Comprehensive Overview of Brass PPR Inserts
We are one of the leading manufacturers and exporters of Brass PPR Inserts and PPR Fitting Inserts from India. We have been supplying precision brass threaded inserts for PPR pipes, brass male and female PPR inserts, brass reducing inserts, brass elbow inserts, brass tee inserts, and specialty brass PPR plumbing inserts to the world market for many decades. Our state-of-the-art manufacturing facility specializes in producing high-quality brass PPR inserts using advanced CNC machining technology, precision threading operations, hot forging processes, surface treatment, and comprehensive quality testing. With over three decades of global experience in brass PPR insert manufacturing, we serve diverse industries including residential plumbing systems, commercial building water supply, industrial piping applications, hot water distribution systems, HVAC and heating systems, irrigation and agricultural systems, fire protection systems, water treatment plants, solar water heating systems, and compressed air distribution networks. Our expertise encompasses working with various brass grades including Brass C37700 forging brass, Brass C36000 free-cutting brass, DZR brass for dezincification resistance, lead-free brass complying with NSF/ANSI 61 standards, and nickel-plated brass for enhanced durability. We manufacture brass PPR inserts ranging from 1/4″ (DN15) to 2″ (DN50) thread sizes with male, female, and reducing configurations, all maintaining precise thread specifications per ISO 228, DIN 2999, or ASME B1.20.1 standards, accurate hexagonal dimensions, excellent sealing performance, superior corrosion resistance, and reliable long-term performance in systems up to 95°C.
Brass PPR Inserts – Threaded Metal Inserts for PPR Pipe Fittings
Brass PPR Inserts are precision-engineered threaded metal fittings designed for permanent integration into polypropylene random copolymer (PPR) plastic pipe fittings, providing reliable threaded connections between PPR piping systems and metal fixtures, valves, appliances, and equipment. These brass inserts feature external knurled or smooth surfaces for secure embedment during PPR fitting manufacturing, precision internal or external threads conforming to international standards, hexagonal wrench flats for installation, and brass material providing excellent corrosion resistance and mechanical strength.
Brass PPR inserts find applications in:
- Residential Plumbing: Faucet connections, water heater connections, washing machine supply, toilet supply lines, shower valves, outdoor hose bibs
- Commercial Buildings: Hotel plumbing, office building fixtures, restaurant equipment, HVAC systems, laundry facilities
- Industrial Applications: Process water distribution, cooling water systems, boiler connections, industrial equipment supply
- Hot Water Systems: Heating system connections rated for 95°C continuous service, radiator connections, heat exchangers
- HVAC Systems: Chilled water distribution, fan coil connections, air handler connections, cooling towers
- Irrigation: Sprinkler connections, valve manifolds, pump connections, drip irrigation headers
- Fire Protection: Sprinkler connections, standpipe valves, fire pump connections (where approved)
- Water Treatment: Filter housing connections, RO system plumbing, water softener installations
- Solar Heating: Solar collector connections, storage tank plumbing, pump stations
- Compressed Air: Low-pressure air distribution, air tool connections, pneumatic control systems
Our brass PPR insert manufacturing services include engineering consultation for insert selection, material recommendation including C37700 forging brass, C36000 free-cutting brass, DZR brass for potable water, and lead-free brass for drinking water compliance, custom insert design for special configurations, production using CNC turning and hot forging, various configurations including male threaded inserts with external BSP/NPT threads, female threaded inserts with internal threads, reducing male-female combination inserts, elbow and tee inserts, thread specifications including BSP parallel (G1/4″ to G2″ per ISO 228), BSP tapered (R1/4″ to R2″ per ISO 7/DIN 2999), NPT tapered (1/4″ to 2″ per ASME B1.20.1), metric threads where required, hexagonal dimensions from 17mm to 50mm across-flats matching standard wrench sizes, dimensional capabilities from 1/4″ (DN15) to 2″ (DN50), tolerance specifications including thread tolerance per ISO/ASME standards verified with Go/No-Go gauges, surface treatments including natural brass finish, nickel plating (5-15 microns), chrome plating, anti-dezincification treatment, performance specifications including pressure rating PN25 at 20°C, PN16 at 60°C, PN10 at 95°C, temperature rating -10°C to +95°C continuous (short-term to 110°C), and complete documentation including material certificates, dimensional inspection reports, pressure test reports, and compliance certificates.
We accommodate production from small quantities of 500-1,000 pieces to ultra-high-volume exceeding 10 million pieces annually, with material specifications conforming to ASTM B16, EN 1982, NSF/ANSI 61, ISO 228, ISO 7, DIN 2999, ASME B1.20.1, and customer requirements. Lead time ranges from four to six weeks for custom designs, with 1-2 weeks for standard sizes from inventory.
