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07 / 10 / 5000 ex. / pictures by Key

CALPEX Low Temperature System
Flexibly towards a safe future
NEW
: CA
22% LPEX P
im LU
insu proved S
latio
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CALPEX district heating pipe CPX 1.0
Table of Contents
1.0 Table of Contents 1.370 Screwed connectors, outer thread, weld end
1.375 Screwed connectors, coupling: equal, reduced
1.1 System description 1.380 Screwed connectors, T-piece
1.100 System description (general) 1.385 Compression connectors, thread, weld end with
1.105 System description (data) sliding sleeve
1.106 System description (data) 1.390 Compression connectors, coupling, angle 90° with
1.110 Long-term behaviour/lifetime calculation sliding sleeve
1.115 CALPEX UNO range, heating 6 bar – 1.395 Compression T-piece, with sliding sleeve
structure, dimensions, materials, weights and 1.400 Electro-fusion joint
delivery lengths 1.405 End cap, standard, shrinkable
1.116 CALPEX DUO range, heating 6 bar – 1.410 Wall sealing ring, for wall openings
structure, dimensions, materials, weights and 1.415 Building entry, wall opening/core bore
delivery lengths 1.420 Wall seal, core bores/cement pipe liners
1.120 CALPEX UNO/DUO range, sanitary 10 bar – 1.425 Building entry, core bores/cement pipe liners
structure, dimensions, materials, weights and 1.430 Pipe warning tape
delivery lengths
1.125 CALPEX QUADRIGA range, heating 6 bar, 1.5 Underground construction, installation
sanitary 10 bar – structure, dimensions, materials, 1.500 Pipe routing
weights and delivery lengths 1.505 Trench dimensions
1.510 Connection (rigid/flexible), CALPEX plastic casing pipe
1.2 Planning, design engineering 1.515 House entry, screwed connector, shaft entry,
1.200 Pressure loss chart, heating, 6 bar fixed point forces
1.205 Pressure loss chart, sanitary, 10 bar 1.520 House connection, compression joint, shaft entry,
1.210 Heat loss, heating, 6 bar fixed point forces
1.215 Heat loss, sanitary, 10 bar 1.525 Installation of house entry
1.220 Heat loss, heating 6 bar, sanitary 10 bar, QUADRIGA 1.530 Installation tool, general and for screwed connector
1.225 Planning and connection technology, heating strip, 1.535 Installation tool, for joint with sliding sleeves
sanitary, 10 bar 1.540 Heating strip, sanitary, 10 bar, drawing in, sensor, joint
1.3 Components
1.300 House entry bend 90°, heating 6 bar, UNO and DUO
1.305 House entry bend 90°, sanitary 10 bar, UNO and DUO
1.310 House entry bend 90°, heating 6 bar, sanitary 10 bar,
QUADRIGA
1.315 CALPEX L-shell
1.316 CALPEX Big L-shell
1.320 Joint (PE-HD shrink sleeve)
1.325 CALPEX I-shell
1.326 CALPEX Big I-shell
1.330 CALPEX T-shell
1.335 CALPEX Big T-shell
1.340 T-joint
1.345 Y-pipe, heating, 6 bar
1.350 Distribution chamber
1.355 Distribution chamber, installation
1.360 Concrete protective plate for distribution shaft
1.365 Insulation material, PE foam
PUR foam containers
9.3.2015
Subject to technical changes
System description
1. General 2. Range of applications
CALPEX district heating pipe is the registered trade name for a flexible pipe system from Brugg Heating, pipe series 5 (SDR 11):
Pipe Systems, specifically designed for the low temperature use. It is ideal for use in small and Max. temp. for
midsize district and local heating networks, in industrial and agricultural applications, for drink- continuous operation TBmax: 80 °C
ing water supplies, sewage systems, cooling systems and swimming pool installations. Max. permitted
operating temp. Tmax: 95 °C (fluctuating)
CALPEX district heating pipe has a carrier pipe made of cross-linked polyethylene, PEXa. Max. permitted
This material was selected because of its excellent thermal and mechanical properties. It is a operating pressure p: 6 bar
corrosion-proof and chemically resistant material. The product is free of harmful substances, see sheet CPX 1.110
making it exceptionally environment-friendly.
Sanitary, pipe series 3.2 (SDR 7.4):
The PEXa pipe in the heating series is equipped with an oxygen diffusion barrier (EVOH). Max. temp. for
continuous operation TBmax: 80 °C
The thermal insulation is CFC-free flexible rigid polyurethane foam with excellent insulation Max. permitted
values. operating temp. Tmax: 95 °C (fluctuating)
Max. permitted
The bending capability of CALPEX district heating pipe means that it is generally possible to operating pressure p: 10 bar
pass over or under existing supply pipes and obstacles can be easily bypassed. see sheet CPX 1.110
With CALPEX district heating pipe, users can choose the shortest pipe route without the restric-
tions required by the classical method of pipe construction.
The flexible CALPEX district heating pipe is delivered to the site continuously in coils or on a
cable drum. Long delivery lengths enable pipes to be laid in the ground largely without joints.
This means that the pipe trench can be considerably narrower. This in turn allows considerable
savings on underground work, especially as regards DUO pipes.
Taking account of the very short time required for installation, CALPEX district heating pipe is
not only the technically ideal solution but also the key to saving time and expense when setting
up district heating networks; less co-ordination is required on site and the pipes are laid simply
and quickly.
The physical properties of the PEXa pipe combined with the composite insulation mean that
thermal expansion can be ignored when using this product.
Installing the connecting pieces is very simple. The joints are fitted quickly and reliably with
conventional screwed connectors, compression joints or electro-fusion joints. The wide range of
accessories ensures that solutions can be chosen for every possible situation.
CALPEX district heating pipes are manufactured according to the current standard
(EN 15632-1 /-2).
9.3.2015
System description
1. Bonded system
Requirements: Factory insulated, flexible pipe systems according EN 15632-1/-2

Fire behaviour: Building material class B2 (normally inflammable) according to DIN 4102
2. Carrier pipe
Materials Basic material: High-density polyethylene (PE-HD), peroxide cross-linked (PEXa), colour: natural
Bonding agent PE-modified, heat-stabilized, colour: red (heating), silver (sanitary)
Oxygen barrier layer Ethylene / vinyl alcohol (EVOH), heat-stabilized, colour: natural
Requirements As per DIN 16892 / DIN 16893 and E DIN EN 12318-2, pipes in series 3.2
as per DVGW worksheet W 544
Impermeability to oxygen As per DIN 4729 at 40 °C, oxygen permeability based on the interior pipe volume
as per DIN 4726 from ≤ 0.10 g / (m3 x d)
Pipe series DIN 16893 Series 5 (SDR 11): for heating (with EVOH barrier)
Series 3.2 (SDR 7.4): for sanitary (with EVOH barrier)
Long-term behaviour See catalog sheet CPX 1.110
Properties Unaffected by aggressive water; low pressure losses; very good chemical and
mechanical resistance
PEXa carrier pipe Reference temperature °C Value Test standard

Density - 932 - 935 kg/m3 ISO 1183
Thermal conductivity - 0.38 W/mK in Anlehnung an ASTM C 1113
Tensil strength 20 min. 18 N/mm2 ISO 6259
Tensil strength 80 min. 8 N/mm2 ISO 6259
Modulus of elasticity 20 600 N/mm2 ISO 527
Modulus of elasticity 80 200 N/mm2 ISO 527
Linear expansion coefficient 20 1.4 · 10 E-4 1/K -
Linear expansion coefficient 100 2.0 · 10 E-4 1/K -
Crystallite melting range - 128 - 134 °C -
Chem. resistance 20 / 40 / 60 - DIN 8075 B.1
9.3.2015
3. Thermal insulation
Materials: CALPEX heating

CFC-free, cyclopentane-blown polyurethane foam (PUR)
CALPEX sanitary
CFC-free, 100 % CO2-blown polyurethane foam (PUR)
PUR insulation Reference temperature °C CALPEX heating CALPEX sanitary Test standard
Density - > 50 kg/m3 > 50 kg/m3 EN 253
Axial shear strength ≥ 90 kPa EN 15632-2
Thermal concuctivity flexible systems* 50 ≤ 0.0216 W/mK ≤ 0.0234 W/mK EN 253 and ISO 8497
Thermal concuctivity rigid systems 50 ≤ 0.0260 W/mK - EN 253 and ISO 8497
Percentage of closed cells - ≥ 90 % ≥ 90 % EN 253
Water absorbtion 100 ≤ 10 % ≤ 10 % EN 15632-1
Note:
Due to the planned revision of standards, the heat losses are not shown as specified within EN 15632.
4. Protective casing
Materials: linear polyethylene, low density (LLD-PE), seamlessly extruded

Purpose: mechanical protection and moisture resistance
LLD-PE protective casing Reference temperature °C Value Test standard

Density - 918 - 922 kg/m3 ISO 1183
Thermal conductivity - 0.33 W/mK DIN 52612
Crystallite melting range - 122 °C ISO 11357-3
9.3.2015
Long-term behaviour
Lifetime calculation
Operating temperature: Heating (pipe series 5 / SDR 11) Sanitary (pipe series 3.2 / SDR 7.4)
°C Operating pressure (bar) Operating pressure (bar)
1 year 5 year 10 year 25 year 50 year 1 year 5 year 10 year 25 year 50 year
10 17.9 17.5 17.4 17.2 17.1 28.3 27.8 27.6 27.3 27.1
20 15.8 15.5 15.4 15.2 15.1 25.1 24.6 24.4 24.2 24.0
30 14.0 13.8 13.7 13.5 13.4 22.3 21.9 21.7 21.4 21.3
40 12.5 12.2 12.1 12.0 11.9 19.8 19.4 19.3 19.1 18.9
50 11.1 10.9 10.8 10.7 10.6 17.7 17.3 17.2 17.0 16.8
60 9.9 9.7 9.7 9.5 9.5 15.8 15.5 15.3 15.2 15.0
70 8.9 8.7 8.6 8.5 8.5 14.1 13.8 13.7 13.6 13.4
80 8.0 7.8 7.7 7.6 - 12.7 12.4 12.3 12.1 -
90 7.2 7.0 6.9 - - 11.4 11.1 11.0 - -
95 6.8 6.6 6.6 - - 10.8 10.6 10.5 - -
1 MPA = 10 bar
Long-term behaviour: (table)
The values have a safety factor of 1.25 and are based on a series of Example of application
measurements covering an average of 32,000 hours. They can be
compared with Table 5 as per DIN 16893. All values have been tested The basis is a typical temperature collective over one year, with fluctu-
and confirmed by the competent organizations in various countries. ating operation. (gem. EN 15632-2)
The max. operating temperature is 95 °C but considers a short-term
over temperature (fault temperature) of 110 °C. 1 year = 365 days = 8760 hours.
A typical fluctuating temperature distribution for the flow in a district Operating Example 1 Example 2 Example 3
heating system gives an average temperature/year of approx. 66 °C. Temperature Annual Annual Annual
Operating time Operating time Operating time
°C h h h
Lifetime calculation using Miner‘s Rule
95 3,3 0 0
90 292 50 50
Lifetime calculation for fluctuating operating temperatures will be
85 0 100 1000
calculated acc. EN ISO 13760.
80 8468 200 3450
75 0 2000 1000
70 0 2410 0
65 0 4000 0
60 0 0 0
total 8763,3 8760 5500
9.3.2015
CALPEX UNO range

Heating, 6 bar
s1
CALPEX in coils:
Dimensions:
CPX 25/76 - 140/202
D
s
PEXa carrier pipe
UNO
PUR foam
PE foil
LLD-PE casing
CALPEX in straight lengths:

Dimensions:
CPX 160/250
D
d
s
PEXa carrier pipe
PE-HD casing pipe
CALPEX heating, 6 bar, UNO

Type PEX carrier pipe Nominal diameter Outer casing Minimum Volume Weight Maximum delivery lengths*
dxs DN Inches D x s1 bending radius Carrier pipe Jumbo coil Maxi coil
mm “ mm m l/m kg/m m m
25/ 76 25 x 2.3 20 ¾ 78 x 1.9 0.45 0.32 0.90 700 1000
25/ 91 PLUS 93 x 2.1 0.65 0.32 1.00 450 715
32/ 76 32 x 2.9 25 1 78 x 1.9 0.50 0.53 1.00 700 1000
32/ 91 PLUS 93 x 2.1 0.70 0.53 1.38 450 715
40/ 91 40 x 3.7 32 1¼ 93 x 2.1 0.55 0.83 1.39 450 715
40/111 PLUS 113 x 2.3 0.75 0.83 1.98 300 450
50/111 50 x 4.6 40 1½ 113 x 2.3 0.60 1.30 1.97 300 450
50/126 PLUS 128 x 2.7 1.20 1.30 2.20 192 291
63/126 63 x 5.8 50 2 128 x 2.7 1.00 2.07 2.60 192 291
63/142 PLUS 143 x 2.9 0.85 2.07 3.49 160 260
75/142 75 x 6.8 65 2½ 143 x 2.9 0.70 2.96 3.39 160 260
75/162 PLUS 163 x 3.2 0.90 2.96 4.35 92 149
90/162 90 x 8.2 80 3 163 x 3.2 1.00 4.25 4.56 92 149
90/182 PLUS 183 x 3.3 1.20 4.25 4.90 52 86
110/162 110 x 10.0 100 4 163 x 3.2 1.10 6.36 5.10 92 149
110/182 183 x 3.3 1.20 6.36 5.68 52 86
110/202 PLUS** 202 x 3.3 1.40 6.36 6.94 46 80
125/182 125 x 11.4 125 5 183 x 3.3 1.30 8.20 6.37 52 86
125/202 PLUS** 202 x 3.3 1.50 8.20 7.80 46 80
140/202 140 x 12.7 125 5 202 x 3.3 1.40 10.31 7.60 46 80
160/250 160 x 14.6 150 6 250 x 3.9 – 13.43 11.31 12 12
* Supply as section length, as coils and on drums possible. The delivered coil lenght may vary (+/- 5%)
** Available on request
- We will produce different dimensions or special items on request (> 500 m).
- Larger or smaller delivery lengths can be supplied on drums if requested.
- Coil dimensions: Jumbo coil outer diameter 2800 mm x 800 mm (width)
Maxi coil outer diameter 2800 mm x 1200 mm (width)
9.3.2015
CALPEX DUO range

Heating, 6 bar
s1
CALPEX in coils:
Dimensions:
CPX 25/76 - 140/202
D
s
PEXa carrier pipe
DUO PUR foam

PE foil
LLD-PE casing
CALPEX heating, 6 bar, DUO

Type PEX carrier pipe Nominal diameter Outer casing Minimum Volume Weight Maximum delivery lengths*
dxs DN Inches D x s1 bending radius Carrier pipe Jumbo coil Maxi coil
mm “ mm m l/m kg/m m m
25 + 25/ 91 2 x 25 x 2.3 20 + 20 2 x ¾ 93 x 2.1 0.55 2 x 0.32 1.34 450 715
25 + 25/111 PLUS 113 x 2.3 0.75 2 x 0.32 1.91 300 450
32 + 32/111 2 x 32 x 2.9 25 + 25 2 x 1 113 x 2.3 0.60 2 x 0.53 1.87 300 450
32 + 32/126 PLUS 128 x 2.7 1.20 2 x 0.53 2.49 192 291
40 + 40/126 2 x 40 x 3.7 32 + 32 2 x 1¼ 128 x 2.7 1.00 2 x 0.83 2.48 192 291
40 + 40/142 PLUS 143 x 2.9 0.85 2 x 0.83 3.28 160 260
50 + 50/162 2 x 50 x 4.6 40 + 40 2 x 1½ 163 x 3.2 1.10 2 x 1.30 3.96 92 149
50 + 50/182 PLUS 183 x 3.3 1.30 2 x 1.30 5.05 52 86
63 + 63/182 2 x 63 x 5.8 50 + 50 2 x 2 183 x 3.3 1.20 2 x 2.07 5.28 52 86
63 + 63/202 PLUS** 202 x 3.3 1.40 2 x 2.07 5.90 46 80
** Available on request
9.3.2015
CALPEX UNO/DUO range

Sanitary, 10 bar
s1
d
D
s
PEXa carrier pipe
PUR foam
UNO DUO
PE foil
LLD-PE casing
Heating strip channel (HBK)

18
(see sheets CPX 1.225, 1.540) ∞
CALPEX sanitary, 10 bar, UNO

Type Nominal diameter PEX carrier pipe Outer casing Minimum Volume Weight Maximum delivery lengths*
DN Inches dxs D x s1 bending radius carrier pipe Jumbo coil Maxi coil
“ mm mm m l/m kg/m m m
22/ 76 16 5⁄
8 22 x 3.0 78 x 2.0 0.45 0.201 0.96 700 1000
28/ 76 20 ¾ 28 x 4.0 78 x 2.0 0.50 0.314 1.06 700 1000
32/ 76 25 1 32 x 4.4 78 x 2.0 0.50 0.423 1.12 700 1000
40/ 91 32 1¼ 40 x 5.5 93 x 2.2 0.55 0.660 1.56 450 715
50/111 40 1½ 50 x 6.9 113 x 2.4 0.60 1.029 2.25 300 450
63/126 50 2 63 x 8.7 128 x 2.7 1.00 1.633 3.06 192 291
32/111 HBK 25 1 32 x 4.4 113 x 2.4 0.60 0.423 1.83 300 450
40/126 HBK 32 1¼ 40 x 5.5 128 x 2.7 1.00 0.660 2.49 192 291
50/126 HBK 40 1½ 50 x 6.9 128 x 2.7 1.00 1.029 2.76 192 291
CALPEX sanitary, 10 bar, DUO

Type Nominal diameter PEX carrier pipe Outer casing Minimum Volume Weight Maximum delivery lengths*
28 + 22/91 20 + 16 ¾ + 5⁄8 28 x 4.0 + 22 x 3.0 93 x 2.2 0.55 0.314 + 0.201 1.47 450 715
32 + 22/111 25 + 16 1 + 5⁄8 32 x 4.4 + 22 x 3.0 113 x 2.4 0.60 0.423 + 0.201 1.95 300 450
40 + 28/126 32 + 20 1¼ + ¾ 40 x 5.5 + 28 x 4.0 128 x 2.7 1.00 0.660 + 0.314 2.60 192 291
50 + 32/126 40 + 25 1½ + 1 50 x 6.9 + 32 x 4.4 128 x 2.7 1.00 1.029 + 0.423 2.96 192 291
9.3.2015
CALPEX QUADRIGA range

Heating 6 bar, sanitary 10 bar
s1
d
D
s
PEXa carrier pipe
PUR foam
PE foil
LLD-PE casing
CALPEX, heating 6 bar, sanitary 10 bar, QUADRIGA

Type Nominal diameter Carrier pipe Outer casing Minimum Volume Weight Maximum delivery length*
H25 + 25/S28 + 22/142 20 ¾ 25 x 2.3 143 x 3.0 0.7 0.327 3.25 110 180
20 ¾ 25 x 2.3 0.327
20 ¾ 28 x 4.0 0.314
16 5⁄
8 22 x 3.0 0.201
H32 + 32/S28 + 22/142 25 1 32 x 2.9 143 x 3.0 0.7 0.539 3.39 110 180
25 1 32 x 2.9 0.539
20 ¾ 28 x 4.0 0.314
16 5⁄
8 22 x 3.0 0.201
H32 + 32/S32 + 22/142 25 1 32 x 2.9 143 x 3.0 0.7 0.539 3.41 110 180
25 1 32 x 2.9 0.539
25 1 32 x 4.4 0.423
16 5⁄8 22 x 3.0 0.201
H40 + 40/S40 + 28/162 32 1¼ 40 x 3.7 163 x 3.2 1.1 0.835 4.15 65 105
32 1¼ 40 x 3.7 0.835
32 1¼ 40 x 5.5 0.660
20 ¾ 28 x 4.0 0.314
* Supply as section length, as coils and on drums possible. The delivered coil length may vary (+/- 5%)
9.3.2015
Pressure loss chart

Heating, 6 bar
Water temperature 80 °C ṁ = Flow rate in kg/h

Surface roughness ε = 0.007 mm (PEXa) Q·860 Q = Power requirement in kW
(1 mmWS = 9.81 Pa) ṁ ≈
∆T ∆T = Temperature difference
VL (flow)/RL (return) in °C
Q [kW] 160/130,8 mm 140/114,6 mm

200 000
125/102.2 mm
5000
3000
110/90.0 mm
100 000
Wa
3000
2000
4,0
ter
90/73.6 mm
vel
m/s
70 000
oci
ty
2000
75/61.4 mm
1000
40 000
Mass flow rate m [kg/h]
30 000
63/51.4 mm
1000
500
20 000
3,0
m/s
50/40.8 mm
500
2,0
300
m/s
10 000
1,5
200
40/32.6 mm
300
m/s
1,0
150
m/s
200
0,7
5000
32/26.2 mm
5m
100
150
4000
/s
0,5
75
3000
m/s
0,4
100
25/20.4 mm
m/s
50
0,3
75
2000
m/s
40
50
30
1000
30
20
15
20
500
10
300
20
30
40
50
80
120
140
160
180
1200
1400
1600
1800
100
200
300
400
500
800
20 °C
30 °C
1000
2000
∆T
Pressure loss ∆p [Pa/m]
9.3.2015
Pressure loss chart

Sanitary, 10 bar
Water temperature 60 °C ṁ = Flow rate in kg/h

Surface roughness ε = 0.007 mm (PEXa) Q = Power requirement in kW
Q·860
(1 mmWS = 9.81 Pa) ṁ ≈
VL (flow)/RL (return) in °C
Q [kW]
40 000
1000
30 000
m
5 , 6m
/ 4 2")
500
20 000 6 3 N 50,
(D
Mass flow rate m [kg/h
500
3,0
mm
300
• 6,211/2”)
m
/ 3
5 0 0,
/s
4
10 000 (DN
300
200
Wa
mm
9,011/4")
te
2
r ve
/
4 0 2, 3
loc
(DN
200
ity
5000
100
m
3 ,2 )m
2,0
2
2 / , 1”
3 25
m/
(DN
3000 m
s
m
1,5
0 , 0 ")
100
8 / 2 , 3/4
m/
2 20
(DN
50
2000
1,0
m
m/
0 m")
0,7
,
s
6
/ 1 5/8
50
2 2 N 16,
5m
30
(D
/s
1000
0,5
30
20
m/
0,4
s
m/
0,3
s
20
m/
500
s
10
300
20
120
140
160
180
30
40
50
80
1200
1400
1600
1800
30 °C
20 °C
100
200
300
400
500
600
1000
2000
∆T
9.3.2015
Heat loss
Heating, 6 bar
CALPEX UNO
Heat losses q [W/m] for one UNO pipe
CALPEX UNO U-value Average operating temperature TB [°C]
[W/mK] 40° 50° 60° 70° 80°
25/ 76 0.1142 3.43 4.57 5.71 6.85 7.99
25/ 91 PLUS 0.0993 2.98 3.97 4.97 5.96 6.95
32/ 76 0.1442 4.33 5.77 7.21 8.65 10.09
32/ 91 PLUS 0.1212 3.64 4.85 6.06 7.27 8.48
40/ 91 0.1510 4.53 6.04 7.55 9.06 10.57
40/111 PLUS 0.1236 3.71 4.94 6.18 7.42 8.65 a = 0.1 m
50/111 0.1551 4.65 6.20 7.76 9.31 10.86
H = 0.8 m
50/126 PLUS 0.1360 4.08 5.44 6.80 8.16 9.52
63/126 0.1767 5.30 7.07 8.84 10.60 12.37
63/142 PLUS 0.1539 4.62 6.16 7.70 9.23 10.77
75/142 0.1908 5.72 7.63 9.54 11.45 13.36
75/162 PLUS 0.1616 4.85 6.46 8.08 9.70 11.31
90/162 0.2057 6.17 8.23 10.29 12.34 14.40
90/182 PLUS 0.1747 5.24 6.99 8.74 10.48 12.23 TE E
110/162 0.2957 8.87 11.83 14.79 17.74 20.70
110/182 0.2355 7.07 9.42 11.78 14.13 16.49
110/202 PLUS 0.1992 5.98 7.97 9.96 11.95 13.94
125/182 0.3026 9.08 12.10 15.13 18.16 21.18
125/202 PLUS 0.2771 8.31 11.08 13.86 16.63 19.40
140/202 0.3084 9.25 12.34 15.42 18.50 21.59
160/250* 0.3028 9.08 12.11 15.14 18.17 21.20
CALPEX DUO (flow and return in one pipe)

Heat losses q [W/m] for one DUO pipe
CALPEX DUO U-value Average operating temperature TB [°C] RL (return)
[W/mK] 40° 50° 60° 70° 80°
25 + 25/ 91 0.1786 5.36 7.14 8.93 10.72 12.50 VL (flow)
25 + 25/111 PLUS 0.1392 4.18 5.57 6.96 8.35 9.74
32 + 32/111 0.1829 5.49 7.32 9.15 10.97 12.80
32 + 32/126 PLUS 0.1571 4.71 6.28 7.86 9.43 11.00 H = 0.8 m
40 + 40/126 0.2108 6.32 8.43 10.54 12.65 14.76
40 + 40/142 PLUS 0.1741 5.22 6.96 8.71 10.45 12.19
50 + 50/162 0.1954 5.86 7.82 9.77 11.72 13.68
50 + 50/182 PLUS 0.1662 4.99 6.65 8.31 9.97 11.63 TE
63 + 63/182 0.2381 7.14 9.52 11.91 14.29 16.67 E
63 + 63/202 PLUS 0.2075 6.23 8.30 10.38 12.45 14.53
Note:
Due to the planned revision of standards, the heat losses are not shown as specified within
EN 15632.
.
Type of installation, CPX UNO: 2-pipe, laid in the ground Heat loss during operation:
Type of installation, CPX DUO: 1-pipe, laid in the ground q = U (TB -TE) [W/m]
Pipe distance: a = 0.10 m U = Heat transfer coefficient [W/mK]
Cover above pipe: H = 0.80 m TB = Average operating temperature [°C]
Ground temperature: TE = 10 °C TE = Average ground temperature [°C]
Soil conductivity: E = 1.0 W/mK VL = Flow
Conductivity of PUR foam: PU = 0.0216 W/mK RL = Return
*Conductivity of PUR foam: PU = 0.0260 W/mK
Conductivity of PEX pipe: PEXa = 0.38 W/mK
Conductivity of PE pipe: PE = 0.33 W/mK
9.3.2015
Heat loss
Sanitary, 10 bar
CALPEX UNO
CALPEX UNO U-value Average operating temperature TB [°C]
[W/mK] 40° 50° 60° 70° 80°
22/ 76 0.1131 3.39 4.52 5.66 6.79 7.92
28/ 76 0.1387 4.16 5.55 6.94 8.32 9.71
32/ 76 0.1588 4.76 6.35 7.94 9.53 11.12
40/ 91 0.1666 5.00 6.66 8.33 10.00 11.66
50/111 0.1713 5.14 6.85 8.57 10.28 11.99
63/126 0.1957 5.87 7.83 9.79 11.74 13.70
H = 0.8 m
32/111 HBK 0.1127 3.38 4.51 5.64 6.76 7.89
40/126 HBK 0.1220 3.66 4.88 6.10 7.32 8.54
50/126 HBK 0.1497 4.49 5.99 7.49 8.98 10.48
TE E
CALPEX DUO
Heat losses q [W/m] for one DUO pipe RL (return)
CALPEX DUO U-value Average operating temperature TB [°C]
[W/mK] 40° 50° 60° 70° 80° VL (flow)
28 + 22/91 0.1956 5.87 7.82 9.78 11.74 13.69
32 + 22/111 0.1677 5.03 6.71 8.39 10.06 11.74
H = 0.8 m
40 + 28/126 0.1878 5.63 7.51 9.39 11.27 13.15
50 + 32/126 0.2476 7.43 9.90 12.38 14.86 17.33
TE
E
Type of installation, CPX UNO: 1-pipe, laid in the ground Heat loss during operation:
Type of installation, CPX DUO: 1-pipe, laid in the ground q = U (TB -TE) [W/m]
Cover above pipe: H = 0.80 m U = Heat transfer coefficient [W/mK]
Ground temperature: TE = 10 °C TB = Average operating temperature [°C]
Soil conductivity: E = 1.0 W/mK TE = Average ground temperature [°C]
Conductivity of PUR foam: PU = 0.0234 W/mK
Conductivity of PEX pipe: PEXa = 0.38 W/mK
9.3.2015
Heat loss
Heating 6 bar, sanitary 10 bar, QUADRIGA
CALPEX QUADRIGA
Heat losses q [W/m] for one QUADRIGA pipe
CALPEX QUADRIGA U-value Average operating temperature TB [°C]
[W/mK] 50° 55° 60° 65°
H 25 + 25/S 28 + 22/142 0.159 6.34 7.13 7.93 8.72
H 32 + 32/S 28 + 22/142 0.184 7.34 8.26 9.18 10.10
H 32 + 32/S 32 + 22/142 0.199 7.97 8.96 9.96 10.96
H = 0.8 m
H 40 + 40/S 40 + 28/162 0.235 9.40 10.58 11.75 12.93
TE
E
Type of installation for QUADRIGA: 1-pipe, laid in the ground Heat loss during operation:
Cover above pipe: H = 0.80 m q = U (TB -TE) [W/m]
Ground temperature: TE = 10 °C U = Heat transfer coefficient [W/mK]
Soil conductivity: E = 1.0 W/mK TB = Average operating temperature [°C]
Conductivity of PUR foam: PU = 0.0234 W/mK TE = Average ground temperature [°C]
Conductivity of PEXa pipe: PEX = 0.38 W/mK
CALPEX QUADRIGA - heat loss during operation
Example of calculation for average operating temperature TB [°C]

Flow - heating: 70 °C
Return - heating: 40 °C
Flow - sanitary: 60 °C
Return - sanitary: 50 °C
70° + 40° + 60° + 50°

TB = = 55 °C
4
9.3.2015
Planning and connection technology

Heating strip, sanitary, 10 bar
1. Requirements for heating strip
1.1 Minimum power
In relation to a maintained temperature of:

Type CALPEX UNO 40 °C 50 °C 60 °C
32/111 5.8 W/m 7.8 W/m 9.6 W/m
40/126 6.3 W/m 8.3 W/m 10.4 W/m
50/126 7.3 W/m 10.3 W/m 12.8 W/m
1.2 Recommendations for heating strip
Hot water: Frost protection:

HWAT-R from Tyco Thermal Controls N.V. meets the FS-B-2X from Tyco Thermal Controls N.V. requires
requirement for Ø 50/126, 60 °C thermostat with temperature sensor, UTR15
Automatic power adjustment with HWAT-ECO
Max. heating circuit length in relation to a cut-in temperature of 12 °C (HWAT) or 0 °C (FS-B-2X)

Heating strip type Fuse Length Lmax
HWAT-R 13 A 60 m
16 A 80 m
20 A 100 m
FS-B-2X 10 A 65 m
16 A 105 m
Fuse protection using automatic cutouts with characteristic C
2. Joint
L ≤ Lmax* L ≤ Lmax*
Through connection Separation of heating strip
Supply Through connection Supply End closure Supply
3. T-branch End closure
Through connection Supply Through connection

Supply
End closure
L ≤ Lmax* L ≤ Lmax*
For the T-branch, note that the sum of two connected pipes must not be > Lmax*. T-switches cannot be supplied.
* Lmax = max. permitted length for heating strip
The heating strip and the accessories are installed by the electrician!
9.3.2015
House entry bend, 90°

Heating 6 bar, UNO and DUO
Bend, 90° Bend, 90° DN 150 (St 37.0) With welded-on compression coupling
Dimensions: CPX 25/76 - 125/182 Dimensions: CPX 140/202 - 160/250
1100 UNO DUO
1114
1114
1600
250
250
Figures in mm
CALPEX UNO
Type PEX carrier pipe Outer casing Volume Weight
dxs D x s1 carrier pipe
mm mm l/m kg/unit
25/ 76 25 x 2.3 75 x 2.9 0.32 2.30
25/ 91 PLUS 25 x 2.3 90 x 3.5 0.32 -
32/ 76 32 x 2.9 75 x 2.9 0.53 2.50
32/ 91 PLUS 32 x 2.9 90 x 3.5 0.53 -
40/ 91 40 x 3.7 90 x 3.5 0.83 3.47
40/111 PLUS 40 x 3.7 110 x 4.3 0.83 -
50/111 50 x 4.6 110 x 4.3 1.30 4.92
50/126 PLUS 50 x 4.6 125 x 4.9 1.30 -
63/126 63 x 5.8 125 x 4.9 2.07 6.50
63/142 PLUS 63 x 5.8 140 x 4.4 2.07 -
75/142 75 x 6.8 140 x 4.4 2.96 8.47
75/162 PLUS 75 x 6.8 160 x 5.0 2.96 -
90/162 90 x 8.2 160 x 5.0 4.25 11.40
90/182 PLUS 90 x 8.2 180 x 5.6 4.25 -
110/162 110 x 10.0 160 x 5.0 6.36 14.23
110/182 110 x 10.0 180 x 5.6 6.36 16.19
110/202 PLUS 110 x 10.0 200 x 6.2 6.36 -
125/182 125 x 11.4 180 x 5.6 8.20 17.20
125/202 PLUS 125 x 11.4 200 x 6.2 8.20 -
140/225 140 x 12.7 225 x 6.9 13.79 40.95
160/250 160 x 14.6 250 x 6.2 20.18 58.40
CALPEX DUO
Type PEX carrier pipe Outer casing Volume Weight
mm mm l/m kg/unit
25 + 25/ 91 2 x 25 x 2.3 90 x 3.5 2 x 0.32 4.32
25 + 25/111 PLUS 2 x 25 x 2.3 110 x 4.3 2 x 0.32 -
32 + 32/111 2 x 32 x 2.9 110 x 4.3 2 x 0.53 4.67
32 + 32/126 PLUS 2 x 32 x 2.9 125 x 4.9 2 x 0.53 -
40 + 40/126 2 x 40 x 3.7 125 x 4.9 2 x 0.83 7.42
40 + 40/142 PLUS 2 x 40 x 3.7 140 x 4.3 2 x 0.83 -
50 + 50/162 2 x 50 x 4.6 160 x 5.0 2 x 1.30 9.90
50 + 50/182 PLUS 2 x 50 x 4.6 180 x 5.6 2 x 1.30 -
63 + 63/182 2 x 63 x 5.8 180 x 5.6 2 x 2.07 13.96
63 + 63/202 PLUS 2 x 63 x 5.8 200 x 6.2 2 x 2.07 -
9.3.2015

