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Technical Info

Gas sizing • Pressure testing • Warranty • Standards

This section summarises the key technical requirements for Lightning PEX, gas and press systems. It is based on the Lightning Technical Manual and is intended to help installers select, install and test systems in accordance with Australian Standards and Lightning warranty conditions.​

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Gas Sizing & Pressure Drop

Pipe Sizing Example – Lightning Gas Systems (Natural Gas)

Lightning gas systems use approved Lightning PEX-AL-PEX (Sleeve) and Lightning Crimp Gas pipe to safely distribute Natural Gas (NG) and Liquefied Petroleum Gas (LPG). Pipe sizing must always be performed using the correct gas type and allowable pressure drop.

The following example demonstrates the sizing method for Natural Gas at a meter pressure of 2.75 kPa with an allowable pressure drop of 0.75 kPa.

  1. Add the megajoule rating of all appliances on the line (e.g. 190 + 30 + 70 = 290 MJ/h).

  2. Determine the length of the longest run (13 + 10 + 8 = 31 m → use next highest table value, e.g. 35 m).

  3. Using the NG table, find the required pipe size for 290 MJ/h at 35 m.

  4. For each branch run, add fitting allowances, calculate the effective length, select the next highest table length, and determine the pipe size for each appliance.

Lightning provides separate sizing tables for Natural Gas and LPG, and for different allowable pressure drops. Always choose the table that matches the installation conditions.

Natural Gas (NG) Reference Conditions

NG sizing tables are based on:

  • Pressure: 1023.15 mbar

  • Gas temperature: 15 °C

  • Heating value (gross): 38.7 MJ/m³

Multiple tables exist for different allowable pressure drops (0.075, 0.12, 0.25,0.75, 1.5 kPa).

LPG Reference Conditions

LPG sizing tables are based on:

  • Pressure: 1023.15 mbar

  • Gas temperature: 15 °C

  • Heating value (gross): 95.4 MJ/m³

​LPG pipe sizing typically uses an allowable pressure drop around 0.25 kPa.

Gas Sizing Charts – Lightning Systems

Lightning provides approved gas sizing charts for Lightning Sleeve Gas Pipe and Lightning Crimp Gas Pipe systems. These tables cover Natural Gas and LPG across multiple allowable pressure drops. On the final website, each table can be provided as a downloadable PDF or displayed in a pop-up for installer convenience.

Natural Gas – Lightning Sleeve Gas Pipe (Sizing Table)

Sizing tables for Lightning PEX-AL-PEX Sleeve Gas pipe (Natural Gas), including length ranges, load values and recommended pipe diameters.

  • Gas type: NG – Natural Gas

  • Suitable pipe: Lightning Sleeve Gas Pipe

  • Temperature: 15 °C

  • Heating value: 38.7 MJ/m³

Tables are available for several allowable pressure drops (0.075, 0.12, 0.25,0.75, 1.5 kPa), depending on meter conditions.

Pressure Testing & Purging – Drinking Water Systems

All Lightning drinking water systems must be flushed, pressure tested and documented in line with AS/NZS 3500and the Lightning Technical Manual. A compliant pressure test is a prerequisite for any warranty claim.

Lightning Crimp Systems

  • Visually inspect joints to confirm the pipe has been pushed fully to the stopper.

  • Check the inspection holes to ensure the pipe is correctly inserted.

  • Use a test gauge on each joint – the gauge must not touch the copper ring of the completed crimp.

  • Flush the system before and after pressure testing.

  • During initial pressurisation, vent air from the furthest point to avoid air pockets.

  • Test in accordance with AS/NZS 3500 at 1500 kPa for not less than 30 minutes, prior to burial or concealment.

Record results on the Lightning pressure test form available at lightningbuildingproducts.com.au.

Lightning Sleeve Systems

  • Visually confirm all sleeve joints have been pulled all the way to the stopper on the fitting.

  • Flush the installation prior to and after pressure testing.

  • Follow AS/NZS 3500 for test procedure and venting of air from the system.

  • Water services must show no leakage when subjected to a hydrostatic pressure of 1500 kPa for a period of not less than 30 minutes.

  • Testing must be completed before any pipework is concealed or buried.

A completed Lightning pressure test form is required to support any future warranty claim.

Lightning Expansion Systems

  • Visually inspect that all expansion rings have been pushed fully to the stopper on the fitting.

  • Allow a minimum of 30 minutes after completing the last expanded ring fitting before beginning the pressure test.

  • Flush the system before and after pressure testing.

  • Carry out testing in accordance with AS/NZS 3500, testing water services at 1500 kPa for at least 30 minutes.

  • Testing should be completed before any pipework is buried or concealed.

Successful execution and documentation of the pressure test is required for Lightning warranty coverage.

Press Systems – Copper & Stainless Testing

Lightning Copper Press and Lightning 316 Stainless Steel Press systems must be tested in accordance with the relevant gas and water installation standards, and any additional local regulations.

  • Gas installations: test in accordance with AS/NZS 5601 – Appendix E.

  • Water installations: test in accordance with AS/NZS 3500.

  • Ensure all joints are visually inspected for leaks during testing.

The Lightning press systems incorporate a Leak Path Design O-ring, which assists in identifying unpressed joints during pressure testing when installed and tested correctly.

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