taking care of energy and environment

product guide

22

Projects since 1981 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FLEXALEN product overview . . . . . . . . . . . . . . . . . . . . . . 4

FLEXALEN 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FLEXALEN 600 - Insulation values . . . . . . . . . . . . . . . . . . 7

FLEXALEN Straight Lengths . . . . . . . . . . . . . . . . . . . . . . 8

FLEXALEN Straight Lengths - Insulation values . . . . . . . 9

FLEXALEN 1000+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

FLEXALEN 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Transition Fittings, Compression Fittings . . . . . . . . . . . 12

Pupped Composite Union . . . . . . . . . . . . . . . . . . . . . . . 12

Pupped stub flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Transition from plastic to steel . . . . . . . . . . . . . . . . . . . 13

Measurements of flange connections . . . . . . . . . . . . . . 13

Rubber end caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Anchor point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Wall Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Electrofusion couplings . . . . . . . . . . . . . . . . . . . . . . . . . 16

Pre-insulated Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Tee-Half Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Polybutene – the perfect material . . . . . . . . . . . . . . . . 18

Lifetime table for PB pipes . . . . . . . . . . . . . . . . . . . . . . 18

FLEXALEN material properties . . . . . . . . . . . . . . . . . . . 19

Trenching Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Electrofusion welding . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Insulation coupler Installation . . . . . . . . . . . . . . . . . . . . 25

Branches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Building Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Expansion Compensation . . . . . . . . . . . . . . . . . . . . . . . 30

FLEXALEN Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Nomogramm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Pipes sizing ready reckoner . . . . . . . . . . . . . . . . . . . . . . 33

European approvals – 3rd Party . . . . . . . . . . . . . . . . . . 34

When using our material please take into account the set Standards, installation instructions, building regulations, our factory standards and laying instructions for the respective field of application.

Flexalen reserves the right to change product and installation detail without prior notice.

Contents

33

World leaders since 1981

44

5

3

66

FLEXALEN product overviewfor Heating – Hot Water – Chilled Water

1

2

FLEXALEN 600 Single pipe(25 mm – 110 mm O.D.)

FLEXALEN 600 Twin pipe(25 mm – 63 mm O.D.)

3 FLEXALEN 1000+ Multi pipe

55

4

1

2

5 FLEXALEN Straight lengths(63 mm – 225 mm O.D.)

6 FLEXALEN 60(16 mm – 32 mm O. D.)

4 FLEXALEN Cold water (HDPE)

Temperature Range– 15° C to + 95° C

5

66

Peak temperature 95 °CTemperature range –15° C to +95° C

Casing Carrier pipe Wall No. of Minimum Standard Weight Product D.N. Inch Pipe O.D. O.D. I.D. thickness medium bending coil length [kg/ code [mm] [mm] [mm] [mm] pipes radius [m] [m] metre]

VS-RS125A2/25 20 ¾ 125 25 20,4 2,3 2 0,6 100 1,40

VS-RS125A2/32 25 1 125 32 26,0 3,0 2 0,6 100 1,60

VS-RS160A2/40 32 1¼ 160 40 32,6 3,7 2 0,8 100 2,50

VS-RS160A2/50 40 1½ 160 50 40,8 4,6 2 0,8 100 3,00

VS-RS200A2/63 50 2 200 63 51,4 5,8 2 1,25 50 4,25

VS-RS90A25 20 ¾ 90 25 20,4 2,3 1 0,4 100 0,75

VS-RS90A32 25 1 90 32 26,0 3,0 1 0,4 100 0,85

VS-RS90A40 32 1¼ 90 40 32,6 3,7 1 0,5 100 1,00

VS-RS125A50 40 1½ 125 50 40,8 4,6 1 0,7 100 1,75

VS-RS125A63 50 2 125 63 51,4 5,8 1 0,8 100 2,05

VS-RS160A75 65 2½ 160 75 61,2 6,9 1 0,8 100 3,05

VS-RS160A90 80 3 160 90 73,6 8,2 1 1,0 100 3,60

VS-R200A110 100 4 200 110 90,0 10,0 1 1,25 50 5,00

Main advantages● Unique construction

● Water tight bond between corrugated outer pipe and polyolefine insulation.

● Top foam quality – proven λ = 0,031 W/mK at 50° C

● Water diffusion resistance µ>3.500

● Light weight system (1.6 kg for 2x32 in 125 outer casing)

● High flexibility at low temperatures <0°C

● Highly flexible – easy to bend around corners

● Single lines 25 – 110 mm and twin lines 25 – 63 mm

● Easy to install, full range of easy to use fittings

● Built in expansion compensation

● Very low friction loss – proven for high flow speed

● Pressure hammer absorption

■ The compact standard system

Temperature/Pressure rating for PB carrier pipes:

FLEXALEN 600 Dimensions

Twin pipes up to 63 mm, Single pipes up to 110 mm

Watertight bond between foam and outer casing

Operating Temperature in °C -15° C 0° C 20° C 40° C 60° C 70° C 80° C 95° C

Operating Pressure in bar 16 bar 16 bar 16 bar 15 bar 12 bar 10 bar 9 bar 8 bar

FLEXALEN 600

77

Heat loss twin pipe (Heating flow & return)

Domestic Hot Water

Heat loss single pipe (Heating flow & return)

Chart data based on following criteria:

Soil temperature: 10° CCovering: 0,8 mHeat Conductivity soil: 0,8 W/mK

The Lambda conductivity for the soil varies between 0,3-3,0 W/mK depending on the humidity.

Now with improved insulating value λ50 = 0,031 W/mK

2

3

1

5

10

20 30 40 50 60 70 80 90°C Tflow + Tret.