Sanitary, 10 bar, UNO and DUO
Bend, 90° DN 16 - DN 50 (PEXa)
1100 UNO DUO
A
1600
250
250
Figures in mm
CALPEX UNO
Type DN Inches PEX carrier pipe Outer casing Volume Weight
“ mm mm l/m kg/unit
22/ 76 16 5⁄
8 22 x 3.0 75 x 2.9 0.20 2.40
28/ 76 20 ¾ 28 x 4.0 75 x 2.9 0.31 2.65
32/ 76 25 1 32 x 4.4 75 x 2.9 0.42 2.80
40/ 91 32 1¼ 40 x 5.5 90 x 3.5 0.66 3.90
50/111 40 1½ 50 x 6.9 110 x 4.3 1.02 5.62
63/126 50 2 63 x 8.7 125 x 4.9 1.63 7.65
CALPEX DUO
28 + 22/ 91 20 + 16 ¾ + 5⁄8 28.0 x 4.0 + 22.0 x 3.0 90 x 3.5 0.31 + 0.20 3.67
32 + 22/111 25 + 16 1 + 5⁄8 32.0 x 4.4 + 22.0 x 3.0 110 x 4.3 0.42 + 0.20 4.87
40 + 28/126 32 + 20 1¼ + ¾ 40.0 x 5.5 + 28.0 x 4.0 125 x 4.9 0.66 + 0.31 6.50
50 + 32/126 40 + 25 1½ + 1 50.0 x 6.9 + 32.0 x 4.4 125 x 4.9 1.02 + 0.42 7.30
9.3.2015

Heating 6 bar, sanitary 10 bar, QUADRIGA
Bend, 90° DN 16 - DN 32
1100
250
A
1600
250
Figures in mm
CALPEX QUADRIGA
H25+25/S28+22/142 20 ¾ 25 x 2.3 140 x 4.4 0.327 8.12
20 ¾ 25 x 2.3 0.327
20 ¾ 28 x 4.0 0.314
16 5⁄ 8 22 x 3.0 0.201
H32+32/S28+22/142 25 1 32 x 2.9 140 x 4.4 0.539 8.47
25 1 32 x 2.9 0.539
20 ¾ 28 x 4.0 0.314
16 5⁄
8 22 x 3.0 0.201
H32+32/S32+22/142 25 1 32 x 2.9 140 x 4.4 0.539 8.52
25 1 32 x 2.9 0.539
25 1 32 x 4.4 0.423
16 5⁄
8 22 x 3.0 0.201
H40+40/S40+28/162 32 1¼ 40 x 3.7 160 x 5.0 0.835 10.37
32 1¼ 40 x 3.7 0.835
32 1¼ 40 x 5.5 0.660
20 ¾ 28 x 4.0 0.314
9.3.2015
CALPEX L-shell
Dimensions Ø 76 - 126 mm
d1
CALPEX
1
4
3
5
2
376
6 2
d
CALPEX
d2
185
376 Figures in mm
CALPEX L-shell, UNO/DUO Structure of the half-shell

Outer casing Ø d2
Ø d1 76 91 111 126 1 ABS half-shells
76 x 2 PEX angle coupling; see CPX 1.390
91 x 3 Sealing clamps (14 pcs.)
111 x 4 Insulation material; see CPX 1.365
126 x 5 Glued surface
6 Reduction ring or sealing ring
CALPEX shells are freely reducible from Ø 126 mm to Ø 76 mm
CALPEX shells are not suitable for use with CALPEX QUADRIGA (distri-
bution chamber: see CPX 1.350).
Note: CALPEX shells are not suggested to be installed UV exposed!
9.3.2015
CALPEX Big L-shell

d1
CALPEX
1
4
3
5
2
508
265
CALPEX
d2
2
d
508
Figures in mm
CALPEX Big L-shell, UNO/DUO Structure of the half-shell

Outer casing Ø d2
Ø d1 142 162 182 1 ABS half-shells
142 x 2 PEX angle coupling; see CPX 1.390
182 x 4 Insulation material; see CPX 1.365
5 Glued surface
CALPEX Big-shells are freely reducible from Ø 182 mm to Ø 76 mm 6 Reduction ring or sealing ring
9.3.2015
Joint using PE-HD shrink sleeve

CALPEX joint 1 2 3 4
CALPEX CALPEX
d2
d1
CALPEX reduction joint
CALPEX CALPEX
d2
d1
CALPEX – Insulated steel pipe 1 2
CALPEX
d2
d1
Insulated steel pipe
1 PEX coupling; see sheet 1.390 Installation note:

2 Insulation material, PUR or PE; see sheet 1.365 1 Weld on
3 Shrink sleeve pipe
4 Shrink hose CALPEX Insulated steel pipe
CALPEX Insulated steel pipe
2
Install
CALPEX-CALPEX CALPEX to insulated steel pipe

Ø d2 76 91 111 126 142 162 182 250 Ø d2 90 110 125 140 160 180 200 225 250 280 315
76 x x 76 x x x
91 x x 91 x x x x
111 x x 111 x x x x
Ø d1 126 x x Ø d1 126 x x x x
142 x x 142 x x x x
162 x x 162 x x x x x x
182 x x 182 x x x x x x
250 x 250 x x x
9.3.2015
CALPEX I-shell
1 4 3 2 5 6
CALPEX CALPEX
d1
185
d2
578 Figures in mm
CALPEX I-shell, UNO/DUO Structure of the half-shell

Outer casing Ø d2
Ø d1 76 91 111 126 1 ABS half-shells
76 x 2 PEX coupling; see CPX 1.390
91 x x 3 Sealing clamps (12 pcs.)
111 x x x 4 Insulation material; see CPX 1.365
126 x x x x 5 Glued surface
9.3.2015
CALPEX Big I-shell

1 4 3 2 5 6
CALPEX
CALPEX
265
d1
d2
752 Figures in mm
CALPEX Big I-shell, UNO/DUO/QUADRIGA Structure of the half-shell

Outer casing Ø d2
142 x 2 PEX coupling; see CPX 1.390
182 x x x 4 Insulation material; see CPX 1.365
5 Glued surface
CALPEX Big-shells are freely reducible from Ø 182 mm to Ø 76 mm
9.3.2015
CALPEX T-shell
d2
CALPEX
3
1
4
6
2 5
373
CALPEX CALPEX
185
d3
d1
578 Figures in mm
CALPEX T-shell, UNO/DUO Structure of the half-shell

Outer casing Branch, Ø d2
Ø d1 - Ø d3 76 91 111 126 1 ABS half-shells
76 - 76 x x x x 2 PEX T-piece; see CPX 1.395
91 - 91 x x x x 3 Sealing clamps (16 pcs.)
91 - 76 x x x x 4 Insulation material; see CPX 1.365
111 - 111 x x x x 5 Glued surface
111 - 91 x x x x 6 Reduction ring or sealing ring
111 - 76 x x x x
126 - 126 x x x x
126 - 111 x x x x
126 - 91 x x x x
126 - 76 x x x x
9.3.2015
CALPEX Big T-shell

d2
CALPEX
1
3
2 4 5 6
508
CALPEX
CALPEX
265
d1
d3
752
Figures in mm
CALPEX Big T-shell, UNO/DUO Structure of the half-shell

Ø d1 - Ø d3 76 91 111 126 142 162 182 1 ABS half-shells
142 - 142 x x x x x x x 2 PEX T-piece; see CPX 1.395
142 - 126 x x x x x x x 3 Sealing clamps (27 pcs.)
142 - 111 x x x x x x x 4 Insulation material;
142 - 91 x x x x x x x see CPX 1.365
142 - 76 x x x x x x x 5 Glued surface
162 - 162 x x x x x x x 6 Reduction ring or sealing ring
162 - 142 x x x x x x x
162 - 126 x x x x x x x
162 - 111 x x x x x x x
162 - 91 x x x x x x x
162 - 76 x x x x x x x
182 - 182 x x x x x x x
182 - 162 x x x x x x x
182 - 142 x x x x x x x
182 - 126 x x x x x x x
182 - 111 x x x x x x x
182 - 91 x x x x x x x
182 - 76 x x x x x x x
9.3.2015
T-joint
Dimension CPX 125/225 - 160/250
CALPEX CALPEX
1
2
A
Structure of T-joint
125/225 mm: Branch line, straight 3
140/225 mm: Branch line, angled 45° 4
160/250 mm: Branch line, angled 45°
5
1 T-piece, insulated steel pipe (St 37.0)
2 Shrink-on hoop
CALPEX

CALPEX
4 In-situ PUR foam

5 CALPEX connector
6
6 CALPEX pipe
View A
45° CALPEX
ed
lat e
n su l pip
I ee
st
CALPEX T-joint
Ø d1 Ø d3 25/76 32/76 40/91 50/111 63/126 75/142 90/162 110/162 110/182 125/182 140/225 160/250
125/225 - 125/225* x x x x x x x x x x – –
140/225 - 140/225* x x x x x x x x x x x –
160/250 - 160/250 x x x x x x x x x x x x
* Reduction sockets are required

We can supply T-pieces with different branches on request
9.3.2015
Y-pipe
Heating, 6 bar
CPX UNO VL (flow) (right) VL (flow) (right)

[D
300
CPX UNO RL (return)
[C
RL return
250 mind. 650 VL (flow) (bottom)
250 11 0/+1
250+20 300
1800 Figures in mm
View: A - A
Note: With UNO pipe, in the direction of
CALPEX DUO / 2 x CALPEX UNO flow, the forward flow (VL) is always on
UNO pipes ØD DUO CPX pipe ØC the right and with DUO pipe, it is always
mm mm mm mm at the bottom.
2 x 25/ 76 75 25 + 25/ 91 90
2 x 25/ 91 PLUS 90 25 + 25/111 110
2 x 32/ 76 75 32 + 32/111 110
2 x 32/ 91 PLUS 90 32 + 32/126 125
2 x 40/ 91 90 40 + 40/126 125
2 x 40/111 PLUS 110 40 + 40/142 140
2 x 50/111 110 50 + 50/162 160
2 x 50/126 PLUS 125 50 + 50/182 180
2 x 63/126 125 63 + 63/182 180
2 x 63/142 PLUS 140 63 + 63/202 200
VL (flow) (right)
KMR VL (flow) (right)
[D
RL (return)
300
KMR
[C
VL (flow) (bottom) RL (return)
150 mind. 650
150 X
250+20 400
1800 Figures in mm
View: A - A
Note: With UNO pipe, in the direction of
flow, the forward flow (VL) is always on
the right and with DUO pipe, it is always
at the bottom.
CALPEX DUO / 2 x pre-insulated steel pipe (St 37.0)
UNO pipes KMR ØD DUO steel pipe X DUO CPX pipe ØC
mm mm mm mm mm mm
26.9 - 110 110 26.9 + 26.9/110 19 25 + 25/ 91 110
33.7 - 110 110 33.7 + 33.7/110 19 32 + 32/111 110
42.4 - 125 125 42.4 + 42.4/125 19 40 + 40/126 125
48.3 - 125 125 48.3 + 48.3/160 19 50 + 50/162 160
60.3 - 140 140 60.3 + 60.3/180 20 63 + 63/182 180
9.3.2015
Distribution chamber
Dimensions CPX 25/76 - 125/182
Distribution chamber for all joints

The distribution chamber is used to cover and protect completed BRUGG pipe joints, shut-off valves or junction branches.
The distribution chamber is a watertight structure made of polyethylene; its multi-functional design makes it possible to
use one chamber type for all pipe dimensions.
145
270
0
104
∅
130
136
166
475
206
∅
∅
∅
800
120
∅
120
200 360 120
8
Figures in mm
Wall thickness approx. 8 mm
Ø Chamber exit Pipe dimensions (outer diameter)

Ø outer, 206 x 8 mm Leadthrough for outer Ø Ø 182, 162*
Ø outer, 166 x 8 mm Leadthrough for outer Ø Ø 142, 126*
Ø outer, 136 x 8 mm Leadthrough for outer Ø Ø 111, 91*, 76*
* with additional centering ring
9.3.2015
Distribution chamber
Installation for dimensions CPX 25/76 - 125/182
1 2
CAL
P EX
6
[ 20
6
[ 16
6
[ 13
3 4
Two-part reduction ring
5 6
See CPX installation instructions
Flat seal M10 x 35

29 x 12
7 8
6
[ 23
9
[ 16
9.3.2015
Protective concrete plate

for distribution chamber
Schematic diagram showing installation of cover plate Load

The cover plate has to be used wherever there
might be public traffic and for low-depth
installations. The maximum load per unit of
area must not exceed
q = 153 kN/m² (SLW 60 to DIN 1055).
Installation method
Correct installation of the sand must be
ensured so that the plate can perform its
function as a load shield for the inspection
Sand, compacted chamber. A Proctor density of dpr = 96 %
should be the target for compaction.
te
For subsequent work on the inspection

r pla
20
ve
chamber, the cover plate has lifting eyes.

ø1
Co
After completing the work and refilling the

pit, make sure that the infill between the
20
inspection chamber and concrete slabs is

restored correctly.
Filling/insulation material
Insp
Some suggestions for filling and insulation
ectio materials that can be used are listed below:
n ch
amb
er - Bulk polystyrene material
- Armaflex or Tubolit
- Foam using BRAG PUR foam canister
Figures in cm
Note
There is no need to use filling material in the
distribution shaft. Likewise, it is not essential
to insulate the pipes! The decision is up to the
customer.
Armouring 6 GOK Note

The plate must be located so that
it completely covers the chamber below
50
1 (see illustration).
Q2 Sand, compacted
20
94
3 17 x [ 10/20
21
133
bo op
tto 3 1t
m Q1 Inspection chamber
2
4 3 x [ 12
80
[ 110
[ 120
1 Q 221 bottom
4 2 Q 131 bottom
5 ME.1 [ 10 3 [ 10/20
2 Q131 top
21
3 17 x [ 10/20 mm (L = 0.5 m) 7.5
Total length 8.5 m 21.5
1 Q221 bottom 5 3.8 continuous
meters [ 10 12
4 3 x [ 12 mm (L = 0.85 m)
Total length 2.55 m 21 21
16 15
Figures in cm
9.3.2015
Insulation material
PE foam (CPX 25/76 - 110/182), PUR foam container(s)
PUR foam bottles (CPX 25/76 - 160/250)
Insulation material for shrink joints
Polyethylene foam tube, (CPX 25/76 - 110/182)

Extruded pipe insulation made of closed-cell polyethylene, excellent for insulating CALPEX
shrink joints (not for CALPEX shells). Various thicknesses of insulation are available for the
most common pipe diameters.
The insulation material (thickness and length) is supplied for the relevant joint types.
The insulation must be fitted precisely into the joints on site.
PE
PUR foam for shrink joints and CALPEX shells (CPX 25/76 - 160/250) Safety regulations
CFC-free, cyclopentane-blown PUR foam in plastic bottles
Protective goggles and gloves must be worn
The required quantity of CFC-free polyurethane foam is delivered in suitable container sizes for when using this product.
the various joints and T-pieces. The components are supplied separately in two bottles and are
only mixed together when needed. Please note the safety regulations in the installation instruc-
tions supplied with the product.
Synthetic gloves
Protective goggles
9.3.2015
Screwed connectors
Outer thread, weld end
Connection with external thread Heating, 6 bar Sanitary, 10 bar

Material: brass Material: brass
PEX pipe Screwed connector L PEX pipe Screwed connector L
PEX 22-75
mm mm mm mm mm mm
L 25 x 2.3 25 x 2.3-¾“ 53 22 x 3.0 22 x 3.0-¾“ 51
32 x 2.9 32 x 2.9-1“ 63 28 x 4.0 28 x 4.0-¾“ 58
40 x 3.7 40 x 3.7-1¼“ 67 32 x 4.4 32 x 4.4-1“ 63
50 x 4.6 50 x 4.6-1½“ 71 40 x 5.5 40 x 5.5-1¼“ 67
PEX 90-110 63 x 5.8 63 x 5.7-2“ 80 50 x 6.9 50 x 6.9-1½“ 71
75 x 6.8 75 x 6.8-2½“ 92 63 x 8.7 63 x 8.7-2“ 80
90 x 8.2 90 x 8.2-3“ 92
L
110 x 10.0 110 x 10.0-4“ 102
Connection with weld end Heating, 6 bar

Material: brass / St 37.0
PEX pipe Weld end L
St 37.0 PEX 25-75 mm mm mm
L 25 x 2.3 26.9 x 2.65 180
32 x 2.9 33.7 x 2.3 180
40 x 3.7 42.4 x 2.6 185
50 x 4.6 48.3 x 2.6 190
63 x 5.8 60.3 x 2.9 195
75 x 6.8 76.1 x 3.2 200
St 37.0 PEX 90-110 90 x 8.2 88.9 x 3.2 240
110 x 10.0 114.3 x 3.6 280
9.3.2015
Screwed connector
Coupling: equal, coupling: reduced
Coupling, equal Heating, 6 bar Sanitary, 10 bar

PEX pipe Coupling L PEX pipe Coupling L
PEX 22-75
mm mm mm mm mm mm
25 x 2.3 25 x 2.3 60 22 x 3.0 22 x 3.0 58
L 32 x 2.9 32 x 2.9 67 28 x 4.0 28 x 4.0 65
40 x 3.7 40 x 3.7 71 32 x 4.4 32 x 4.4 67
50 x 4.6 50 x 4.6 75 40 x 5.5 40 x 5.5 71
63 x 5.8 63 x 5.7 81 50 x 6.9 50 x 6.9 75
PEX 90-110 75 x 6.8 75 x 6.8 89 63 x 8.7 63 x 8.7 81
90 x 8.2 90 x 8.2 130
110 x 10.0 110 x 10.0 130
L
Coupling, reduced Heating, 6 bar Sanitary, 10 bar

PEX pipe Coupling PEX pipe Coupling L
PEX 22-75 mm mm mm mm mm
L 32 x 2.9 / 25 x 2.3 32-1“ / 25-¾“ 28 x 4.0 / 22 x 3.0 28-¾“/ 22-½“ 58
40 x 3.7 / 32 x 2.9 40-1¼“/ 32-1“
50 x 4.6 / 40 x 3.7 50-1½“/ 40-1¼“
75 x 6.8 / 63 x 5.8 75-2½“/ 63-2“
PEX 90-110 on request different dimensions available (soldered)
9.3.2015
Screwed connectors
T-piece
d2
d2
d1
d3
d1
d3
PEX [ 22-75 PEX [ 90-110
Heating, 6 bar
Material: brass
Ø d1 Ø d3 Branch, Ø d2
mm mm
25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0
25 x 2.3- 25 x 2.3 x x
32 x 2.9- 32 x 2.9 x x
32 x 2.9- 25 x 2.3 x x
40 x 3.7- 40 x 3.7 x x x x
40 x 3.7- 32 x 2.9 x x
50 x 4.6- 50 x 4.6 x x x x
50 x 4.6- 40 x 3.7 x x x x
63 x 5.8- 63 x 5.8 x x x x x x
63 x 5.8- 50 x 4.6 x x x x x
75 x 6.8- 75 x 6.8 x x x x x x
75 x 6.8- 63 x 5.8 x x x x x x
90 x 8.2- 90 x 8.2 x x x x x x
90 x 8.2- 75 x 6.8 x x
110 x 10.0-110 x 10.0 x x x x x x
110 x 10.0- 90 x 8.2 x x x
Other T-pieces can be supplied on request.
9.3.2015
Compression connectors
Outer thread, weld end
Connector with external thread Heating, 6 bar Sanitary, 10 bar

PEX pipe Screwed connector L PEX pipe Screwed connector L
mm mm mm mm mm mm
25 x 2.3 25 x 2.3-¾“ 62 22 x 3.0 22 x 3.0-¾“ 58
32 x 2.9 32 x 2.9-1“ 72 28 x 4.0 28 x 4.0-¾“ 62
40 x 3.7 40 x 3.7-1¼“ 82 32 x 4.4 32 x 4.4-1“ 72
L
50 x 4.6 50 x 4.6-1½“ 89 40 x 5.5 40 x 5.5-1¼“ 82
63 x 5.8 63 x 5.7-2“ 109 50 x 6.9 50 x 6.9-1½“ 89
75 x 6.8 75 x 6.8-2½“ 110 63 x 8.7 63 x 8.7-2“ 109
90 x 8.2 90 x 8.2-3“ 115
110 x 10.0 110 x 10.0-4“ 120
125 x 11.4 125 x 11.4-5” 125
160 x 14.6 160 x 14.6-6” 130
Connector with weld end Heating, 6 bar

Material: Steel
L2
PEX pipe Weld end L1 L2
mm mm mm mm
25 x 2.3 26.9 x 2.65 50 20
St 37
32 x 2.9 33.7 x 2.3 60 24
40 x 3.7 42.4 x 2.6 70 29
50 x 4.6 48.3 x 2.6 85 37
L1
63 x 5.8 60.3 x 2.9 90 32
75 x 6.8 76.1 x 3.2 95 35
90 x 8.2 88.9 x 3.2 95 35
110 x 10.0 114.3 x 3.6 90 30
125 x 11.4 139.7 x 3.6 108 48
140 x 12.7 139.7 x 3.6 112 50
160 x 14.6 168.3 x 4.1 114 50
9.3.2015
Coupling: equal, coupling: reduced, angle piece: 90°
Coupling Heating, 6 bar Sanitary, 10 bar

mm mm mm mm mm mm
25 x 2.3 25 x 2.3 67.0 22 x 3.0 22 x 3.0 58
32 x 2.9 32 x 2.9 88.0 28 x 4.0 28 x 4.0 70
L 40 x 3.7 40 x 3.7 100.0 32 x 4.4 32 x 4.4 82
50 x 4.6 50 x 4.6 114.0 40 x 5.5 40 x 5.5 90
63 x 5.8 63 x 5.7 141.0 50 x 6.9 50 x 6.9 104
75 x 6.8 75 x 6.8 137.5 63 x 8.7 63 x 8.7 122
90 x 8.2 90 x 8.2 137.5
110 x 10.0 110 x 10.0 137.5
125 x 11.4 125 x 11.4 141.0
140 x 12.7 140 x 12.7 140.0
160 x 14.6 160 x 14.6 149.0
Coupling, reduced Heating, 6 bar Sanitary, 10 bar

Material: brass/steel* Material: brass
mm mm mm mm mm mm
32 x 2.9 25 x 2.3 80.0 32 x 4.4/28 x 4.0 32 x 4.4/28 x 4.0 76
40 x 3.7 32 x 2.9 100.0 40 x 5.5/32 x 4.4 40 x 5.5/32 x 4.4 86
L 50 x 4.6 40 x 3.7 108.0 50 x 6.9/40 x 5.5 50 x 6.9/40 x 5.5 97
63 x 5.8 50 x 4.6 129.0 63 x 8.7/50 x 6.9 63 x 8.7/50 x 6.9 113
75 x 6.8 63 x 5.8 138.0
90 x 8.2 75 x 6.8 142.0
110 x 10.0 90 x 8.2 142.0
125 x 11.4* 110 x 10.1 228.0
140 x 12.7* 125 x 11.4 220.0
160 x 14.6* 125 x 11.4 262.0
Angle piece, 90° Heating, 6 bar Sanitary, 10 bar

Material: brass/*steel Material: brass
z PEX pipe PEX pipe a z PEX pipe PEX pipe a z
mm mm mm mm mm mm mm mm
25 x 2.3 25 x 2.3 54 32 22 x 3.0 22 x 3.0 – –
32 x 2.9 32 x 2.9 64 37 28 x 4.0 28 x 4.0 – –
40 x 3.7 40 x 3.7 74 42 32 x 4.4 32 x 4.4 66 39
50 x 4.6 50 x 4.6 87 48 40 x 5.5 40 x 5.5 74 42
63 x 5.8 63 x 5.8 106 60 50 x 6.9 50 x 6.9 87 39
z
75 x 6.8 75 x 6.8 117 67 63 x 8.6 63 x 8.6 106 60

a
90 x 8.2 90 x 8.2 127 76

110 x 10.0 110 x 10.0 137 87
125 x 11.4* 125 x 11.4 298 260
a
9.3.2015
d2 d2
T-piece
d1
d3
d1
d3
Brass/CrNi St. 37.0
Heating, 6 bar
mm mm
25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0 125 x 11.4
25 x 2.3 - 25 x 2.3 o/x
32 x 2.9 - 32 x 2.9 o/x o/x
32 x 2.9 - 25 x 2.3 o/x
40 x 3.7 - 40 x 3.7 o/x o/x o/x
40 x 3.7 - 32 x 2.9 o/x¹ o/x¹
50 x 4.6 - 50 x 4.6 o/x o/x o/x o/x
50 x 4.6 - 40 x 3.7 o/x o/x o/x¹
63 x 5.8 - 63 x 5.8 o/x o/x o/x o/x o/x
63 x 5.8 - 50 x 4.6 o/+ o/x o/x o/x
75 x 6.8 - 75 x 6.8 o/x o/x o/x o/x o/x o/x
75 x 6.8 - 63 x 5.8 o/+ o/x o/+ o/x o/x
90 x 8.2 - 90 x 8.2 o/+ o/x o/x o/+ o/x o/+ o/x
90 x 8.2 - 75 x 6.8 o/+ o/+ o/+ o/+ o/+ o/+
110 x 10.0 - 110 x 10.0 o/+ o/x o/+ o/x o/x o/+ o/+ o/x
110 x 10.0 - 90 x 8.2 o/+ o/+ o/+ o/+ o/+ o/+ o/+
125 x 11.4 - 125 x 11.4 o o o o o o o o o
Sanitary, 10 bar
mm mm
22 x 3.0 28 x 4.0 32 x 4.4 40 x 5.5 50 x 6.9 63 x 8.7
22 x 3.0 - 22 x 3.0 x x
28 x 4.0 - 28 x 4.0 x x x x
28 x 4.0 - 28 x 3.0 x
32 x 4.4 - 32 x 4.4 x x x x
32 x 4.4 - 28 x 4.0 x x x x
40 x 5.5 - 40 x 5.5 x x x x x
40 x 5.5 - 32 x 3.0 x x x x
40 x 5.5 - 28 x 4.0 x x x
50 x 6.9 - 50 x 6.9 x x x x x
50 x 6.9 - 40 x 5.5 x x x x x
50 x 6.9 - 32 x 4.4 x x x x x
50 x 6.9 - 28 x 4.0 x x x
63 x 8.7 - 63 x 8.7 x x x x x x
63 x 8.7 - 50 x 6.9 x x x x
63 x 8.7 - 40 x 5.5 x x x x
¹ Soldered fittings Material:

- T-pieces made of steel can be supplied on request x = Brass CuZn39Pb3 (DN 20 - DN 50),
- Other T-pieces can be supplied on request. Gunmetal Rg7 (DN 65 - DN 100)
- Dimension DN 150 is supplied in prefabricated and pre-insulated form o = St 37.0, welded
(see sheet CPX 1.340). + = CrNi 1.4404, 1.4432, 1.4435 (316L)
9.3.2015
Electro-fusion joints
Coupling Heating, 6 bar Angle piece, 90° on request

Material: cross-linked polyethylene
Heating, 6 bar
PEX pipe PEX pipe
mm mm
PEX pipe PEX pipe
75 x 6.8 75 x 6.8
mm mm
90 x 8.2 90 x 8.2
75 x 6.8 75 x 6.8
110 x 10.0 110 x 10.0
90 x 8.2 90 x 8.2
125 x 11.4 125 x 11.4
110 x 10.0 110 x 10.0
160 x 14.6 160 x 14.6
125 x 11.4 125 x 11.4
Transition sleeve/joint with flange on request Reduction piece* on request

(AG)
Heating, 6 bar Heating, 6 bar
Material: cross-linked polyethylene Material: cross-linked polyethylene
PEX pipe PEX pipe PEX pipe
mm mm mm
75 x 6.8 90 75
90 x 8.2 110 75
110 x 10.0 110 90
125 x 11.4 125 75
125 90
125 110
160 75
T-piece, equal on request 160 90
160 110
Heating, 6 bar
160 125
PEX pipe
mm
75 x 6.8
90 x 8.2
110 x 10.0
125 x 11.4
Leasable basic tool for PEXa electro-fusion joints

comprising welding machine and pipe clamps
Article
Tool set without pipe cutter
Additional pipe clamps-set
Pipe cutter 50-125 mm
Pipe cutter 110-160 mm
*Note: Reductions cannot be used when using CALPEX clip shells.
Only trained personnel, using suitable fusion equipment, may install the electro-fusion joints for PEXa connections.
9.3.2015
End cap
Standard, shrinkable
Shrink-on end cap, UNO End cap, UNO (LD-PE)
Shrink-on end cap, DUO End cap, DUO (LD-PE)
Shrink-on end cap, QUADRIGA End cap, QUADRIGA (LD-PE)
A A
View A View A
CALPEX UNO CALPEX DUO QUADRIGA

Type Heating Type Sanitary Type Type
25/ 76 22/ 76 25 + 25/ 91 25 + 25/28 + 22/142
25/ 91 PLUS 28/ 76 25 + 25/111 PLUS 32 + 32/28 + 22/142
32/ 76 32/ 76 28 + 22/ 91 32 + 32/32 + 22/142
32/ 91 PLUS 32/111 HBK 32 + 22/111 40 + 40/40 + 28/162
40/ 91 40/ 91 32 + 32/111
40/111 PLUS 40/126 HBK 32 + 32/126 PLUS
50/111 50/111 40 + 28/126
50/126 PLUS 50/126 HBK 40 + 40/126
63/126 63/126 40 + 40/142 PLUS
63/142 PLUS 50 + 32/126
75/142 50 + 50/162
75/162 PLUS 50 + 50/182 PLUS
90/162 63 + 63/182
90/182 PLUS 63 + 63/202 PLUS
110/162
110/182
125/182
125/202 PLUS LD-PE end caps are fitted on;
140/202 suitable for dry rooms
9.3.2015
Wall sealing ring

for wall openings
Ø Da
Ø Di
50 Figures in mm
CALPEX UNO, DUO, QUADRIGA

Outer casing diameter Neoprene wall sealing ring
Ø Di, inner Ø Da, outer
mm mm mm
76 74 118
91 88 133
111 107 153
126 122 168
142 137 183
162 155 203
182 175 223
202 195 230
225 180 240
250 243 290
Building entry (see sheet CPX 1.415)
9.3.2015
Building entry
Wall opening
Wall leadthrough
approx. 80 mm
PEX connection piece:
see sheet 1.370
or sheet 1.390
80 mm
CALPEX
D
CALPEX pipe;
see sheets 1.115, 1.120
End cap:
see sheet 1.405 Wall seal: see sheet 1.410
Wall opening Outer casing L min H min

ØD
mm mm mm
78 450 250
93 500 250
113 500 300
128 550 300
H
143 600 350

163 650 350
183 670 380
202 720 400
80 D 100 D 80 Figures in mm 225 740 400
250 810 450
L
Core bores Outer casing A D1

min. 30
ØD
mm mm mm
78 210 180
93 230 180
113 250 230
128 270 230
143 290 230
D1
163 310 280

183 330 280
202 400 350
225 400 350
Figures in mm 250 420 380
9.3.2015
Wall seal
Core bores/cement liner pipes
Standard With additional centering ring

Outer side of
Outer side of
Inner side of
Inner side of
basement
basement
basement
basement
3 2 3
R
D
1 1
Core bores
Perfect bores are required for installation. As hairline cracks may 1 CALPEX district heating pipe
be present in the concrete or result from drilling, it is advisable to 2 Seal set, single-seal
seal the entire length of the borehole with suitable sealant (such as 1 x 40 mm, Shore hardness D 35
AQUAGARD). 3 Seal set, double-seal*
2 x 40 mm, Shore hardness D 35
Tightness can only be guaranteed if this recommendation is fol- 4 Liner pipe: made of fibre cement or coated core bore
lowed.
* Suitable for pressure from water up to 0.5 bar
Outer pipe Liner pipe, core bore Seal set Core bore
ØR ØD Ø inner Ø
mm mm mm mm
76 150 78 - 85 150
91 150 86 - 94 150
111 200 105 - 115 200
126 200 125 - 135 200
142 200 137 - 145 200
162 250 157 - 165 250
182 250 180 - 190 250
202 300 198 - 207 300
225 300 225 - 233 300
250 350 250 - 259 350
Building entry (see sheet CPX 1.425)
9.3.2015
Building entry
Core bores/cement pipe liners
Wall leadthrough
PEX connection piece: 80 mm CALPEX pipe:

see sheet CPX 1.370 see sheets CPX 1.115, 1.120
or CPX 1.390
CALPEX
D
End cap: Seal set:
see sheet CPX 1.405 see sheet CPX 1.420
Core bores Outer casing A D1

min. 30
ØD
mm mm mm
78 180 150
93 180 150
113 230 200
128 230 200
143 230 200
D1
163 280 250

183 280 250
202 330 300
225 330 300
250 380 350
A Figures in mm
9.3.2015
Pipe warning tape

CALPEX pipe warning tape
Pipe warning tape to be laid in the ground.

