated with Milwaukee expander grease. Expanding dry cones causes premature wear and inhibits smooth auto-rotation. If an expansion joint shows a gap exceeding 1/16" from the shoulder, have the student cut the fitting out, inspect the head rotation, and re-attempt.
Rough In Lesson PlanDay 5 of 5 • Capstone Exploratory Mock Rough-In & Career Blueprint 30-Minute Fast-Track Capstone Lesson Plan • Multi-Material Synthesis & Testing Capstone Focus PVC + Copper + PEX-A System Material Matrix Evaluate cost, durability, temperature, and code applications to select between PVC, copper, and PEX-A. System Testing Perform a simulated pneumatic pressure test (50 PSI holding test) to verify airtight mechanical integrity. Career Decision Complete personal exploratory trade reflection and map next steps toward vocational plumbing program selection. 30-Minute Tactical Timeline 00–05 Min The Capstone Brief: "The Wall Rough-In Challenge" Display Slides 1–2. Explain what a rough-in inspection is: all plumbing pipes installed inside framing before sheetrock closes the wall. Emphasize that zero leaks are tolerated. 05–10 Min System Blueprint & Material Selection Review Slide 3. Review the Tri-Material Schematic: PVC drain stack, copper valve stub-out (structural rigidity), and PEX-A cold expansion supply branch lines. 10–22 Min Hands-On Assembly Challenge & Pressure Test Demo Student teams assemble a pre-dimensioned mock lavatory rough-in tree combining 1 PVC drain connection, 1 copper transition stub, and 1 PEX-A expansion branch. Connect to test manifold for 50 PSI pressure gauge holding check. 22–30 Min Exploratory Debrief & Career Pathway Exit Card Students complete the 5-Day Material Selection Matrix and Career Intent reflection. Instructor signs off on the 5-Day Exploratory Skill Passport. Station Layout Setup 1 mock stud bay test board per bench pair Pre-cut 1.5" PVC trap assembly 1/2" copper stub-out bracket with drop-ear elbow 1/2" PEX-A water supply branch with ProPEX rings & M12 expander 1 bicycle air pump with 0–100 PSI Schraeder test plug Key Debrief Questions "Why not make the whole house out of copper?" → Cost and installation speed. "Why not make the whole house out of PEX-A?" → PEX degrades under direct UV sunlight and cannot be used for exposed outdoor drops or fire suppression. Flow Masters Exploratory Series • Lesson 5 Teacher Facilitation Plan Uniform Plumbing Code (UPC) & IPC Aligned
Rough In SlidesFreshman Plumbing Exploratory • Day 5 Capstone 30-Minute Fast Track The Mock Rough-In & Your Trade Career Blueprint Unite all three piping systems—PVC, copper, and PEX—into a leak-proof wall assembly and chart your pathway into high-demand trade apprenticeships and junior Co-Op. Tri-Material System 50 PSI Pressure Test Co-Op Starts Jan (Jr Yr) Strategic Decision Making When to Use Which Material: The Trade Matrix Drain-Waste-Vent Schedule 40 PVC Impervious to sewer acids and rust. Large diameters (1.5" to 4") allow smooth, non-clogging gravity drainage and roof vents. Lowest cost • DWV Only Rigid High-Stress Supply Type L Copper Handles extreme heat, UV sunlight, and 400+ PSI. Used for exposed boiler rooms, water heater hookups, and exterior hose bibbs. Max Durability • Fireproof Concealed Distribution Flexible PEX-A Tubing Fastest to install inside stud bays and joists. Bends without fittings, resists freeze-bursts, and connects with Milwaukee M12 expander. Fastest install • Freeze Proof A Master Plumber designs systems using the exact right pipe for each application. System Harmony Code Compliance The 50 PSI Rough-In Pressure Test What is a Rough-In? The phase where all pipes, vents, and supply stubs are fastened inside open wall studs before drywall, tile, and cabinets are installed. Once drywall goes up, fixing a missed leak costs thousands! The Pressure Holding Test The system is capped and pumped with compressed air to 50 PSI (or 10-ft head of water for DWV). The gauge needle