2

15

20

25

30

W/m

1: VS-R125A2/252: VS-R125A2/32 VS-R160A2/403: VS-R160A2/50 VS-R200A2/63

Wärmeverlust Doppelleitungen

8 9

10

4 5 7 6

5

10

20 30 40 50 60 70 80 90°C

15

20

25

30

W/m

4: VS-R90A25 5: VS-R90A32 6: VS-R90A40 7: VS-R125A50 8: VS-R125A63 9: VS-R160A7510: VS-R160A90 VS-R200A110

Wärmeverlust Einzelleitungen

Wärmeverlust Einzelleitungen-Rohrpaar(Vorlauf + Rücklauf)

4: VS-RS90A25 5: VS-RS90A32 6: VS-RS90A40 7: VS-RS125A50 8: VS-RS125A63 9: VS-RS160A7510: VS-RS160A90 VS-R200A110

10

20

20 30 40 50 60 70 80 90°C

30

40

50

60

89

10

4576

W/m

Heat loss for chilled and cold water pipes for medium temperature >10° C

Single pipe

7

634

2

1

W/m

5

10

10 20 30 40°C

7

5

36

1

W/m

-5

-10

-15°C -5 5 100-10

Heat loss for chilled- and cold water pipes for medium temperature >10°C

Single pipe

Heat transmission of chilled- and cold water pipes for medium temperature <10°C

Single pipe

1: VS-RS90A25 2: VS-RS90A32 3: VS-RS90A404: VS-RS125A505: VS-RS125A636: VS-RS160A757: VS-RS160A90 VS-R200A110

5

1: VS-RS90A25 2: VS-RS90A323: VS-RS90A404: VS-RS125A505: VS-RS125A636: VS-RS160A757: VS-RS160A90 VS-R200A1104

2

Heat transmission of chilled and cold water pipes for medium temperature <10° C

Single pipe

7

634

2

1

W/m

5

10

10 20 30 40°C

7

5

36

1

W/m

-5

-10

-15°C -5 5 100-10

Heat loss for chilled- and cold water pipes for medium temperature >10°C

Single pipe

Heat transmission of chilled- and cold water pipes for medium temperature <10°C

Single pipe

1: VS-RS90A25 2: VS-RS90A32 3: VS-RS90A404: VS-RS125A505: VS-RS125A636: VS-RS160A757: VS-RS160A90 VS-R200A110

5

1: VS-RS90A25 2: VS-RS90A323: VS-RS90A404: VS-RS125A505: VS-RS125A636: VS-RS160A757: VS-RS160A90 VS-R200A1104

2

FLEXALEN 600 – Insulation values

88

Heating/Hot waterFLEXALEN straight lengths with PB (Polybutene) carrier pipes – acc. to EN-ISO 15876 – PUR insulation and HDPE outer casing. Alternatively metal outer casings can be offered. Pipe length 3mtr, 6mtr or 12mtr.

Product code D.N. Inch Casing Carrier pipe Insulation No. of Minimum Length Weight pipe O.D. O.D. I.D. thickness medium bending [m] [kg/ [mm] [mm] [mm] [mm] pipes radius [m] metre]

FV-RS125A63 50 2 125 63 51,4 28,0 1 10 6 2,8

FV-RS160A75 65 2½ 160 75 61,4 39,0 1 12 6 4,4

FV-RS160A90 80 3 160 90 73,6 30,0 1 12 6 4,8

FV-R200A110 100 4 200 110 90,0 40,0 1 16 12 6,3

FV-R200A125 100 4 200 125 102,2 32,0 1 16 12 7,4

FV-R250A160 150 6 250 160 130,8 38,0 1 20 12 11,7

FV-R315A225 200 8 315 225 184,0 35,0 1 26 5,80 22

Cold/Chilled WaterFLEXALEN straight lengths with HDPE (Polyethylene) carrier pipes – PUR insulation and HDPE outer casing. Alternatively metal outer casings can be offered. Pipe length 3mtr, 6mtr or 12mtr.

Product code D.N. Inch Casing Carrier pipe Insulation No. of Minimum Length Weight pipe O.D. O.D. I.D. thickness medium bending [m] [kg/ [mm] [mm] [mm] [mm] pipes radius [m] metre]

FV-R125A63PE 50 2 125 63 51,4 28,0 1 10 6 2,8

FV-R160A75PE 65 2½ 160 75 61,4 39,0 1 12 6 4,4

FV-R160A90PE 80 3 160 90 73,6 30,0 1 12 6 4,8

FV-R200A110PE 100 4 200 110 90,0 40,0 1 16 6 6,3

FV-R200A125PE 100 4 200 125 102,2 32,0 1 16 6 7,4

FV-R225A140PE 125 5 225 140 114,6 37,0 1 18 6 9,0

FV-R250A160PE 150 6 250 160 130,8 38,0 1 20 6 11,7

FV-R250A180PE 150 6 250 180 147,2 29,0 1 20 6 14,2

FV-R280A200PE 200 8 280 200 163,6 33,0 1 23 6 17,8

FV-R280A225PE 200 8 280 225 184,0 21,0 1 23 6 19,9

FV-R315A250PE 250 10 315 250 204,6 23,0 1 26 6 24,5

PB carrier pipe PE carrier pipe with trace heating

FLEXALEN Straight Lengths

Please note, that these products are only fabricated according to special request. This may lead to extended delivery time.

99

Chart data based on following criteria:

Soil temperature: 10° CCovering: 0,8 mHeat Conductivity soil: 0,8 W/mK

The Lambda conductivity for the soil varies between 0,3-3,0 W/mK depending on the humidity.