Roll length: 250 m
CALPEX trench structure
1 2 3 1 Pipe warning tape

2 Excavated material
3 Washed sand
Installation depth; see sheet CPX 1.505

60
30
T
10
D
10
9.3.2015
Pipe routing
CALPEX – Connection to insulated steel pipe
CALPEX
CALPEX
A
CALPEX
Loop-in method CALPEX – CALPEX connection
CALPEX
B
D
C
C
B
D
CALPEX
9.3.2015
Trench dimensions
Trench profile, 2 CALPEX pipes
UNO DUO, QUADRIGA
1 2 3 1 2 3
60
60
30
10 30
T
T
10
D
D
10
10
10 D 10 D 10 10 D 10
Figures in cm
B B
Casing pipe Width Depth Minimum Casing pipe Width Depth Minimum
ØD B T bending radius ØD B T bending radius
mm cm cm m mm cm cm m
78 45 80 0.7 93 30 80 0.8
93 50 80 0.8 113 30 85 0.9
113 55 85 0.9 128 35 85 1.0
128 55 85 1.0 143 35 85 1.1
143 60 85 1.1 163 35 90 1.2
163 65 90 1.2 183 38 95 1.4
183 70 95 1.4
202 75 95 1.4
250 80 100 -
Trench profile, 4 CALPEX pipes

1 2 3
1 2 3
10 30
60
60
D 10 30
T
T
5 D
10 D
10
10 D 10 D 10 D 10 D 10 10 Figures in cm
D 10 D 10
B (4 x D + 5 x 10) B
1 Pipe warning tape; see sheet CPX 1.430 SLW 30 300 kN total load as per DIN 1072; if subject to higher traffic
2 Excavated material loads (e.g. SLW 60), a load-distributing superstructure as per RStO75
3 Sand, washed, max. grain size 8 mm is required.
Installation depth: With no traffic load, the minimum trench depth T can be reduced by
Max. installation depth: 2.6 m 20 cm.
Our approval is required for installation at greater depths.
9.3.2015
Connection (rigid/flexible)
CALPEX to insulated steel pipes
Installation instructions for transition from CALPEX to insulated steel pipe (KMR)
1. Junction with T-piece 2. Transition with fixed point

L1 ≤ 2.0
CALPEX ≤ 2.0
∆I
∆I
DK FP
Joint/sleeve Insulated Joint/sleeve Insulated steel pipe
Rmin steel pipe
CALPEX
2.0 m
CALPEX
∆I
DK
Rmin CPX T-shell
Figures in m
CALPEX
The transverse expansion ∆l must not exceed the expansion that can The thermal movement Δl of the insulated steel pipe cannot be com-
be accommodated by junction pipe DS and the CALPEX pipe. pensated by the CALPEX pipes. A fixed point must be installed.
3. Transition with Z-bend 4. Transition with expansion bend
L1 ≤ 2.5 L1 ≤ 2.5
CALPEX CALPEX
DK
Joint/sleeve Joint/sleeve
∆I
Insulated Insulated
L
steel pipe steel pipe
FP
∆I
Figures in m
Static design of the Z-bend according to expansion variable ∆l. If pipe length L or ∆l is more than permitted for L1,
a fixed anchor point must be installed.
∆l = Thermal movement - Design of expansion components

FP = Fixed point (plastic casing pipe) - Positioning of expansion pads
DK = Expansion pad as per the section on PREMANT
9.3.2015
House entry, screwed connector

Shaft entry, fixed point forces
Connection with external thread Heating, 6 bar

PEX pipe A
approx. 80 Figures in mm mm mm
25 x 2.3 210
*A 32 x 2.9 220
40 x 3.7 220
*80
max. 100
50 x 4.6 220
63 x 5.8 230
75 x 6.8 235
90 x 8.2 260
110 x 10.0 270
Sanitary, 10 bar
PEX connecting piece 22 x 3.0 210
with external thread: 28 x 4.0 210
Fixed point 32 x 4.4 220
see sheet 1.370
End cap: Wall sealing ring: CALPEX pipe 40 x 5.5 220
see sheet 1.405 see sheet 1.410 see sheets 50 x 6.9 220
1.115 and1.120 63 x 8.7 230
Connection with weld end Heating, 6 bar

PEX pipe B
1 Weld on approx. 80 mm mm
Figures in mm
CALPEX® 25 x 2.3 340
*B 32 x 2.9 340
CALPEX®
40 x 3.7 340
*80
50 x 4.6 360
2 63 x 5.8 340
Install
75 x 6.8 340
90 x 8.2 410
110 x 10.0 450
PEX connecting piece

with weld end: Fixed point End cap:
see sheet 1.370 see sheet 1.405
* Dimensions can be reduced by max. 60 mm if end cap is walled in.
Fixed point forces occurring

CALPEX heating, 6 bar CALPEX sanitary, 10 bar
Maximum fixed point forces occurring per pipe for: Maximum fixed point forces occurring per pipe for:
TB = 60 °C, pB = 6 bar TB = 90 °C, pB = 6 bar TB = 60 °C, pB = 10 bar
Type Type Fmax [N] Fmax [N] Type DN Fmax [N]
25/ 76 25/ 91 PLUS 640 924 22/ 76 16 820
32/ 76 32/ 91 PLUS 1036 1493 28/ 76 20 1350
40/ 91 40/111 PLUS 1639 2367 32/ 76 25 1730
50/111 50/126 PLUS 2553 3686 40/ 91 32 2700
63/126 63/142 PLUS 4013 5782 50/111 40 4230
75/142 75/162 PLUS 5693 8205 63/126 50 6715
90/162 90/182 PLUS 8228 11864
110/182 110/202 PLUS 12260 17675
125/182 125/202 PLUS 15872 22888
140/202 19928 28747
160/250 26004 37502
9.3.2015
House entry, compression joint

Shaft entry, fixed point forces
Connection with external thread Heating, 6 bar

approx. 80 PEX pipe A
Figures in mm
mm mm
*A 25 x 2.3 260
32 x 2.9 260
*80
max. 100
40 x 3.7 270
50 x 4.6 270
63 x 5.8 320
75 x 6.8 320
90 x 8.2 330
110 x 10.0 340
with external thread: 160 x 14.6 340
Fixed point see sheet 1.385 Sanitary, 10 bar
End cap: Wall sealing ring: CALPEX pipe: 22 x 3.0 260
see sheet 1.405 see sheet 1.410 see sheets 28 x 4.0 260
1.115 and 1.120 32 x 4.4 260
40 x 5.5 270
50 x 6.9 270
63 x 8.7 320
Connection with weld end
1 Weld on
approx. 80 Heating, 6 bar
Figures in mm PEX pipe B
CALPEX®
*B mm mm
CALPEX®
25 x 2.3 250
*80 32 x 2.9 250
2
40 x 3.7 260
Install
50 x 4.6 270
63 x 5.8 310
75 x 6.8 310
90 x 8.2 310
110 x 10.0 310
Fixed point
with weld end: End cap: 140 x 12.7 340
see sheet 1.370 see sheet 1.405 160 x 14.6 340
* Dimensions can be reduced by max. 60 mm if end cap is walled in.
Fixed point forces occurring

CALPEX heating, 6 bar CALPEX sanitary, 10 bar
Maximum fixed point forces occurring per pipe for: Maximum fixed point forces occurring per pipe for:
TB = 60 °C, pB = 6 bar TB = 90 °C, pB = 6 bar TB = 60 °C, pB = 10 bar
Type Type Fmax [N] Fmax [N] Type DN Fmax [N]
25/ 76 25/ 91 PLUS 640 924 22/ 76 16 820
32/ 76 32/ 91 PLUS 1036 1493 28/ 76 20 1350
40/ 91 40/111 PLUS 1639 2367 32/ 76 25 1730
50/111 50/126 PLUS 2553 3686 40/ 91 32 2700
63/126 63/142 PLUS 4013 5782 50/111 40 4230
75/142 75/162 PLUS 5693 8205 63/126 50 6715
90/162 90/182 PLUS 8228 11864
110/182 110/202 PLUS 12260 17675
125/182 125/202 PLUS 15872 22888
140/202 19928 28747
160/250 26004 37502
9.3.2015
Installation of house entry
1 Mark the distance (x, y, z) + 1 cm 2 Cut the casing pipe with saw. 3 Split the casing pipe with knife.
from the end of the pipe. Note: Don‘t damage the carrier pipe!
4 Peel off the casing. 5 Cut back/remove the insulation along 6 Install the wall sealing ring.
length (X, Y, Z).
Note: Don‘t damage the carrier pipe!
7 Carefully shrink on the pipe end closure 8 Install the fitting as per the enclosed
according to the Raychem DHEC installa- installation instructions.
tion instruction.
9 UNO 10 DUO y
CALPEX CALPEX®
x z
UNO screwed connector DUO screwed connector UNO compression joint DUO compression joint
House connection: House connection: House connection: House connection:
ø 22 - 75: X = 90 mm ø 22 - 50: Y = 80 mm ø 22 - 50: X = 140 mm ø 22 - 50: Y,Z = 140 mm
ø 90 - 110: X = 140 mm ø 22 - 50: Z = 180 mm ø 63 - 125: X = 180 mm ø 63 Y,Z = 160 mm
Joint/sleeve: Joint/sleeve: Joint/sleeve: Joint/sleeve:
ø 22 - 75: X = 70 mm ø 22 - 50: Y = 60 mm ø 22 - 50: X = 110 mm ø 22 - 50: Y,Z = 110 mm
ø 90 - 110: X = 140 mm ø 22 - 50: Z = 160 mm ø 63 - 110: X = 140 mm ø 63 Y,Z = 140 mm
ø 125 - 160: X = 150 mm
Note: Install the CPX-Clip-Shells according to the installation instruction!
9.3.2015
Installation tools
general and for screwed connector
Cut to length and strip insulation Shrink procedure
The saw is used to cut the casing pipe and

the insulation
The gas burner is used to shrink hoses and joints
Knife to split casing and remove insulation
Hammer as auxiliary tool It is recommended that gloves are worn for shrinking work.
Fit of connection piece
Cleaning products and cleaning cloths
Pipe cutter for PEX pipe

24 mm
Spanner wrench Flat bit for cutting filler hole
9.3.2015
Installation tools
for press fit joints
Manual tool for PEX Ø 22 - 40 mm (packed in one case)
Press tool, up to Ø 40 mm
Expander tool, up to Ø 32 mm Expander tool for Ø 40 mm Case with basic tool
(basic tool) (basic tool) including head and yoke
Expander head, up to Ø 32 mm Expander head, over Ø 40 mm Press yoke, Ø 22 - 40 mm
Hydraulic tool for PEX Ø 50 - 110 mm (packed in two cases)
Hydraulic press and expander tool Case with basic tool

Ø 50 - 110 mm including foot pump (basic tool) (without heads and yoke)
Expander head Press yoke Reducer Ø 75/90 mm Case with expander heads
Ø 50 - 110 mm Ø 50, 63 mm for yoke, Ø 110 mm and press yoke
Electro-hydraulic tool for PEX Ø 125 - 160 mm (packed in two cases)
Case with basic tool

Hydraulic press and expander tool
(without heads and yoke)
Ø 125 - 160 mm including foot pump (basic tool)
Expander head Press yoke Reducer Ø 125 mm Case with expander heads
Ø 125 - 160 mm Ø 140 mm, 160 mm for yoke, Ø 160 mm and press yoke
9.3.2015
Heating strip, sanitary, 10 bar

Drawing in, sensor, joint
1. Pulling through the heating strip

1. Unroll the pipe so that it is straight, next to the trench (without
CALPEX
bends). See also CPX 1.120. Shorten the casing and cut back the
channel. From one end, push the glass fibre wire (ø 6.5 mm) through
the channel. The heating strip can be pushed in for straight lengths of
Glass fibre wire
up to 30 m.
CALPEX
2. Connect the heating strip or pull cord to the wire (drill a hole in the
Heating strip strip) and pull through the heating strip.
Detail A
2. Installation of the temperature sensor for frost protection

The temperature sensor has to be installed on the carrier pipe, opposite the heating strip. It must be installed at the coldest point of the pipe
(outside the building). For this purpose, cut open an area of the casing measuring 10 x 7 cm and peel it off, cut open 10 x 7 cm of foam, fix the
temperature sensor onto the carrier pipe with adhesive tape, fill the hole with the insulation material supplied, apply filling adhesive S1113 below
and above the temperature sensor cable (see Detail B), and seal with the sealing set.
approx. 10 cm
CALPEX
approx. 7 cm
Temperature sensor cable CALPEX
Shrink hose Filling adhesive, S 1113, 60 mm long
Shrink hose Temperature sensor

Detail B Detail C
3. Remove the insulation

Shorten the casing by 120 mm and
cut off the exposed channel.
CALPEX
approx. 120 mm
4. Joint Detail D
Through connection L ≤ Lmax* Separate of heating strips L > Lmax*

Feed in from one end Feed in from both end (each strip ≤ Lmax)
250 mm 300 mm
CALPEX CALPEX CALPEX CALPEX
Heating strip Heating strip joint Heating strip End closure

(HWAT-R; FS-B-2X) (S-06 for HWAT-R and FS-B-2X) (HWAT-R; FS-B-2X) (E-03 for HWAT-R and FS-B-2X)
Detail E Detail F
Protect the heating strip against moisture

* Lmax = max. permitted length for heating strip
The heating strip and the accessories are supplied and installed by the electrician!
9.3.2015
COOLMANT / COOLFLEX
Energy- and cost-efficient systems for district cooling
COOLFLEX CLX 2.0
Table of Contents
2.0 Table of Contents
2.1 System description

2.100 System description (general)
2.105 System description (data)
2.115 COOLFLEX range, DN 20 - DN 125 / SDR 11 (coils)
2.2 Planning, design engineering

2.200 Pressure loss chart for water, DN 20 - DN 125 / SDR 11
2.201 Pressure loss chart for ethylene glycol, DN 20 - DN 125 / SDR 11
2.210 Heat losses
2.3 Components
2.300 House entry bend, 90°
2.315 COOLFLEX L-shell, dimension Ø 76 - 126 mm
2.316 COOLFLEX Big L-shell, dimension Ø 162 - 182 mm
2.320 Joint (PE-HD shrink sleeve), dimension Ø 76 - 182 mm
2.325 COOLFLEX I-shell, dimension Ø 76 - 126 mm
2.326 COOLFLEX Big I-shell, dimension Ø 162 - 182 mm
2.330 COOLFLEX T-shell, dimension Ø 76 - 126 mm
2.335 COOLFLEX Big T-shell, dimension Ø 162 - 182 mm
2.345 Insulation material

2.350 PE jointing methods, screwed connectors (external thread, weld end, coupling)
2.355 PE jointing methods, screwed connectors, T-pieces
2.359 PE jointing methods, fusion welded
2.360 PE jointing methods, alternative connections
2.365 End closure, shrink-type closure, end cap (LD-PE)

2.370 Wall sealing ring for wall openings
2.375 Building entry, wall opening
2.380 Building entry, core bores/cement pipe liners
2.5 Underground construction, installation

2.500 Pipe routing
2.505 Trench dimensions
2.510 Open installation
8.1.2015
Subject to technical modifications.
COOLFLEX CLX 2.100
System description
COOLFLEX is the registered trade name for a flexible pipe system from Brugg Pipe Systems. This Max. continuous operating
pipe system is especially suitable for use in local and district cooling networks, in industrial and temperature TBmax: –20 to +40 °C*
with restrictions also for combined heat pump systems (cooling and heating). Max. permitted operating
pressure p: max. 16 bar
The COOLFLEX district cooling pipe has a carrier pipe produced from high-density polyethylene
(PE100) as per standard EN 12162. The polyethylene pressure pipes are the standard for drinking *warm water application with limited lifetime
water and waste water systems, and also for the gas supply sector. The pipes are joined by means and operating pressure (as per DIN 8074)
of standard screwed connectors, mechanical pipe couplings, with normal commercial electro fu-
sion fittings or by means of butt fusion welding technology.
The heat insulation consists of CFC-free polyurethane foam with excellent insulating properties.
COOLFLEX district cooling pipe can be adapted to all pipe routing conditions without problems.
It is possible to pass over or under existing supply pipes, and obstacles are easily bypassed. With
the flexible COOLFLEX district cooling pipe, you can choose the shortest pipe route without con-
sidering the classical method of pipe construction.
The flexible COOLFLEX district cooling pipe is delivered to the site in continous coils or on a drum.
Generous delivery lengths enable pipes to be laid largely without underground connections. Pipe
trench can be considerably narrower and this allows considerable savings on underground work.
Taking account of the very short time required for installation, COOLFLEX district cooling pipe is
not only a technically perfect solution but also the key to saving time and expense when setting
up district cooling networks, because less coordination is required on site and the pipes are laid
simply and quickly.
8.1.2015
COOLFLEX CLX 2.105
System description
1. Medium pipe
Material: Polyethylene class PE100 with high density, to DIN EN ISO 12162
Life expectancy: 50 years at 20 °C (16 bar) or 40 °C (11.6 bar) as per DIN 8074 (SF 1.25)
Properties: suitable as district cooling, cold water and waste water pipe
PE carrier pipe Reference temperature Value Test standard
Density – 952 - 960 kg/m³ DIN 53479
Thermal conductivity 40 °C 0.40 W/mK DIN 52612
Tensile strengts 20 °C 32 N/mm2 DIN 53455
Modulus of elasticity 20 °C 1000 N/mm2 DIN 53457
Linear expansion coefficient 20 °C 1.8 · 10 E-4 1/K DIN 52328
Crystallite melting range – 130 - 135 °C –
Material: CFC-free, 100 % CO2-blown polyurethane foam (PUR)

PUR insulation Reference temperature Flexible pipes Test standard
DN 20 - DN 125
Density – > 60 kg/m³ ISO 845
Thermal conductivity 30 ≤ 0.0234 W/mK EN 253 and ISO 8497
Percentage of closed cells – ≥ 90 % –
Water absorption after 24 hours – ≤ 10 % EN 253
Material: linear polyethylene, low density (LLD-PE), seamlessly extruded

LLD-PE protective casing Reference temperature Flexible pipes Test standard
Density – 918 - 922 kg/m³ ISO 1183
Thermal conductivity – 0.33 W/mK DIN 52612
Crystallite melting range – 122 °C ISO 11357-3
8.1.2015
COOLFLEX CLX 2.115
COOLFLEX range
Dimensions DN 20 - DN 125 / SDR 11 (coils)
s1
D
d
s
PE 100 carrier pipe
PUR foam
PE foil
LLD-PE casing
Dimensions DN 20 - DN 125 / SDR 11

Type DN Inches PE inner pipe Outer casing Minimum Volume Weight Maximum delivery lengths*
dxs D x s1 Bending radius Inner pipe Jumbo coil Maxi coil
“ mm mm m I/m kg/m m m
25/ 76 20 ¾ 25 x 2.3 78 x 2.0 0.7 0.327 0.90 520 780
32/ 76 25 1 32 x 2.9 78 x 2.0 0.7 0.539 1.00 520 780
40/ 91 32 1¼ 40 x 3.7 93 x 2.2 0.8 0.835 1.39 370 570
50/ 91 40 1½ 50 x 4.6 93 x 2.2 0.8 1.307 1.54 370 570
63/126 50 2 63 x 5.8 128 x 2.7 1.0 2.091 2.60 192 291
75/126 65 2½ 75 x 6.8 128 x 2.7 1.0 2.961 2.75 192 291
90/162 80 3 90 x 8.2 163 x 3.2 1.2 4.254 4.56 92 149
110/162 100 4 110 x 10.0 163 x 3.2 1.2 6.362 5.69 92 149
125/182 125 5 125 x 11.4 183 x 3.3 1.4 8.200 6.37 52 86
* Partial lengths can be delivered
- All dimensions are available in straight lengths on request.

8.1.2015
COOLFLEX CLX 2.200
Pressure loss chart for water

DN 20 - DN 125 / SDR 11
Water temperature 10 °C
Roughness  = 0.01 mm (PE100)

(1 mmWS = 9.81 Pa)
Velocity 125/102.2 mm
(DN 125) 110/90.0 mm
(DN 100)
100000
90/73.6 mm
(DN 80)
60000
Flow rate ṁ [kg/h]
75/61.4 mm
30000 40000
(DN 65)
63/51.4 mm
(DN 50)
20000
3.0
m/
s
50/40.8 mm
(DN 40)
2.0
m/
10000
s
1.5
40/32.6 mm
m/
(DN 32)
s
1.0
m/
5000
32/26.2 mm
0.7
4000
5m
(DN 25)
/s
3000
0.5
m/
s
25/20.4 mm
0.4
(DN 20)
m/
2000
s
0.3
m/
s
1000
500
300
20
30
40
50
80
100
120
140
160
180
200
300
400
500
800
1000
1200
1400
1600
1800
2000
8.1.2015
COOLFLEX CLX 2.201
Pressure loss chart for ethylene glycol concentration

DN 20 - DN 125 / SDR 11
Medium temperature 10 °C
Ethylene glycol 30 % concentration

(1 mmWS = 9.81 Pa)
Velocity
125/102.2 mm
(DN 125)
100000
110/90.0 mm
(DN 100)
90/73.6 mm
60000
(DN 80)
30000 40000
75/61.4 mm
(DN 65)
3.0
m/s
63/51.4 mm
(DN 50)
20000
50/40.8 mm
2.0
(DN 40)
m/
10000
s
1.5
m/
s
40/32.6 mm
(DN 32)
1.0
m/
5000
s
0.7
5m
32/26.2 mm
4000
/s
(DN 25)
0.5
3000
m/
s
0.4
m/
s
25/20.4 mm
2000
0.3
(DN 20)
m/
s
1000
500
300
1000
1200
1400
1600
1800
2000
100
120
140
160
180
200
300
400
500
800
20
30
40
50
80
8.1.2015
COOLFLEX CLX 2.210
Energy losses
Applications laid in the ground
Dimensions DN 20 - DN 40
Heat losses q [W/m]
COOLFLEX U-value Average operating temperature TB [°C]
[W/mK] 6° 8° 10° 12° 14°
25/ 76 - SDR 11 0.1254 –0.5 –0.3 0.0 0.3 0.5
32/ 76 - SDR 11 0.1588 –0.6 –0.3 0.0 0.3 0.6
40/ 91 - SDR 11 0.1657 –0.7 –0.3 0.0 0.3 0.7
50/ 91 - SDR 11 0.2243 –0.9 –0.4 0.0 0.4 0.9
63/126 - SDR 11 0.1941 –0.8 –0.4 0.0 0.4 0.8
75/126 - SDR 11 0.2523 –1.0 –0.5 0.0 0.5 1.0
H = 0.6 m
90/162 - SDR 11 0.2269 –0.9 –0.5 0.0 0.5 0.9 a = 0.1 m
110/162 - SDR 11 0.3287 –1.3 –0.7 0.0 0.7 1.3
125/182 - SDR 11 0.2275 –0.9 –0.5 0.0 0.5 0.9
TE E
Installation type CLX: 2-pipe, laid in the ground Heat loss during operation:
Pipe distance: a = 0.10 m q = U (TB -TE) [W/m]
Covera above pipe: H = 0.60 m U = Heat transfer coefficient [W/mK]
Ground temperature: TE = 10.00 °C TB = Average operating temperature [°C]
Soil conductivity: lE = 1.2 W/mK TE = Average ground temperature [°C]
Conductivity of PUR foam: lPU = 0.0234 W/mK VL = Flow
Conductivity of PE pipe: lPE = 0.40 W/mK RL = Return
Conductivity of PE casing: lPE = 0.33 W/mK
On request, we shall be glad to calculate the heat losses for surface mounted pipe systems.
8.1.2015
COOLFLEX CLX 2.300
Bend, 90°
1000 UNO
A
1500
250
Figures in mm
Dimensions DN 20 - DN 100 / SDR 11

Type DN Inches PE inner pipe Outer pipe Volume
dxs D x s1 Inner pipe
“ mm mm I/m
25/ 76 20 3/4 25 x 2.3 75 x 4.5 0.327
32/ 76 25 1 32 x 2.9 75 x 4.5 0.539
40/ 91 32 1¼ 40 x 3.7 90 x 3.5 0.835
50/ 91 40 1½ 50 x 4.6 90 x 3.5 1.307
63/126 50 2 63 x 5.8 125 x 4.8 2.091
75/126 65 2½ 75 x 6.8 125 x 4.8 2.961
90/162 80 3 90 x 8.2 160 x 4.9 4.254
110/162 100 4 110 x 10.0 160 x 4.9 6.362
8.1.2015
COOLFLEX CLX 2.315
COOLFLEX L-shell
Dimensions DN 20 - DN 65 (Ø 76 - 126 mm)
d1
COOLFLEX
1
4
3
5
2
376
COOLFLEX d2
Figures in mm
376
COOLFLEX L-shell Structure of the half-shell

Outer casing Ø d2
76 x 2 PE fusion welded joints; see CLX 2.359
126 x 4 Insulation material; see CLX 2.345
5 Glued surface
PE jointing methods; see CLX 2.350 - 2.360
6 Reducer ring or sealing ring
8.1.2015
COOLFLEX CLX 2.316
COOLFLEX Big L-shell

d1
COOLFLEX
1
4
3
5
2
508
COOLFLEX d2
Figures in mm
508
COOLFLEX Big L-shell Structure of the half-shell

Outer casing Ø d2
Ø d1 76 91 126 162 182 1 ABS half-shells
76 2 PE fusion welded joints; see CLX 2.359
91 3 Sealing clamps (24 pcs.)
126 4 Insulation material; see CLX 2.345
182 x 6 Reducer ring or sealing ring
COOLFLEX Big-shells are freely reducible from Ø 182 mm to Ø 76 mm
8.1.2015
COOLFLEX CLX 2.320

COOLFLEX joints and reduction joints
1 2 3 4
d2
COOLFLEX COOLFLEX
d1
d2
1 PE fusion welded joints; see CLX 2.359
2 Insulation material, PUR or PE; see CLX 2.345
4 Shrink hose
COOLFLEX – COOLFLEX
Ø d2 76 91 126 162 182
Ø d1 76 x
91 x x
126 x x x
162 x x
182 x x x
8.1.2015
COOLFLEX CLX 2.325
COOLFLEX I-shell
1 2 3 4 5 6
COOLFLEX COOLFLEX
d1
d2
578
Figures in mm
COOLFLEX I-shell Structure of the half-shell

Outer casing Ø d2
76 x 2 PE jusion welded joints; see CLX 2.359
126 x x x 4 Insulation material; see CLX 2.345
5 Glued surface
8.1.2015
COOLFLEX CLX 2.326
COOLFLEX Big I-shell

1 4 3 2 5 6
COOLFLEX COOLFLEX
d1
d2
Figures in mm
752
COOLFLEX Big I-shell Structure of the half-shell

Outer casing Ø d2
76 2 PE jusion welded joints; see CLX 2.359
126 4 Insulation material; see CLX 2.345
162 x x 5 Glued surface
182 x x 6 Reducer ring or sealing ring
COOLFLEX Big-shells are freely reducible from Ø 182 mm to Ø 76 mm
8.1.2015
COOLFLEX CLX 2.330
COOLFLEX T-shell
d2
COOLFLEX
3
1
4
6
5
2
373
COOLFLEX COOLFLEX
d1
d3
578
Figures in mm
COOLFLEX T-shell Structure of the half-shell

Outer pipe Branch, Ø d2
Ø d1 - Ø d3 76 91 126 1 ABS half-shells
76 - 76 x x x 2 PE T-piece; see CLX 2.359
91 - 91 x x x 3 Sealing clamps (16 pcs.)
91 - 76 x x x 4 Insulation material; see CLX 2.345
126 - 126 x x x 5 Glued surface
126 - 91 x x x 6 Reducer ring or sealing ring
126 - 76 x x x
8.1.2015
COOLFLEX CLX 2.335
COOLFLEX Big T-shell

d2
COOLFLEX
2
1
3 5 6
4
508
COOLFLEX COOLFLEX
d1
d3
Figures in mm
752
COOLFLEX Big T-shell Structure of the half-shell

Outer pipe Branch, Ø d2
Ø d1 - Ø d3 76 91 126 162 182 1 ABS half-shells
162 - 162 x x x x x 2 PE T-piece; see CLX 2.359
162 - 126 x x x x x 3 Sealing clamps (27 pcs.)
162 - 91 x x x x x 4 Insulation material; see CLX 2.345
162 - 76 x x x x x 5 Glued surface
182 - 182 x x x x x 6 Reducer ring or sealing ring
182 - 162 x x x x x
182 - 126 x x x x x
182 - 91 x x x x x
182 - 76 x x x x x
8.1.2015
COOLFLEX CLX 2.345
Insulation material
PUR foam containers (DN 20 - DN 125)
Insulation material for shrink joints and shell systems
PUR foam containers (DN 25 - DN 125)

CFC-free, cyclopentane-blown PUR foam in plastic bottles
The required quantity of polyurethane foam is delivered in suitable container sizes for the
various joints and T-pieces. The components are supplied separately in two bottles, and are
only mixed together when needed. Please note the safety regulations in the installation
instructions supplied with the product.
Safety regulations

during the foaming process.
Synthetic gloves
Protective
goggles
8.1.2015
COOLFLEX CLX 2.350
PE jointing methods
Screwed connectors (outer thread, weld end, coupling)
Connection with outer thread/weld end Cold water, 16 bar

Material: brass
St 37.0 PE pipe Screwed connector L Weld end L
mm mm mm mm mm
L L 25 x 2.3 25 x 2.3-¾“ 53 26.9 x 2.65 180
32 x 2.9 32 x 2.9-1“ 63 33.7 x 2.3 180
40 x 3.7 40 x 3.7-1¼“ 67 42.4 x 2.6 185
50 x 4.6 50 x 4.6-1½“ 71 48.3 x 2.6 190
St 37.0 63 x 5.8 63 x 5.7-2“ 80 60.3 x 2.9 195
75 x 6.8 75 x 6.8-2½“ 92 76.1 x 3.2 200
90 x 8.2 90 x 8.2-3“ 92 88.9 x 3.2 240
L L 110 x 10.0 110 x 10.0-4“ 102 114.3 x 3.6 280
90° angle coupling

Cold water, 16 bar
z
Material: brass
PE pipe PE pipe a z
mm mm mm mm
25 x 2.3 25 x 2.3 54 32
32 x 2.9 32 x 2.9 64 37
z
40 x 3.7 40 x 3.7 74 42
a
50 x 4.6 50 x 4.6 87 48
63 x 5.8 63 x 5.8 106 60
75 x 6.8 75 x 6.8 117 67
a
Cold water, 16 bar

Material: brass
Coupling, equal PE pipe Coupling L
mm mm mm
25 x 2.3 25 x 2.3 60
PE 22-75
32 x 2.9 32 x 2.9 67
L 40 x 3.7 40 x 3.7 71
50 x 4.6 50 x 4.6 75
63 x 5.8 63 x 5.7 81
75 x 6.8 75 x 6.8 89
PE 90-110
90 x 8.2 90 x 8.2 130
110 x 10.0 110 x 10.0 130
L
Coupling, reduced Cold water, 16 bar

Material: brass
PE pipe Coupling
PE 22-75 mm mm
32 x 2.9 / 25 x 2.3 32-1“ / 25-¾“
L
40 x 3.7 / 32 x 2.9 40-1¼“/ 32-1“
50 x 4.6 / 40 x 3.7 50-1½“/ 40-1¼“
63 x 5.8 / 50 x 4.6 63-2“ / 50-1½“
PE 90-110 75 x 6.8 / 63 x 5.8 75-2½“/ 63-2“
90 x 8.2 / 75 x 6.8 90-3“ / 75-2 ½“
110 x 10.0 / 90 x 8.2 110-4“ / 90-3“
L
8.1.2015
COOLFLEX CLX 2.355
PE jointing methods
screwed connectors, T-pieces
d2
d2
d1
d3
d1
PE  25 - 75 PE  90 - 110
Material: brass
mm mm
25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0
22 x 3.0 - 22 x 3.0
25 x 2.3 - 25 x 2.3 x
28 x 4.0 - 28 x 4.0 x
32 x 2.9 - 32 x 2.9 x x
32 x 2.9 - 28 x 4.0 x
32 x 2.9 - 25 x 2.3 x
40 x 3.7 - 40 x 3.7 x x x
40 x 3.7 - 32 x 2.9 x x
50 x 4.6 - 50 x 4.6 x x x x
50 x 4.6 - 40 x 3.7 x x x
63 x 5.8 - 63 x 5.8 x x x x x
63 x 5.8 - 50 x 4.6 x x x x
75 x 6.8 - 75 x 6.8 x x x x x x
75 x 6.8 - 63 x 5.8 x x x x x
90 x 8.2 - 90 x 8.2 x x x x x x x
90 x 8.2 - 75 x 6.8 x x x x x x
110 x 10.0 - 110 x 10.0 x x x x x x x x
110 x 10.0 - 90 x 8.2 x x x x x x x
Any other T-pieces that may be required can be supplied on request
8.1.2015
COOLFLEX CLX 2.359
PE jointing methods
Fusion welded
Sleeves Cold water, 16 bar

Material: PE 100 / SDR 11
PE pipe Sleeve d1 L
mm mm mm mm
25 x 2.3 25 36 68
32 x 2.9 32 44 72
40 x 3.7 40 54 80
50 x 4.6 50 66 88
63 x 5.8 63 81 96
75 x 6.8 75 96 110
90 x 8.2 90 113 125
110 x 10.0 110 138 145
125 x 11.4 125 154 158
Reduction sleeves Cold water, 16 bar

PE pipe Sleeve d1 L L1 L2 z
mm mm mm mm mm mm mm
32 x 2.9 / 25 x 2.3 32 / 25 44 79 33 36 10
40 x 3.7 / 32 x 2.9 40 / 32 54 88 33 39 13
50 x 4.6 / 40 x 3.7 50 / 40 66 96 39 43 14
63 x 5.8 / 50 x 4.6 63 / 50 81 106 43 48 15
75 x 6.8 / 63 x 5.8 on request
90 x 8.2 / 75 x 6.8 on request
110 x 8.2 / 90 x 8.2 110 / 90 138 173 73 63 38
125 x 11.4 / 110 x 10.0 on request
Angle piece, 90° equal Cold water, 16 bar

PE pipe Sleeve d1 L L1 z
mm mm mm mm mm mm
25 x 2.3 25 35 54 34 20
32 x 2.9 32 44 53 36 17
40 x 3.7 40 54 62 39 23
50 x 4.6 50 66 71 43 28
63 x 5.8 63 81 81 48 32
75 x 6.8 75 97 94 54 40
90 x 8.2 90 115 122 62 60
110 x 10.0 110 140 147 72 76
125 x 11.4 125 151 142 74 68
T-pieces Cold water, 16 bar

PE pipe T-piece d1 L L1 z z1 H
25 x 2.3 25 35 90 34 11 92 70
32 x 2.9 32 44 102 36 15 100 74
40 x 3.7 40 54 120 39 21 114 82
50 x 4.6 50 66 135 43 24 126 90
63 x 5.8 63 81 152 48 28 150 102
75 x 6.8 75 97 178 54 35 143 87
90 x 8.2 90 115 205 62 41 161 94
110 x 10.0 110 140 255 72 56 184 104
125 x 11.4 125 161 276 78 60 207 113
(Source: Georg Fischer AG)
8.1.2015
COOLFLEX CLX 2.360
PE jointing methods
Alternative connections
Butt-fusion
(Source: PF-Schweisstechnologie GmbH)
Mechanical pipe couplings
To join:
plastic to plastic, or
plastic to metal pipes
Ø 40 - 250 mm
(Source: Straub Werke AG)
All jointing methods listed on this sheet are available on request.
8.1.2015
COOLFLEX CLX 2.365
End closure
Shrink-type closure, end caps (LD-PE)
Shrink-on closure
COOLFLEX shrink-on closures protect the PUR insulation on the front of the COOLFLEX pipes against splashing water
in buildings and shafts. Important: in contact with water (flooding), the shrink-on closure is not necessarily watertight!
The shrink-on closure also stops gas escaping from the PUR insulation.
Important fitting note
COOLFLEX shrink-on closures must be

pushed onto the end of the COOLFLEX pipes
before welding the inner pipes and must be
protected against the action of heat during
welding.
min. 120 Material:
Heat-shrunk, cross-linked polyolefin.