Brass Material Grades for PPR Inserts
| Brass Grade | Composition | Key Properties | Applications | Standards |
|---|---|---|---|---|
| Brass C37700 | 60% Cu, 38% Zn, 2% Pb | Forging brass, 380 MPa tensile, excellent hot workability | Hot forged inserts, standard plumbing | ASTM B16, EN 12165 |
| Brass C36000 | 61% Cu, 36% Zn, 3% Pb | Free-cutting, 380-470 MPa, excellent machinability | CNC machined inserts, precision threads | ASTM B16, EN 12164 |
| DZR Brass CW602N | 58% Cu, 39% Zn, As/Sn | Dezincification resistant, 400 MPa, superior corrosion | Potable water, aggressive water conditions | EN 12165, DIN 50930-6 |
| Lead-Free C69300 | Cu-Zn-Si alloy | <0.25% lead, 450 MPa, NSF compliant | Drinking water applications, USA/Canada | NSF/ANSI 61, AB1953 |
| Lead-Free CW724R | Cu-Zn-Si-P alloy | Low lead, 450 MPa, EN compliant | European potable water applications | EN 1982, EN 12165 |
PPR Insert Types and Configurations
Male Threaded PPR Inserts
External threads (BSP G, BSP R, or NPT) for connection to female threaded fixtures, hexagonal body for wrench engagement, knurled section for PPR embedment. Common sizes: 1/4″ to 2″ matching DN15 to DN50 PPR pipes. Applications: connection to faucets, valves, water heaters, appliances requiring male thread.
Female Threaded PPR Inserts
Internal threads (BSP G, BSP R, or NPT) for connection to male threaded equipment, hexagonal body or integrated nut design, knurled external surface for PPR retention. Common sizes: 1/4″ to 2″. Applications: connection to male nipples, thermometers, gauges, valve stems, equipment with male threads.
Reducing Male-Female PPR Inserts
Combination of external male thread and internal female thread in different sizes within single insert, space-saving design eliminating separate reducer and adapter. Common combinations: 3/4″ male × 1/2″ female, 1″ male × 3/4″ female, 1-1/4″ male × 1″ female. Applications: direct size transitions, water heater connections, manifold branches, fixture supplies.
Elbow and Tee PPR Inserts
Elbow inserts with 90° or 45° angle and threaded end, tee inserts with threaded branch connection. Applications: wall-mount fixtures, radiator connections, manifold construction, gauge ports, drain connections, equipment tap-ins.
Manufacturing Process
Hot Forging Process
Brass C37700 billets heated to 650-750°C, closed-die forging forming near-net shape, flash trimming and annealing, shot blasting surface finish. Advantages: high production rates (500-2000 pieces/hour), excellent grain flow and strength, suitable for millions of pieces annually, lower per-piece cost.
CNC Machining Process
Brass C36000 or DZR brass bar stock, CNC turning operations including facing, turning, drilling, threading, knurling, chamfering. Thread manufacturing by cutting or rolling. Advantages: precision threads with tight tolerances, flexibility for custom designs, excellent surface finish, suitable for small to medium volumes.
Surface Treatment
Cleaning and preparation, optional nickel plating (5-15 microns) for corrosion protection and appearance, chrome plating for decorative applications, passivation treatments. Quality control including coating thickness measurement, adhesion testing, salt spray testing (500+ hours for plated).
Quality Control
Dimensional inspection with CMM and optical comparators, thread verification using Go/No-Go gauges per ISO/ASME standards, pressure testing to 1.5× rated pressure, thermal cycling testing (1000+ cycles 20-95°C), material verification with spectrographic analysis, corrosion testing per ASTM B117, dezincification testing per ISO 6509, NSF/ANSI 61 lead leaching testing for lead-free grades, statistical process control with Cpk ≥1.33 target.