Domestic Hot WaterHeat loss single pipe (Heating flow & return)

5 4

2

3

1

W/m

10

20

30

40

50

60

20 30 40 50 60 70 80 90°C

1: FV-RS125A63 FV-RS160A75 2: FV-RS160A90 3: FV-R200A110 4: FV-R200A125 FV-R225A140 5: FV-R250A160 6: FV-R315A225

65

Heat loss single pipe (Heating flow & return)

6

Tflow + Tret.2

54

2

3

1

W /m

1: FV-RS125A63 FV-RS160A752: FV-RS160A903: FV-R200A1104: FV-R200A125 FV-R225A1405: FV-R250A1606: FV-R315A225

5

10

15

20

25

30

Domestic Hot Water

20 30 40 50 60 70 80 90°C

35

40 6

Heat loss for chilled and cold water pipes for medium temperature >10° C

Single pipe

Heat transmission of chilled and cold water pipes for medium temperature < 10° C

Single pipe

5

4

2

3

1

1: FV-R125A63 2: FV-R160A90 FV-R200A1103: FV-R200A125 FV-R225A140 FV-R250A1604: FV-R250A180 FV-R280A2005: FV-R280A225 FV-R315A250

FV-R160A75

W/m

5

10

15

20

30

25

10 20 30 40°C

5

4

2

3

1

W/m

-5

-10

-15

-20

-30

-25

-15°C -5 5 100-10

Heat loss for chilled- and cold water pipes for medium temperature >10°C

Single pipe

Heat transmission of chilled- and cold water pipes for medium temperature <10°C

Single pipe

1: FV-R125A63 2: FV-R160A90 FV-R200A1103: FV-R200A125 FV-R225A140 FV-R250A1604: FV-R250A180 FV-R280A2005: FV-R280A225 FV-R315A250

FV-R160A75

5

4

2

3

1

1: FV-R125A63 2: FV-R160A90 FV-R200A1103: FV-R200A125 FV-R225A140 FV-R250A1604: FV-R250A180 FV-R280A2005: FV-R280A225 FV-R315A250

FV-R160A75

W/m

5

10

15

20

30

25

10 20 30 40°C

5

4

2

3

1

W/m

-5

-10

-15

-20

-30

-25

-15°C -5 5 100-10

Heat loss for chilled- and cold water pipes for medium temperature >10°C

Single pipe

Heat transmission of chilled- and cold water pipes for medium temperature <10°C

Single pipe

1: FV-R125A63 2: FV-R160A90 FV-R200A1103: FV-R200A125 FV-R225A140 FV-R250A1604: FV-R250A180 FV-R280A2005: FV-R280A225 FV-R315A250

FV-R160A75

FLEXALEN Straight Lengths – Insulation values

1010

■ FLEXALEN 1000+ The multi functional system

Flexalen 1000+: Carefully selected & matched compon-ents combine to make a system that offers easy installati-on and superior insulation for special requirements

● Free moving carrier pipes

● Single line, double line and quattro-pipes multi-line capability

● Cellular waterproof insulation

● Top foam quality – proven λ = 0,031 W/mK at 50 °C

● Superior flexibility at low temperatures < 0°C

● Smooth sliding PB carrier pipes offer easy installation

● Good interconnection between jacket pipe and insulation

● Full compatibility with Flexalen 1000 and Flexalen 600

● Fit to meet future standards

● It satisfies the requirements for sustainable construction

● Certified by KIWA in accordance with BRL policy

Product code D.N. InchCasing

Pipe O.D.[mm]

Carrier pipeO.D.[mm]

I.D.[mm]

Wallthickness

[mm]

No. ofmedium

pipes

Minimumbendingradius[m]

Standardcoil lenght

[m]

Weight[kg /

metre]

FV+RS125A32A25 25 1

125 32 26,0 3,0 1

0,60 100 1,50 20 ¾ 25 20,4 2,3 1

FV+RS160A40A25 32 1¼

160 40 32,6 3,7 1

0,80 100 2,60 20 ¾ 25 20,4 2,3 1

FV+RS200A50A25 40 1½

200 50 40,8 4,6 1

0,90 100 2,90 20 ¾ 25 20,4 2,3 1

FV+RS200A63A32 50 2

200 63 51,4 5,8 1

1,00 100 3,35

25 1 32 26,0 3,0 1

FV+R160A2/25A2/20 20 ¾ 160

25 20,4 2,3 2 0,8 50 2,05

15 ½ 20 14,4 2,8 2

FV+R160A3/25A20 20 ¾ 160

25 20,4 2,3 3 0,8 50 2,10

15 ½ 20 14,4 2,8 1

25 1 32 26,0 3,0 2 FV+R160A2/32A25A20

20 ¾ 160 25 20,4 2,3 1 0,8 50 2,35

15 ½ 20 14,4 2,8 1

FV+R200A3/32A20 25 1 200 32 26,0 3,0 3 0,8 50 2,95

15 ½ 20 20,4 2,8 1

32 1¼ 40 32,6 3,7 2 FV+R200A2/40A25A20

20 ¾ 200 25 20,4 2,3 1 0,8 50 3,15

15 ½ 20 14,4 2,8 1

32 1¼ 40 32,6 3,7 2 FV+R200A2/40A32A25

25 1 200 32 26,0 3,0 1 0,8 50 3,30

20 ¾ 25 20,4 2,3 1

40 1½ 50 40,8 4,6 2 FV+R200A2/50A25A20

20 ¾ 200 25 20,4 2,3 1 0,9 50 3,65

15 ½ 20 14,4 2,8 1

40 1½ 50 40,8 4,6 2 FV+R200A2/50A32A25

25 1 200 32 26,0 3,0 1 0,9 50 3,80

20 ¾ 25 20,4 2,3 1

FLEXALEN 1000+ Dimensions

Temperature/Pressure rating for PB carrier pipes:

Temperature range –15° C to +95° C

Operating Temperature in °C -15° C 0° C 20° C 40° C 60° C 70° C 80° C 95° C

Operating Pressure in bar 16 bar 16 bar 16 bar 15 bar 12 bar 10 bar 9 bar 8 bar

FLEXALEN 1000+

Do not combine heating and hot water with cold water lines!!!