Coated with sealing adhesive
End caps (PE-LD)
End caps are fitted as end closures for dry areas/rooms (up to Ø 182 mm).
min. 120
8.1.2015
COOLFLEX CLX 2.370
Wall sealing ring

for wall openings
Wall sealing ring
COOLFLEX
Type CLX Da
25/ 76 118
32/ 76 118
40/ 91 133
50/ 91 133
63/126 168
75/126 168
90/162 203
Da
D
110/162 203
125/182 223
50
Pipe warning tape
• To be laid in the ground

• Standard roll length: 250 m
• Installation depth: see sheet CLX 2.505
8.1.2015
COOLFLEX CLX 2.375
Building entry
Wall opening
Wall leadthrough
approx. 80 mm
PE connection piece:
see sheet CLX 2.350
80 mm
COOLFLEX
D
COOLFLEX pipe:
see sheets CLX 2.115
End cap:
see sheet CLX 2.365
Wall seal: see sheet CLX 2.370

ØD
mm mm mm
78 450 250
93 540 250
113 580 300
H
128 640 300

143 640 350
163 680 350
183 720 350
80 D 100 D 80
L
Figures in mm
8.1.2015
COOLFLEX CLX 2.380
Building entry
Wall leadthrough
80 mm COOLFLEX pipe:
PE connection piece: see sheets CLX 2.115
see sheet CLX 2.350
COOLFLEX
D
End cap:
see sheet CLX 2.365
Core bores Outer casing D1 A

min. 30 ØD
mm mm mm
76 150 180
91 150 180
126 200 230
162 250 280
D1
182 250 280
A Figures in mm
Core bores Key
Perfect bores are required for installation. As hairline cracks may be 1 COOLFLEX
present in the concrete or result from drilling, it is advisable to seal 2 Sealing set, single-seal, width 1 x 40 mm, Shore hardness D35
the entire length of the borehole wall with suitable sealant (such as 3 Sealing set, double-seal*, width 2 x 40 mm, Shore hardness D35
AQUAGARD). 4 Liner pipe: made of fiber cement or coated core bore
Tightness can only be guaranteed if this recommendation is followed. * Suitable for pressure from water up to 0.5 bar
8.1.2015
COOLFLEX CLX 2.500
Pipe routing
COOLFLEX – COOLMANT connection
COOLFLEX
COOLFLEX
A
C
COOLMANT
COOLFLEX
Loop-in method COOLFLEX – COOLFLEX connection
COOLFLEX
B
D
C
C
B
D
COOLFLEX
8.1.2015
COOLFLEX CLX 2.505
Trench dimensions
Trench profile, 2 COOLFLEX pipes (DN 20 - DN 125)
UNO
1 2 3
60
30
T
10
10 D
10 D 10 D 10
B Figures in cm
1 Pipe warning tape; see sheet CLX 2.370

3 Sand, washed, max. grain size 8 mm
Casing pipe Width Depth Minimum

Ø D B T Bending radius
mm cm cm m
76 45 80 0.7
91 50 80 0.8
111 55 85 0.9
126 55 85 1.0
162 65 90 1.2
182 70 95 1.4
Installation depth:
max. installation depth: 2.6 m
SLW 30 ^ = 300 kN total load as per DIN 1072; if subject to higher traffic
loads (e.g. SLW 60), a load-distributing superstructure as per RStO75
is required.
With no traffic load, the minimum trench depth T can be reduced by

20 cm.
8.1.2015
COOLFLEX CLX 2.510
Surface installation
Special measures are required for surface installation of COOLFLEX district cooling pipes:
– Provide supports for changes of direction

– Secure with clamps and pressure distribution plates at specified intervals, in the 90° bend
– Clamps
– Fix ends with fixed points
– Assistance with design engineering and planning from BRUGG
Type Weight Minimum distance between

including Bending clamps
water radius a
kg/m m m
25/ 76 1.2 0.7 0.6
32/ 76 1.5 0.7 0.8
40/ 91 2.2 0.8 1.0
50/ 91 2.8 0.8 1.2
63/126 4.7 1.0 1.4
75/126 5.7 1.0 1.7
90/162 8.8 1.2 1.8
110/162 12.1 1.2 2.1
125/182 14.6 1.4 2.2

8.1.2015
COOLMANT CLM 2.0
Table of Contents

2.115 COOLMANT range, Ø 125 - Ø 315 / SDR 11/SDR 17 (bars)

2.200 Pressure loss chart for water, Ø 125 - Ø 315 / SDR 11
2.201 Pressure loss chart for ethylene glycol, Ø 125 - Ø 315 / SDR 11
2.202 Pressure loss chart for water, Ø 125 - Ø 315 / SDR 17
2.203 Pressure loss chart for ethylene glycol, Ø 125 - Ø 315 / SDR 17
2.210 Heat losses
2.3 Components
2.300 House entry bend, 90°
2.340 T-piece, angled at 45°, dimension Ø 125 - 315 mm / SDR 11/SDR 17
2.345 Insulation material

2.359 PE jointing methods, fusion welded
2.360 PE jointing methods, alternative connections
2.365 End closure, shrink-type closure, end cap (LD-PE)

2.370 Wall sealing ring for wall openings
2.375 Building entry, wall opening

2.500 Pipe routing
26.3.2012
COOLMANT CLM 2.100
System description
COOLMANT is the registered trade name for a rigid pipe system from Brugg Pipe Systems with Max. continuous operating
carrier pipes made of polyethylene. This pipe system is especially suitable for use in local and temperature TBmax: –20 to +40 °C*
district cooling networks, in industrial and with restrictions also for combined heat pump systems Max. permitted operating
(cooling and heating). pressure p: max. 16 bar
The COOLMANT district cooling pipe has a carrier pipe produced from high-density polyethylene *warm water application with limited lifetime
(PE100) as per standard EN 12162. The polyethylene pressure pipes are the standard for drinking and operating pressure (as per DIN 8074)
water and waste water systems, and also for the gas supply sector. The pipes are joined by means
of standard screwed connectors, mechanical pipe couplings, with normal commercial electro fu-
sion fittings or by means of butt fusion welding technology.
The insulation is made of fine-pore CFC-free rigid polyurethane foam and, together with the me-
dium pipe, it forms a compact composite system with excellent insulation properties. The outer
casing meets the requirements for plastic casing pipes as per EN 253, ensuring that the district
cooling pipe is reliably protected against mechanical influences and the possibility that water
could penetrate the system. The pipes can therefore be installed at outdoor temperatures down
to 0°C.
In combination with the flexible COOLFLEX district cooling system, these features make it possible
to implement applications involving widely varying requirements imposed by the terrain – so the
installation outlay is substantially reduced.
26.3.2012
COOLMANT CLM 2.105
System description
1. Medium pipe
Material: Polyethylene class PE100 with high density, to DIN EN ISO 12162
Life expectancy: 50 years at 20 °C (16 bar) or 40 °C (11.6 bar) as per DIN 8074 (SF 1.25)
Properties: suitable as district cooling, cold water and waste water pipe
PE carrier pipe Reference temperature Value Test standard
Density – 952 - 960 kg/m³ DIN 53479
Thermal conductivity 40 °C 0.40 W/mK DIN 52612
Tensile strengts 20 °C 32 N/mm2 DIN 53455
Modulus of elasticity 20 °C 1000 N/mm2 DIN 53457
Linear expansion coefficient 20 °C 1.8 · 10 E-4 1/K DIN 52328
Material: CFC-free, 100 % CO2-blown polyurethane foam (PUR)

PUR insulation Reference temperature Rigid pipes Test standard
Ø 125 - Ø 315
Thermal conductivity 30 ≤ 0.024 W/mK EN 253 and ISO 8497
Percentage of closed cells – ≥ 90 % –
Water absorption after 24 hours – ≤ 10 % EN 253
Material: Polyethylene class PE 100 with high density

PE protective casing Reference temperature Rigid pipes Test standard
Density – 956 kg/m³ ISO 1133
Thermal conductivity – 0.40 W/mK DIN 52612
Tensile strengts – ≥ 19 N/mm2 DIN EN 253
26.3.2012
COOLMANT CLM 2.115
COOLMANT range
Ø 125 - 315 mm / SDR 11/SDR 17 (bars)
D
s
PE 100 carrier pipe
PUR-foam
PE-HD casing
Dimensions Ø 125 - 315 mm / SDR 11

Type Inches PE inner pipe Outer casing Volume Weight Standard
dxs D x s1 Inner pipe length
“ mm mm I/m kg/m m
125/225 5 125 x 11.4 225 x 3.5 8.203 7.61 6/12
140/225 - 140 x 12.7 225 x 3.5 10.315 8.38 6/12
160/250 6 160 x 14.6 250 x 3.9 13.437 10.67 6/12
180/280 7 180 x 16.4 280 x 4.4 17.018 13.45 6/12
200/315 8 200 x 18.2 315 x 4.9 21.021 16.77 6/12
225/315 9 225 x 20.5 315 x 4.9 26.590 18.91 6/12
250/355 10 250 x 22.7 355 x 5.6 32.878 23.68 6/12
280/400 11 280 x 25.4 400 x 6.3 41.259 29.85 6/12
315/450 12 315 x 28.6 450 x 7.0 52.198 37.69 6/12

Type Inches PE inner pipe Outer casing Volume Weight Standard
dxs D x s1 Inner pipe length
“ mm mm I/m kg/m m
125/225 5 125 x 7.4 225 x 3.5 9.230 6.63 6/12
140/225 - 140 x 8.3 225 x 3.5 11.960 6.82 6/12
160/250 6 160 x 9.5 250 x 3.9 15.610 8.60 6/12
180/280 7 180 x 10.7 280 x 4.4 19.760 10.85 6/12
200/315 8 200 x 11.9 315 x 4.9 24.380 13.58 6/12
225/315 9 225 x 13.4 315 x 4.9 30.850 14.86 6/12
250/355 10 250 x 14.8 355 x 5.6 38.150 18.67 6/12
280/400 11 280 x 16.6 400 x 6.3 47.840 23.60 6/12
315/450 12 315 x 18.7 450 x 7.0 60.520 29.78 6/12
26.3.2012
COOLMANT CLM 2.200

Ø 125 - 315 mm / SDR 11

(1 mmWS = 9.81 Pa)
Velocity
1.5 · 106
315/257.8 mm
106
280/229.2 mm
8
250/204.6 mm
225/184.0 mm
5
200/163.6 mm
4
180/147.2 mm
3
160/130.8 mm
2
140/114.6 mm
3.0
m/
s
125/102.2 mm
105
2.0
m/
s
1.5
m/
s
5
1.0
m/
s
4
0.7
5m
/s
3
2
104
20
30
40
50
80
100
120
140
160
180
200
300
400
500
800
1000
26.3.2012
COOLMANT CLM 2.201

Ø 125 - 315 mm / SDR 11

(1 mmWS = 9.81 Pa)
Velocity
1.5 · 106
315/257.8 mm
106
280/229.2 mm
8
250/204.6 mm
225/184.0 mm
5
4
200/163.6 mm
3
180/147.2 mm
160/130.8 mm
2
140/114.6 mm
3.0
m/
125/102.2 mm
105
s
2.0
m/
s
1.5
m/
5
s
4
1.0
m/
s
0.7
3
5m
/s
0.5
2
0m
/s
104
20
30
40
50
80
100
120
140
160
180
200
300
400
500
800
1000
26.3.2012
COOLMANT CLM 2.202

Ø 125 - 315 mm / SDR 17

(1 mmWS = 9.81 Pa)
Velocity
2
315/277.6 mm
280/246.8 mm
106
250/220.4 mm
225/198.2 mm
6
200/176.2 mm
4
180/158.6 mm
3
160/141.0 mm
2
140/123.4 mm
3.0
m/s
125/110.2 mm
2.0
105
m/
s
1.5
m/
s
1.0
m/
5
s
0.7
4
5m
/s
3
2
104
20
30
40
50
80
100
120
140
160
180
200
300
400
500
800
1000
26.3.2012
COOLMANT CLM 2.203

Ø 125 - 315 mm / SDR 17

(1 mmWS = 9.81 Pa)
Velocity
2
315/277.6 mm
280/246.8 mm
106
250/220.4 mm
8
225/198.2 mm
6
200/176.2 mm
4
180/158.6 mm
3
160/141.0 mm
2
140/123.4 mm
3.0
125/110.2 mm
m/s
105
2.0
m/
s
1.5
m/
s
5
1.0
m/
s
4
0.7
5m
/s
3
0.5
m/
s
2
104
20
30
40
50
80
100
120
140
160
180
200
300
400
500
800
1000
26.3.2012
COOLMANT CLM 2.210
Energy losses
Applications laid in the ground

Heat losses q [W/m]
COOLMANT U-value Average operating temperature TB [°C]
[W/mK] 6° 8° 10° 12° 14°
125/225 - SDR 11 0.233 –0.9 –0.5 0.0 0.5 0.9
140/225 - SDR 11 0.282 –1.1 –0.6 0.0 0.6 1.1
160/250 - SDR 11 0.299 –1.2 –0.6 0.0 0.6 1.2
180/280 - SDR 11 0.303 –1.2 –0.6 0.0 0.6 1.2
200/315 - SDR 11 0.296 –1.2 –0.6 0.0 0.6 1.2
225/315 - SDR 11 0.385 –1.5 –0.8 0.0 0.8 1.5
H = 0.6 m
250/355 - SDR 11 0.373 –1.5 –0.7 0.0 0.7 1.5 a = 0.1 m
280/400 - SDR 11 0.366 –1.5 –0.7 0.0 0.7 1.5
315/450 - SDR 11 0.370 –1.5 –0.7 0.0 0.7 1.5
Dimensions Ø 125 - 315 mm / SDR 17 TE E

Heat losses q [W/m]
COOLMANT U-value Average operating temperature TB [°C]
[W/mK] 6° 8° 10° 12° 14°
125/225 - SDR 17 0.234 –0.9 –0.5 0.0 0.5 0.9
140/225 - SDR 17 0.284 –1.1 –0.6 0.0 0.6 1.1
160/250 - SDR 17 0.301 –1.2 –0.6 0.0 0.6 1.2
180/280 - SDR 17 0.305 –1.2 –0.6 0.0 0.6 1.2
200/315 - SDR 17 0.299 –1.2 –0.6 0.0 0.6 1.2
225/315 - SDR 17 0.389 –1.6 –0.8 0.0 0.8 1.6
250/355 - SDR 17 0.378 –1.5 –0.8 0.0 0.8 1.5
280/400 - SDR 17 0.373 –1.5 –0.7 0.0 0.7 1.5
315/450 - SDR 17 0.374 –1.5 –0.7 0.0 0.7 1.5
Installation type CLM: 2-pipe, laid in the ground Heat loss during operation:
Covera above pipe: H = 0.60 m U = Heat transfer coefficient [W/mK]
Ground temperature: TE = 10.00 °C TB = Average operating temperature [°C]
Conductivity of PUR foam: lPU = 0.024 W/mK VL = Flow
Conductivity of PE pipe: lPU = 0.40 W/mK RL = Return
Conductivity of PE casing: lPU = 0.33 W/mK
On request, we shall be glad to calculate the heat losses for surface mounted pipe systems.
26.3.2012
COOLMANT CLM 2.300
Bend, 90°
1000 UNO
1000
250
Figures in mm

Type Inches PE inner pipe Outer pipe Volume
“ mm mm I/m
125/225 5 125 x 11.4 225 x 6.9 8.203
140/225 - 140 x 12.7 225 x 6.9 10.315
160/250 6 160 x 14.6 250 x 6.2 13.437
180/280 7 180 x 16.4 280 x 6.9 17.018
200/315 8 200 x 18.2 315 x 7.7 21.021
225/315 9 225 x 20.5 315 x 7.7 26.590
250/355 10 250 x 22.7 355 x 5.6 32.878
280/400 11 280 x 25.4 400 x 6.3 41.259
315/450 12 315 x 28.6 450 x 7.0 52.198

Type Inches PE inner pipe Outer pipe Volume
“ mm mm I/m
125/225 5 125 x 7.4 225 x 6.9 9.230
140/225 - 140 x 8.3 225 x 6.9 11.960
160/250 6 160 x 9.5 250 x 6.2 15.610
180/280 7 180 x 10.7 280 x 6.9 19.760
200/315 8 200 x 11.9 315 x 7.7 24.380
225/315 9 225 x 13.4 315 x 7.7 30.850
250/355 10 250 x 14.8 355 x 5.6 38.150
280/400 11 280 x 16.6 400 x 6.3 47.840
315/450 12 315 x 18.7 450 x 7.0 60.520
26.3.2012
COOLMANT CLM 2.320

COOLMANT joints and reduction joints
1 2 3 4
d2
COOLMANT COOLMANT
d1
d2
1 PE fusion welded joints; see CLM 2.350
2 Insulation material, PUR or PE; see CLM 2.345
4 Shrink hose
COOLMANT – COOLMANT
Ø d2 225 250 280 315 355 400 450
Ø d1 225 x
250 x x
280 x x
315 x x x
355 x x x x
400 x x x
450 x x x x x x
PE
jointing methods; see CLM 2.350
26.3.2012
COOLMANT CLM 2.340
T-piece, angled 45°

Dimension Ø 125 - 315 mm / SDR 11/SDR 17
45°
D2
H
D1
L1
L1 L2
Dimensions Ø 125 - 315 mm / SDR 11/ SDR 17

Type D1 L1 D2 L2 H
mm m mm m mm

125/225 225 1.0 225 1.0 300

140/225 225 1.0 225 1.0 300

160/250 250 1.0 250 1.0 320

180/280 280 1.0 280 1.0 350

200/315 315 1.0 315 1.0 390

225/315 315 1.0 315 1.0 390

250/355 355 1.0 355 1.0 425

280/400 400 1.0 400 1.0 470

315/450 450 1.0 450 1.0 520
Other dimensions can be supplied on request.
26.3.2012
COOLMANT CLM 2.345
Insulation material
PUR foam containers (Ø 125-315 mm)
Insulation material for shrink joints and shell systems
Safety regulations

during the foaming process.
Synthetic gloves
Protective
goggles
PUR foam canister (Ø 125 - 315 mm)

CFC-free PUR foam in a canister
The required quantity of polyurethane foam is measured out with the help of foam tables and is
mixed in a plastic container using a stirring device.
26.3.2012
COOLMANT CLM 2.359
PE jointing methods
Fusion welded
Sleeves Cold water, 16 bar

PE pipe Sleeve d1 L
mm mm mm mm
125 x 11.4 125 154 158
140 x 12.7 140 172 168
160 x 14.6 160 196 180
180 x 16.4 180 219 194
200 x 18.2 200 244 208
225 x 20.5 225 273 224
250 x 22.7 250 304 244
280 x 25.4 280 340 252
315 x 28.6 315 382 268
Reduction sleeves Cold water, 16 bar

PE pipe Sleeve d d1 L L1 z
mm mm mm mm mm mm mm
125 x 11.4/110 x 10.0 125/110 125 110 92 86 212
140 x 12.7/125 x 11.4 140/125 140 125 110 90 235
160 x 14.6/140 x 12.7 160/140 160 140 120 110 260
180 x 16.4/160 x 14.6 180/160 180 160 107 102 255
200 x 18.2/180 x 16.4 200/180 200 180 117 107 265
225 x 20.5/200 x 18.2 225/200 225 200 122 117 280
250 x 22.7/225 x 20.5 250/225 250 225 130 120 332
280 x 25.4/250 x 22.7 280/250 280 250 140 130 340
315 x 28.6/280 x 25.4 315/280 315 280 150 139 365
Cold water, 16 bar

Angle piece, 90° equal
PE pipe Sleeve d1 L L1 z
mm mm mm mm mm mm
125 x 11.4 125 151 142 74 68
140 x 12.7* 140 only possible with spigot fittings
160 x 14.6 160 196 178 92 86
180 x 16.4 180 219 195 95 100
200 x 18.2 200 245 265 104 161
225 x 20.5 225 274 305 112 193
250 x 22.7 250 305 335 123 212
315 x 28.6* 315 dto.
Cold water, 16 bar

T-pieces equal
PE pipe T-piece d1 L L1 z z1 H
125 x 11.4 125 161 276 78 60 207 113
160 x 14.6 160 196 325 92 71 206 103
180 x 16.4 180 225 344 90 82 250 110
200 x 18.2 200 245 560 104 176 250 117
225 x 20.5 225 274 610 112 193 270 122
250 x 22.7 250 305 667 123 211 288 127
315 x 28.6* 315 dto.
*on request available, just as further reductions and fittings for pipe class SDR 17
(Source: Georg Fischer AG)
26.3.2012
COOLMANT CLM 2.360
PE jointing methods
Alternative connections
Butt-fusion
Mechanical pipe couplings
To join:
plastic to plastic, or
plastic to metal pipes
Ø 40 - 250 mm
(Source: Straub Werke AG)
26.3.2012
COOLMANT CLM 2.365
End closure
Shrink-type closure, end caps (LD-PE)
Shrink-on closure
COOLMANT shrink-on closures protect the PUR insulation on the front of the COOLMANT pipes against splashing water
in buildings and shafts. Important: in contact with water (flooding), the shrink-on closure is not necessarily watertight!
The shrink-on closure also stops gas escaping from the PUR insulation.
Important fitting note
COOLMANT shrink-on closures must be

pushed onto the end of the COOLMANT pipes
before welding the inner pipes and must be
protected against the action of heat during
welding.
min. 120 Material:
Heat-shrunk, cross-linked polyolefin.

Coated with sealing adhesive
26.3.2012
COOLMANT CLM 2.370
Wall sealing ring

for wall openings
Wall sealing ring
COOLMANT
Type CLM Da
125/225 265
140/225 265
160/250 290
180/280 355
200/315 355
225/315 355
250/335 395
Da
D
280/400 440
315/450 490
50
Pipe warning tape

• Installation depth: see sheet CLM 2.505
26.3.2012
COOLMANT CLM 2.375
Building entry
Wall opening
Wall leadthrough
ca. 80 mm
see sheet CLM 2.350
80 mm
COOLMANT
D
End cap: COOLMANT pipe:
see sheet CLM 2.365 see sheets CLM 2.115
Wall seal: see sheet CLM 2.370

ØD
mm mm mm
225 810 400
250 860 400
280 920 450
H
315 990 450

355 1070 500
400 1160 550
450 1260 600
80 D 100 D 80
L
Figures in mm
26.3.2012
COOLMANT CLM 2.380
Building entry
Wall leadthrough
80 mm COOLMANT pipe:
PE connection piece: see sheet CLM 2.115
see sheet CLM 2.350
COOLMANT
D
End cap:
see sheet CLM 2.365

min. 30 ØD
mm mm mm
225 300 330
250 350 380
280 350 380
315 400 430
D1
355 450 480

400 500 530
450 600 630
A Figures in mm
Core bores Key
Perfect bores are required for installation. As hairline cracks may be 1 COOLMANT
present in the concrete or result from drilling, it is advisable to seal 2 Sealing set, single-seal, width 1 x 40 mm, Shore hardness D35
the entire length of the borehole wall with suitable sealant (such as 3 Sealing set, double-seal*, width 2 x 40 mm, Shore hardness D35
AQUAGARD). 4 Liner pipe: made of fiber cement or coated core bore
Tightness can only be guaranteed if this recommendation is followed. * Suitable for pressure from water up to 0.5 bar
26.3.2012
COOLMANT CLM 2.500
Pipe routing
COOLFLEX – COOLMANT connection
COOLFLEX
COOLFLEX
A
C
COOLMANT
COOLFLEX
Loop-in method COOLFLEX – COOLFLEX connection
COOLFLEX
B
D
C
C
B
D
COOLFLEX
26.3.2012
COOLMANT CLM 2.505
Trench dimensions
Trench profile, 2 COOLMANT pipes (Ø 125 - Ø 315)
1 2 3
min. 0.60
0.40
0.10
min. 0.15
min. 0.23
Figures in m
ca. 0.20 D D ca. 0.20

B
1 Pipe warning tape; see sheet CLM 2.370

Casing pipe Width Depth

Ø D B T
mm cm cm
225 105 as per trench profile
Installation depth:
loads (e.g. SLW 60), a load-distributing superstructure as per RStO75
is required.
With no traffic load, the minimum trench depth T can be reduced by

20 cm.
26.3.2012
COOLMANT CLM 2.510
Surface installation
Special measures are required for surface installation of COOLMANT district cooling pipes:
– Provide supports for changes of direction

– Secure with clamps and pressure distribution plates at specified intervals, in the 90° bend
– Clamps
– Fix ends with fixed points
– Assistance with design engineering and planning from BRUGG
Type Weight Minimum distance between

including Bending clamps
water radius a
kg/m m m
125/225 15.9 – 2.0
140/225 18.8 – 2.2
160/250 24.2 – 2.4
180/280 30.6 – 2.6
200/315 38.0 – 2.8
225/315 45.7 – 3.1
250/355 56.8 – 3.3
280/400 71.4 – 3.6
315/450 90.3 – 3.9
26.3.2012
EIGERFLEX®
Cold water pipe
EIGERFLEX CPE 3.0
Table of Contents

3.115 EIGERFLEX DN 20 - DN 100 with frost protection strip in the U-channel, carrier pipe Ø 25 - 110 mm

3.200 Pressure loss chart, DN 20 - DN 100 (SDR 11)
3.210 Heat loss in the buried-/installed above ground
3.3 Components
3.315 EIGERFLEX L-shell, dimension Ø 76 - 126 mm
3.316 EIGERFLEX Big-L-shell, dimension Ø 162 mm
3.325 EIGERFLEX I-shell, dimension Ø 76 - 126 mm
3.326 EIGERFLEX Big-I-shell, dimension Ø 162 mm
3.330 EIGERFLEX T-shell, dimension Ø 76 - 126 mm
3.335 EIGERFLEX Big-T-shell, dimension Ø 162 mm
3.345 Insulation material, PUR-foam containers / PE-Isolation
3.350 PE-jointing methods 1, screwed connectors (external thread, weld end, coupling)
3.355 PE-jointing methods 2, screwed connectors (T-pieces)
3.360 PE-jointing methods 3, fusion-welded and alternative connections
3.365 End closure, shrink-type closure
3.370 Wall sealing ring, pipe warning tape
3.375 Building entry, wall opening/core bore

3.510 FSB connection technology, sleeve joint
3.515 FSB connection technology, T-piece
3.520 Connection to end of frost protection strip
16.12.2013
EIGERFLEX CPE 3.100
System description
EIGERFLEX is Brugg Pipe Systems protected name for a flexible, pre-insulated cold water pipe Max. continuous operating
featuring an integrated frost protection strip (FPC). This pipe system is especially suitable for temperature TBmax: –30 to +20 °C
cold water and waste water pipes which can either be installed above ground or at depths with Max. permitted operating
frost. pressure p: max. 16 bar
The EIGERFLEX cold water pipe features a medium pipe produced from high-density polyethy-
lene (PE100) as per standard DIN EN 12201. Polyethylene pressure pipes are the standard
for drinking water and waste water systems, and also for the gas supply sector, and they are
excellently suited to the areas of application just mentioned. The pipes are joined by means of
standardised screwed connectors, mechanical pipe couplings, with normal commercial electro-
welded fittings or by means of polyfusion welding technology.
The heat insulation consists of CFC-free flexible rigid polyurethane foam with excellent insu-
lating properties. The bending capacity of the flexible EIGERFLEX cold water pipe means that
it can be adapted to all pipe routing conditions without problems. It is possible to pass over or
under existing supply pipes, and obstacles are easily bypassed. With flexible EIGERFLEX cold
water pipe, you can choose the shortest pipe route without having to consider classical pipe
construction methods.
The self-limiting frost protection strip (FPC) has direct contact to the medium pipe within the
heat trace channel and a power capacity of 18 W/m. EIGERFLEX cold water pipe is prefabrica-
ted as appropriate and supplied in the required lengths; it always offers the same performance,
regardless of the quantities ordered. The maximum length of the heating circuit varies according
to the cut-in temperature, which must be controlled by a thermostat.
The desired length of flexible EIGERFLEX cold water pipe is delivered to site in continuous
form, either in rings or on a cable drum. Thanks to the generous delivery lengths, pipes can be
laid largely without connection points in the ground, so the width of the pipe trench can be
considerably reduced. Substantial savings are possible because underground construction work
is minimised and installation is fast as well as simple.
16.12.2013
EIGERFLEX CPE 3.105
System description
1. Medium pipe
Material: Polyethylene class PE100 with high density, to DIN EN 12201 / DIN 8074 / DIN 8075
Life expectancy: 50 years at 20 °C (16 bar) resp. 40 °C (11.6 bar) to DIN 8074 (SF 1.25)
Characteristics: Suitable for cold water and sewage/waste water pipes
PE medium pipe Ref. temp. °C Value Test standard
Density – 952 - 960 kg/m³ DIN 53479
Heat conductivity 40 - 46 0.40 W/mK DIN 52612
Ultimate tensile strength (tearing resistance) 20 32 N/mm2 DIN 53455
Modulus of elasticity 20 1000 N/mm2 DIN 53457
Linear expansion coefficient 20 1.8 · 10 E-4 1/K DIN 52328
2. Frost protection strip

Outer casing (PTFE)
Material: Screened protective braiding
Insulation
Conductive heating element
Copper conductor ( 0,56 mm2)
Frost protection strip, selfregulating 25 - 110 mm

power output Power delivery 18 W/m
Dimensions Width 7.6 mm, Thickness 5.2 mm
Minimum bending radius 20 mm
Operating voltage 230 V AC 50 Hz
Max. operating temperature powered Continuous operation 65 °C,
short periods 85 °C, to –30 °C
Max. heating circuit length: 102 m / 16 A at 10 °C
60 m / 10 A at 10 °C
Power delivery 18 W/m at 10 °C
To protect people and equipment, we basically specify a 30 mA residual current-operated device (FI).
3. Heat insulation
Material: CFC-free, 100% CO2-driven polyurethane foam (PUR)

PUR-insulation Ref. temperature °C Value Test standard
Heat conductivity 30 ≤ 0.023 W/mK EN 253 and ISO 8497
Closed cellular structure – ≥ 88 % EN 253
Water absorption after 24 hrs. – ≤ 10 % EN 15632-1
4. Enveloppe de protection
Material: Polyethylene of low density, PE-LLD, extruded seamless

Purpose: Protection against mechanical effects and moisture
PE-LLD-protective casing Ref. temperature °C Value Test standard
Density – 918 - 922 kg/m³ ISO 1183
Heat conductivity – 0.33 W/mK DIN 52612
Crystallite melting range – 122 °C ISO 11357-3
16.12.2013
EIGERFLEX CPE 3.115
EIGERFLEX range (with frost protection strip)

Dimensions DN 20 - DN 100
Aluminium foil, Frost protection strip Plastic Aluminium foil,

102 mm wide Power delivery, 18 W/m channel 102 mm wide
s1
D
d
EIGERFLEX
s
PE Medium pipe
PUR-foam
PE-foil
LLD-PE casing, corrugated
EIGERFLEX
EIGERFLEX
7,0
9,2 Frost protection strip channel (thickness: 2,25 mm)
Frost protection strip;

Power delivery 18 W/m
Dimensionen DN 20 - DN 100
Type DN Inches Medium pipe PE Outer casing Min. Medium pipe Weight max.delivery length*
dxs D x s1 bending radius Volume Jumbo coil Maxi coil
“ mm mm m I/m kg/m m m
25/ 76 20 ¾“ 25 x 2.3 78 x 2.0 0.7 0.327 0.90 520 780
32/ 76 25 1“ 32 x 2.9 78 x 2.0 0.8 0.539 1.20 370 570
40/ 91 32 1 ¼“ 40 x 3.7 93 x 2.2 0.8 0.835 1.39 370 570
50/ 91 40 1 ½“ 50 x 4.6 93 x 2.2 0.9 1.307 1.85 271 401
63/126 50 2“ 63 x 5.8 128 x 2.7 1.0 2.091 2.60 192 291
75/126 65 2½“ 75 x 6.8 128 x 2.7 1.0 2.961 2.75 192 291
90/162 80 3“ 90 x 8.2 163 x 3.2 1.2 4.254 4.56 92 149
110/162 100 4“ 110 x 10.0 163 x 3.2 1.2 6.362 5.69 92 149
* Supplies with partial lengths are possible
- other dimensions on request (> 500 m)

- larger or shorter lengths delivered on drums
- Ring dimensions: Jumbo coil Outer diameter 2800 mm x 800 mm (width)
Maxi coil Outer diameter 2800 mm x 1200 mm (width)
16.12.2013
EIGERFLEX CPE 3.200
Pressure loss
DN 20 - DN 100 (SDR 11)

(1 mmWS = 9.81 Pa)
Water velocity
110/90 mm 90/73.6 mm
75/61.4 mm
(DN 100) (DN 80)
(DN 65)
40000
30000
63/51.4 mm
(DN 50)
20000
3.0
m/s
50/40.8 mm
(DN 40)
Mass flow rate ṁ [kg/h]
2.0
m/
10000
s
1.5
40/32.6 mm
m/
s
(DN 32)
1.0
m/
s
5000
0.7
32/26.2 mm
5m
(DN 25)
4000
/s
0.5
3000
m/
s
0.4
25/20.4 mm
m/
s
0.3
2000
(DN 20)
m/
s
1000
500
300
1000
1200
1400
1600
1800
2000
100
120
140
160
180
200
300
400
500
800
20
30
40
50
80
16.12.2013
EIGERFLEX CPE 3.210
Heat loss
Heat losses at different external temperatures or surface temperatures of the surface temperatures
casing pipe.
The frost protection strip can no longer compensate for a heat loss of more than
14 W/m, and there is a danger of freezing.
Tmed = 2 °C
For EIGERFLEX pipes no minimal soil temperature is required.
Heat loss figures for buried EIGERFLEX pipes

Dimension U-value Surface temperature [°C]
[W/mK] -5° -10° -15° -20° -25°
25/ 76 0.1265 0.9 1.5 2.2 2.8 3.4
32/ 76 0.1611 1.1 1.9 2.7 3.5 4.3
40/ 91 0.1685 1.2 2.0 2.9 3.7 4.5
50/ 91 0.2273 1.6 2.7 3.9 5.0 6.1
63/126 0.1982 1.4 2.4 3.4 4.4 5.4
75/126 0.2592 1.8 3.1 4.4 5.7 7.0
90/162 0.2318 1.6 2.8 3.9 5.1 6.3
110/162 0.3392 2.4 4.1 5.8 7.5 9.2
The minimal temperature for above ground installation is -30°C.
Heat loss figures for EIGERFLEX pipes installed above ground

Heat losses q [W/m] ffor one UNO pipe
Dimension U-value Surface temperature [°C]
[W/mK] -5° -10° -15° -20° -25°
25/ 76 0.1326 1.0 1.6 2.3 3.0 3.7
32/ 76 0.1711 1.2 2.1 3.0 3.9 4.8
40/ 91 0.1798 1.3 2.2 3.2 4.1 5.0
50/ 91 0.2484 1.8 3.1 4.4 5.7 7.0
63/126 0.2137 1.5 2.6 3.7 4.8 5.9
75/126 0.2863 2.1 3.6 5.1 6.5 8.0
90/162 0.2528 1.8 3.1 4.4 5.7 7.0
110/162 0.3860 2.8 4.8 6.8 8.9 10.9
Type of installation: Ground installation

Cover above pipe: H = 0.80 m
Ground temperature: TE = Variable (see table)
Soil conductivity: lE = 1.0 W/mK
Medium temperature: Tmed = 2 °C
Conductivity of PUR foam: lPUR = 0.023 W/mK
Conductivity of PE pipe: lHDPE = 0.40 W/mK
Conductivity of PE casing: lLLDPE = 0.33 W/mK
Type of installation: Open installation

Wind speed: BFT 10 whole gale (25.2 - 29 m/s)
16.12.2013
EIGERFLEX CPE 3.315
EIGERFLEX L-shell
Dimension DN 20 - DN 65 (Ø 76 - 126 mm)
d1
EIGERFLEX
1
4
3
5
2
7
376
EIGERFLEX
d2
Figures in mm
376
EIGERFLEX L-shell Structure of the half-shell

Outer casing Ø d2
Ø d1 76 91 111 126 1 ABS-half-shells
76 x 2 Electro-fusion-joints; see CPE 3.360
111 x 4 Insulation material; see CPE 3.345
PE-jointing methods; see CPE 3.350 - 3.360 6 Reducer ring or sealing ring
7 Frost protection strip
Note: Install protected against climatic influences (UV radiation).
16.12.2013
EIGERFLEX CPE 3.316
EIGERFLEX Big-L-shell
Dimension DN 80 - DN 100 (Ø 162 mm)
d1
EIGERFLEX
1
4
3
5
2
7
508
EIGERFLEX
d2
Figures in mm
508
EIGERFLEX Big-L-shell Structure of the half-shell

Outer casing Ø d2
Ø d1 76 91 111 126 162 1 ABS half shells
76 2 PE-fusion welded joints; see CPE 3.360
111 4 Insulation material; see CPE 3.345
126 5 Glued surface
162 x 6 Reducer ring or sealing ring