must NOT drop for 15 minutes. Zero pressure loss = Inspector passes the job! Leak Detection: If pressure drops, spray soapy water on joints to spot escaping bubbles. Quality Guarantee Your Future in the Trades The CTE Pathway: Co-Op to Journeyman Grade 10 Foundation Vocational Shop Earn OSHA 10, hot work credentials, trade math, and master commercial blueprint reading in the school shop. Build Hands-On Competency Starting Jan • Grade 11 Paid Junior Co-Op Work alternating weeks with a licensed plumbing contractor. Earn $18–$24/hr while logging apprentice hours before graduating! Earn $10k+ Junior Year Spring By Age 23–25
Rough In WorksheetDay 5 Capstone Rough-In & Trade Blueprint Freshman Plumbing Exploratory • Multi-Material Synthesis & Junior Co-Op Goals Name: Date: Period: 1 Tri-Material Selection Matrix Fill in the best matching material: PVC, Copper (Type L), or PEX-A for each scenario: 1. Main soil stack and drain lines carrying waste from toilet and sinks: 2. Water heater inlet/outlet connections requiring rigid flame/heat resistance: 3. Long flexible potable runs expanded with Milwaukee M12 tool to fixtures: 2 Rough-In Inspection & Pressure Testing Q1. Why must all plumbing piping undergo an official pressure test BEFORE drywall is installed? Q2. If the test gauge needle drops from 50 PSI to 35 PSI during a test, how does a technician locate the exact leak? 3 Junior Co-Op Horizon (Starting Jan Grade 11) & Self-Evaluation Plumbing CTE students can start paid Co-Op jobs in January of Junior year ($18–$24/hr). What two personal habits will you develop in 9th/10th grade to qualify for Co-Op placement? Are you interested in selecting Plumbing & Pipefitting as your high school CTE technical major? YES MAYBE NO Flow Masters Exploratory Series • 5-Day Vocational Passport Certified Instructor Final Endorsement: ___________________
Rough In Answer KeyTeacher Reference • Answer Key Rough-In & Blueprint Key Day 5 Capstone Exploratory Grading & Junior Co-Op Recruitment Guide Max Score: 100 Pts Standard: Uniform Plumbing Code & CTE Co-Op Part 1: Tri-Material Selection Matrix Key 30 Points (10 pts each) 1. Main soil stack and drain lines carrying waste from toilet and sinks: PVC (Schedule 40) 2. Water heater inlet/outlet connections requiring rigid flame/heat resistance: Copper (Type L) 3. Long flexible potable runs expanded with Milwaukee M12 tool to fixtures: PEX-A Tubing Part 2: Rough-In & Pressure Testing Key 40 Points (20 pts each) Q1 Expected Answer: All rough-in plumbing must be pressure tested before drywall, tile, and flooring are installed because fixing a hidden leak inside closed walls requires expensive demolition, causes catastrophic mold and structural water rot, and violates building code. Municipal inspectors must witness a sustained pressure reading before issuing insulation/drywall permits. Q2 Expected Answer: The technician applies or sprays a commercial leak detection fluid (or soapy water solution) around every joint, valve, and fitting. Escaping pressurized air will immediately blow active bubbling froth at the defective connection, pinpointing the leak without guesswork. Part 3: Final 5-Day Exploratory & Junior Co-Op Rubric 30 Points Shop Safety & PPE (10 pts) ANSI Z87.1 eyewear worn 100% across all 5 days; tools handled safely by pulling only. Piping Competency (10 pts) Demonstrated correct cutting, reaming, chamfering, and M12 expansion/inspection. Co-Op Goal Setting (10 pts) Articulated concrete attendance/grade habits needed to qualify for Jan Junior Co-Op. Junior Year Co-Op Counseling Timeline Highlight the high school timeline: Grade 9 Exploratory → Grade 10 Technical Shop (OSHA 10 & Hot Work) → Grade 11 Fall (Pre-Co-Op Interview Prep) → Grade 11 January (Start Paid Co-Op Job @ $18–$24/hr) → Grade 12 (Full Co-Op Year) → Graduation directly into Journeyman Apprenticeship. Flow Masters Exploratory Series • Lesson 5 Answer Key Instructor Confidential