Standard PPR Insert Dimensions
BSP Thread Sizes (ISO 228/ISO 7)
| PPR Size | Thread Size | Hex A/F | Insert Length | Typical Application |
|---|---|---|---|---|
| DN15 | G 1/4″ or R 1/4″ | 17mm | 18-25mm | Small fixtures, drain valves |
| DN15 | G 3/8″ or R 3/8″ | 19mm | 20-28mm | Faucets, small appliances |
| DN20 | G 1/2″ or R 1/2″ | 22mm | 25-35mm | Standard faucets, shower valves |
| DN25 | G 3/4″ or R 3/4″ | 27mm | 30-42mm | Water heaters, washing machines |
| DN32 | G 1″ or R 1″ | 32mm | 35-50mm | Main distribution, pumps |
| DN40 | G 1-1/4″ or R 1-1/4″ | 41mm | 40-55mm | Industrial equipment |
| DN50 | G 2″ or R 2″ | 50mm | 50-70mm | Main headers, industrial |
NPT Thread Sizes (ASME B1.20.1)
| PPR Size | Thread Size | TPI | Hex A/F | Insert Length | Application |
|---|---|---|---|---|---|
| DN15 | 1/4″ NPT | 18 | 17mm | 18-25mm | Gauges, small connections |
| DN20 | 1/2″ NPT | 14 | 22mm | 25-35mm | Standard fixtures, valves |
| DN25 | 3/4″ NPT | 14 | 27mm | 30-42mm | Water heaters, HVAC |
| DN32 | 1″ NPT | 11.5 | 32mm | 35-50mm | Pumps, industrial |
| DN50 | 2″ NPT | 11.5 | 50mm | 50-70mm | Main distribution |
Performance Specifications
Pressure and Temperature Ratings
Maximum working pressure: PN25 (25 bar) at 20°C, PN16 (16 bar) at 60°C, PN10 (10 bar) at 95°C. Temperature range: -10°C to +95°C continuous, short-term to 110°C. Burst pressure: >100 bar. Note: System rating determined by PPR pipe/fitting, not brass insert.
Thread Sealing Performance
BSP parallel threads: 20-30 Nm assembly torque with washer, >100 assembly cycles. BSP tapered threads: 25-55 Nm with sealant, 50-75 cycles. NPT threads: 20-50 Nm with sealant, 40-60 cycles. All tested leak-free to 37.5 bar at 20°C.
Corrosion Resistance
Standard brass C37700/C36000: 96-240 hours salt spray. DZR brass CW602N: 500+ hours salt spray, <0.2mm dezincification depth. Lead-free brass: 300-500 hours salt spray, excellent dezincification resistance. Nickel-plated: 1000+ hours salt spray.
Installation Guidelines
Moulding-In Process
Brass insert placed in injection mould cavity, molten PPR injected at 220-280°C, plastic flows around knurled surface creating mechanical interlock, cooling and solidification. Pull-out strength: 500-3000N depending on size. Advantages: strongest retention (90-100% theoretical), perfect alignment, highest production rates, eliminates secondary operation.
Heat-Set Installation
Pre-molded PPR cavity slightly undersized (interference 0.1-0.3mm), brass insert heated to 280-350°C, pressed into cavity with controlled force (200-1500N), surrounding PPR melts and re-solidifies around insert, cooling 10-30 seconds. Advantages: suitable for field modification, moderate equipment cost ($500-$5,000), pull-out strength 80-90% theoretical.
Thread Connection Assembly
BSP parallel threads: use bonded seal washer or O-ring, apply 20-50 Nm torque. BSP tapered and NPT threads: apply PTFE tape (2-4 wraps) or thread sealant paste, ensure 4-6 full thread engagement, apply 20-55 Nm torque per size. Avoid over-tightening. Pressure test at 1.5× operating pressure.
Applications and Industry Examples
Residential Plumbing: G1/2″ male inserts for bathroom and kitchen faucets, G3/4″ inserts for water heater connections, G1/2″ inserts for washing machine supply, reducing inserts for fixture connections.
Commercial Buildings: G1/2″ to G1″ inserts for multi-story riser connections, G3/4″ inserts for commercial restroom fixtures, G1″ inserts for hotel and restaurant equipment.
Industrial Systems: G1″ to G2″ inserts for process water distribution, DZR brass for cooling water systems, threaded inserts for flow meters and gauges.
HVAC Systems: G3/4″ to G1-1/4″ inserts for chiller and boiler connections, G1/2″ inserts for air handler drains, reducing inserts for humidifier supplies.
Irrigation: G3/4″ to G1″ male inserts for sprinkler manifolds, G1/2″ inserts for valve connections, G1″ female inserts for pump discharge.
Solar Heating: G3/4″ to G1″ inserts for solar collector connections rated for glycol mixtures, G1/2″ inserts for temperature sensors and expansion tanks.
Advantages of Brass PPR Inserts
Superior Strength: Brass tensile strength 380-550 MPa vs. PPR 25-35 MPa, withstands 50-100+ assembly cycles vs. 5-10 for plastic threads, maintains dimensional stability across -10°C to +95°C range, proven 50+ year service life.
Reliable Connections: Precision threads per ISO 228, ISO 7, or ASME B1.20.1 ensuring compatibility with all standard fittings, threads maintain form through thousands of thermal cycles, metal-to-metal or gasket seal provides leak-free performance.
Corrosion Resistance: Excellent resistance in potable water with proper grade selection, DZR and lead-free brass superior in aggressive water, optional plating enhances protection, brass superior to steel (no rust).