EIGERFLEX Big-shells are freely reducible from Ø 162 mm to Ø 76 mm 7 Frost protection strip
PE-jointing methods; see CPE 3.350 - 3.360
16.12.2013
EIGERFLEX CPE 3.320

Dimension Ø 76 - 162 mm
EIGERFLEX joints and reduction joints 1 2 3 4
EIGERFLEX
EIGERFLEX
d1
d2
1 PE fusion welded joints; see CPE 3.360
2 Insulation material, PUR or PE; see CPE 3.345
4 Shrink hose
EIGERFLEX
Ø d2 76 91 126 162
Ø d1 76 x
91 x x
126 x x x
162 x x


16.12.2013
EIGERFLEX CPE 3.325
EIGERFLEX I-shell
1 7 2 3 4 5 6
EIGERFLEX
EIGERFLEX
d1
d2
578 Figures in mm
1 ABS half-shells
2 PE jusion welded joints; see CPE 3.360
3 Sealing clamps (12 pcs.)
4 Insulation material; see CPE 3.345
5 Glued surface
7 Frost protection strip
EIGERFLEX I-shell
Outer casing Ø d2
Ø d1 76 91 111 126
76 x
91 x x
111 x x x
126 x x x x

16.12.2013
EIGERFLEX CPE 3.326
EIGERFLEX Big-I-shell
1 4 3 2 7 5 6
EIGERFLEX
EIGERFLEX
d1
d2
Figures in mm
752
EIGERFLEX Big-I-shell Structure of the half-shell

Outer casing Ø d2
76 2 PE jusion welded joints; see CPE 3.360
111 4 Insulation material; see CPE 3.345
162 x x 6 Reducer ring or sealing ring
EIGERFLEX Big-shells are freely reducible from Ø 162 mm to Ø 76 mm 7 Frost protection strip
16.12.2013
EIGERFLEX CPE 3.330
EIGERFLEX T-shell
d2
EIGERFLEX
3
1
4
6
5
7 2
373
EIGERFLEX
EIGERFLEX
d1
d3
578
Figures in mm
EIGERFLEX T-shell Structure of the half-shell

Ø d1 - Ø d3 76 91 111 126 1 ABS half-shells
76 - 76 x x x x 2 PE T-piece; see CPE 3.360
91 - 91 x x x x 3 Sealing clamps (16 pcs.)
91 - 76 x x x x 4 Insulation material; see CPE 3.345
111 - 111 x x x x 5 Glued surface
111 - 91 x x x x 6 Reducer ring or sealing ring
111 - 76 x x x x 7 Frost protection strip
126 - 126 x x x x
126 - 111 x x x x
126 - 91 x x x x
126 - 76 x x x x
PE jointing methods; see CPE 3.350 - 3.360
16.12.2013
EIGERFLEX CPE 3.335
EIGERFLEX Big-T-shell
d2
EIGERFLEX
2
1
3 5 6
4
508
EIGERFLEX EIGERFLEX
d1
d3
Figures in mm
752
EIGERFLEX Big-T-shell Structure of the half-shell

Ø d1 - Ø d3 76 91 111 126 162 1 ABS half-shells
162 - 162 x x x x x 2 PE T-piece; see CPE 3.360
162 - 126 x x x x x 3 Sealing clamps (27 pcs.)
162 - 111 x x x x x 4 Insulation material; see CPE 3.345
162 - 91 x x x x x 5 Glued surface
162 - 76 x x x x x 6 Reducer ring or sealing ring
182 - 182 x x x x x 7 Frost protection strip
182 - 162 x x x x x
182 - 126 x x x x x
182 - 111 x x x x x
182 - 91 x x x x x
182 - 76 x x x x x
EIGERFLEX Big-shells are freely reducible from Ø 162 mm to Ø 76 mm

PE jointing methods; see CPE 3.350 - 3.360
16.12.2013
EIGERFLEX CPE 3.345
Insulation material
PUR foam containers, PE-Insulation
PUR foam containers Safety regulations
CFC-free PUR foam in plastic bottles Protective goggles and gloves must be worn during
the foaming process.
Synthetic gloves
Protective goggles
Shrink joints
Polyethylene foam tube
Extruded pipe insulation made of closed-cell polyethylene, excellent for insulating EIGERFLEX shrink joints.
Various thicknesses of insulation are available for the most common pipe diameters.
The insulation material (thickness and length) is supplied for the relevant joint types. The insulation must be fitted
precisely into the joints on site.
PE
16.12.2013
EIGERFLEX CPE 3.350
PE jointing methods
Screwed connectors (outer thread, weld end, coupling)
Connection with outer thread/weld end Coldwater, 16 bar

Material: brass
St 37.0 PE-pipe Screwed connector L Weld end L
mm mm mm mm mm
L L 25 x 2.3 25 x 2.3-¾“ 53 26.9 x 2.65 180
32 x 2.9 32 x 2.9-1“ 63 33.7 x 2.3 180
40 x 3.7 40 x 3.7-1¼“ 67 42.4 x 2.6 185
50 x 4.6 50 x 4.6-1½“ 71 48.3 x 2.6 190
St 37.0 63 x 5.8 63 x 5.7-2“ 80 60.3 x 2.9 195
75 x 6.8 75 x 6.8-2½“ 92 76.1 x 3.2 200
90 x 8.2 90 x 8.2-3“ 92 88.9 x 3.2 240
L L 110 x 10.0 110 x 10.0-4“ 102 114.3 x 3.6 280
90° angle coupling Coldwater, 16 bar

Material: brass
PE-pipe PE-pipe a z
z
mm mm mm mm
25 x 2.3 25 x 2.3 54 32
32 x 2.9 32 x 2.9 64 37
40 x 3.7 40 x 3.7 74 42
50 x 4.6 50 x 4.6 87 48
z
63 x 5.8 63 x 5.8 106 60

a
75 x 6.8 75 x 6.8 117 67

90 x 8.2 90 x 8.2 – –
110 x 10.0 110 x 10.0 – –
a
Coldwater, 16 bar
Material: brass
Coupling, equal
PE-pipe PE-pipe L
mm mm mm
PE 25-75 25 x 2.3 25 x 2.3 60
32 x 2.9 32 x 2.9 67
L 40 x 3.7 40 x 3.7 71
50 x 4.6 50 x 4.6 75
63 x 5.8 63 x 5.7 81
PE 90-110 75 x 6.8 75 x 6.8 89
90 x 8.2 90 x 8.2 130
110 x 10.0 110 x 10.0 130
L
Coldwater, 16 bar
Coupling, reduced Material: brass
PE-pipe PE-pipe L
mm mm mm
PE 25-50
32 x 2.9 25 x 2.3 86
L 40 x 3.7 32 x 2.9 87
50 x 4.6 40 x 3.7 96
16.12.2013
EIGERFLEX CPE 3.355
PE jointing methods
Screwed connectors, T-pieces
d2
d2
d1
d3
d1
d3
PE  25 - 75 PE  90 - 110
Material: brass
mm mm
25 x 2.3 32 x 2.9 40 x 3.7 50 x 4.6 63 x 5.8 75 x 6.8 90 x 8.2 110 x 10.0
25 x 2.3 - 25 x 2.3 x x
32 x 2.9 - 32 x 2.9 x x
32 x 2.9 - 25 x 2.3 x x
40 x 3.7 - 40 x 3.7 x x x x
40 x 3.7 - 32 x 2.9 x x
50 x 4.6 - 50 x 4.6 x x x x
50 x 4.6 - 40 x 3.7 x x x x x
63 x 5.8 - 63 x 5.8 x x x x x
63 x 5.8 - 50 x 4.6 x x x x
75 x 6.8 - 75 x 6.8 x x x x x x
75 x 6.8 - 63 x 5.8 x x x x x x
90 x 8.2 - 90 x 8.2 x x x x x x
90 x 8.2 - 75 x 6.8 x x
110 x 10.0 - 110 x 10.0 x x x x x x
110 x 10.0 - 90 x 8.2 x x x
Any other T-pieces that may be required can be supplied on request.
16.12.2013
EIGERFLEX CPE 3.360
PE jointing methods
Fusion welded and alternative joints
PE100 electro fusion-welded fittings

SDR 11/SDR 17
Sleeves Reduction sleeves

Ø 25 - 110 mm Ø 25 - 110 mm
Angle piece, 90° equal Angle piece, 90° equal (without fusion joint)
Ø 25 - 75 mm Ø 90 - 110 mm
T-piece, equal/reduced T-piece, equal/reduced (without fusion joint)

Ø 25 - 110 mm Ø 25 - 110 mm
(Source: Georg Fischer

Rohrleitungssysteme AG)
Butt-fusion
16.12.2013
EIGERFLEX CPE 3.365
End closure
Shrink-on closure
Shrink-on closure
EIGERFLEX shrink-on closures protect the PUR insulation on the front of the EIGERFLEX pipes against splashing water in
buildings and shafts. Important: in contact with water (flooding), the shrink-on closure is not necessarily watertight! The
shrink-on closure also stops gas escaping from the PUR insulation.
Important fitting note:
EIGERFLEX shrink-on closures must be pushed onto

the end of the EIGERFLEX pipes before welding
the inner pipes and must be protected against the
action of heat during welding.
Material:
Heat-shrunk, cross-linked polyolefin. Coated with

sealing adhesive
min. 120
16.12.2013
EIGERFLEX CPE 3.370
Wall sealing ring

Pipe warning tape
Wall sealing ring
EIGERFLEX
Type CPE Da
25/ 76 118
32/ 91 133
40/ 91 133
50/111 153
63/126 168
75/126 168
90/162 203
Da
110/162 203
D
50
Pipe warning tape

• Installation depth: see sheet CPE 3.505
16.12.2013
EIGERFLEX CPE 3.375
Building entry
Wall opening
Wall leadthrough
ca. 80 mm
60 mm 80 mm
EIGERFLEX
D
EIGERFLEX pipe:
see sheet CPE 3.350
see sheets CPE 3.115, 3.120
End cap; see sheet CPE 3.365 Wall seal: see sheet CPE 3.370
Wall opening Core bores

Outer A Outer D
casing casing
ØD ØD
mm mm mm mm
A
78 240 78 180
D
93 250 93 200
113 270 113 220
128 290 128 240
80 D 80 163 320 163 280
A
Figures in mm
16.12.2013
EIGERFLEX CPE 3.380
Building entry
Wall leadthrough
80 mm EIGERFLEX pipe:
PE connection piece: see sheet CPE 3.115, 3.120
see sheet CPE 3.350
EIGERFLEX
D
End cap:
see sheet CPE 3.365
Core bores
Outer casing D1
ØD
mm mm
76 150
D1
91 150
111 200
126 200
162 250
Core bores
Key
Perfect bores are required for installation. As hairline cracks may be
present in the concrete or result from drilling, it is advisable to seal 1 EIGERFLEX
the entire length of the borehole wall with suitable sealant (such as 2 Sealing set, single-seal, width 1 x 40 mm, Shore hardness D35
AQUAGARD). 3 Sealing set, double-seal*, width 2 x 40 mm, Shore hardness D35
4 Liner pipe: made of fiber cement or coated core bore
Tightness can only be guaranteed if this recommendation is followed.
16.12.2013
EIGERFLEX CPE 3.505
Trench dimensions
Trench profile, 1 CPE pipe
1 2 3
min. 60
30
T
10
D
10
10 D 10
B
Figures in cm
1 Pipe warning tape; see sheet CPE 3.370

Casing pipe Width Depth Minimum

Ø D B T Bending radius
mm cm cm m
78 25 80 0.7
93 30 80 0.8
113 30 80 0.9
128 35 80 1.0
163 35 80 1.2
Installation depth:
loads (e.g. SLW 60), a load-distributing superstructure as per RStO75 is
required.
With no traffic load, the minimum trench depth T can be reduced by 40 cm.
16.12.2013
EIGERFLEX CPE 3.510
FSB connection technology

Sleeve joint
1. Planning
L ≤ 100 m L > 100 m

Continous joint Separation
Connection strip End closure
End closure
Supply Supply Supply
max. 100 m max. 100 m max. 100 m
2. Preparation
Figure 1 Figure 2
40 cm
EIGERFLEX
15 cm 15 cm
Shorten as shown in illustration 2
Remove 40 cm of insulation at the ends and carefully expose the strip.

Then shorten the inner pipe to length as shown in illustration 2.
3. Sleeve joint
Continuous joint L ≤ 100 m Separation

Connection strip L > 100 m
Screwed joint or 30 cm
welded sleeve
EIGERFLEX EIGERFLEX
30 cm
30 cm
EIGERFLEX EIGERFLEX
Protect heating strip against moisture
Connect the cables according to the installation instructions
16.12.2013
EIGERFLEX CPE 3.515
FSB connection technology

T-Piece
1. Planning
End closure
T-piece Micro Uni Clip MUC
End closure Connection
End closure
Supply
L 100 m
Example 1: Total lenght ≤ 100 m Example 2: Total lenght ≤ 100 m
Supply Connection
End closure
End closure Protect heating strip against moisture
L 100 m
Example 3: Total lenght > 100 m
Make sure that the sum of the connected pipes is not more then 100 m.
2. Preparation
30 cm
Remove 50 cm of insulation at the ends and carefully
EIGERFLEX
expose the strip. Then shorten the inner pipe to length
according to the fitting instructions.
3. Fitting T-piece with T-junction

EIGERFLEX
EIGERFLEX
EIGERFLEX EIGERFLEX
EIGERFLEX EIGERFLEX
16.12.2013
EIGERFLEX CPE 3.520
Connection and end

Frost protection strip
1. Technical data
Frost protection strip: Max. heating circuit length based on switch-on temperature of 10 °C: 16 A max. 100 m
10 A max. 60 m
Regulation: Thermostat UTR15 Adjustment range: –5 °C to +15 °C

pipe contact thermostat
2. Preparation
35 - 40 cm
Remove 35-40 cm of insulation at the ends and carefully expose the
strip. Then shorten the inner pipe to length according to the fitting
instructions. EIGERFLEX
Shorten as described in fitting instructions
3. Installation procedure
230 V Protect the heating strip against moisture
Connection box
(provided by the customer)
Thermostat UTR 15
with temperature sensor Connection: Heating strip/cold lead
Frost protection strip

max. 100 m
Sensor cable length 3 m; can be

EIGERFLEX
extended to a max. of 100 m with
screened cable, 1.5 mm
Temperature sensor on pipe

• Electrical installation according to local regulations End closure
• Only to be connected by an authorised electrical installer
• 30 mA residual current-operated device (FI)-required by regulations!
• Automatic fuse, C-characteristic
4. Installing the temperature sensor on the pipe
The temperature sensor has to be installed on the medium pipe opposite the heating strip. It must be fitted at the coldest
point on the pipe (outside the building). For this purpose, cut open a 10x7 cm area of the outer casing and peel back, cut
out 10x7cm foam, and fix the temperature sensor on the inner pipe with adhesive tape. Fill the hole with the insulating
material that is provided: apply filling adhesive S1113 below and above the temperature sensor cable (see sketch), seal
with shrinkdown tube.
ca. 10 cm
EIGERFLEX
Temperature
ca. 7 cm
sensor cable EIGERFLEX
Shrinkdown tube Filling adhesive S1113, 80 mm long

Shrinkdown tube Temperature sensor
16.12.2013
CASAFLEX Local and District Heating Pipe system
With quality into a safe future
NE
Opt
W
con imised
n
tech ection
nolo
gy
W
NE
CASAFLEX district heating pipe CFL 4.0
Table of Contents

4.115 CASAFLEX UNO range, heating, 16 to 25 bar
4.120 CASAFLEX DUO range, heating, 16 bar

4.200 Pressure loss chart
4.210 Heat loss
4.3 Components
4.300 T-joint
4.310 Flex-T-branch 45°, branch - main pipe, plastic casing pipe
4.315 Flex-T-branch 45°, with and without tapping cock
4.320 Y-branch pipe Type G (straight)
4.321 Y-branch pipe CASAFLEX DUO
4.325 Joint
4.330 Connector, CASAFLEX UNO, DN 20 - DN 80 (PN 16)
4.331 Connector Mini, CASAFLEX UNO, DN 20 - DN 80 (PN 16)
4.345 Connector, CASAFLEX UNO, DN 100 (PN 16)
4.350 Connector, CASAFLEX DUO, DN 20 - DN 50 (PN 16)
4.355 Accessories: PUR foam containers, pipe warning tape
4.356 Installation set for compression connection CASAFLEX - Mini
4.360 Wall seal for wall openings
4.365 Ring seal for core bore / fiber cement liner pipe – impermeable to pressure from water

4.500 Pipe routing
4.510 Connection (rigid/flexible): CASAFLEX – plastic casing pipe
4.515 Entry into building: Fixed-point forces
4.520 Entry into building: Wall opening
4.525 Entry into building: Core bore
4.530 Shaft structures: Entry into building
4.535 Construction work: Open trench lengths
8.1.2015 INT
System description
1. General 2. Range of use
CASAFLEX district heating pipe is the registered trade name for a flexible house connection Max. temp. for continuous
pipe from BRUGG Pipe Systems. It is ideal for use in small and midsize district and local heating operation TBmax 160 °C*
networks, in industrial and agricultural applications and in solar collector plants and swimming Max. Peak temperature Tmax 180 °C
pool installations. Max. permitted
operating pressure PN 16 to PN 25
CASAFLEX district heating pipe has a spiral-corrugated carrier pipe made of stainless steel. The
design of the corrugated pipe takes account of factors related to fluid dynamics. * Type 60+60/182 Tmax 130 °C
The thermal insulation is positioned below the PE-LD casing pipe and consists of a CFC-free,
flexible PIR rigid foam (polyisocyanurate foam) with excellent heat insulation properties; a bar-
rier film to impede diffusion of the cellular gases.
The bending capability of CASAFLEX district heating pipe ensures easy adaptation to virtually all
pipe routing conditions. It is possible to pass over or under existing supply pipes, and obstacles
are easily bypassed.
With CASAFLEX district heating pipe, users can choose the shortest pipe route without consid-
ering the classical method of pipe construction.
CASAFLEX district heating pipe is delivered to the site in coils or on drums in the required
lengths. The pipe can generally be laid in the ground without joints. This means that the pipe
trench can be considerably narrower. This in turn allows considerable savings on underground
work, When one considers the very short time required for installation, CASAFLEX district heat-
ing pipe is not only a technically perfect solution but also the key to saving time and expense
when setting up district heating networks. Less coordination is required on site and the pipes
are laid simply and quickly.
The physical characteristics of the spiral-corrugated carrier pipe enable it to be laid without
having to consider thermal expansion.
Fitting the connectors is a very simple procedure. The connections are fitted quickly and se-
curely with simple components.
8.1.2015 INT
System description
1. Carrier pipe
Materials Corrugated carrier pipe made of nickel chromium steel

X5 CrNi 18-10 (1.4301, AISI 304) or
X2 CrNiMo 17-12-2 (1.4404, AISI 316L)
Requirements: Steel quality to EN 10088
Material: CFC-free, cyclopentane-blown polyisocyanurate rigid foam (PIR)

with l50 value: 0.025 W/mK.
PIR insulation Reference temperature °C CASAFLEX value Test standard

Density - > 60 kg/m3 DIN 53420
Thermal conductivity 50 ≤ 0.025 W/mK DIN 52612
Percentage of closed cells - ≥ 90 % EN 253
Water absorption after 24 hours - ≤ 10 % EN 253
3. Expanded metal mesh
Material: Steel
Purpose: Mechanical reinforcement of the flexible pipe system
4. Barrier film
Material: Multiple-layer composite film

Purpose: To impede diffusion of the cyclopentane cellular gas
Material: Low-density polyethylene (PE-LD), seamlessly extruded

Purpose: Protection against mechanical action and humidity
PE-LD protective casing Reference temperature °C Value Test standard

Density - 931 kg/m3 ISO 1183
6. Monitoring wires
Materials: 1 x NiCr, red, insulated/perforated, Ø 1.1 mm/0.5 mm2

1 x Cu, green, insulated, Ø 1.3 mm/0.8 mm2
1 x Cu, white with nonwoven, Ø 1.55 mm/1.13 mm2
Systems: Conductor pairs: NiCr-red + Cu-green ^ = WIREM/Brandes system
Cu-green + Cu-white ^ = Nordic system
Purpose: Identification and location of moisture by means of resistance or pulse measurements
8.1.2015 INT
CASAFLEX UNO range

Heating, 16 to 25 bar
6 1 2 3 4 5
s
d1
D
d
Structure
1 Stainless steel carrier pipe

2 PIR foam
3 Expanded metal mesh
4 Barrier film
5 PE-LD casing
6 Monitoring wires
CASAFLEX UNO
Type DN Inches Inner pipe Outer casing Minimum Volume Weight Maximum delivery lengths
d x d1 x s D Bending radius Inner pipe Coil1) Coil2) Coil3) Coil4)
” mm mm m l/m kg/m m m m m
22/ 91 20 ¾” 25 x 22 x 0.3 91 0.8 0.44 1.30 320 480 560 810
30/111 25 1” 34 x 30 x 0.3 111 1.0 0.80 1.93 205 290 360 500
39/126 32 1 ¼” 44 x 39 x 0.4 126 1.2 1.35 2.60 155 230 280 340
48/126 40 1 ½” 55 x 48 x 0.5 126 1.2 2.04 2.92 155 230 280 340
60/142 50 2” 66 x 60 x 0.5 142 1.3 3.12 3.54 100 150 200 300
75/162 65 2 ½” 86 x 75 x 0.6 162 1.8 5.12 4.80 55 100 145 190
98/162 80 3” 109 x 98 x 0.8 162 1.8 8.43 5.70 55 100 145 190
127/202 100 4” 143 x 127 x 0.9 210 2.8 14.30 8.80 – 40 – 75
1) Coil dimensions Ø 2800 x 800 mm (width)

4) Coil dimensions Ø 3000 x 1600 mm (width) just ex work Wunstorf
Supplied in drums on request
8.1.2015 INT
CASAFLEX DUO range

Heating, 16 bar
6 1 2 3 4 5
s
d1
d
D
Structure

2 PIR foam
4 Barrier film
5 PE-LD casing
6 Monitoring wires
CASAFLEX DUO
Type DN Inches Inner pipe Outer casing Minimum Volume Weight Maximum delivery lengths
d x d1 x s D Bending radius Inner pipe Coil1) Coil2) Coil3) Coil4)
” mm mm m l/m kg/m m m m
22 + 22/111 20 ¾” 25 x 22 x 0.3 111 1.1 0.44 2.5 205 290 360 500
30 + 30/126 25 1” 34 x 30 x 0.3 126 1.4 0.80 3.1 155 230 280 340
39 + 39/142 32 1 ¼” 44 x 39 x 0.4 142 1.5 1.35 3.7 100 150 200 300
48 + 48/162 40 1 ½” 55 x 48 x 0.5 162 1.8 2.04 4.2 55 100 145 190
60 + 60/182* 50 2” 66 x 60 x 0.5 182 2.0 3.12 5.1 55 80 – –
* Max. permitted operating temp. Tmax. 130 °C (not available in Germany)

4) Coil dimensions Ø 3000 x 1600 mm (width) just ex work Wunstorf
Supplied in drums on request
8.1.2015 INT
Pressure loss chart

ṁ = Flow rate in kg/h
Q · 860 Q = Power requirement in kW
ṁ ≈
VL (flow) / RL (return) in °C
100.000
9
8
7
6
Mass flow rate ṁ kg/h
10.000
9
8
1.0
7
0.9
127
m/s
0.8
6
CFL
m/s
0.7
m/s
5
0.6
m/s
4
98
m/s
0.5
CFL m/s
3
0.4
m/s
0.3
75
CFL
2
m/s
60
0.2
CFL
m/s
1.000
9
48
8
CFL
0.1
7
6 39
m/s
5 CFL
4
30
3 CFL
22
CFL
100
1 2 3 4 5 6 7 8 9 2 3 4 5 6 7 8 9 2 3 4 5 6 7 8 9
10 100 1000 [Pa/m]
0,1 1,0 10 100 [mm WS/m]
Pressure loss ∆p
Example:
Mass flow rate 7000 kg/h; CASAFLEX type CFL 75
–> Pressure loss 90 Pa/m
8.1.2015 INT
Heat loss
CASAFLEX UNO
Heat loss q [W/m] for one UNO pipe
CASAFLEX U-value Average operating temperature TB [°C]
UNO [W/mK] 40° 50° 60° 70° 80° 90° 100° 110° 120° 130°
22/ 91 0.113 3.4 4.5 5.7 6.8 7.9 9.0 10.2 11.3 12.4 13.5
30/111 0.123 3.7 4.9 6.1 7.3 8.5 9.8 11.0 12.2 13.4 14.6
39/126 0.137 4.1 5.5 6.8 8.2 9.6 10.9 12.3 13.6 15.9 16.4
48/126 0.170 5.1 6.8 8.5 10.2 11.8 13.5 15.2 16.9 18.6 20.3
60/142 0.187 5.6 7.4 9.3 11.2 13.0 14.9 16.8 18.6 20.5 22.4
75/162 0.218 6.5 8.7 10.9 13.0 15.2 17.4 19.5 21.7 23.9 26.1
98/162 0.355 10.1 13.4 16.8 20.1 23.5 26.8 30.2 33.5 36.9 40.2
H = 0.6 m
127/202 0.366 11.0 14.7 18.3 22.0 25.6 29.3 33.0 36.6 40.3 44.0
TE E
a = 0.1 m
CASAFLEX DUO
Heat loss q [W/m] for one DUO pipe
RL (return)
CASAFLEX U-value Average operating temperature TB [°C]
DUO [W/mK] 40° 50° 60° 70° 80° 90° 100° 110° 120° 130°
VL (flow)
22 + 22/111 0.156 4.7 6.2 7.8 9.4 10.9 12.5 14.0 15.6 17.2 18.7
30 + 30/126 0.181 5.4 7.2 9.0 10.9 12.7 14.5 16.3 18.1 19.9 21.7
39 + 39/142 0.224 6.7 8.9 11.2 13.4 15.7 17.9 20.2 22.4 24.6 26.9
H = 0.6m
48 + 48/162 0.251 7.5 10.0 12.5 15.0 17.6 20.1 22.6 25.1 27.6 30.1
60 + 60/182* 0.271** 8.1 10.8 13.6 16.3 19.0 21.7 24.4 27.1 29.8 32.5
*not available in Germany
TE
E
Pipe distance: a = 0.10 m Heat loss during operation:

Coverage height: H = 0.60 m q = U (TB – TE) [W/m]
Ground temperature: T E = 10 °C U = Heat transfer coefficient [W/mK]
Soil conductivity: E = 1.2 W/mK TB = Average operating temperature [°C]
Conductivity of PIR foam: PIR = 0.0250 W/mK at average temperature of 50 °C TE = Average ground temperature [°C]
**Conductivity of PUR foam: PIR = 0.0234 W/mK at average temperature of 50 °C VL = Flow
Conductivity of PE casing: PE = 0.43 W/mK RL = Return
8.1.2015 INT
T-joint
CASAFLEX connected to pre-insulated steel pipe
Pre-insulated steel pipe Pre-insulated steel pipe
A 2
3
4
Structure
5
1 T-piece, pre-insulated steel pipe 6

2 Shrink-on hoop
4 In-situ PUR foam
5 Detection wires
6 CASAFLEX connector 7
CFL
7 CASAFLEX pipe
View A
e
ip
lp
45° CASAFLEX
ee
st
ed
lat
su
in
e-
Pr
8.1.2015 INT
Flex-T-branch, 45°
Branch, main pipe
CASAFLEX to steel pipe – 45° connection
Type designation
e.g.: Swing joint,160/140
160 = ØA main pipe
140 = ØA junction
Flex-branch pipe
Swing joint
T-branch, steel pipe with CASAFLEX junction

Main pipe Junction Branch pipe Swing joint
ØA Ø A Type Type
mm mm
110 90 90 110/ 90
125 90 or 110 110 125/110
140 90 or 110 110 140/110
140 125 125 140/125
160 90 or 110 110 160/110
160 125 or 140 140 160/140
180 90 or 110 110 180/110
180 125 or 140 140 180/140
200 90 or 110 110 200/110
200 125 or 140 140 200/140
225 90 or 110 110 225/110
225 125 or 140 140 225/140
250 90 or 110 110 250/110
250 125 or 140 140 250/140
280 90 or 110 110 280/110
280 125 or 140 140 280/140
315 90 or 110 110 315/110
315 125 or 140 140 315/140
Supplied on request.
8.1.2015 INT
Flex-T-branch, 45°
with and without tapping cock
Insulated steel pipe – Flex-T-branch 45°, with or without tapping cock
ØA
Flex-branch pipe
Pre-insulated
steel pipe Tapping cock
Pre-insulated
steel pipe
Flex-branch pipe for connection with or without tapping cock

CASAFLEX DN Junction ØA Junction ØA
Type Type: Flex-branch pipe Type: Flex-branch pipe
without tapping cock with tapping cock, through passage
full reduced
mm mm mm
CFL 22/ 91 20 110 110 110
CFL 30/111 25 110 110 110
CFL 39/126 32 140 140 140
CFL 48/126 40 140 140 140
CFL 60/142 50 140 – 140
Supplied on request
Execution example
Desired execution: 45° branch with tapping cock, with full through passage
Pre-insulated steel pipe: ØA = 315 mm
Branch DN 40
Table on CFL 4.315:

CASAFLEX type 48/111, tapping cock - full through passage - results in junction ØA or flex-branch pipe type = 125 mm
Table on CFL 4.310:

Main pipe ØA = 315 mm, results in flex-T-branch, type 315/125
8.1.2015 INT
Y-branch pipe Type G (straight)

CASAFLEX UNO
Y-branch pipes are employed to provide a transition from conventionally laid piping using
two single pipes CASAFLEX UNO to the space-saving PREMANT DUO format. The upper pipe
(preferably the return pipe) runs straight ahead through the Y-branch pipe while the lower pipe
is angled at 90°. In the Type G pipe the double pipe and the single pipe are axially parallel.
Mounting plates are fixed to the side of the double pipe connection joint.
Construction variants
Two different construction variants of the Y-branch pipe Type G are available. The type required
should be given when ordering. The arrows in the sketch show the flow direction of the feed.
confluence separation
Carrier pipe: welded steel pipe DIN EN 253
Heat insulation: PUR hard foam
Casing pipe: PE-HD
Insulation thickness: N – standard
Note: The flow (VL) in UNO pipes is always

A on the right in the direction of flow. The
flow (VL)in DUO pipes it is always at the
bottom in the direction of flow.
L2
ØD
VL (flow)
(right)
L1
VL (flow)
RL (return)
(bottom)
a
A
ØC
DN Diameter Installation Junction Distance Ø C A 2 x single ØD

length steel pipe
da L1* L2** a
20 26.9 1000 450 250 125 45.9 26.9 x 2.6 90
25 33.7 1000 460 250 140 52.7 33.7 x 2.6 90
32 42.4 1000 480 300 160 61.4 42.4 x 2.6 110
40 48.3 1200 480 300 160 67.3 48.3 x 2.6 110
* free pipe end 200 mm

** measured from the middle of the branch line
A reducing socket must be used on the side with the single pipe to connect the straight through pipe.
Not available in Switzerland.
8.1.2015 INT
Y-branch pipe
CASAFLEX-DUO
Y-branch pipes are employed to provide a transition from conventionally laid piping using two View: A - A
single pipes PREMANT UNO to the space-saving CASAFLEX DUO format. Note: The flow (VL) in UNO pipes is always on
the right in the direction of flow. The flow (VL)
in DUO pipes it is always at the bottom in the
direction of flow.
VL (flow) (right)
VL (flow)
ØD Steel pipe (right)
A
300
CFL detection wire
RL (return)
ØC
Steel pipe
RL (return)
VL (flow)
60+10 CFL DUO min. 650 (bottom) X
250+20 400 150
ØC Figures in mm
1800
Type DN Inches Pipe connection Ø C A 2 x single ØD

d x s steel pipes
” mm mm mm mm mm
22 + 22/111 20 ¾” 26.9 x 2.6 140 55 26.9 x 2.6 90 / 110
30 + 30/126 25 1” 33.7 x 3.2 160 65 33.7 x 2.6 90 / 110
39 + 39/142 32 1 ¼” 42.4 x 3.2 200 81 42.4 x 2.6 110 / 125
48 + 48/162 40 1 ½” 48.3 x 3.2 225 93 48.3 x 2.6 110 / 125
60 + 60/182 50 2” 60.3 x 3.6 250 109 60.3 x 2.9 125 / 140
not available in Germany
8.1.2015 INT
Joint
CASAFLEX to CASAFLEX joint
1 3 4 1 5
CASAFLEX
d2
d1
CASAFLEX
Ø inner pipe identical
CASAFLEX to steel pipe joint
2 4 3 5
CASAFLEX
d1
d2
Pre-insulated steel pipe
Structure
1 Through coupling (2 connectors, welded by customer or others)

2 ME connector; see sheet CFL 4.335, item 3
3 Insulating material (PUR foam); see sheet CFL 4.345
5 Shrink hose
CASAFLEX – CASAFLEX CASAFLEX – steel pipe

d2 91 111 126 142 162 182 202 d2 90 110 125 140 160 180 200
91 X 91 X X X
111 X 111 X X X
126 X 126 X X
d1 d1
142 X 142 X X
162 X 162 X
182 RMBD 182 RMBD RMBD
202 RMBD 202 RMBD

* further joint systems and reduction sleeves are available
on request Figures in mm
8.1.2015 INT
Connector
CASAFLEX UNO, DN 20 - DN 80 (PN 16)
The CASAFLEX connector is specifically designed for CASAFLEX district heating pipes. It is used to make all connections
on pipe installations in buildings and shafts and for through-type and T-joints. The connectors are intended for hot water
pipes up to operating pressures of 16 bar.
3 5 2 1 6 4 7 8
s
d
Structure
1 Support ring
2 Graphite sealing ring
3 Connection piece
4 Compression ring
5 Hexagon socket screw
6 Detection wires
7 Protective cap, 2-part
8 CASAFLEX pipe
CASAFLEX UNO / PN 16 Uses

Type DN Inches Pipe connection Type Execution
dxs Dry building as per drawing
” mm T-piece/joint Pos. 7, no protective cap
22/ 91 20 ¾” 26.9 x 2.6 Shaft see CFL 4.530
30/111 25 1” 33.7 x 3.2
39/126 32 1 ¼” 42.4 x 3.2
48/126 40 1 ½” 48.3 x 3.2
60/142 50 2” 60.3 x 3.6
75/162 65 2 ½” 76.1 x 3.6
98/162 80 3” 88.9 x 4.0

8.1.2015 INT
Connector Mini
CASAFLEX-UNO / PN 16
The CASAFLEX Mini pipe connector has been specially developed for connecting branch pipes of up to DN 40. It forms a
permanent connection which is made via a compression process and has been designed for hot-water pipelines with an
operating pressure of up to 16 bar. Like the Standard pipe connectors, it is used for connecting CASAFLEX district heating
pipes with distribution pipes in buildings and in the ground.
1 2 3 4 5 6 7
S
Structure
1 Connection piece
2 Sliding sleeve
4 Protective cap, 2-part
5 Retaining ring
6 Compression ring
7 CASAFLEX pipe