1111

Technical data:Dimensions:

Temperature and Pressure resistance:Polybutene PB-1 Carrier Pipes

Product code PB carrier pipe Insulation Bending radius Coil length Weight O.D. [mm] I.D. [mm] [mm] [m] [m] [kg/lm]

FS-RS42A16 16 11,6 13 0,16 50 0,20

FS-RS46A20 20 14,4 13 0,20 50 0,29

FS-RS51A25 25 20,4 13 0,25 50 0,33

FS-RS58A32 32 26,0 13 0,32 50 0,40

Material: New Thermoplast- Elastomere foamTemperature range: -80 to +95°C (Insulation only)Volume weight: 25-35 kg/m3

Insulation thickness: min. 13 mmHeat conductivity at 10°C: 0,035 W/m*KHeat conductivity at 40°C: 0,038 W/m*KVapour resistance [µ] : ≥ 7000

Fire resistance BS 476 Part6 Class 1 (GB)

BS 476 Part7 Class 0 (GB)

ÖNORM B3800 B1 (AT)

DIN 4102 B1 (DE)

P-92507 M1 (FR)

NEN 6065 Class 1 (NL)

NEN 6066 Class 0 (NL)

Insulation:

Continuous pre-insulated connection line for Heating and Cooling Installations

FOR● Split Air-conditioning● Reversible Heating- Cooling Units● Heat Pumps● Domestic Water● Fluid Connection lines for Beer, soft drinks etc.

IN● Office Buildings● Shopping Centres● Leisure Parks● Domestic Houses● Industry

APPLICABLE in ● False ceilings● Concrete ducts● Embedded into concrete

Operation Temperature (°C) -15° C 0° C 20° C 40° C 60° C 70° C 80° C 95° C

max. operation pressure (bar) 16 bar 16 bar 16 bar 15 bar 12 bar 10 bar 9 bar 8 bar

FLEXALEN 60

1212

■ Pupped stub flanges

■ Pupped Composite Union

Compression BSP thread fitting Product code Pipe OD DN Thread in inch Type

BCA-PB25/2,3 25 20 ¾

BCA-PB32/3,0 32 25 1

BCA-PB40/3,7 40 32 1¼

BCA-PB50/4,6 50 40 1½

BCA-PB63/5,8 63 50 2

BCA-PB75/6,8 75 65 2½

WAK90/8,2 90 80 3

WAK110/10,0 110 100 3

Made of brass with a BSP threadconnection to metal

Product code Pipe OD DN Inch Type

GF-FLANSCH63 63 50 2

GF-FLANSCH75 75 65 2½

GF-FLANSCH90 90 80 3

GF-FLANSCH110 110 100 4

GF-FLANSCH125 125 100 4

GF-FLANSCH140 140 125 5

GF-FLANSCH160 160 150 6

GF-FLANSCH225 225 200 8

Consisting of a loose galvanised backing ring, pupped stub flange and sealing gasket.Connected to carrier pipe by electrofusion coupler

Connection to carrier pipe by butt fusion

Pupped PB weld x NP flange

Product code Pipe OD DN Thread in inch Type

GF-HVEM25/R3/4 25 20 ¾

GF-HVEM32/R1 32 25 1

GF-HVEM40/R5/4 40 32 1¼

GF-HVEM50/R6/4 50 40 1½

GF-HVEM63/R2 63 50 2

PB weld x BSP thread

Connected to carrier pipes

Fittings and flanges

■ Transition Fittings, Compression Fittings

1313

Transition from plastic to steel ■

Measurements of flange connections ■

Item BCA-PB BCA-PB WAK PB flange PB-HV

Description compression fitting compression fitting compression fitting flange connection composite union

Dimensions OD 16 - 50 OD 63 - 75 OD 90 - 110 OD 63 - 225 OD 25 - 63

Transition BSP thread BSP thread BSP thread flange PN 10 BSP thread

Underground laying Yes Yes No No No

Assembly easy fitting without easy fitting without easy fitting without by electrofusion by electrofusion any special tools any special tools any special tools (63-110) welding or butt welding (110-225)

* Underground laying may be allowed, if fitting is made traceable for inspecion.

A check should always be made to ensure a complete seal between flange face and metal valve/metal flange

OD 125 - 225 mmOD 63 - 110 mm

Pipe diameter [mm] 63 75 90 110 125 140 160 225

Flange drilling 50PN10 65PN10 80PN10 100PN16 100PN16 125PN16 150PN16 200PN16

d1 Backing ring diameter [mm] 165 185 200 220 226 250 296 350

D1 Flange face diameter [mm] 90 106 125 150 160 188 216 268

B Flange thickness [mm] 14 15 16 18 25 25 25 32

d Internal diameter (bore) [mm] 78 92 110 133 135 158 178 238

dB Bolt hole diameter [mm] 18 18 18 18 18 18 22 22

k Bolt circle diameter [mm] 125 145 16 180 180 210 240 295

b Backing ring thickness [mm] 18 18 20 20 23 26 28 31

ds Sealing ring diameter [mm] 100 142 135 188

s Sealing ring thickness [mm] 6 8,6 8 8

.k. d D1

.

dB

.

b.

ds

.

s.

D D1

B

Transition and Measurements

1414

Product code Carrier pipe O.D. Type

VS-MAN90A40-A25 25/32/40

VS-MAN125A63-A50 50/63

VS-MAN160A90-A75 75/90

VS-MAN200A110 110

VS-MAN125A2/32-A2/25 2x25/2x32

VS-MAN160A2/50-A2/40 2x40/2x50

VS-MAN200A2/63 2x63

Rubber end caps double

Rubber end caps single

Rubber end caps Multipipe system

Heat shrink end caps

Rubber end caps serving as a seal between the two carrier pipes and the corrugated casing pipe (incl. zip ties)

Rubber end caps serving as a seal between the carrier pipe and the corrugated casing pipe (incl. zip ties)

FV-MAN110/140FL

FV-MAN160FL

FV-MAN225FL

Heat shrink end caps to suit 110 –140 mm carrier / 200 – 225 mm casing

Heat shrink end caps to suit 160 mm carrier / 250 mm casing

Product code Type

FV-MAN160ML

FV-MAN200ML

Rubber end caps serving as a seal between the individual carrier pipes and the corrugated casing pipe (incl. zip ties)

