After-Hours Leak Repair on a Copper Cooling Tower Makeup Line

Nov 14, 2026 Last reply: 4 hours ago 4 Replies
Jump to replies (4)

When this repair is done, a leaking copper makeup line feeding a cooling tower is sealed again and the building is protected from serious water damage. The whole job happened after hours, which makes the tidy result even more impressive in my eyes.



The maker isolated the run by closing adjacent inline ball valves and only pulled the faulty piping apart once those valves were confirmed to be holding. The replacement used two no-stop slip couplings and a 90-degree copper press elbow. Everything was dry-fitted, measured and marked before the permanent work, then the connections were secured with a cordless Milwaukee press tool. The line came back by slowly reopening the ball valves, and the finished joints were inspected and verified leak-free.



The surface prep is the detail that stands out to me: an abrasive sanding cloth plus a Ridgid inner and outer reaming tool. That matters because the failed elbow had unreamed, deformed edges on one side, simply never crimped in the first place. Cleaning up the tube properly before pressing looks like the right lesson learned from that failure.



One thing worth chewing over: a point raised in discussion was that older Viega fittings had tight tolerances and could stay watertight even when never pressed, hiding failures until damage showed up months or years later. Viega now uses wider tolerances so an unpressed connection reveals itself right away. This repair, with every joint pressed and checked, seems like the safer side of that history.



Project by Jumper man Tech. Watch it on their YouTube channel:

formatting link


Solid bit of after-hours plumbing. I am curious how the maker actually confirmed the ball valves were holding before cutting the old section out. Was it watching a gauge, cracking a fitting loose slightly, or just observing the line for a while? That check seems like the step everything else depends on.

The dry-fit, measure and mark routine before pressing is the cleverest part here in my view. Pressed joints cannot be nudged into position after the fact, so getting every length and orientation locked down on a dry assembly removes the chance of a misaligned press on a repair running against the clock. It costs a few extra minutes and buys a lot of certainty.

One improvement for next time: tag or mark those two inline ball valves once the job is done, noting what they isolate. On an after-hours emergency repair the next person on site will not have the context, and clear identification of the isolation points for the makeup line would make any future work on that run faster and safer.

The maker did not say exactly how the check was done. What is known is the sequence: the inline ball valves were closed to isolate the run, the valves were confirmed to be holding, and only then was the faulty piping assembly removed. The method behind that confirmation was never described, so it remains an open point.

Join the Discussion

Have something to add? Share your thoughts — no account required.

Didn't find your answer?

Ask the community — no account required