CASAFLEX-UNO / PN 16 Uses
Type DN Inches Pipe connection Typ Execution
dxs Dry building as per drawing
” mm T-piece/joint Pos. 7, no protective cap
22/ 91 20 ¾” 26.9 x 2.6 Shaft see CFL 4.530
30/111 25 1” 33.7 x 3.2
39/126 32 1 ¼” 42.4 x 3.2
48/126 40 1 ½” 48.3 x 3.2
8.1.2015 INT
Connector
The CASAFLEX connector is specifically designed for CASAFLEX district heating pipes. It is used to make all
connections on pipe installations in buildings and shafts and for through-type and T-joints.
The connectors are intended for hot water pipes up to operating pressures of 25 bar.
Only trained personnel may install this connector.
6 9 8 10
3 5 1 2 4 7
Structure
1 Support ring
3 Connection piece
4 Compression ring
6 Detection wires
7 Protective cap and wire outlet
8 CASAFLEX pipe
10 Shrink-on collar
CASAFLEX UNO / PN 25
Type DN Inches Pipe connection
dxs
” mm
22/ 91 20 ¾” 26.9 x 2.6
30/111 25 1” 33.7 x 3.2
39/126 32 1 ¼” 42.4 x 3.2
48/126 40 1 ½” 48.3 x 3.2
60/142 50 2” 60.3 x 3.6

8.1.2015 INT
Connector
The CASAFLEX connector is specifically designed for CASAFLEX district heating pipes. It is used to make all
connections on pipe installations in buildings and shafts and for through-type and T-joints.
On connector type PN 25, the expanded mesh (9) is fixed by a metal clamp; this increases mechanical stability,
as is necessary for operating pressures above 16 bar.
The connectors are intended for hot water pipes up to operating pressures of 25 bar.
6 10 7 8 11
3 5 1 2 4 9
Structure
1 Support ring
3 Connection piece
4 Compression ring
5 Hexagonal socket head screw
6 Detection wires
7 Protective cap and monitor lead exit
8 CASAFLEX pipe
9 Clamping ring
10 Expanded metal
11 Shrink-on cellar
dxs
” mm
75/162 65 2 ½” 76.1 x 3.6
98/162 80 3” 88.9 x 4.0
8.1.2015 INT
Connector
CASAFLEX UNO, DN 100 (PN 16)
on pipe installations in buildings and shafts and for through-type and T-joints. The connectors are intended for hot water
pipes up to operating pressures of 16 bar.
11 10
3 5 2 4 1 7 6 8 12 9
Structure
1 Support ring
3 Connection piece
4 Compression ring
5 Hexagonal socket head screw
6 O-ring
7 screw
8 Protective cap
9 Shrink-on cellar
10 Detection conductor
11 Connector for monitoring wires
12 CASAFLEX pipe
dxs
” mm
127/202 100 4” 114.3 x 4.5
8.1.2015 INT
Connector
CASAFLEX DUO, DN 20 - DN 50 (PN 16)
on pipe installations in buildings and shafts and for through-type and T-joints.
A plastic protective cap is used with type CASAFLEX DUO. The connectors are intended for hot water pipes up to operat-
ing pressures of 16 bar.
3 2 1 6 9 4 5 8 10
dxs
D2
A
Structure
1 Support ring
2 Graphite seal
3 Connection piece
4 Compression ring
5 Pressure plate A
6 Conical plate B
8 Protective cap (2-part)
9 Hose clamp
10 Hose clamp
CASAFLEX DUO / PN 16
Type DN Inches Pipe connection Axis distance Length
d x s A L D2
” mm mm mm mm
22 + 22/111 20 ¾” 26.9 x 2.6 45.9 ≈138 131
30 + 30/126 25 1” 33.7 x 3.2 52.7 ≈141 145
39 + 39/142 32 1 ¼” 42.4 x 3.2 61.4 ≈208 164
48 + 48/162 40 1 ½” 48.3 x 3.2 69.0 ≈232 184
60 + 60/182* 50 2” 60.3 x 2.9 79.7 ≈210 245
*not available in Germany
8.1.2015 INT
Accessories
PUR foam containers, pipe warning tape
PUR foam containers

The required quantity of CFC-free polyurethane foam is delivered in suitable container sizes for
the various joints and T-pieces. The components are supplied separately in two bottles and are
only mixed together when needed.
Important:
Please note the safety regulations in the installation instructions supplied with the product.
Synthetic gloves
Protective goggles
Important:
The PUR foam can be used up to a maximum temperature of 130 °C.
For higher operating temperatures (max. 160 °C), please consult
BRUGG.
Pipe warning tape

Pipe warning tape to be laid in the ground
Standard roll length: 250 m
Installation depth; see sheet CFL 4.505
8.1.2015 INT
Connector Mini
Installation set
Installation set for compression connection CASAFLEX - Mini for
CASAFLEX - district heating pipe 22/ 91

CASAFLEX - district heating pipe 30/111
3
4
Consisting of:
1 4 Allen screws (6 pc. for CASAFLEX 48/126)

2 1 Split flange with screw thread
3 1 Split flange with through hole
4 1 Flange with through hole
8.1.2015 INT
Wall seal
for wall openings
Ø Da
Ø Di
50 mm
CASAFLEX UNO/DUO
Outer casing diameter Neoprene wall sealing ring
Ø Di, inner Ø Da, outer
mm mm mm
91 79 125
111 99 145
126 114 160
142 128 174
162 146 192
182 166 210
Building entry (see sheet CFL 4.520)
8.1.2015 INT
Ring seal
For core bore / fiber cement liner pipes
Ring seal set, type C40 Ring seal set, type A

1 x per opening 1 x per opening
CASAFLEX UNO/DUO
Outer casing Liner pipe, core bore Seal set Seal set
Ø Ø Ø D, inner Ø D, outer
mm mm mm mm
91 150 93 150
111 200 113 200
126 200 128 200
142 200 144 200
162 250 163 250
182 250 183 250
Building entry/core bore (see sheet CFL 4.525)
8.1.2015 INT
Pipe routing
CASAFLEX – pre-insulated steel pipe connection
CASAFLEX
B
Pre-insulated steel pipe

A
CASAFLEX
CASAFLEX
CASAFLEX
Loop-in method
CASAFLEX
A B C D
House-to-house connection
A B CASAFLEX C
8.1.2015 INT
Trench dimensions
Trench profile, CFL UNO
1 2 3
CASAFLEX Width Depth Minimum

Outer casing Bending
Ø D B T radius
60
30
mm cm cm m
T
D 10
91 50 80 1.0
111 55 85 1.0
126 55 85 1.2
10
142 60 85 1.5
162 65 90 1.8
10 D 10 D 10
202 70 95 2.8
B Figures in cm
Trench profile, CFL DUO 1 2 3
CASAFLEX Width Depth Minimum

Outer casing Bending
Ø D B T radius
60
30
mm cm cm m
T
111 30 85 1.1
10
126 35 85 1.4
D
142 35 85 1.5
10
162 35 90 1.8
182 38 90 2.0
10 D 10
Figures in cm
B
Installation depth
Max. installation depth: 2.6 m
Ground plan of trench for house connection
Our approval is required for deeper installations.
SLW 30 ^ = 300 kN total load to DIN 1072;

if subject to higher traffic loads (e.g. SLW 60), a load-distributing
superstructure as per RStO75 is required.
With no traffic load, the minimum trench depth T can be reduced
1.0 m
4 4 by 20 cm.
Ground plan of trench for T-piece connection
5
X 0.9 m
Structure
0.5 m
0.9 m
1 Pipe warning tape; see sheet CFL 4.345

0.5 m
2 Excavated material, compactable

A
3 Sand, washed, grain size 0 - 8 mm
4 CASAFLEX district heating pipe
A
5 Connector; see sheet CFL 4.330 - CFL 4.350 0.5 m
0.9 m 4
0.5 m
X = 1m when connecting a T-piece to CFL

0.9 m
or 3m when connecting a T-piece to KMR

A = Pipe distance see sheet PRE 6.500 Rmin
0.9 m
B
When connecting KMR DUO to CASAFLEX DUO the same dimen-
sions are valid for one pipe axis
8.1.2015 INT
Connection (rigid/flexible)
CASAFLEX – pre-insulated steel pipe
Installation instructions for transition from CASAFLEX to pre-insulated steel pipe
1. Junction with T-piece 2. Transition with fixed point All figures in m
≤ 2.0
L1 = 3 m*
CASAFLEX
∆I ≤ ± 10 mm ∆I
DP KMR FP
Rmin. Joint/sleeve
Joint/sleeve Steel pipe
The transverse expansion ∆l must not exceed the expansion that can The expansion Δl of the plastic casing pipe (due to the increase in tem-
be accommodated by junction pipe L1 and the CASAFLEX pipes. perature) cannot be compensated by the CASAFLEX pipes. Installation
requires a fixed point.
3. Transition with Z-bend 4. Transition with expansion bend All figures in m
L1 = 3 m L1 = 3.0 m
2m
2m
DP Muffe
Muffe
KMR
KMR
DP
∆I
∆I
* shorter lengths are possible on request and static verification

Static design of the Z-bend according to expansion variable ∆l.
∆l = Expansion - Design of expansion components

FP = Fixed point (pre insulated steel pipe) - Positioning of expansion pads
EP = Expansion pad as per the section on PREMANT
8.1.2015 INT
Entry into building

Fixed point forces
CASAFLEX district heating pipe is a self-compensating, statically resolved system, i.e. it accom-
modates thermally induced changes in length within the system. The system itself only has
a limited ability to accommodate loads and deformations acting from outside. Connections to
conventional systems must be executed on a 'low-load' basis. The following fixed point forces
must be taken into account for each pipe, depending on self-compensation and inner pressure:
Fixed point forces per pipe

Type F F F F F F*
(6 bar) (10 bar) (16 bar) (21 bar) (25 bar) (37.5 bar)
KN KN KN KN KN KN
DN 20 0.3 0.5 0.8 1.0 1.2 1.8
DN 25 0.5 0.8 1.4 1.8 2.1 3.2
DN 32 0.8 1.4 2.2 2.9 3.5 5.3
DN 40 1.3 2.1 3.4 4.5 5.4 8.1
DN 50 1.9 3.2 5.1 6.7 8.0 12.0
DN 65 3.1 5.2 8.3 10.9 12.9 19.4
DN 80 5.1 8.5 13.7 17.9 21.3 32.0
DN 100 8.6 14.4 23.0 30.2 36.0 54.0
* test pressure
The fixed points forces will be influenced by structural conditions - please contact our
technology in advance!
8.1.2015 INT
Entry into building

Wall opening
Detection wires Monitoring box on wall All figures in mm

Monitoring box on pipe
approx. 80
Wire
connection
min. 250
Fixed point; 160 CASAFLEX pipe;

see text
see sheet CFL 4.115
Connector; Wall sealing ring;

see sheet CFL 4.330 Protective cap see sheet CFL 4.360
The connector and/or the CASAFLEX pipe are not suitable for accommodating expansion of ongoing pipes. A fixed point
clamp must be fitted for this reason (see worksheet CFL 4.515).
Wall opening
Outer casing L min H min

Ø D
mm mm mm
91 500 300
H
111 500 300

126 550 300
142 600 350
80 D 100 D 80 162 650 350
L min
All figures in mm
Core bores for wall sealing rings

30
Outer casing D1 A
ØD
mm mm mm
91 200 230
D1
111 220 250

126 240 270
142 260 290
162 280 310
All figures in mm
8.1.2015 INT
Entry into building

Core bore
Detection wires Monitoring box on wall All figures in mm

Monitoring box on pipe
Wire
conn-
ection
min. 250
Fixed point; 160 CASAFLEX pipe;

see text see sheet CFL 4.115
Connector;
see sheet CFL 4.330 Protective cap
The connector and/or the CASAFLEX pipe are not suitable for accommodating expansion of ongoing pipes. A fixed point
clamp must be fitted for this reason (see worksheet CFL 4.515).
Core bores Seal set type A single-seal

1 x 40 mm, Shore hardness D 35
Perfect bores are required for installation. As hairline cracks may
be present in the concrete or could be caused by processing, it is Seal set type C40 double-seal*
advisable to seal the entire length of the borehole wall with suitable 2 x 40 mm, Shore hardness D 35
sealant (such as AQUAGARD). Tightness can only be guaranteed if
this recommendation is followed. Liner pipe made of fiber cement, or core bore coated

30 ØD
mm mm mm
91 150 180
111 200 230
126 200 230
142 200 230
D1
162 250 280
All figures in mm
8.1.2015 INT
Shaft structures
Entry into building
Planning and engineering of shaft structures
The construction and maintenance of shaft structures in local and district heating networks is usually very expensive and
time-consuming. They must include inbound and outbound ventilation and must be built so that they are watertight; any
surface water which penetrates should be removed as quickly as possible so as to prevent damage to the shaft installa-
tions and the heat insulation for the inbound pipes (insulated steel pipes and flexible district heating pipes).
Depending on local conditions, the pipe entries must be fitted with seals. For surface water which does not exert pres-
sure, simple labyrinth seals are usually adequate. For groundwater an adjustable packing seal is generally required. As a
rule, the pipe end seals are only designed to protect against water splashes. A design which is impermeable to surface
water is also possible in principle, but flooding of lengthy duration, especially below operating temperature, should be
avoided.
Due to these requirements, little use is made of shaft constructions nowadays. Instead, pre-insulated T-pieces and (if
necessary) pre-insulated shut-off and drainage/venting fittings are used. This makes it possible to avoid the substantial
costs of producing and maintaining shaft constructions and to increase the operational reliability of the system.
Do not immerse in water. Do not use in wet situations.
8.1.2015 INT
Construction work
Open trench lengths
The static equilibrium of the CASAFLEX district heating pipe must be maintained during construction work; see the open
trench lengths (L) stipulated in the table. If greater lengths have to be left unsupported, sand supports must be posi-
tioned at the intervals indicated. T-pieces must be separately fixed by means of sand supports.
In case of open digging parallel with the CASAFLEX pipe route, distance (A) must be respected. Where other trenches are
parallel to the CASAFLEX route, the distance A must be maintained.
Type L L L L L A
(6 bar) (10 bar) (16 bar) (21 bar) (25 bar)
m m m m m m
DN 20 6 4 3 2 2 0.5
DN 25 6 4 3 2 2 0.5
DN 32 6 4 3 2 2 0.5
DN 40 5 4 3 2 2 0.5
DN 50 5 4 3 2 2 0.5
DN 65 5 4 3 2 2 0.6
DN 80 5 4 3 2 2 0.6
DN 100 5 4 3 2 2 0.6
Ground layout plan A
Open trench length L Ls = 4 · Da Open trench length L Sand support dimensions:
Hs = 2 x Da
Bs = 7 x Da
Ls = 4 x Da
7 · Da
Da
B s=
Sand support
Trench profile Bs = 7 · Da
A-A
Sand support
Hs = 2 · Da
8.1.2015 INT
Open installation
Special measures are required for open installation of CASAFLEX district heating pipes:
- Installation on a continuous mounting rail (steel angle profile, galvanized)

- Changes of direction must also be supported
- In a 90° bend secure with clamps and pressure distribution plates at specified intervals
- Clamps
- Limitation to PN 10
- Fix ends with anchor points
- Assistance with design engineering and planning from BRUGG
CASAFLEX Angle steel Distance between clamps Minimum

Type (galvanized) bending
radius
mm m m
CFL 22/ 91 60 x 60 x 6 2 0.8
CFL 30/111 70 x 70 x 7 2 1.0
CFL 39/126 80 x 80 x 8 2 1.2
CFL 48/126 80 x 80 x 8 2 1.2
CFL 60/142 90 x 90 x 9 2 1.3
CFL 75/162 90 x 90 x 9 2 1.8
CFL 98/162 90 x 90 x 9 2 1.8
CFL 127/202 90 x 90 x 9 2 2.0
8.1.2015 INT
FLEXWELL FHK
Flexible district heating pipe
FLEXWELL district heating cable FHK 5.0
Table of Contents

5.100 General
5.110 System structure
5.115 FLEXWELL district heating cable range

5.200 Pressure loss chart
5.210 Heat losses
5.3 Components
5.300 T-joint
5.305 Through connection, PN 16, types 30/91 to 147/220
5.310 Through connection, PN 25, types 30/91 to 200/310, welded
5.315 Through connection, PN 25, types 30/91 to 75/171, GR version
5.320 Connector, PN 16, types 98/171 to 147/220, versions A and DE
5.325 Connector, PN 16, types 30/91 to 200/310, G version, welded
5.330 Wall leadthrough
5.335 Wall leadthrough with core bore or fiber cement liner pipe (impermeable to pressure from water)
5.350 House entry bend

5.500 Loop-in method, type of routing/installation
5.505 Loop-in method, building entries
5.510 Dimensions for axis and wall distances, connector types 30/91 to 75/171
5.515 Dimensions for axis and wall distances, connector types 98/171 to 147/220
5.520 Dimensions for axis and wall distances, welded connector types 30/91 to 200/310
5.525 Installation through protective pipes
5.530 Installation through protective pipes
5.535 Horizontal directional drilling (HDD) method
5.540 Installation without trenches
5.545 Information for underground construction – technical regulations, standards, information on execution
5.550 Information for underground construction, trench dimensions
5.555 Information for underground construction, wall openings
5.560 Information for underground construction, core bores
5.565 Information for underground construction, through connection
5.570 Information for underground construction, T-joint – downward branch
5.575 Information for underground construction, T-joint – upward branch
5.580 Information for underground construction, house entry bends
5.585 Distance from other supply lines
21.8.2014
System description
FLEXWELL district heating cable is the registered name of a flexible pipe system from BRUGG Max. permitted
Pipe Systems, used to transport district heat and domestic hot water. This pipe - which is laid operating temp. TBmax: -170 to +150 °C
directly in the ground - has proven its merits in practice for many years under a wide range of Max. permitted
extreme conditions. operating pressure p: PN 25 bar
FLEXWELL district heating cable has a helically corrugated inner pipe made of stainless steel.
The materials used are extremely resistant to corrosion, making this product ideal for trans-
porting a wide variety of media such as heating water, domestic hot water, drinking water,
condensate and others.
The corrugation of the inner pipe not only ensures the flexibility of the whole pipe, but also
compensates intrinsically for the temperature-induced change in length. There is no need for
precautions to accommodate expansion (U-bends, L-limbs or fixed points) of the sort required
with rigid pipe systems.
Thanks to its corrugated outer steel case, FLEXWELL district heating cable belongs to the steel
casing pipe family. The continuous multi-layer anti-corrosion protection on the outside ensures
unparalleled security and reliability in the ground during operation.
FLEXWELL district heating cable is a reliable solution, especially when the ground is not very
stable and subsidence is possible, and in very wet ground (high groundwater levels). This prod-
uct can be laid through water (siphon method) with no problems.
Thanks to this product's continuous anti-corrosion protection, the pipe trenches for FLEXWELL
district heating cable can be substantially narrower than for rigid pipe systems. This in turn
allows considerable savings on underground construction work.
Because of its flexibility and the high loading capacity of its casing, FLEXWELL district heating
cable is particularly suitable for the horizontal directional drilling (HDD) method. This method is
used wherever valuable surfaces require protection or difficult crossings would otherwise have
to be constructed.
Taking account of the very short time required for installation, FLEXWELL district heating cable
offers a solution for district heat transport that is not only technically perfect but also very cost-
effective, with minimal disruption for district heat customers and the general public during the
construction period.
21.8.2014
System description
1. Medium pipe
Materials: Corrugated medium pipe made of nickel chromium steel, X5 CrNi 18-10 (1.4301, AISI 304)
or X6 CrNiMoTi 17-12-2 (1.4571, AISI 316Ti)
or X2 CrNiMo 17-12-2 (1.4404, AISI 316L)
Requirements: Steel quality to EN 10088
Materials: CFC-free, flexible polyurethane foam (PUR) with l50 value of 0.032 W/mK, resistant up to 150 °C
PUR insulation Reference temperature FHK value Test standard

Density - > 60 kg/m3 DIN 53420
Thermal conductivity 50 °C ≤ 0.032 W/mK DIN 52612
Percentage of closed cells - ≥ 90 % -
Water absorption after 24 hours - ≤ 10 % EN 253
3. CrNi steel casing
Materials: Corrugated steel casing in 1.4512, DIN EN 10088-2
4. Anti-corrosion protection
Materials: Polyment layer (bitumen-caoutchouc paste)
5. PE-LD protective casing
Materials: Made of polyethylene 2YM2 (PE) to VDE 0209

Purpose: Protection against mechanical actions and humidity
PE-LD protective casing Reference temperature Value Test standard

Density 50 °C 931 kg/m3 ISO 1183
6. Monitoring wires
Materials: 1 x NiCr, red, insulated/perforated, Ø 1.1 mm/0.5 mm2

1 x Cu, green, insulated, Ø 1.3 mm/0.8 mm2
1 x Cu, white with nonwoven, Ø 1.55 mm/1.13 mm2
Systems: Conductor pairs: NiCr-red (a) + Cu-green (b) ^
= WIREM/Brandes system
Cu-green (b) + Cu-white (c) ^
= Nordic system
Purpose: Identification and location of moisture by means of resistance and pulse measurements
21.8.2014
FLEXWELL district heating cable range

1 6 3 2 4 5
s2
a b c
s1
d1
D
Structure

2 PUR foam
3 Steel casing
4 Anti-corrosion protection
5 PE-LD casing
6 Monitoring wires
FLEXWELL district heating cable

Type DN Carrier pipe Casing pipe External diameter Minimum Volume Weight Maximum
d1 x s1 s2 D bending radius carrier pipe delivery lengths*
mm mm mm m l/m kg/m m
30/ 91 25 30.0 x 0.3 0.6 94 1.0 0.81 3.9 1000
39/116 32 38.9 x 0.4 0.6 121 1.2 1.35 5.7 640
60/148 50 60.0 x 0.5 0.7 156 1.5 3.12 9.1 590
75/171 65 75.8 x 0.6 0.8 178 2.0 5.12 12.2 480
98/171 80 98.0 x 0.8 0.8 178 2.0 8.43 12.8 480
98/220 80 98.0 x 0.8 0.9 233 4.0 8.43 19.3 270
127/220 100 127.0 x 0.9 0.9 233 4.0 14.30 19.8 270
147/220 125 147.0 x 1.0 0.9 233 4.0 17.30 20.3 250
200/310 150 197.5 x 1.2 1.3 313 6.0 33.50 33.2 230
* based on maximum possible drum capacity and normal production length
21.8.2014
Pressure loss chart

ṁ = Flow rate in kg/h
(1 mmWS = 9.81 Pa)
Q·860 Q = Power requirement in kW
ṁ ≈
VL(flow)/RL(return) in °C

[kg/h]

Mass flow rate

)+ .

)+.

P

P
V

)+.

P

V

P

V

)+.
P

V

P
)+.
V

P

V

)+.
P

V

)+.
P
V

P

V
)+.

)+.

>PEDUP@
Pressure loss ∆p
Example:
Mass flow rate 7000 kg/h; FLEXWELL district heating cable type 75/171
–> Pressure loss 90 Pa/m
21.8.2014 Correction
Heat losses
H = 0.6 m
TE lE
a = 0.1 m

FHK type U-value Average operating temperature TB [°C]
[W/mK] 40° 50° 60° 70° 80° 90° 100° 110° 120° 130°
30/ 91 0.1983 5.95 7.93 9.92 11.90 13.88 15.86 17.85 19.83 21.81 23.80
39/116 0.1998 5.99 7.99 9.99 11.99 13.99 15.98 17.98 19.98 21.98 23.98
60/148 0.2384 7.15 9.54 11.92 14.30 16.69 19.07 21.46 23.84 26.22 28.61
75/171 0.2748 8.24 10.99 13.74 16.49 19.24 21.98 24.73 27.48 30.23 32.98
98/171 0.4177 12.53 16.71 20.89 25.06 29.24 33.42 37.59 41.77 45.95 50.12
98/220 0.2643 7.93 10.57 13.22 15.86 18.50 21.14 23.79 26.43 29.07 31.72
127/220 0.4043 12.13 16.17 20.22 24.26 28.30 32.34 36.39 40.43 44.47 48.52
147/220 0.5587 16.76 22.35 27.94 33.52 39.11 44.70 50.28 55.87 61.46 67.04
200/310 0.5585 16.76 22.34 27.93 33.51 39.10 44.68 50.27 55.85 61.44 67.02
Type of installation, FHK UNO: 2-pipe, laid in the ground Heat loss during operation:
Coverage height: H = 0.60 m U = Heat transfer coefficient [W/mK]
Ground temperature: TE = 10 °C TB = Average operating temperature [°C]
Conductivity of PUR foam: lPU = 0.032 W/mK
21.8.2014
T-joint
1900
1000
700
Structure 3 6 2 7 4 5 1
A
1 FLEXWELL district heating cable
with connector
2 Monitoring wires
3 T-piece
4 PE-HD shrink sleeve
5 Shrink-on collar
6 Shrink-on collar
7 Rigid PUR foam
View A
45°
D1
H
50
D2 150
1000
~1450
H = D1 + D2 + 50
2
Depending on the pressure level, the T-pieces are supplied with either standard or welded connectors. Figures in mm
21.8.2014
Through connection, PN 16
Types 30/91 to 147/220
Structure of through connection, PN 16
5 6 4 3 2 4 5 1
Structure
L
1 FLEXWELL district heating cable with connector

2 Monitoring wires
3 Connecting pipe with support sockets
5 Shrink-on collar
6 Rigid PUR foam
Dimensions of through connection

FHK-Type L Ø Dmax RMBD
mm mm
30/ 91 800 160 1
39/116 800 180 2
60/148 800 225 3
75/171 850 250 4
98/171 850 280 5
98/220 850 315 6
127/220 850 315 6
147/220 850 315 6
Ø Dmax
21.8.2014
Through connection, PN 25
Types 30/91 to 200/310, welded
6 4 3 2 7 5 1
Ø Dmax
Structure
1 FLEXWELL district heating

cable with connector L FLEXWELL district
2 Circumferential seam weld heating cable
(provided by customer or others) Types 30/91 to 147/220
3 Connecting pipe with welding lip
5 Shrink-on collar
FLEXWELL district
6 Rigid PUR foam
heating cable
7 Monitoring wires
Type FHK 200/310
1 3 4 5 6 2 7 1
Ø Dmax
Structure
1 FLEXWELL district L
heating cable
2 Shrink-on collar
3 Metal plate collar
4 Sealing plug
5 Weld ring
6 Rigid PUR foam
7 Jointing compound
Dimensions of through connection
FHK type L Ø Dmax
mm mm
30/ 91 800 160
39/116 800 180
60/148 800 225
75/171 850 250
98/171 850 280
98/220 850 315
127/220 850 315
147/220 850 315
200/310 900 320
21.8.2014
Connector, PN 25
Types 30/91 to 75/171, GR version
The FHK connector with the type GR graphite ring seal (Figure 1) is specifically designed for use with
FLEXWELL district heating cable for heating and domestic water pipes, up to a dimension of DN 65.
It is used to make all connections on pipe installations in buildings and shafts, and for through-type and T-joints.
The monitoring wires pass through a watertight exit on the connector.
This connector can withstand loads of up to nominal pressure stage PN 251) at a maximum temperature of 150 °C.
Figure 1 : Connector with graphite ring seal, type GR
4 3 7 1 12 11 10 9 6 Structure
1 Compression ring
2 Support ring
4 Connecting piece
5 Panhead screw
6 Threaded cap
7 O-ring
8 Washer
9 Clamp
10 Monitoring wires
X 11 Monitoring wires-
screwed connector
12 PTFE-tube
13 Insulation
14 Compression joint
15 Shrink hose
5 8
Detail X
15 14 13 10
Version for
domestic water pipes can Sensor wires, NiCr insul. red
Nordic wires, insul. white
be supplied with external
12 Cu wires, insul. green
thread
Nominal widths, pipe connection dimensions

FHK type 30/91 39/116 60/148 75/171
Comparable nominal width [DN] 25 32 50 65
Pipe connection dimensions for hot water pipe [mm] 33.7 x 2.6 42.4 x 2.6 60.3 x 2.9 76.1 x 2.9
Pipe thread for domestic water pipe R 1 R 1 1/4 R 2 R 2 1/2
1)
Note: For pressure tests in a partially filled trench or with unsupported connectors: max. permitted pressure = 0.5 bar overpressure
21.8.2014
Connector, PN 16
Types 98/171 to 147/220, versions A and DE
The FHK connector (Figure 1) is a connecting component specifically designed for FLEXWELL district heating cables.
It is used to make all connections on pipe installations in buildings and shafts and also for through-type and T-joints
(FHK 5.305 and FHK 5.300).
Two variants of the connector can be supplied (Figure 2). When delivered, the pipe ends are protected with plastic caps
to prevent impurities from entering the inner pipe. Type A connector is intended for hot water pipes. The type DE connec-
tor is additionally available in a special version for domestic water pipes. It is supplied with a PTFE-sheathed IT seal. This
PTFE sheath must not be removed or damaged.
The monitoring wires pass through a watertight exit on the connector.

These connectors can withstand loads of up to nominal pressure stage PN 161) at a maximum temperature of 150 °C.
Structure
Figure 1 : Connector (type A)
24 7 10 8 6 2 5 3 17 18 19 4 14 1 13 15 16 1 Face ring
2 Support socket (type A or DE according to choice)
3 Lead sealing ring
4 Inner wire ring
5 Outer wire ring
6 Flange ring
X 7 Locking screw
8 Washer
9 Hexagon nut
10 Hexagon nut with transverse bore
11 Sealing wire
12 Lead seal
13 Folded collar
14 Strain washer
9 11 12 15 Permanently plastic synthetic strip
16 PE anti-corrosion strip
Detail X 17 Silicone pipe
23 22 21 20
18 Cable leadthrough, R 1/4"
Sensor wires, NiCr insul. red 19 Copper sealing ring
Nordic wires, insul. white 20 Monitoring wires
17 Cu wires, insul. green 21 Insulation
23 Shrink hose
24 Protective cap
FHK type 98/171 127/220 147/220
98/220
Comparable nominal width DN 80 100 125
Pipe connection dimensions mm 88.9 x 3.2 114.3 x 3.6 139.7 x 4.0
Figure 2 : Types of execution for the connector
Type A Heating Type DE Sanitary special design

Flange connection dimensions after PN 16
Special version available for domestic water pipes.
1)
21.8.2014
Connector, PN 25
Types 30/91 to 200/310, G versions, welded
FLEXWELL district heating cable types 30/91 to 147/220
1 9 8 6 7 3 2 11 10 4 5
Structure
1 Connecting piece with

Tungsten inert weld-on end
gas welding 2 Protective cap
3 Threaded component, R ½“
X
4 Permanently flexible jointing
compound
5 Shrink hose
6 Monitoring wire leadthrough, R ½“
7 Sealing ring
8 Shrink hose
9 PTFE hose line
10 Monitoring wires
11 Shrink hose
Detail X Tungsten inert gas welding 13 Shrink hose
13 12 14 10 14 Insulation
Sensor wires, NiCr insul. red

Nordic wires, insul. white
Cu wires, insul. green
FLEXWELL district heating cable type FHK 200/310 Structure

1 12 9 8 3 2 4 7 5 13 10 11
Y 1 Connecting piece with
weld-on end
2 Protective cap
3 Reduction nipple
4 PTFE hose line
5 Monitoring wires
6 Compression joint
14
7 Glass fiber hose
8 Sealing ring
9 Screwed cable joint
15 13
10 Permanently flexible jointing
compound
11 Shrink-on collar
12 Weld seam
Detail Y (protective cap/connection piece)
7 16 6 17 5 13 Weld seam
(protective cap/outer corrugated pipe)
Sensor wires, NiCr insul. red 14 Weld seam ("black" / "white")
Nordic wires, insul. white 15 Weld seam ("white" / "white")
4 Cu wires, insul. green
16 Shrink hose
17 Insulation
FHK type 30/91 39/116 60/148 75/171 98/171 127/220 147/220 200/310
98/220
Comparable nominal width DN 25 32 50 65 80 100 125 150
Pipe connection dimensions mm 33.7 x 2.6 42.4 x 2.6 60.3 x 2.9 76.1 x 2.9 88.9 x 3.2 114.3 x 3.6 139.7 x 4.9 168.3 x 4.5
21.8.2014
Wall leadthrough
3 B
2 4
5
Structure
1 Fixing ring
2 Hexagon screw, M6 x 20
3 Washer
4 Cast ring
5 Sealing ring
7 Concrete
FHK type A B Sealing rings
mm mm Piece
30/ 91 160 40 1
39/116 186 40 1
60/148 221 40 1
75/171 243 40 1
98/171 243 40 1
98/220 298 40 1
127/220 298 40 1
147/220 298 40 1
200/310 378 75 2
21.8.2014
Wall leadthrough
with core bore or fiber cement liner pipe (impermeable to pressure from water)
Seal set type C40 Seal set type A

1 x per opening 1 x per opening
Core bore or fiber cement

liner pipe, type 3000 (customer or others)
Ø Dinner Ø Douter
1 x type C40 + 1 x type A must be provided for each pipe leadthrough!
FHK type DN Ø core bore or sealing set

Liner pipe 3000 Ø D inner Ø D outer
mm mm mm
30/ 91 25 150 94 150
39/116 32 200 121 200
60/148 50 250 156 250
75/171 65 250 178 250
98/171 80 250 178 250
98/220 80 350 / Switzerland: 300 233 350 / Switzerland: 300
200/310 150 400 313 400
When ordering the sealing insert, diameters "Dinner" and "Douter" must be stated.
Perfect bores are required for installation. As hairline cracks may be present in the concrete or could be caused by processing,
it is advisable for customers or others to seal the entire length of the borehole wall with suitable sealant
(such as AQUAGARD). Tightness can only be achieved if this recommendation is followed.
After fitting the sealing insert, no further axial movement of the pipe is permitted.
21.8.2014
House entry bend

7
1 2 3 4
D2
5
D1
700
Structure
1 FLEXWELL district heating cable with connector (A, DE or GR)

2 Shrink-on collar
4 Shrink-on collar
5 Bend, 90° pre-insulated, 1.5 x 1.5 m, steel or stainless steel
6 Labyrinth seal
7 End cap
FHK type DN FHK outer Ø Bend dimensions

D1 D2
30/ 91 25 94 90
39/116 32 121 110
60/148 50 156 125
75/171 65 178 140
98/171 80 178 160
98/220 80 233 200
127/220 100 233 200
147/220 125 233 225
200/310 150 313 250 Figures in mm
21.8.2014
Loop-in method
Type of routing/installation
The flexible design of FLEXWELL district heating cable makes it suitable for installation using
the 'loop-in method' which originated in the cable technology business (Figure 2).
The benefits of this are:
- no branches or connection points in the ground

- risks are reduced
- safety and reliability are increased
- costs are cut
- fittings can be installed at low cost inside buildings.
Figure 1 Conventional type of installation, joints and branches in the ground
Figure 2 Loop-in method, joints in buildings
21.8.2014
Loop-in method
Building entries
min. 350 mm (DN 20 - DN 125) 1

min. 550 mm (DN 150)
3
min. 350 mm (DN 20 - DN 125) Ongoing

min. 550 mm (DN 150) pipes
2
Return
Flow
Flow
Structure
1 FLEXWELL district heating cable Return