FLEXALEN 1000+ end caps

FLEXALEN 600 end caps

FLEXALEN straight lengths

Rubber end caps

Heat shrink end caps to suit 225 mm carrier / 315 mm casing

1515

Anchor Point ■

Wall Entry ■

Double pipe anchors

Product code Pipe OD DN Inch Type

FV-FlXSCH2/25 25 20 2 x ¾

FV-FIXSCH2/32 32 25 2 x 1

FV-FIXSCH2/40 40 32 2 x 1¼

FV-FIXSCH2/50 50 40 2 x 1½

FV-FIXSCH2/63 63 50 2 x 2

FV-FIXSCH25 25 20 ¾

FV-FIXSCH32 32 25 1

FV-FIXSCH40 40 32 1¼

FV-FIXSCH50 50 40 1½

FV-FIXSCH63 63 50 2

FV-FIXSCH75 75 65 2½

FV-FlXSCH90 90 80 3

FV-FIXSCH110 110 100 4

FV-FIXSCH110ST 110 100 4

FV-FIXSCH125 125 100 4

FV-FIXSCH140 140 125 5

FV-FIXSCH160 160 150 6

FV-FIXSCH225 225 200 8

End caps are not included.Installation guideline: It is recommended that outer surface of the polybutylene pipe is wiped clean with a TANGIT cleaning fluid and a lint free cloth prior to installation of anchor.

Anchor points recommended at transition points to other materials

Product code Diameter Core drill Type Outer casing diameter [mm] [mm]

FV-MD90KB 90 120

FV-MD125KB 125 150

FV-MD160KB 160 200

FV-MD200KB 200 250

FV-MD225KB 225 250

FV-MD250KB 250 300

FV-MD315KB 315 400

Single pipe anchors

Single pipe anchors

Ring-sealing for wall entrysuitable for water pressure up to 1,5 bar

Anchor Point and Wall Entry

Anchor points recommended at transition points to other materials

Anchor points recommended at transition points to other materials

Anchor points recommended at transition points to other materials

Single pipe anchors

1616

Note: Full range of electrofusion elbows, reducers + tees avaible (25 mm - 110 mm)

Product code Pipe OD DN Inch Type

GF-EM25 25 20 ¾

GF-EM32 32 25 1

GF-EM40 40 32 1¼

GF-EM50 50 40 1½

GF-EM63 63 50 2

GF-EM75 75 65 2½

GF-EM90 90 80 3

GF-EM110 110 100 4

Electrofusion coupler PB

Electrofusion welding socket GF

Electrofusion couplings

1717

Pre-insulated Fittings ■

Tee-Half Shells ■

Pre-insulated T-piece for twin pipe

Insulation Half Shells available in Single and Double Format. Complete Set with pipe insulation, Sealing mastic and fixing material. Suitable for all pipe formats with outer casing of 125/160/200. Can also be adapted to 90 mm od casings.

Pre-insulated Y-piece used for the transi-tion from two single pipes to a twin one

Pre-insulated elbow 90º and 45º for twin pipes

Pre-insulated elbow 90º and 45º for single pipes

Pre-insulated twin branch piece, which connects two single pipes with a twin-pipe house service connection

Pre-insulated T-piece used for singleand twin pipes

The following pictures represent only a small part of the possibilities available from our frabrication department. Please forward any design requirements to us, and we will be happy to supply prices.

Pre-insulated Fittings and Tee-Half Shells

1818

■ Polybutene – the perfect material

Our carrier pipes are made from Polybutene (PB-1), commercially available and used successfully for over 35 years

● Temperature range -15 °C up to 95 °C

● Compression end connections for small, simple jobs

● Completely welded jointing system produces homogenous connections

● No build up of scale and calcification

● Very low resistance / pressure loss due to smooth interior walls

● High chemical resistance (also suitable for Geothermal water)

● Drinking water certification for Polybutene grey with international approvals (e.g. KIWA, CSTB)

PB pipes for heating and do-mestic hot water with drinking water approvals

Compression Fittings

Electrofusion - the safe con-nection (longitudinal section)

That Polybutene is the only plastic pipe system currently used in heating systems that can be fully fusion welded and ope-rate up to 95° C!

And, polybutene fusion welded pipes have been used for al-most 40 years!

You can use PB pipe systems in complete confidence, with the knowledge that you are using a tried and trusted welding system.

We are founding members of the Polybutene Piping Systems Association. For more information on the principles of the PBPSA, please contact www.pspba.com.

■ Lifetime table for PB pipesThe life cycle of plastics mainly depends on the surroun-ding temperature.

The data required for a calculation are the following:running season (winter/summer season)running time (in hrs) with the operating temperature

The calculation is based on the results of internal pres-sure/pull-out tests and the extrapolation time factors for polybutylene.

Polybutene

1919

Polybutene carrier

Temperature resistance – 15° C to + 95° C

Density 0,940 g/cm3

Melt index 0,4 g/10 min

Stretch tension 20 N/mm2

Tearing strength 35 N/mm2

Tearing expansion 300 %

E-module 420 N/mm2

Shore hardness D53

Notch ductility without breakage

Ductility without breakage

Length expansion coefficient 0,13 mm/mK

λ−value 0,16 W/mK

Polyethylene casing Stretch tension 22 N/mm2

Tearing strength 32 N/mm2

Tearing expansion 800 %

E-module 800 N/mm2

Notch ductility without breakage

Ductility without breakage

Length expansion coefficient 0,18 mm/mK

λ−value 0,43 W/mK

Polyurethane insulation

Volume weight 50 - 80 kg/m3

Temperature – 40° C to + 110° Cresistance

λ−value 0,033 W/mK

Closed cells 94%

Load resistance: >0,2 N/mm2

Polyethylene insulation

Volume weight 30 - 40 kg/m3

Temperature – 80° C to + 95° Cresistance

λ−value 0,031 W/mK

Closed cells

That Polybutene pipes are far more flexible that other plastic pipes?

ComparisonMaterial E-module (stiffness) [N/mm2]

Polybutene 420PE-X 600 (40% stiffer than Polybutene)Polypropylene 800 (90% stiffer than Polybutene)

Polybutene is the most flexible pipe system for heating and cooling.