Regulatory Compliance: Lead-free brass grades comply with NSF/ANSI 61, California AB1953, Vermont Act 193, Federal S.3874 (USA), EN 1982 (Europe), suitable for worldwide drinking water applications.
Cost-Effective: Lower total cost than all-stainless alternatives, minimal maintenance over lifetime, easy replacement during fixture changes, compatible with universal plumbing standards.
Frequently Asked Questions
Q1: What is the difference between BSP and NPT threads on PPR inserts? BSP (British Standard Pipe) has 55° thread angle, used in Europe/Asia/Australia, available as parallel (G-series requiring gasket) or tapered (R-series self-sealing). NPT (National Pipe Thread) has 60° thread angle, used in North America, tapered design requiring thread sealant. Both provide reliable sealing – select based on regional standards and connecting equipment.
Q2: Which brass grade should I specify for potable water applications? For drinking water, specify DZR brass (CW602N) for maximum dezincification resistance, or lead-free brass (C69300 USA, CW724R Europe) for regulatory compliance. Standard C37700/C36000 acceptable for general water but avoid aggressive conditions. Lead-free mandatory in USA/Canada for drinking water contact per NSF/ANSI 61.
Q3: Can brass PPR inserts handle hot water systems up to 95°C? Yes, brass inserts rated for continuous 95°C service with short-term capability to 110°C. Brass maintains full mechanical properties across this temperature range. Pressure rating reduces with temperature: PN25 at 20°C, PN16 at 60°C, PN10 at 95°C. Select DZR or lead-free brass for long-term hot water exposure.
Q4: What installation method is recommended – moulding-in or heat-set? Moulding-in preferred for new fitting production: highest strength (90-100% theoretical), perfect alignment, fastest production, lowest labor cost. Heat-set suitable for field modification, retrofit, or low-volume custom applications. Both methods provide reliable performance when properly executed.
Q5: What are typical lead times and minimum order quantities? Standard sizes (G1/4″ to G2″, R1/4″ to R2″, 1/4″ to 2″ NPT): 1-2 weeks, MOQ 1,000-5,000 pieces. Custom specifications (special threads, lengths, reducing combinations): 4-6 weeks, MOQ 5,000-20,000 pieces. Prototypes: 100-500 pieces within 2 weeks. High-volume (>100,000 pieces): volume discounts 15-30%, blanket orders available.
Why Choose Our Brass PPR Insert Services
- Three Decades of Manufacturing Excellence: 30+ years producing brass PPR inserts for residential, commercial, industrial, and HVAC applications worldwide
- Comprehensive Material Options: C37700 forging brass, C36000 free-cutting brass, DZR brass CW602N, lead-free brass complying with NSF/ANSI 61 and EN 1982
- Precision Manufacturing: Hot forging for high-volume production, CNC machining for precision and custom designs, thread rolling for enhanced strength
- Complete Thread Standards: BSP parallel (ISO 228), BSP tapered (ISO 7/DIN 2999), NPT (ASME B1.20.1), metric threads, all sizes 1/4″ to 2″
- All Insert Configurations: Male threaded, female threaded, reducing male-female combinations, elbow inserts, tee inserts, custom designs
- Quality Certification: ISO 9001:2015 certified, NSF/ANSI 61 compliance for lead-free grades, EN 1982 compliance, complete material traceability
- Surface Treatment Options: Natural brass finish, nickel plating (5-15 microns) for corrosion protection, chrome plating for decorative applications
- Comprehensive Testing: Pressure testing to 1.5× rating, thermal cycling 1000+ cycles, corrosion testing per ASTM B117, dezincification testing per ISO 6509
- High-Volume Production Capacity: Hot forging lines producing 500-2000 pieces/hour, CNC machining centers for precision work, 10+ million pieces annually
- Competitive Pricing: India manufacturing providing 35-45% cost savings vs. North American/European manufacturers, volume discounts for large orders
- Global Export Experience: Serving plumbing manufacturers, PPR fitting producers, distributors worldwide with established logistics and export documentation
Contact Us Today
Ready to discuss your brass PPR insert requirements for PPR fitting manufacturing, plumbing distribution, or project specifications?
Request a Quote: Send specifications including thread type (BSP/NPT), size, male/female/reducing configuration, brass grade, surface finish, quantity to sales@jambrass.com for quotation within 24 hours.
Call Us: +91-22-43449300 / +91-22-43449323 (Monday-Saturday, 9:00 AM – 6:00 PM IST)
Office Address: 1406, 14th Floor, Dalamal Tower, Nariman Point, Mumbai – 400021, Maharashtra, India
Factory Address: Plot 10B, GIDC Industrial Estate, Shanker Tekari, Udyognagar, Jamnagar, Gujarat, India – 361004
Contact Person: Mr. Mehul Vora
Email: sales@jambrass.com