2 Connector
3 Wall leadthrough
Incoming
4 Wall opening
pipes
(sealed watertight by customer or others)
Facilities for drainage or venting must be provided by the customer or others depending on the elevation (high/low points).
For the size and positioning of wall openings, see worksheets FHK 5.555 and FHK 5.560.
21.8.2014
Dimensions for axis and wall distances

Connector types 30/91 to 75/171
Connector with graphite ring seal, type GR
l1
min. 350 e1
L1 4
min. 350 1
3
2
Structure

2 Wall leadthrough
3 Connector type GR
4 Wall opening sealed watertight by customer or others
(For the size and positioning of wall openings, see worksheets FHK 5.555 and FHK 5.560)
Nominal widths, dimensions for pipe connections, wall and axis distances
FHK type 30/91 39/116 60/148 75/171
Comparable DN 25 DN 32 DN 50 DN 65
nominal width
D x s 33.7 x 2.6 42.4 x 2.6 0.3 x 2.9 76.1 x 2.9
e1 165 200 240 270
L1 120 130 145 145
I1 220 240 280 300 Figures in mm
21.8.2014

Connector types 98/171 to 147/220
Connector (type A)
l1
L1 4
3
min. 350 1
min. 350 e1
Structure

2 Wall leadthrough
3 Connector (type A)
4 Wall opening sealed watertight by customer or others
(For the size and positioning of wall openings,
see worksheets FHK 5.555 and FHK 5.560)
FHK type 98/171 98/220 127/220 147/220
Comparable DN 80 DN 80 DN 100 DN 125
nominal width
D x s 88.9 x 3.2 88.9 x 3.2 114.3 x 3.6 139.7 x 4.0
e1 270 310 310 310
L1 235 280 280 280
r 122 122 150 180
l1 385 385 430 430
I2 385 385 455 490
I3 400 400 445 445 Figures in mm
21.8.2014

Connector, welded, types 30/91 to 200/310
Figure 1: Connector, version G, welded
l1
L1 1
3
Structure Figure 2: Wall and axis distances

2 Wall leadthrough
3 Connector min. 350
4 Wall opening sealed watertight by customer or others (550) 1) e1
(For size and position of wall openings,
see worksheets FHK 5.555 and FHK 5.560)
min. 350
(550) 1)
FHK type 30/91 39/116 60/148 75/171 98/171 98/220 127/220 147/220 200/310
Comparable DN 25 DN 32 DN 50 DN 65 DN 80 DN 80 DN 100 DN 125 DN 150
nominal width
D x s 33.7 x 2.6 42.4 x 2.6 60.3 x 2.9 76.1 x 2.9 88.9 x 3.2 88.9 x 3.2 114.3 x 3.6 139.7 x 4.0 168.3 x 4.5
e1 165 200 240 270 270 310 310 310 410
L1 215 215 230 235 235 280 280 280 210 (310)1
l 1 377 373 383 388 385 385 426 426 300 (400)1
Dimensions in parenthesis are valid for installing connectors on site. Dimensions without
1)
Figures in mm
parentheses are valid for pipes fabricated in the factory.
21.8.2014
Installation through protective pipes

The following points should be noted when installing FLEXWELL district heating cable (FHK) through protective pipes:
1. In order to ensure that the FHK is guided perfectly as it is drawn in. One protective pipe is required for each FHK. The
protective pipe must be laid straight, with no angles. Protective pipes must not have any offsets on their joints which
could impede or prevent the drawing-in procedure, or which could cause damage to the outer PE protective casing.
2. When the throughpress process is used, it is not always possible to introduce two small protective pipes into the
ground next to one another; in these cases, one large protective pipe is pressed in instead. It is essential to contact us
beforehand in order to agree on a structural solution.
3. Sufficient working space must be available at ground level in front of and behind the protective pipe to enable the
traction engine to shunt easily with the cable trailer, so it can draw the FHK into the protective pipe without any
angular deviations from the pipeline axis.
4. Bends in the pipe routing must be avoided directly upstream or downstream of the protective pipes. If this cannot be
ensured, the pipe routing must be agreed with us beforehand.
5. For protective pipes made of PVC, PE or fiber cement, the FHK is drawn in without skids. For steel and concrete
protective pipes skids should be used. The inner diameter of the protective pipes should be at least 20 mm larger than
the outer diameter of the FHK or the skids (FHK 5.530, Figures 1 and 2).
21.8.2014
Installation through protective pipes

Figure 1: Installing FHK through straight-running protective pipes without offset, not using skids.
Max. length of protective pipe ≥ 50 m1)
Min. play 40 mm
FHK
Plug-in sleeve for PVC - sewage pipe PVC/PE/AZ sewage pipe

PE - sewage pipe
AZ - sewage pipe
Figure 2: Installing FHK through straight-running protective pipes without offset, using skids.
Max. length of protective pipe ≥ 50 m1)
Min. play 40 mm
FHK Protective pipe made of steel4) or concrete
max. 1.0 m Skid distance L Plastic skid

from end
FLEXWELL district heating cable type 30/91 39/116 60/148 75/171 98/220 200/310
98/171 127/220
147/220
FHK casing pipe Ø max. mm 95 121 156 178 233 313
Skid distance L m 2.00 2.00 2.50 3.00 3.00 4.00
without skids
PVC sewage pipe to DIN 19 534 2) mm 125 x 3 160 x 3.6 200 x 4.5 250 x 6.1 315 x 7.7 400 x 9.8
Play between FHK and PVC pipe mm 24 32 35 60 67 67
AZ sewage pipe to DIN 19 850 2) mm 141 x 8 168 x 9 220 x 10 274 x 12 328 x 14 436 x 18
Inner pipe Ø mm 125 150 200 250 300 400
Play between FHK and AZ pipe mm 30 29 44 72 67 87
with skids
Steel pipe to DIN 2458 3) 4) mm 168.3 x 4 219.1 x 4.5 219.1 x 4.5 273 x 5 323.9 x 5.6 406.4 x 6.3
Inner pipe Ø mm 160 210 210 263 313 394
Skid (company: Frankenplastik) 3 S19 4 S19 4 T19 2 F + 1 G25 3 F + 1 G25 4 F + 1 G25
Play between FHK and pipe mm 27 51 20 35 30 31
1) after consulting BRUGG Pipe Systems
2) Min. coverage height for SLW 60 = 0.80 m; for SLW 30 or below a road surface: 0.60 m
3) Min. coverage = 0.60 m
4) Joints without root seam
21.8.2014
Horizontal directional drilling (HDD) method

Because of its flexibility and its corrosion-proof outer casing, FLEXWELL district heating cable is particularly suitable
for the horizontal directional drilling (HDD) method described below. This application is possible for the entire series of
dimensions from FHK 30/91 to FHK 200/310.
The horizontal directional drilling (HDD) method was developed to install supply pipes and lines without trenches. The
horizontal directional drilling method is used wherever protection is required for valuable surface areas (such as parks,
protected countryside zones, pedestrian zones, pavements and cobbled paths, gardens in front of buildings, etc.) or
where difficult crossings have to be constructed (waterways, canals, roads with heavy traffic, rail lines, embankments or
built structures, etc).
Brief technical process description
The boring tool consists of individual hollow drill assemblies which are screwed together, and a drill head equipped with
jets.
A water-bentonite mixture atomized under high pressure, in small quantities, cuts and loosens the adjacent ground whilst
stabilizing and lubricating the bore hole.
The special shape of the drill head allows targeted changes of direction and precise control of the bore.
At the end of the pilot bore, the drill head is exchanged for a widening head fitted with jets, and the FLEXWELL district
heating cable that is to be drawn in is connected.
At the same time as the drilling assembly is withdrawn, the FLEXWELL district heating cable is drawn into the bore hole
which has been widened and supported by the water-bentonite suspension.
Benefits of the system
• No pipe trenches, earthworks only required for installation pits

• Minimal damage to surfaces
• No consequential damage, e.g. due to subsidence of the ground or road surface
• Disruptions and hazards to stationary and moving traffic are minimal
• Consideration is given to protecting trees and plants
• Process is largely independent of weather conditions
• High-speed working
21.8.2014
Installation without trenches

Pulling head
Ø D
FHK type Dmax FZ Recommended min. Recommended min. Normal
bore hole radius bore hole diameter bore length
mm KN m mm m
30/ 91 100 12 25 150 121
39/116 125 15 30 185 112
60/148 160 20 35 240 110
75/171 180 30 50 270 141
98/171 180 40 50 270 190
98/220 230 50 100 345 167
127/220 230 50 100 345 167
147/220 230 60 100 345 201
200/310 320 100 150 480 224
500
Bore length, m
450
400
350
300
250
200
150
100
50
0
30/91
39/116
60/148
75/171
98/171
98/220
127/220
147/220
200/310
The “normal bore length = ” is taken as the standard value and is attainable where ground and installation conditions present no particular
difficulties; the project-specific “maximum bore length” must be determined on a case-by-case basis, taking account of local conditions and
permissible tensile/tractive forces.
FZ = permissible tensile/tractive force for the HDD process

A special pulling head must be used for this purpose. The bore hole should be widened to the recommended minimum bore hole diameter before
the FLEXWELL district heating cable is drawn in.
21.8.2014
Information for underground construction

Technical regulations, standards, information on execution
Technical regulations, standards
The following standards, regulations and guidelines should be observed as a minimum when carrying out underground construction work for
FLEXWELL district heating cable:
DIN 1072 Road and path bridges, load assumptions

DIN 4033 Drainage ducts and conduits made of prefabricated pipes, guidelines on execution
DIN 4124 Construction pits and trenches, embankments, working space widths, timbering
DIN 18300 VOB, Part C, General technical regulations; earthworks
DIN 18303 VOB, Part C, General technical regulations; cladding work in construction pits
DIN 18304 VOB, Part C, General technical regulations; piling work
DIN 18305 VOB, Part C, General technical regulations; dewatering work
DIN 18307 VOB, Part C, General technical regulations; gas and water pipework in the ground
DIN 18308 VOB, Part C, General technical regulations; drainage work
DIN 18320 VOB, Part C, General technical regulations; landscaping work
DIN 18330 VOB, Part C, General technical regulations; brickwork
DIN 18337 VOB, Part C, General technical regulations; sealing against water not exerting pressure
DIN 18354 VOB, Part C, General technical regulations; asphalting work
Code of practice: "Securing pipe trenches and construction pits1"
Information sheet on infilling pipe trenches2
Accident prevention regulations
The trench widths 'B' indicated in the table on worksheet FHK 5.550 are recommended values. However, they do not release those engaged in
underground construction work from the duty of diligence in respect of accident prevention regulations or of the aforementioned standards and
regulations.
Information on execution
The minimum distances from external supply lines stated in worksheet FHK 5.585 must be respected.
Underground construction data for through connections: see worksheet FHK 5.565; for T-pieces, FHK 5.570.
1
Employers' Liability Insurance Association of the Construction Industry
2
Research Society for Roadbuilding, Underground Working Group, Maastrichter Str. 45, 50672 Cologne
21.8.2014

Trench dimensions
Figure 1: Layout plan of trench Figure 2: Cross-section of trench

Section A - A
1 5 6 7
A
Rmin
min 0.6 Tmin

0.3
0.1
d
B
0.1
LK Figures in m
2B x
x x
B x = min 0.1
Structure
1 FLEXWELL district heating cable (FHK)

2 Connector
3 Sealing bushing (wall leadthrough)
4 Working space in front of buildings and shafts
5 Pipe warning tape (supplied by
BRUGG Pipe Systems, installed by customer or others)
6 Sand filling (0 - 4 mm round particles)
2 3 1 4 7 Filling material (reusable excavated material)
Trench and working space dimensions, quantities of excavated material and sand filling
FLEXWELL district heating cable type 30/91 39/116 60/148 75/171 98/220 200/310
98/171 127/220
147/220
Outer diameter of FHK d mm 94 121 156 178 233 313
Trench depth Tmin m
for SLW 60 1) 0.80 0.85 0.85 0.90 0.95 1.05
Minimum coverage height t for SLW 60 m 0.60 0.60 0.60 0.60 0.60 0.60
Trench width B m 0.50 0.55 0.60 0.65 0.75 0.95
Working space width 2B m 1.00 1.10 1.20 1.30 1.50 2.00
Working space length Lk m 0.50 0.50 1.00 1.00 1.50 2.50
Minimum trench radius2) Rmin. m 1.00 1.20 1.50 2.00 4.00 5.00
Material excavated from trench 3) for SLW 60 m3/m 0.40 0.47 0.51 0.59 0.72 1.00
Sand filling m3/m 0.14 0.16 0.18 0.20 0.24 0.39
Trench widths "B" are recommended values. Please follow generally valid technical rules, guidelines and accident prevention regulations.
1) SLW 60 = 100 kN wheel load to DIN 1072
2) Smaller radii only after consulting BRUGG Pipe Systems
3) Excavation quantities ignoring gradient of embankment
21.8.2014

Wall openings
Figure 3 : Wall opening for FLEXWELL connector
a b
2 3
4
1
min. 0.35 a
Structure
min. 0.35
1 FLEXWELL district heating cable (FHK)
2 Connector
3 Wall leadthrough
4 Concrete (wall opening to be sealed watertight by customer or others)
Figure 4 : Wall opening for loop-in method

b
mind. 2 x h
a mind. 2 x b a min. 0.35
min. 0.35
With the loop-in method, wall openings must be widened according to the pipe routing and the dimensions stated below
(building statics may need to be checked by customer or others). Figures in m
Dimensions for wall opening, wall distances

FHK 30/91 39/116 60/148 75/171 98/220 200/310
98/171 127/220
147/220
a 0.26 0.24 0.22 0.21 0.18 0.10
b 0.35 0.45 0.50 0.55 0.65 0.85
h 0.20 0.25 0.30 0.35 0.40 0.50
21.8.2014

Core bores
B
B
OK trench bottom
C
Core bores for Doyma seals, see worksheet 5.335
Ø D Ø B
Reference dimensions for core bores
A Axial distance
B Core bore diameter
C Distance: trench bottom-pipe axis
D Diameter of wall leadthrough
Core bore dimensions*

FHK type A B C D
30/ 91 260 250 50 160
39/116 310 300 60 185
60/148 310 300 80 221
75/171 360 350 90 243
98/171 360 350 90 243
127/220 410 400 120 298
147/220 410 400 120 298
200/310 460 450 155 378
* only valid for standard wall leadthrough
Figures in mm
21.8.2014

Through connection
Figure 1: Working space for through connection (side view)
3
0.1
1
0.1
Structure
0.3
2 Through connection
4 Filling material (reusable excavated material)
Figure 2: Working space for through connection (top view)
0.1 B B1
A1
Trench dimensions
FHK type A A1 B B1
30/ 91 1.5 2.5 0.5 1.5
39/116 1.5 2.5 0.55 1.55
60/148 1.5 2.5 0.6 1.6
75/171 2.0 2.5 0.65 1.65
98/171 2.0 4.0 0.65 1.65
98/220 2.0 4.0 0.75 1.75
127/220 2.0 4.0 0.75 1.75
147/220 2.0 4.0 0.75 1.75
200/310 2.0 5.0 1.00 2.00
In case of repair, dimension A1 must be increased by 2.5 m to allow for the radius of the FLEXWELL district heating cable. Figures in m
21.8.2014

T-joint, downward branch
Figure 1 : Connection, working space (top view)

Dimensions indicated are valid for all FHK types
≈ 1.3 1.8 1.8 ≈ 1.3

0.9 0.9
0.25 0.25
0.9
0.9
1.8
Figure 2 : T-joint, working space

Downward branch (cross-section)
4 2 3 1
Structure
min. coverage 0.6

2 T-joint
3 Sand filling (0 - 4 mm round particles) Trench bottom, main pipe
4 Filling material (reusable excavated
material) H
0.1
0.3
Trench dimensions, downward branch (Figure 2)

FHK FHK branch pipe
Main
pipe
30/91 39/116 60/148 75/171 98/171 98/220 127/220 147/220 200/310
30/ 91 0.23
39/116 0.23 0.25
60/148 0.23 0.25 0.28
75/171 0.23 0.25 0.28 0.30
98/171 0.23 0.25 0.28 0.30 0.32
98/220 0.23 0.25 0.28 0.30 0.32 0.34
127/220 0.23 0.25 0.28 0.30 0.32. 0.34 0.36
147/220 0.23 0.25 0.28 0.30 0.32 0.34 0.36 0.36
200/310 0.19 0.21 0.24 0.26 0.28 0.30 0.32 0.32 0.36
H = dimension of height difference between trench bottom/main pipe and trench bottom/branch pipe Figures in m
21.8.2014

T-joint, upward branch
Figure 1 : T-joint, working space (top view)

Dimensions indicated are valid for all FHK types
≈ 1.3 1.8 1.8 ≈ 1.3

0.9 0.9
0.25 0.25
0.9
0.9
1.8
Figure 2 : T-joint, working space

Upward branch (cross-section)
Structure 4 2 3 1
1 FLEXWELL district heating cable min. coverage 0.6

2 T-joint
4 Filling material (reusable excavated
material) 0.6
H
Trench bottom 0.3
Main pipe
Trench dimensions, upward branch (Figure 2)

FHK FHK branch pipe
Main
pipe
30/91 39/116 60/148 75/171 98/171 98/220 127/220 147/220 200/310
30/ 91 0.23
39/116 0.25 0.25
60/148 0.28 0.28 0.28
75/171 0.30 0.30 0.30 0.30
98/171 0.32 0.32 0.32 0.32 0.33
98/220 0.34 0.34 0.34 0.34 0.35 0.35
127/220 0.36 0.36 0.36 0.34 0.38 0.38 0.36
147/220 0.36 0.36 0.36 0.36 0.38 0.37 0.36 0.36
200/310 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.36
H = dimension of height difference between trench bottom/main pipe and trench bottom/branch pipe Figures in m
21.8.2014

House entry bend
Figure 1: House entry bend 9 6

Cross-section
1 8 7 2 4 3
5
0.10
Structure

2 HD-PE shrink sleeve Tmax.
3 House entry bend, 1.5 x 1.5 m, 90°
4 Shrink-on collar
5 Labyrinth seal
6 End cap 0.10
7 Sand filling (0 - 4 mm round particles) 0.20
8 Filling material (reusable excavated material)
9 Pipe fixture
Figure 2: House entry bend 1.50

Top view
a1
1)
2 x B B
b
a22)
h
FHK type Minimum dimensions

B a1 a2 2) b h T max.
Trench lateral wall distance Length Width Distance
width wall distance to middle of of to
to middle opening opening opening lower edge
opening Foundation
30/ 91 0.50 0.30 0.15 0.49 0.20 1.00
39/116 0.55 0.32 0.16 0.53 0.25 1.00
60/148 0.60 0.34 0.16 0.57 0.30 0.98
75/171 0.65 0.36 0.17 0.62 0.35 0.98
98/171 0.65 0.38 0.18 0.66 0.35 0.97
98/220 0.75 0.41 0.20 0.72 0.40 0.96
127/220 0.75 0.42 0.20 0.74 0.40 0.95
147/220 0.75 0.43 0.21 0.77 0.40 0.93
200/310 0.95 0.53 0.26 0.95 0.50 0.92
Figures in m
1) Measured on trench bottom
2) Dimension a2 determined on the assumption that pre-formed bend components are not impeded by foundations, etc.
21.8.2014
Distance from other supply lines

The ground temperature in the immediate vicinity of district heat pipes laid in the ground is higher than normal.
This can influence the transmission performance of electrical lines laid underground. Appropriate minimum distances are
therefore required between the supply lines and the district heating pipes (also see VDE 0100 and VDE 0101).
Figure 1: Crossing lines/pipes
3
1 District heating pipe
2 Other supply line
3 Distance limit
Figure 2: Parallel lines/pipes
Table 1: Table 2:
Minimum distance from crossing pipes/lines Minimum distance from parallel lines/pipes
Type of supply line Minimum distance Type of supply line Minimum distance
1 kV, signal/measuring cable 0.3 Parallel routing
10 kV or one 30 kV cable 0.6 Length
Several 30 kV cables or 1.0 5m >5m
cable above 60 kV 1 kV, signal/measuring cable 0.3 0.3
Gas and water pipes 0.2 10 kV or one 30 kV cable 0.6 0.7
Figures in m Several 30 kV cables or 1.0 1.5
cable above 60 kV
Gas and water pipes 0.4 0.4
Figures in m
21.8.2014
PREMANT
Pre-insulated steel pipe system
PREMANT district heating pipe PRE 6.0
Table of Contents

6.105 Medium pipe
6.106 Heat insulation, casing pipe, monitoring wires
6.115 District heating pipe – UNO

6.200 Pressure drop
6.210 Heat loss, insulation thickness 1
6.230 Pipe routing
6.231 Maximum installed length, Lmax
The design
6.232 Natural fixed point, NFP
engineering
6.240 Maximum permitted coverage height, Hmax
worksheets are
6.241 Installation without pre-stressing, Lmax, insulation thickness 1
not included in
6.242 Installation without pre-stressing, Lmax, insulation thicknesses 2 and 3
this catalogue.
6.243 Thermal pre-stressing
6.244 Installation with thermal pre-stressing, DN 20 - DN 300, insulation thickness 1
Please contact
your BRUGG
6.246 Installation with thermal pre-stressing, DN 350 - DN 500, insulation thicknesses 1 and 2
Partner in this
regard.
6.250 Impeded expansion
6.251 Impeded expansion; expansion up to 90 °C, DN 20 - DN 125, insulation thickness 2,
permitted without pre-stressing
6.252 Impeded expansion; expansion up to 90 °C, DN 20 - DN 125, insulation thickness 3,
permitted without pre-stressing
6.253 Free expansion
6.260 Expansion components; L, Z and U bends
6.261 Expansion components, transverse shift
6.262 Positioning of expansion pads
6.263 Installation guidelines, sheet 1
6.300 Components
6.300 District heating pipe – UNO
6.304 Elbow pipe
6.305 Bend, with equal legs 90°
6.306 Bend, with equal legs 90° short
6.307 Bend, with equal legs 45°
6.308 Bend, with equal legs 45° short
6.310 Bend, 1.0 x 2.0 m 90°
6.312 T-piece, angled 45°; Insulation thickness 1
6.316 Parallel T-piece; Insulation thickness 1
6.317 Parallel T-piece; Insulation thickness 2
8.1.2015 BRG
Table of Contents
6.318 Parallel T-piece; heating, insulation thickness 3
6.320 Fixed point; thermally and electrically separated, insulation thickness 2
6.321 Reduction piece
6.322 Vent
6.323 Drainer
6.325 Fittings installed in the ground; description, installation and operating instructions
6.330 Ball valve
6.332 Ball valve with 2 vents
6.333 Ball valve with 1 vent
6.334 Ball valve for installation in the ground, installation diagram
6.335 Accessories: shut-off fitting, ball valve
6.340 Joint; shrink sleeves
6.342 Joint, shrink-on reduction sleeve/end sleeve
6.345 Brugg VISUCON
6.350 EWELCON electro-welding joint, system description
6.351 EWELCON electro-welding joint, technical data
6.352 EWELCON-S electro-welding joint
6.353 EWELCON-S electro-welding joint
6.354 Fitting bend
6.356 Shrink-on closure
6.357 Rigid foam beam
6.360 Ring seal
6.365 Expansion pad
6.400 Transport and storage

6.403 Storage of preformed parts
6.410 Assembly foam

6.500 Underground construction work, installation
6.501 Underground construction work, installation
6.502 Filling in the pipe trenches
6.505 House lead-in, wall seal – neoprene rubber
6.510 Installation instructions
6.515 Concrete block for fixed point, for maximum fixed point forces
6.520 Sectional drainage, sectional venting
6.525 Underground construction work for ball valve, shafts with drive-over cast cover
6.530 Tapping technology, system description
6.531 Tapping technology, dimensions and measurements
6.532 Tapping technology, weld seam preparation and structure
6.533 Tapping technology, junction branch at top with 45° PRE bend
6.534 Tapping technology, junction branch at top with 45° welded bend
6.535 Tapping technology, junction branch at bottom with 45° PRE bend
6.536 Tapping technology, junction branch at bottom with 45° welded bend
6.537 Tapping technology, junction branch at top with 90° PRE bend
8.1.2015 BRG
System description
PREMANT is the protected name for a pre-insulated steel pipe system used to transport district Max. temperature for continuous operation
heat. It is a pipe system for direct installation in the ground, without channels. The system has TBmax: 144 °C (160 °C)
proven its excellence over several decades and is now recognized as the industry standard for Max. permitted operating pressure p: 25 bar
normal cases.
Depending on the purpose of use, PREMANT district heating pipe has a medium pipe made of
steel, either welded, seamless or galvanized, or made of stainless steel. This makes PREMANT
district heating pipe suitable to transport heating water, domestic hot water, water/glycol mix-
ture, condensates and other fluids, but not for steam. (with observation of the temperature)
Heat insulation for PREMANT district heating pipe is performed by a rigid polyurethane foam
which can withstand temperatures of up to 144 °C. PE-HD casing pipe provides external protec-
tion. All three components form one fixed unit, so this pipe system is a member of the compos-
ite pipe family.
PREMANT district heating pipe is available in three categories of insulation thickness.

Depending on the dimensions, the pipe construction units can be supplied in lengths of
6 + 12 m (or 16 m). The construction units and all associated preformed parts such as bends,
T-pieces and fixed points, etc., are prefabricated in the factory. The result is a modular system
which is correspondingly easy to plan and install.
All the components are connected together on site with circumferential seams. Supplemen-
tary insulation of the the weld seam and the weld-on ends is provided by means of joints. The
supplementary insulation work is usually carried out by system suppliers or qualified specialist
companies on our behalf. During the planning phase, we offer support based on our system
experience to system users who request this.
PREMANT district heating pipe, and the preformed parts and fittings, are manufactured
according to the latest standards (EN 253, 448, 488 and 489).
All the illustrations are schematic representations that do not correspond to the original
components in every detail.
8.1.2015 BRG
System description
1. Medium pipe
Bars: steel pipes with longitudinal or helical seam welds

Quality: Ø ≤ 323.9 mm P235TR1 or P235GH as per; EN 10220/EN 10217-1
Ø > 323.9 mm P 235 GH as per; EN 10220/EN 10217-2
Standard: EN 253
Test certificate: EN 10204 - 3.1
Welding bevel: Wall thickness > 3.2 mm acc. to DIN 2559-1 Index 21 and 22
Preformed parts: T-pieces are flared, from longitudinal seam-welded steel pipes, or made of welded t-pieces acc. to EN 10253;
material is the same as for straight welded pipes.
Quality: P235TR1 or P235GH as per; EN 10220/EN 10217
Standard: EN 448
Test certificate: EN 10204 - 3.1
Bends, DN 20 - DN 200 are made of cold-bent (seamless or welded) steel pipes

or with a welding elbow acc. to EN 10253.
Quality: P235TR1 or P235GH as per; EN 10220/EN 10217
Standard: EN 448
Factory certificate: EN 10204-2.2
Acceptance test certificate: EN 10204-3.1
Bends, DN 250 - DN 1000 are made of welded bends acc. to EN 10253 with weld-on pipe ends.
Quality: P235GH or P235TR1/TR2
Standard: EN 448
Note:
To ensure the longevity of PREMANT plastic sheathing pipe systems, it is important to make sure the heating water is of
sufficient quality. To prevent magnetite formation (iron(II,III) oxide) and calcification in particular, the requirements of VDI
2035, AGFW FW510 and EN 12953-10 must be met.
Before commissioning, a newly-installed heat distribution network, without a heat exchanger if possible, should be circu-
lated and suspended solids must be removed by means of a suitable filter system. This process should also be repeated
after every expansion of the network or every repair.
8.1.2015 BRG
System description
Material: Polyurethane foam (pentane-blown), manufactured from 3 components:

polyol, isocyanate and cyclopentane
High-pressure plants are used for mixing and metering.
PUR insulation Reference temperature °C PREMANT value Test standard

Compression strength - ≥ 0.3 MPa EN 253
Percentage of closed cells - ≥ 96 %
Water absorption after 24 hours - ≤ 10 %
2.1 Supplementary insulation
Standard: EN 489
Execution: - Executed by trained installation staff
- Polyurethane foam is used to foam and seal the joints
- Sealing with shrink-on sleeve or electro-welding joint
- Connecting the monitoring wires
- Installing the expansion pads, consisting of an elastic foam material which is resistant to ageing
3. Casing pipe
Quality: PE-HD, GM 5010 T3 or equivalent

Standard: EN 253
Dimensions of PE-HD casing pipes Dimensions of PE-HD casing pipes

Outer ø Min. wall thickness Outer ø Min. wall thickness
Pipes Bends/T-pieces Pipes/Bends/T-pieces
mm mm mm mm mm
90 3.0 4.0 400 5.3
110 3.0 4.0 450 5.6
125 3.0 4.0 500 6.3
140 3.0 4.0 560 7.0
160 3.0 4.0 630 7.6
180 3.0 4.0 670 8.0
200 3.2 4.0 710 8.7
225 3.5 4.0 800 9.0
250 3.6 5.0 900 10.1
280 4.4 5.0 1000 11.2
315 4.5 6.3 1100 12.0
355 5.1 5.1 1200 12.8
4. Monitoring wires
Brandes system: 1 x CrNi, red, insulated and perforated, Ø 0.5 mm/0.2 mm2

1 x Cu, green, insulated, Ø 0.8 mm / 0.5 mm2
Nordic system: 1 x Cu blank: 1.5 mm2
1 x Cu tinned: 1.5 mm2
Task: Identification and location of moisture by means of resistance or pulse measurements
8.1.2015 BRG
District heating pipe – UNO
D
d
s
t
200
L Figures in mm
D = outer diameter of casing pipe s = wall thickness of medium pipe
d = outer diameter of medium pipe t = insulation thickness
PREMANT
Nominal Steel pipe Insulation thickness 1 Insulation thickness 2 Insulation thickness 3 Standard Volume
width d x s D D D length Inner pipe
DN mm mm kg/m mm kg/m mm kg/m m l/m
20 26.9 x 2.6 90 2.7 110 3.1 125 3.4 6 0.37
25 33.7 x 2.6 90 3.1 110 3.5 125 3.8 6 0.67
32 42.4 x 2.6 110 4.0 125 4.3 140 4.7 6 / 12 1.09
40 48.3 x 2.6 110 4.4 125 4.7 140 5.0 6 / 12 1.46
50 60.3 x 2.9 125 5.8 140 6.1 160 6.6 6 / 12 2.33
65 76.1 x 2.9 140 7.1 160 7.6 180 8.2 6 / 12 3.88
80 88.9 x 3.2 160 9.0 180 9.6 200 10.3 6 / 12 5.35
100 114.3 x 3.6 200 13.0 225 13.9 250 15.0 6 / 12 / 16 9.01
125 139.7 x 3.6 225 15.9 250 16.9 280 18.7 6 / 12 / 16 13.79
150 168.3 x 4.0 250 20.5 280 22.3 315 24.0 6 / 12 / 16 20.18
200 219.1 x 4.5 315 30.5 355 32.5 400 35.8 6 / 12 / 16 34.67
250 273.0 x 5.0 400 43.5 450 47.0 500 51.3 6 / 12 / 16 54.33
300 323.9 x 5.6 450 56.2 500 60.5 560 66.1 6 / 12 / 16 76.80
350 355.6 x 5.6 500 63.7 560 69.3 630 76.3 6 / 12 / 16 93.16
400 406.4 x 6.3 560 81.0 630 88.0 670 92.4 6 / 12 / 16 121.80
450 457.2 x 6.3 630 93.5 670 97.9 710 103.1 6 / 12 / 16 155.25
500 508.0 x 6.3 710 (670) 108.3 800 118.6 900 133.1 6 / 12 / 16 192.75
600 610.0 x 7.1 800 140.0 900 154.5 1000 170.7 6 / 12 / 16 278.80
700 711.0 x 8.0 900 180.3 1000 196.5 1100 213.5 6 / 12 / 16 379.37
800 813.0 x 8.8 1000 223.8 1100 240.8 1200 259.4 6 / 12 / 16 496.98
900 914.0 x 10.0 1100 279.6 1200 298.2 - - 6 / 12 627.72
1000 1016.0 x 11.0 1200 337.1 - - - - 6 776.00
We will deliver different dimensions on request.
8.1.2015 BRG
Pressure drop chart

Surface roughness e = 0.045 mm ṁ = Flow rate in kg/h
Q · 860
(1 mmWS = 9.81 Pa) ṁ ≈ Q = Power requirement in kW
∆T
∆T = Temperature difference, VL(flow)/RL(return) in °C
344.4 mm 312.7 mm 263.0 mm 210.1 mm

(DN 350) (DN 300) (DN 250) (DN 200)
1000000
160.3 mm
(DN 150)
500000 132.5 mm
400000 (DN 125)
300000
107.1 mm
(DN 100)
200000
82.5 mm
(DN 80)
100000
Wa
70.3 mm
ter
(DN 65)
vel
o
city
50000 54.5 mm
40000 (DN 50)
30000
43.1 mm
(DN 40)
20000
37.2 mm
(DN 32)
3.6
3.2
m/
s
2.8
m/
10000
29.1 mm
s
m/
2.4
(DN 25)
m/
2.0
s
1.8
m/
1.6
s
m/
5000
s
m/
1.4
s
m/
21.6 mm
1.2
4000
s
(DN 20)
m/
1.0
s
m/
3000
0.8
s
m/
s
0.6
2000
m/
0.5
s
m/
0.4
s
m/
s
1000
500
400
50 100 200 300 500 1000 2000 3000 5000 Pa/m
5 10 20 30 50 100 200 300 500 mm WS/m
Pressure loss ∆p
8.1.2015 BRG
Heat loss
Insulation thickness 1
Heat losses q [W/m] for one pipe