We test our Polybutene pipes to ONORM B5153 for 1000 hrs at 95°C.Our Polybutene pipes are tested to higher pressures than other plastic pipes.

Comparison of testMaterial Test pressure

Polybutene 15 BarPE-X 9.8 Bar (tested to a pressure 34% lower than PB)Polypropylene 5.6 Bar (tested to a pressure 62% lower than PB)

Polybutene is the proven, reliable, robust pipe system.

FLEXALEN material properties

2020

Structure of the pipe trench for long-distance heating pipes

The structure of a long-distance heating pipe is determi-ned by the designer on the basis of the instructions sup-plied by the pipe manufacturer, the valid standards and the individual circumstances in the building.

A sand bed of at least 10 cm in any direction must surround the pipeline after the sand has been compressed. The gra-nulation of the sand (= riddle line) is determined by the pipe manufacturer. There must be no coarse grains. After the back filling, the sand is compressed. Thus some small air holes remain in the sand which are only connected by narrow channels (high flow resistance - no air convection in the sand).

Further back filling is normally undertaken using spoil from the trench. Coarse-grain gravel or road metal with or without a small soil portion are not suitable for the filling as they produce air channels with relatively big cross-sec-tions and thus encourage the convection of the encircled air or the water which has invaded the trench. The filling must have a portion of fine-grained material, which pre-vents the development of continuous air channels. After the filling has been poured in, it must be compressed to produce a compact packing of the material.

The covering depends on the location of the ditch. In roads it is formed by the building profile of the road, in meadows and fields it is formed by a „humus layer“. In no case the filling may reach the surface. A clear layering of the materi-als represents an additional barrier for the heat transpor-tation in transitional areas between the different layers.

The ditch must be prepared in accordance with the above pictures. For those areas that must bear transport loads, the law provides a minimum cover of 0.8 m (load class SLW 60); in areas without transport load a minimum cover of 0.5 m is required.

Please consider the corresponding standards and regulati-ons regarding the pipeline course of long-distance heating pipes.

During construction, the trench must be kept dry. For very damp soil, drainage of the trench is recommended to improve the heat insulation effect of the distributing network.

Trenching Details

2121

The polybutylene medium pipes can be connected homogeneously by means of fu-sion welding.

The following welding procedures are applied:

● GF electrofusion welding (dimensions 25 mm – 110 mm)

● Butt welding (dimensions 110 mm – 225 mm)

Call your local representative for details on butt fusion hire facilities

It is recommended that all welding of PB pipes must be undertaken only by trained ope-ratives. Furthermore our laying instructions and the instruction manual for the recom-mended individual welding machines and equipment must be considered.

Please see our laying instructions for the laying and processing guidelines.

Electrofusion

Butt Fusion

Welding

2222

Electrofusion welding – Pipe preparation

Clean the pipe ends Pipe ends must be cleaned and free from oil, dirt and grease. We recommend the use of Tangit fluid cleaner or Tangit cleaning wipes.

Do not chamfer pipe ends.

Abrade Pipe EndsAbrade outer surface of pipe ends with emery cloth (180 grade waterproof) in a radial direction. Make sure that at least the insertion depth is abraded.

Do not abrade the outer surface of the pipe ends in the longitudinal direction.

Clean the pipe ends and internal weld area of the fitting Pipe ends and internal weld area of the fitting must be cleaned and free from oil, dirt and grease. We recommend the use of Tangit fluid cleaner or Tangit cleaning wipes.

Pipe CuttingThe casing pipe should be cut using a sharp cable knife or similar. Cut evenly all the way around the corrugation. Carefully cut away / remove insulation. Cut the carrier pipe with an appropriate pipe cutter as shown.

Use only a wheel cutter for plastic pipe.

Attach rubber end caps. Pull the end cap over the first or second complete corrugation of the casing pipe. Use the supplied zip ties to seal the end cap to the casing pipe and the carrier pipe(s).

Electrofusion welding

2323

Mark Insertion depthMark the depth of insertion on the pipe. Insertion depth guides are marked on the fitting.

Do not use a wax pencil!

Insert pipes into the fittingInsert pipes into the fitting as far as the insertion mark.

Do not tighten the fitting screws! Use only separate alignment clamps. See next step.

Fix and Tighten Fitting Alignment ClampsAlignment clamps must be used for all pipe sizes 25mm to 110mm.

Execution of ElectrofusionConnect the fusion control box to the power supply. Connect fusion cable to fitting terminal. Start the fusion operation by pressing the START button.Fusion process runs automatically.

Fusion CheckThe optical fusion check is verified by the appearance of the welding indicators. Fitting must be allowed to cool with clamps in place for the following

Cooling times:25 mm – 50 mm: 10 mins63 mm – 110 mm: 15 mins

Clamps must not be removed before cooling time has elapsed.

Max. ambient temperature +5° C to +35° C

Electrofusion welding

2424

Pressure Testing

Start pressure testing not earlier than 1 hour after cooling down period

Preparations:Measurement devices have to be installed at the lowest point of the piping system.The piping system should be filled with potable water thoroughly ventilated and separated from main supply.

Preliminary test:The duration depends on the size of the system. Usually it takes 1 hour. Test pressure is 1,5 times working pressure. The pressure has to be checked and built up again after 10, 20 and 30 mins. The pre-test is successful, if the pressure drop between 30 mins and 1 hour is less than 0,6 bar.

Main Test:Should be carried out immediately after the preliminary test.The duration is 2 hours.The main test is successful if the pressure drop is less than 0,2 bar.

a

c

b

d

max

. 0.6

bar

max

. 0.2

bar

Test

pre

ssu

re in

bar

Testpressure

0 10 20 30 60 180(time in minutes)

Preliminary test Main test

Test pressure:For an operating pressure of 10 bar*,a testing pressure of 15 bar should be used.

* according to DIN 1988 TRWI

Ptest = 1.5 x Poperating

Pressure Test Diagram

Pressure Testing

2525

Slide the tubular heat shrink sleeves and the PE casing sleeve over one pipe end. Weld the carrier pipe(s) with electrofusion coupler(s).

Place the PUR half shells over the e/f joint and fix them with tape or a zip tie. Clean both ends of the casing pipe (+ 10 cm on each side) using tangit cleaner.

Slide the PE casing sleeve over the PUR half shells.

Remove the wrapping and the protective polythene covers from the tu-bular heat shrinks. Place the tubular heat shrink over the transition area between the casing pipe and the PE casing sleeve.

Heat the tubular heat shrink sleeve gently and uniformly using a soft (yel-low) flame.

Take care while heating to prevent any damage to the casing pipe.

Insulation coupler Installation

Remark: instead of PUR half shells other insulation materials can be used e.g. PE foam mats.

2626

Tee Half Shell Installation

1. Half Shell Tees

Our half shell tees come as two part mouldings. The tees are designed to accommodate casing sizes of 200mm, 160, 125mm and 90mm (using the adapter). The tee can be cut to suit the casing size by using a sharp wood saw or hacksaw.

2. Prepare Pipe / Fuse fittings

Flexalen pipe and fittings should be prepared and fused as shown in our electrofusion welding instruction.

3. Fit Insulation

Use tubular insulation material to insulate the inner tee areas.Apply two runs of mastic underneath each pipe leg prior to fitting of bottom half shell.

4. Fit bottom half shell

Place bottom half shell (with flat face flange) underne-ath the pipework.

Branches

2727

5. Apply Sealant

Fit bottom half shell.Run two beads of mastic sealant along flange face and run two beads around area where half shell meets casing pipe. Apply mastic in two beads around top of pipe.

6. Fit top half shell

Place top half shell on top of bottom half and secure using zip ties.

7. Drill holes and secure top half shell

Drill the flange area and fix top half shell with supplied screws and flat nuts.

8. Allow mastic to set.

Leave shells to allow mastic to set for approx 30 mins.

Branches

2828

There are several methods of entering a building with Flexalen ...

2. Electrofusion end connection Typical On Line Termination Detail

1. Compression End connection Typical On Line Termination Detail

3. Pre fabricated building entry elbow detail The exposed joint area is then covered with the insula- tion coupling set (see broken out line) comprising of

1. Two half shells of pre cast foam 2. One large wrap aroundheat shrink wrap

Anchor End Cap

Compression Union

Wall

Space betweenFlexalen casingand wall to filled withour waterseal fitting orwaterproof grout.

Anchor End Cap

E/F Coupler

Composite Union

Wall

Space betweenFlexalen casingand wall to filled withour waterseal fitting orwaterproof grout.

Elbow riserC/W end

terminations on

Rubber End Cap

E/F CouplerFlexalen Pipe

Wall

Building Entry

2929

5. Riser Entry Detail using Flexalen 60

6. Entry using Flexalen 60 and builder supplied duct pipe

4. Bending the pipe using its flexibility

Termination fitting

Section of Flexalen 60jointed to carrier pipeby electro-fusion elbow

Heat Shrink connectionbetween insulation casing and duct entry pipe

Termination fitting

Section of Flexalen 60jointed to carrier pipeby electro-fusion couplerand ducted

Building Entry

3030

PB has 35% lower expansion rate than PE-X

The elasticity of the system allows the total pipe system to self compensate, so that expansion loops and bellows are not required.

Only at the building entry point must the pipe ends be fixed with our recommended fixing anchor system, in order to avoid excess stress on transitional fitting(s).

Standard building entry elbow risers do not require anchors

External pipelines, internal pipelines:

For above ground horizontal lines, we recommend that all coiled FLEXALEN pipelines are supported along their entire length by securing to an angle bar bed or adequate cable tray with strong clips or ties placed every metre. The FLEXALEN anchoring system must be used with transition ends.

External pipelines, internal pipelines:

For vertical lines we recommend that the pipeline is secured to the wall or cable tray with strong clips or ties every metre. Transition ends must be used with our anchoring system.

Non-insulated polybutene pipelines:

Precautious must be taken against expansion and contraction, as well as for pipe support, when using un-insulated PB. Ple-ase refer to the comprehensive instructions supplied in the GF Georg Fischer +GF+Instaflex Manual. However, you can find some values regarding the expected length changes and the maximum expansion forces in the following table.

Building connection twin pipe (DIA 25 - 63 mm)

Building connection single pipe (DIA 63 - 110 mm)

Carrier pipe Max. expansion forces X Y Z O.D./[mm] per carrier pipe [N] [mm] [mm] [mm]

25 250 ~175 ~335 ~52

32 410 ~175 ~345 ~55

40 640 ~175 ~360 ~57

50 1000 ~175 ~375 ~68

63 1600 ~175 ~410 ~78

Carrier pipe Max. expansion forces X Y O.D./[mm] per carrier pipe [N] [mm] [mm]

63 1600 ~174 ~420 - 475

75 2200 ~174 ~435 - 485

90 3200 ~174 ~455 - 515

110 4700 ~174 ~485 - 540

That Polybutene has a 35% lower expansion rate than PE-X?

All plastic PB & PE-X pipes carrying hot water require anchoring at transition ends.

All good system manufacturers should recommend anchoring!

Expansion Compensation

Pipe length Temperature difference Δt [K]

[m] 50 60 70 80 35 0,23 0,27 0,32 0,36

40 0,26 0,31 0,36 0,42

45 0,29 0,35 0,41 0,47

50 0,32 0,39 0,45 0,52

60 0,39 0,47 0,55 0,62

70 0,45 0,55 0,64 0,73

80 0,52 0,62 0,73 0,83

90 0,58 0,70 0,82 0,94

100 0,65 0,78 0,91 1,04

Other dimensions on request

3131

Please use our technical support which is available on our FLEXALEN software.1 Free program: FLEXALEN QUICKCALC for source to building applications

Data required for the calculation:Temperature of the flow run [°C] Load [kW]Temperature of the return run [°C] Depth [m]Trench Length of the main line [m] Heat conductivity soil [W/mK] After calculation the following data is available as a hard copy:

● Pipe size (OD) [mm]

● Flow speed [m/s]

● Quantity [l/s and/or m3/h]

● Pressure loss [Pa and/or bar]

● Pressure reserve [bar]

● Temperature drop in flow run [°C]

● Usable load [kW]

● The network volume [l]

2 FLEXALEN FASTNETfor large networks support for network estimation

Data required for the calculations:Sketch of the location line with the load [kW] and the lengths of the pipeline [m]and/ or a verified scale and the geodetic level of the net-work pointsTemperature of the flow run [°C] Temperature of the return run [°C] Pre-pressure for the trans-mitting-station to the house [bar]Depth [m]Heat conductivity soil [W/ mK] After the calculation, the following data is available as hard copy:

● Recommended pipe sizes (OD) [mm]

● Flow speed [m/ s]

● Quantity [l/ s and/ or m3/ h]

● Pressure loss [Pa and/ or bar]

● Simultaneous use

● Pressure reserve [bar]

● Length of the location line in total [m]

● Network volume [l]

● Network code line

● Pump pressure with simulation in relation to variable load requirements

● Another calculation module allows a dynamic analysis of the pipeline [heat loss, fall in temperature]

Data from fastnet provided by Flexalen for products.Ask your representative for details of this service!

FREE

SOFTWARE

FLEXALEN Software

3232

"Nomogramm" to determine the pressure losses when using FLEXALEN pipe systems at a temperature of 90° C.

At a temperature of 60° C the pressure loss has to be assumed 10% higher.

Dimensioning example in red colour

FLEXALEN pipe type Water quantity

l/s Velocity of flow m/s

Heat load at a difference temperature in K

Pressure loss Pa / m

The "Nomogramm" is useful for quick dimensioning of district heating networks with FLEXALEN pipes. The data is exact enough in most cases.

No responsibility is taken for the correctness of data for an individual application.

4

3,5

3

2,5

2

1,5

1,00,9

0,8

0,7

0,6

0,5

0,4

0,35

0,3

0,25

0,2

0,15

0,1

0,090,08

0,07

0,06

0,05

600

500

400

300

250

200

150

100908070

60

50

40

30

20

10987

6

5

4

3

2

3,5

2,5

25

15

kW

150

60504030

1520

108654

21,5

0,80,60,50,40,3

0,2

0,15

10

1520

30

40

50

80100

125150

200

250300

400

500

750

1.0001.2501.500

2.0002.5003.000

4.0005.000

7.500

10.000

15.000

20.000

0,10,08

0,060,05

1

3

80100

200

20 35 50 8 - Bar System

A 25

A 32

A 40

A 50

A 63

A 75

A 90

A 110

A 125

A 140

A 160

A 225

Nomogramm

3333

Please use the following multipliers for authorized higher flowing speeds:

The factors only refer to the transmittable performance, not to the pressure loss!!!!

v=2m/s Factor: 2

v=3m/s Factor: 3

Pipe sizing ready reckoner

DN 30 25 32 40 50 65 80 100 100 125 150 200

¾ 1 1¼ 1½ 2 2½ 3 4 4 5 6 8

ID 20,4 26 32,6 40,8 51,4 61,2 73,6 90 102,2 114,4 130,8 184,0

OD 25 32 40 50 63 75 90 110 125 140 160 225

kW 25 44 69 110 173 246 356 533 687 861 1126 2228

v=1m/s (velocity)

kW 31 56 87 137 217 308 445 666 859 1077 1408 2785

v=1m/s (velocity)

kW 38 67 104 165 260 370 534 800 1031 1292 1690 3342

v=1m/s (velocity)

kW 50 89 140 220 346 494 712 1066 1375 1722 2253 4456

v=1m/s (velocity)

Pa/m(1m/s)

555 402 300 231 175 140 112 88 75 66 56 38

Pa/m(2m/s)

510 410 319 274 239 204 135

Pa/m(3m/s)

595 520 440 284

kW 14 24 38 60 95 135 196 293 378 474 619 1226

v=1m/s (velocity)

kW 6 11 17 27 43 61 89 133 172 215 282 557

v=1m/s (velocity)

DN = diameter standard OD = diameter external ID = diameter internal

Pressure loss approx:

25 K (e.g.: 90º C - 65º C)

30 K (e.g.: 90º C - 60º C)

40 K (e.g.: 90º C - 50º C)

20 K (e.g.: 90º C - 70º C)

11 K (e.g.: 82º C - 71º C)

5 K (e.g.: 7º C - 12º C chilled water)

3434

Test reports andApprovals for POLYBUTENE and FLEXALEN pipes and fittings

FLEXALEN products are carefully monitored and tested by 3rd party test institutes.Approvals for the use in Domestic Hot & Cold Water, Heating and Thermal Water applications are made e.g. in:France: CSTBNetherlands: ISO, KIWA

European approvals – 3rd Party

3535

Notes

AUSTRIA (central support)

THERMAFLEX-FLEXALENRohr- und Isoliersysteme GmbHKaiserstrasse 45, 1070 Wien

Phone: +43.1.523 26 25.0Fax: +43.1.523 26 25.24E-Mail: info@flexalen.comwww.flexalen.comwww.thermaflex.com

NEW ZEALAND

ENERGY PRODUCTS INTERNATIONALGallagher Drive, P.O. Box 15058Hamilton

Phone: +64.07.847 27 05Fax: +64.07.847 42 22E-Mail: pmckenzie@energy-products.co.nzwww.energy-products.co.nz

UK & IRELAND

FLEXALEN Heating & Cooling Products LimitedUnit 1, Station Ind EstStation Road,Methil, Fife, KY8 3 HA, United Kingdom

Phone: +44.845.644 37 93Fax: +44.845.644 38 93E-Mail: ian@flexalen.co.ukwww.flexalen.co.uk

9060

72-E

N

PR

E-INSULATED PIPE SYST

EMS

CER

TI

FICATE FOR FLEXIBLE

CERTIFIEDKIWA

BRL k17401BRL 5609

PART A