PREMANT U-value Average temperature between VL/RL TB [°C]
W/mK 50 °C 60 °C 70 °C 80 °C 90 °C 100 °C 110 °C 120 °C 130 °C
26.9 - 90 0.1292 5.2 6.5 7.8 9.0 10.3 11.6 12.9 14.2 15.5
33.7 - 90 0.1572 6.3 7.9 9.4 11.0 12.6 14.2 15.7 17.3 18.9
42.4 - 110 0.1607 6.4 8.0 9.6 11.2 12.9 14.5 16.1 17.7 19.3
48.3 - 110 0.1843 7.4 9.2 11.1 12.9 14.7 16.6 18.4 20.3 22.1
60.3 - 125 0.2054 8.2 10.3 12.3 14.4 16.4 18.5 20.5 22.6 24.6
76.1 - 140 0.2410 9.6 12.0 14.5 16.9 19.3 21.7 24.1 26.5 28.9
88.9 - 160 0.2484 9.9 12.4 14.9 17.4 19.9 22.4 24.8 27.3 29.8
114.3 - 200 0.2599 10.4 13.0 15.6 18.2 20.8 23.4 26.0 28.6 31.2
139.7 - 225 0.3002 12.0 15.0 18.0 21.0 24.0 27.0 30.0 33.0 36.0
168.3 - 250 0.3557 14.2 17.8 21.3 24.9 28.5 32.0 35.6 39.1 42.7
219.1 - 315 0.3887 15.5 19.4 23.3 27.2 31.1 35.0 38.9 42.8 46.6
273.0 - 400 0.3779 15.1 18.9 22.7 26.5 30.2 34.0 37.8 41.6 45.3
323.9 - 450 0.4342 17.4 21.7 26.0 30.4 34.7 39.1 43.4 47.8 52.1
355.6 - 500 0.4239 17.0 21.2 25.4 29.7 33.9 38.2 42.4 46.6 50.9
406.4 - 560 0.4514 18.1 22.6 27.1 31.6 36.1 40.6 45.1 49.6 54.2
457.2 - 630 0.4548 18.2 22.7 27.3 31.8 36.4 40.9 45.5 50.0 54.6
508.0 - 710 0.4413 17.7 22.1 26.5 30.9 35.3 39.7 44.1 48.5 53.0
610.0 - 800 0.5380 21.5 26.9 32.3 37.7 43.0 48.4 53.8 59.2 64.6
711.0 - 900 0.6097 24.4 30.5 36.6 42.7 48.8 54.9 61.0 67.1 73.2
813.0 - 1000 0.6840 27.4 34.2 41.0 47.9 54.7 61.6 68.4 75.2 82.1
914.0 - 1100 0.7550 30.2 37.7 45.3 52.8 60.4 67.9 75.5 83.0 90.6
1016.0 - 1200 0.8315 33.3 41.6 49.9 58.2 66.5 74.8 83.1 91.5 99.8
Type of installation: 2-pipe, laid in the ground

Pipe distance: a = 0.20 m
a
Ground temperature: TE = 10 °C
H
Coverage height: H = 0.8 m
Conductivity of PE jacket: lPE = 0.4 W/mK
E
TE
Heat loss during operation:

q = U · (TB - TE) [W/m]
U = Heat transfer coefficient [W/mK]
TB = Average temperature between VL/RL [°C]
TE = Average ground temperature [°C]
8.1.2015 BRG
Heat loss

W/mK 50 °C 60 °C 70 °C 80 °C 90 °C 100 °C 110 °C 120 °C 130 °C
26.9 - 110 0.1110 4.4 5.5 6.7 7.8 8.9 10.0 11.1 12.2 13.3
33.7 - 110 0.1311 5.2 6.6 7.9 9.2 10.5 11.8 13.1 14.4 15.7
42.4 - 125 0.1424 5.7 7.1 8.5 10.0 11.4 12.8 14.2 15.7 17.1
48.3 - 125 0.1606 6.4 8.0 9.6 11.2 12.8 14.5 16.1 17.7 19.3
60.3 - 140 0.1794 7.2 9.0 10.8 12.6 14.4 16.1 17.9 19.7 21.5
76.1 - 160 0.2009 8.0 10.0 12.1 14.1 16.1 18.1 20.1 22.1 24.1
88.9 - 180 0.2105 8.4 10.5 12.6 14.7 16.8 18.9 21.0 23.2 25.3
114.3 - 225 0.2193 8.8 11.0 13.2 15.4 17.5 19.7 21.9 24.1 26.3
139.7 - 250 0.2530 10.1 12.7 15.2 17.7 20.2 22.8 25.3 27.8 30.4
168.3 - 280 0.2870 11.5 14.3 17.2 20.1 23.0 25.8 28.7 31.6 34.4
219.1 - 355 0.3047 12.2 15.2 18.3 21.3 24.4 27.4 30.5 33.5 36.6
273.0 - 450 0.2985 11.9 14.9 17.9 20.9 23.9 26.9 29.9 32.8 35.8
323.9 - 500 0.3412 13.6 17.1 20.5 23.9 27.3 30.7 34.1 37.5 40.9
355.6 - 560 0.3297 13.2 16.5 19.8 23.1 26.4 29.7 33.0 36.3 39.6
406.4 - 630 0.3425 13.7 17.1 20.5 24.0 27.4 30.8 34.2 37.7 41.1
457.2 - 710 0.3899 15.6 19.5 23.4 27.3 31.2 35.1 39.0 42.9 46.8
508.0 - 800 0.3357 13.4 16.8 20.1 23.5 26.9 30.2 33.6 36.9 40.3
610.0 - 900 0.3879 15.5 19.4 23.3 27.2 31.0 34.9 38.8 42.7 46.5
711.0 - 1000 0.4381 17.5 21.9 26.3 30.7 35.0 39.4 43.8 48.2 52.6
813.0 - 1100 0.4899 19.6 24.5 29.4 34.3 39.2 44.1 49.0 53.9 58.8
914.0 - 1200 0.5405 21.6 27.0 32.4 37.8 43.2 48.6 54.0 59.4 64.9


a
H
Conductivity of PUR foam: lPUR = 0.0260 W/mK E
TE

q = U · (TB - TE) [W/m]
8.1.2015 BRG
Heat loss

W/mK 50 °C 60 °C 70 °C 80 °C 90 °C 100 °C 110 °C 120 °C 130 °C
26.9 - 125 0.1019 4.1 5.1 6.1 7.1 8.2 9.2 10.2 11.2 12.2
33.7 - 125 0.1186 4.7 5.9 7.1 8.3 9.5 10.7 11.9 13.0 14.2
42.4 - 140 0.1294 5.2 6.5 7.8 9.1 10.3 11.6 12.9 14.2 15.5
48.3 - 140 0.1442 5.8 7.2 8.7 10.1 11.5 13.0 14.4 15.9 17.3
60.3 - 160 0.1562 6.2 7.8 9.4 10.9 12.5 14.1 15.6 17.2 18.7
76.1 - 180 0.1754 7.0 8.8 10.5 12.3 14.0 15.8 17.5 19.3 21.0
88.9 - 200 0.1857 7.4 9.3 11.1 13.0 14.9 16.7 18.6 20.4 22.3
114.3 - 250 0.1930 7.7 9.7 11.6 13.5 15.4 17.4 19.3 21.2 23.2
139.7 - 280 0.2162 8.6 10.8 13.0 15.1 17.3 19.5 21.6 23.8 25.9
168.3 - 315 0.2388 9.6 11.9 14.3 16.7 19.1 21.5 23.9 26.3 28.7
219.1 - 400 0.2505 10.0 12.5 15.0 17.5 20.0 22.5 25.0 27.6 30.1
273.0 - 500 0.2514 10.1 12.6 15.1 17.6 20.1 22.6 25.1 27.7 30.2
329.0 - 560 0.2774 11.1 13.9 16.6 19.4 22.2 25.0 27.7 30.5 33.3
355.3 - 630 0.2676 10.7 13.4 16.1 18.7 21.4 24.1 26.8 29.4 32.1
406.4 - 670 0.3044 12.2 15.2 18.3 21.3 24.3 27.4 30.4 33.5 36.5
457.2 - 710 0.3435 13.7 17.2 20.6 24.0 27.5 30.9 34.4 37.8 41.2
508.0 - 900 0.2704 10.8 13.5 16.2 18.9 21.6 24.3 27.0 29.7 32.4
610.0 - 1000 0.3105 12.4 15.5 18.6 21.7 24.8 27.9 31.1 34.2 37.3
711.0 - 1100 0.3494 14.0 17.5 21.0 24.5 28.0 31.4 34.9 38.4 41.9
813.0 - 1200 0.3895 15.6 19.5 23.4 27.3 31.2 35.1 39.0 42.8 46.7


a
H
Conductivity of PUR foam: lPUR = 0.0260 W/mK E
TE

q = U · (TB - TE) [W/m]
8.1.2015 BRG
Pipe routing
Pipe routing for PREMANT district heating pipe is not subject to any special requirements. In relation to the pipe, it
should mainly be selected on the basis of expansion capability. In normal pipe routing, changes of direction using
L-bends are the first choice for this purpose. Then come Z-bends and U-bends, which accommodate the expansion that
occurs at precisely defined points.
The angular dimensions of the 'expansion bend' should not exceed 90°, otherwise substantially longer expansion limbs
are needed; whenever possible, right-angled pipe routing should be the aim.
A B A B
Figure 1 Straight pipe routing between two build- Figure 4 Straight pipe routing between two build-
ings; the expansion of the district heating pipes ings, with expansion accommodated by U-bends
has to be accommodated in building A or B. within the pipeline.
A A
B B
Figure 2 Angled pipe routing, expansion accom- Figure 5 Angled pipe routing between two build-
modated by natural change of direction in the ings, with expansion accommodated by Z-bends
L-bend and building A. within the pipeline.
A B A B
Figure 3 Straight pipe routing between two build- Figure 6 Straight pipe routing, with expansion ac-
ings, with expansion accommodated by Z-bends commodated by U-bends within the pipeline.
within the pipeline.
3m
Building
If no expansion can be accommodated in buildings,
∆I FP fixed points must be positioned in the building wall
or approx. 3 m in front of it.
8.1.2015 BRG
Installation guidelines
Sheet 1
Positioning of branches
When positioning branches, e.g. house connection pipes on the main pipe, attention must be paid to the special features
of the plastic casing pipe system. Even short connecting pipes with small dimensions are 'clamped in' by the surround-
ing ground, so their movement is impeded. Again, the natural fixed point is formed in the length of the connection pipe,
so restoring forces act on the main pipe. The different movements and force ratios of the main pipes and the connection
pipe must therefore be considered in every case.
Direct connection Building

Connection pipe ≤ 6 m
Main pipe
DP
max. 6 m
With fixed point Building

Connection pipe > 6 m
max. 3 m
FP
Main pipe
DP
>6m
With Z-bend next to Building

DP
main pipe
a
Main pipe
>6m
FP = fixed point
DP = Expansion pad
8.1.2015 BRG
Sheet 2
L-bend over main pipe

(parallel T-piece)
Main pipe
Building
DP
b
a
DP
Main pipe
DP = expansion pad
The limb length a depends on the length l. Length b is based on the possible movement of the main pipe. The total length
a + b must be surrounded with expansion pads. Expansion of the main pipe is also possible on connections in the adhe-
sion area due to subsequent repair work, so expansion pads should also be installed as a precaution. The thickness of the
expansion pads which are necessary in such cases can be reduced if the connecting pipes are still exposed and can be
aligned under low stress when the main pipe is pre-stressed.
8.1.2015 BRG
Sheet 3
Pipe bends, minimum bending radius Bending radius for elastic-plastic strain on site
DN da Rmin
If district heating pipes have to be laid along roads, it may be necessary to use pipe bends in mm m
order to keep close to curves. In this case, the bends can be assembled from several straight 20 26.9 19
lengths of pipe. Up to an angle of 3°/5, these bends can be produced with mitre cuts but for 25 33.7 23
larger angles, only preformed parts can be used. 32 42.4 29
40 48.3 33
This pipe curvature causes bending stresses in the pipe which make it mandatory to set a 50 60.3 41
minimum bending radius in relation to the pipe dimension. The minimum bending radius and the 65 76.1 51
resultant maximum deflection are calculated as follows: 80 88.9 60
100 114.3 77
125 139.7 95
150 168.3 115
200 219.1 150
250 273.0 170
h = R · [1-   1-(s/(2 · R))² ] [m]
h
Rzul Rpermitted = minimum bending radius [m]

S = chord length [m]
h = maximum deflection [m]
S
da = outer diameter of steel pipe [m]
Installation with small bends (kinks)
Sliding zone: Bends up to a maximum of 3° are allowed in mitre cuts.

Adhesion area: Bends up to a maximum of 5° are allowed in mitre cuts.
The bends must be installed without expansion pads.
Reductions in the adhesion area
In accordance with the various stress cross-sections, there is inevitably a sudden rise in the axial compressive force
progression in the reduction.
The greater compressive force in the area of the larger dimension may result in an overload in the smaller stress cross-
section, as a reactive force. This can be excluded either by avoiding reductions in the adhesion area, or by positioning a
fixed point on the side with the larger dimension.
Fixed point Reductions in the adhesion area
d1 d2
8.1.2015 BRG
Sheet 4
Changes of direction on longer pipe lengths
For ≠ 40° - 50°
∆L
∆L
∆L
a < 40°
∆L 40°
a > 50° 50°
a) For angles a < 40°, an additional 90° bend must be installed outside (see picture)
b) For angles a > 50°, the additional 90° bend must be positioned inside (see picture)
For 40° - 50°
FP
∆L ∆L
45°
∆L
∆L
The second, newly formed angle is always larger in both cases, leading to weaker compensation.
8.1.2015 BRG
District heating pipe – UNO

Heating
D
d
s
t
200
D = outer diameter of casing pipe s = wall thickness of medium pipe

d = outer diameter of medium pipe t = insulation thickness
Figures in mm
PREMANT
Nominal Steel pipe Insulation thickness 1 Insulation thickness 2 Insulation thickness 3 Delivery Volume
length Inner pipe
width d x s D D D
DN mm mm kg/m mm kg/m mm kg/m m l/m
20 26.9 x 2.6 90 2.7 110 3.1 125 3.4 6 0.37
25 33.7 x 2.6 90 3.1 110 3.5 125 3.8 6 0.67
32 42.4 x 2.6 110 4.0 125 4.3 140 4.7 6 / 12 1.09
40 48.3 x 2.6 110 4.4 125 4.7 140 5.0 6 / 12 1.46
50 60.3 x 2.9 125 5.8 140 6.1 160 6.6 6 / 12 2.33
65 76.1 x 2.9 140 7.1 160 7.6 180 8.2 6 / 12 3.88
80 88.9 x 3.2 160 9.0 180 9.6 200 10.3 6 / 12 5.35
100 114.3 x 3.6 200 13.0 225 13.9 250 15.0 6 / 12 / 16 9.01
125 139.7 x 3.6 225 15.9 250 16.9 280 18.7 6 / 12 / 16 13.79
150 168.3 x 4.0 250 20.5 280 22.3 315 24.0 6 / 12 / 16 20.18
200 219.1 x 4.5 315 30.5 355 32.5 400 35.8 6 / 12 / 16 34.67
250 273.0 x 5.0 400 43.5 450 47.0 500 51.3 6 / 12 / 16 54.33
300 323.9 x 5.6 450 56.2 500 60.5 560 66.1 6 / 12 / 16 76.80
350 355.6 x 5.6 500 63.7 560 69.3 630 76.3 6 / 12 / 16 93.16
400 406.4 x 6.3 560 81.0 630 88.0 670 92.4 6 / 12 / 16 121.80
450 457.2 x 6.3 630 93.5 670 97.9 710 103.1 6 / 12 / 16 155.25
500 508.0 x 6.3 710 (670) 108.3 800 118.6 900 133.1 6 / 12 / 16 192.75
600 610.0 x 7.1 800 140.0 900 154.5 1000 170.7 6 / 12 / 16 278.80
700 711.0 x 8.0 900 180.3 1000 196.5 1100 213.5 6 / 12 / 16 379.37
800 813.0 x 8.8 1000 223.8 1100 240.8 1200 259.4 6 / 12 / 16 496.98
900 914.0 x 10.0 1100 279.6 1200 298.2 - - 6 / 12 627.72
1000 1016.0 x 11.0 1200 337.1 - - - - 6 776.00
8.1.2015 BRG
Elbow pipe
Elbow pipes are plastic casing pipes made to customer specifications and pre-insulated at the factory. Elbow pipes
are produced as curved plastic casing pipes with a large radius and serve to optimise pipe routing when the direction
changes.
Elbow pipes behave in the same way as straight pipes; in other words, heat expansion does not cause any bending mo-
ment. The deflection angle "a" of the pipe routing or the bend radius "R" must be known in order to produce elbow pipes.
All elbow pipes have straight ends between 1.2 and 2.0 m due to machine-based production.
The PUR foam is subject to lateral pressure as a consequence of heat expansion and the curve of the pipe. The magnitu-
de of this pressure must not exceed the permissible force of 0.15 MPa. The outcome of this is a maximum permissible
deflection angle "a" or a minimum bend radius "R".
The permissible values are contained in the following table.
Deflection angle for elbow pipes

Nominal Deflection angle perm. radius perm. radius
width bar 12 m
DN a min. [°] a max. R min. [m]
40 10 42 16.4
50 8 38 18.1
65 5 36 19.1
80 4 34 20.2
100 4 33 20.8
125 3 29 23.7
150 3 24 28.6
200 3 20 34.4
250* 3 18 38.2
300** 3 11 62.5
350** 3 10 69.0
* DS1 and DS2 only
** DS1 only
8.1.2015 BRG
Bend, with equal legs 90°

D = outer diameter of casing pipe
d = outer diameter of medium pipe
200
s = wall thickness of medium pipe

t = insulation thickness
R
D
d
90°
L Figures in mm
PREMANT
Nominal Steel Leg length Design Insulation thickness 1 Insulation thickness 2 Insulation thickness 3
width pipe
DN d L DE* D D D
mm mm mm kg mm kg mm kg
20 26.9 1000 5D 90 5.3 110 6.1 125 6.7
25 33.7 1000 5D 90 6.1 110 6.9 125 7.5
32 42.4 1000 5D 110 8.4 125 9.0 140 9.7
40 48.3 1000 5D 110 9.2 125 9.8 140 10.4
50 60.3 1000 5D 125 12.1 140 12.7 160 13.7
65 76.1 1000 5D 140 14.8 160 15.7 180 16.8
80 88.9 1000 5D 160 18.9 180 19.9 200 21.0
100 114.3 1000 5D 200 25.2 225 26.7 250 29.3
125 139.7 1000 5D 225 30.1 250 32.7 280 35.0
150 168.3 1000 5D 250 39.4 280 41.6 315 46.0
200 219.1 1000 5D 315 57.4 355 61.1 400 65.5
250 273.0 1000 3D 400 78.7 450 85.2 500 92.6
300 323.9 1000 3D 450 100.0 500 108.0 560 118.0
350 355.6 1000 3D 500 111.0 560 121.0 630 133.0
400 406.4 1000 3D 560 139.0 630 151.0 670 179.0
450 457.2 1100 3D 630 177.0 670 186.0 710 217.0
500 508.0 1200 3D 710 225.0 800 249.0 900 305.0
600 610.0 1300 3D 800 314.0 900 342.0 1000 410.0
700 711.0 1500 3D 900 463.0 1000 500.0 1100 541.0
800 813.0 1700 3D 1000 647.0 1100 694.0 1200 748.0
* DE: The design of the radius is acc. EN 10253-2/3.3.
DE ≈ 2R
d

8.1.2015 BRG
Bend, with equal legs 90°, short

200
s = wall thickness of medium pipe

R
D
d
90°
L Figures in mm
PREMANT
width pipe
DN d L DE* D D D
20 26.9 600 5D 90 2.9 110 3.3 125 3.6
25 33.7 600 5D 90 3.4 110 3.8 125 4.1
32 42.4 600 5D 110 4.7 125 5.0 140 5.3
40 48.3 600 5D 110 5.1 125 5.4 140 5.7
50 60.3 600 5D 125 6.8 140 7.1 160 7.5
65 76.1 650 5D 140 9.1 160 9.6 180 10.2
80 88.9 650 5D 160 11.6 180 12.1 200 12.7
100 114.3 650 3D 200 15.5 225 16.4 250 17.8
125 139.7 650 3D 225 18.5 250 19.9 280 21.1
150 168.3 700 3D 250 26.3 280 27.6 315 30.3
200 219.1 750 3D 315 41.2 355 43.6 400 46.5
250 273.0 850 3D 400 65.0 450 70.2 500 76.1
300 323.9 900 3D 450 88.6 500 94.9 560 103.0
DE ≈ 2R
d

8.1.2015 BRG
Bend, with equal legs 45°

20
0 s = wall thickness of medium pipe
R t = insulation thickness
s
t
45°
D
d
L Figures in mm
PREMANT
witdh pipe
DN d L DE* D D D
20 26.9 1000 5D 90 5.5 110 6.3 125 6.9
25 33.7 1000 5D 90 6.3 110 7.1 125 7.7
32 42.4 1000 5D 110 8.7 125 9.3 140 10.0
40 48.3 1000 5D 110 9.5 125 10.1 140 10.8
50 60.3 1000 5D 125 12.5 140 13.2 160 14.1
65 76.1 1000 5D 140 15.4 160 16.4 180 17.5
80 88.9 1000 5D 160 19.8 180 20.8 200 22.0
100 114.3 1000 3D 200 26.0 225 27.5 250 30.3
125 139.7 1000 3D 225 31.3 250 34.1 280 36.4
150 168.3 1000 3D 250 41.3 280 43.6 315 48.3
200 219.1 1000 3D 315 61.3 355 65.2 400 70.0
250 273.0 1000 3D 400 85.4 450 92.6 500 100.8
300 323.9 1000 3D 450 111.0 500 119.0 560 130.0
350 355.6 1000 3D 500 125.0 560 136.2 630 150.2
400 406.4 1000 3D 560 160.0 630 173.2 670 182.2
450 457.2 1000 3D 630 184.0 670 192.9 710 202.2
500 508.0 1000 3D 710 212.3 800 235.4 900 260.0
600 610.0 1000 3D 800 276.8 900 301.3 1000 328.2
700 711.0 1000 3D 900 351.1 1000 377.9 1100 407.5
800 813.0 1000 3D 1000 430.2 1100 459.8 1200 493.3
DE ≈ 2R
d

8.1.2015 BRG
Bend, with equal legs 45°, short

20
R t = insulation thickness
s
t
45°
D
d
L Figures in mm
PREMANT
width pipe
DN d L DE* D D D
20 26.9 500 5D 90 2.5 110 2.8 125 3.0
25 33.7 500 5D 90 2.9 110 3.2 125 3.5
32 42.4 500 5D 110 4.0 125 4.3 140 4.5
40 48.3 500 5D 110 4.4 125 4.7 140 4.9
50 60.3 500 5D 125 5.9 140 6.1 160 6.5
65 76.1 500 5D 140 7.3 160 7.6 180 8.0
80 88.9 500 5D 160 9.3 180 9.7 200 10.2
100 114.3 500 *2 3D 200 12.2 225 12.8 250 15.5
125 139.7 500 *1 3D 225 14.8 250 17.6 280 18.6
150 168.3 550 3D 250 21.7 280 22.7 315 24.7
200 219.1 550 3D 315 32.0 355 33.7 400 35.8
250 273.0 600 3D 400 49.0 450 52.5 500 56.6
300 323.9 600 3D 450 63.7 500 67.7 560 73.2
350 355.6 650 3D 500 78.2 560 84.4 630 92.2
400 406.4 700 3D 560 108.0 630 116.7 670 122.3
450 457.2 700 3D 630 124.3 670 129.9 710 135.7
500 508.0 750 3D 710 154.5 800 170.3 900 187.0
600 610.0 800 3D 800 216.7 900 234.9 1000 254.9
700 711.0 850 3D 900 294.0 1000 315.7 1100 339.6
*1
Insulation thickness 2 and 3 = 550 mm
*2
Insulation thickness 3 = 550 mm
DE ≈ 2R
d

8.1.2015 BRG
Bend, 1.0 x 2.0 m, 90°

L1
D
d
L2 Figures in mm
PREMANT
width pipe
DN d L1 L2 DE* D D D
mm mm mm mm kg mm kg mm kg
20 26.9 1000 2000 5D 90 7.5 110 8.6 125 9.5
25 33.7 1000 2000 5D 90 8.7 110 9.8 125 10.7
32 42.4 1000 2000 5D 110 12.9 125 13.8 140 14.7
40 48.3 1000 2000 5D 110 14.1 125 15.0 140 16.0
50 60.3 1000 2000 5D 125 17.6 140 18.5 160 19.9
65 76.1 1000 2000 5D 140 21.8 160 23.2 180 24.7
80 88.9 1000 2000 5D 160 25.8 180 27.3 200 29.2
100 114.3 1000 2000 5D 200 37.3 225 40.0 250 43.3
125 139.7 1000 2000 5D 225 45.5 250 48.7 280 53.1
150 168.3 1000 2000 5D 250 59.2 280 63.3 315 69.2
200 219.1 1000 2000 5D 315 87.9 355 95.4 400 104.6
250 273.0 1000 2000 3D 400 126.9 450 138.3 500 151.2
300 323.9 1000 2000 3D 450 164.8 500 177.8 560 195.3
350 355.6 1000 2000 3D 500 186.9 560 204.4 630 226.6
400 406.4 1000 2000 3D 560 238.0 630 260.2 670 274.7
450 457.2 1100 2000 3D 630 275.8 670 290.2 710 305.1
500 508.0 1200 2000 3D 710 319.8 800 356.7 900 395.9
DE ≈ 2R
d

8.1.2015 BRG

45°
D2
200 mm
H = 70 mm
D1
d
L L
L1 L2
Main pipe Branch pipe

DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800
D2 90 90 110 110 125 140 160 200 225 250 315 400 450 500 560 630 710 800 900 1000
DN D1
20 90 L2 610
L1 1000
25 90 L2 610 610
L1 1000 1000
L = 1 L1
32 110 L2 620 620 630 2
L1 1000 1000 1000
40 110 L2 620 620 630 630
L1 1000 1000 1000 1000
50 125 L2 628 628 638 638 645
L1 1000 1000 1000 1000 1000
65 140 L2 635 635 645 645 653 660
L1 1000 1000 1000 1000 1000 1000
80 160 L2 645 645 655 655 663 670 680
L1 1000 1000 1000 1000 1000 1000
1000
100 200 L2 665 765 675 675 683 690 700 720
L1 1000 1000 1000 1000 1000 1000 1000 1000
125 225 L2 678 778 688 688 695 703 713 733 745
L1 1000 1000 1000 1000 1000 1000 1000 1000 1200
150 250 L2 690 790 700 700 708 715 725 745 758 820
L1 1000 1000 1000 1000 1000 1000 1000 1000 1200 1200
200 315 L2 723 723 733 733 740 748 758 778 790 853 935
L1 1000 1000 1000 1000 1000 1000 1000 1000 1200 1200 1200
250 400 L2 765 765 775 775 783 790 800 820 833 895 978 1070
L1 1000 1000 1000 1000 1000 1000 1000 1000 1200 1200 1200 1400
300 450 L2 890 800 800 808 815 825 845 858 920 1003 1095 1120
L1 1000 1000 1000 1000 1000 1000 1000 1200 1200 1200 1400 1500
350 500 L2 825 833 840 850 870 883 945 1028 1120 1145 1220
L1 1000 1000 1000 1000 1000 1200 1200 1200 1400 1500 1600
400 560 L2 863 870 880 900 913 975 1058 1150 1175 1250 1330
L1 1000 1000 1000 1000 1200 1200 1200 1400 1500 1600 1600
450 630 L2 915 935 948 1010 1093 1185 1210 1285 1365 1400
L1 1000 1000 1200 1200 1200 1400 1500 1600 1600 1800
500 710 L2 975 988 1050 1133 1225 1250 1325 1405 1440 1530
L1 1000 1200 1200 1200 1400 1500 1600 1600 1800 1800
600 800 L2 1033 1095 1178 1270 1295 1370 1450 1485 1575 1670
L1 statically unfavourable 1200 1200 1500 1500 1600 1800 1800 1800 1800 1900
700 900 L2 1145 1228 1320 1345 1420 1500 1535 1625 1720 1820
L1 1200 1500 1500 1800 1800 1800 1800 1800 1900 2000
800 1000 L2 1278 1370 1395 1470 1550 1585 1675 1770 1870 1970
L1 1500 1500 1800 1800 1800 1800 1800 1900 2000 2100
Larger dimensions can be supplied on request. Figures in mm
8.1.2015 BRG

45°
D2
200 mm
H = 70 mm
D1
d
L L
L1 L2

DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800
D2 110 110 125 125 140 160 180 225 250 280 355 450 500 560 630 670 800 900 1000 1100
DN D1
20 110 L2 630
L1 1000
25 110 L2 630 630
L1 1000 1000
L = 1 L1
32 125 L2 638 638 645 2
L1 1000 1000 1000
40 125 L2 638 638 645 645
L1 1000 1000 1000 1000
50 140 L2 645 645 653 653 660
L1 1000 1000 1000 1000 1000
65 160 L2 655 655 663 663 670 680
L1 1000 1000 1000 1000 1000 1000
80 180 L2 665 665 673 673 680 690 700
L1 1000 1000 1000 1000 1000 1000
1000
100 225 L2 688 688 695 695 703 713 723 745
L1 1000 1000 1000 1000 1000 1000 1000 1100
125 250 L2 700 700 708 708 715 725 735 758 770
L1 1000 1000 1000 1000 1000 1000 1000 1100 1200
150 280 L2 715 715 723 723 730 740 750 773 785 850
L1 1000 1000 1000 1000 1000 1000 1000 1100 1200 1200
200 355 L2 753 753 760 760 768 778 788 810 823 888 975
L1 1000 1000 1000 1000 1000 1000 1000 1100 1200 1200 1200
250 450 L2 800 800 808 808 815 825 835 858 870 935 1023 1120
L1 1000 1000 1000 1000 1000 1000 1000 1100 1200 1200 1200 1400
300 500 L2 825 833 833 840 850 860 883 895 960 1048 1145 1170
L1 1000 1000 1000 1000 1000 1000 1100 1200 1200 1200 1400 1500
350 560 L2 863 870 880 890 913 925 990 1078 1175 1200 1280
L1 1000 1000 1000 1000 1100 1200 1200 1200 1400 1500 1600
400 630 L2 905 915 925 948 960 1025 1113 1210 1235 1315 1400
L1 1000 1000 1000 1100 1200 1200 1200 1400 1500 1600 1600
450 670 L2 945 968 980 1045 1133 1230 1255 1335 1420 1440
L1 1000 1100 1200 1200 1200 1400 1500 1600 1600 1800
500 800 L2 1033 1045 1110 1198 1295 1320 1400 1485 1505 1620
L1 1100 1200 1200 1200 1400 1500 1600 1600 1800 1800
600 900 L2 1095 1160 1248 1345 1370 1450 1535 1555 1670 1770
700 1000 L2 1210 1298 1395 1420 1500 1585 1605 1720 1820 1920
L1 1200 1500 1500 1800 1800 1800 1800 1800 1900 2000
800 1100 L2 1348 1445 1470 1550 1635 1655 1770 1870 1970 2070
L1 1500 1500 1800 1800 1800 1800 1800 1900 2000 2100
8.1.2015 BRG

45°
D2
200 mm
H = 70 mm
D1
d
L L
L1 L2

DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800
D2 125 125 140 140 160 180 200 250 280 315 400 500 560 630 670 710 900 1000 1100 1200
DN D1
20 125 L2 645
L1 1000
25 125 L2 645 645
L1 1000 1000
L = 1 L1
32 140 L2 653 653 660 2
L1 1000 1000 1000
40 140 L2 653 653 660 660
L1 1000 1000 1000 1000
50 160 L2 663 663 670 670 680
L1 1000 1000 1000 1000 1000
65 180 L2 673 673 680 680 690 700
L1 1000 1000 1000 1000 1000 1000
80 200 L2 683 683 690 690 700 710 720
L1 1000 1000 1000 1000 1000 1000
1000
100 250 L2 708 708 715 715 725 735 745 770
L1 1000 1000 1000 1000 1000 1000 1000 1100
125 280 L2 723 723 730 730 740 750 760 785 800
L1 1000 1000 1000 1000 1000 1000 1000 1100 1200
150 315 L2 740 740 748 748 758 768 778 803 818 885
L1 1000 1000 1000 1000 1000 1000 1000 1100 1200 1200
200 400 L2 783 783 790 790 800 810 820 845 860 928 1020
L1 1000 1000 1000 1000 1000 1000 1000 1100 1200 1200 1200
250 500 L2 833 833 840 840 850 860 870 895 910 978 1070 1170
L1 1000 1000 1000 1000 1000 1000 1000 1100 1200 1200 1200 1400
300 560 L2 863 870 870 880 890 900 925 940 1008 1100 1200 1230
L1 1000 1000 1000 1000 1000 1000 1100 1200 1200 1200 1400 1500
350 630 L2 905 906 925 935 960 975 1043 1135 1235 1265 1350
L1 1000 1000 1000 1000 1100 1200 1200 1200 1400 1500 1600
400 670 L2 935 945 955 980 995 1063 1155 1255 1285 1370 1440
L1 1000 1000 1000 1100 1200 1200 1200 1400 1500 1600 1600
450 710 L2 975 1000 1015 1083 1175 1275 1305 1390 1460 1480
L1 1000 1100 1200 1200 1200 1400 1500 1600 1600 1800
500 900 L2 1095 1110 1178 1270 1370 1400 1485 1555 1575 1720
L1 1100 1200 1200 1200 1400 1500 1600 1600 1800 1800
600 1000 L2 1160 1228 1320 1420 1450 1535 1605 1625 1770 1870
700 1100 L2 1278 1370 1470 1500 1585 1655 1675 1820 1920 2020
L1 1200 1500 1500 1800 1800 1800 1800 1800 1900 2000
800 1200 L2 1420 1520 1550 1635 1705 1725 1870 1970 2070 2170
L1 1500 1500 1800 1800 1800 1800 1800 1900 2000 2100
8.1.2015 BRG
Parallel T-piece
Insulation thickness 1 L2
200 mm* *DN 20 – DN 150: 150 mm
D2
d2
H
D1
d1
L L
L1

DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800
D2 90 90 110 110 125 140 160 200 225 250 315 400 450 500 560 630 710 800 900 1000
L2 450 460 480 480 500 510 510 510 530 570 700 750 850 1000 1000 1100 1200 1300 1500 1700
DN D1
20 90 H 120
L1 1000
25 90 H 120 120
L1 1000 1000
L = 1 L1
32 110 H 120 120 120 2
L1 1000 1000 1000
40 110 H 120 120 120 120
L1 1000 1000 1000 1000
50 125 H 120 120 120 120 120
L1 1000 1000 1000 1000 1000
65 140 H 120 120 120 120 120 120
L1 1000 1000 1000 1000 1000 1000
80 160 H 120 120 120 120 120 120 120
L1 1000 1000 1000 1000 1000 1000
1000
100 200 H 120 120 120 120 120 120 120 120
L1 1000 1000 1000 1000 1000 1000 1000 1000
125 225 H 120 120 120 120 120 120 120 120 140
L1 1000 1000 1000 1000 1000 1000 1000 1000 1200
150 250 H 120 120 120 120 120 120 120 120 140 122
L1 1000 1000 1000 1000 1000 1000 1000 1000 1200 1200
200 315 H 120 120 120 120 120 120 120 120 120 164 168
L1 1000 1000 1000 1000 1000 1000 1000 1000 1200 1200 1200
250 400 H 120 120 120 120 120 120 120 120 130 151 197
L1 1000 1000 1000 1000 1000 1000 1000 1200 1200 1200 1400
300 450 H 120 120 120 120 120 120 147 152 197 261
L1 1000 1000 1000 1000 1000 1200 1200 1200 1400 1500
350 500 H 120 120 120 120 120 140 146 188 252 312
L1 1000 1000 1000 1000 1200 1200 1200 1400 1500 1600
400 560 H 120 120 120 140 140 184 247 308 355
L1 1000 1000 1200 1200 1200 1400 1500 1600 1600
450 630 H 120 120 140 180 175 238 298 345 399
L1 1000 1200 1200 1200 1400 1500 1600 1600 1800
500 710 H 120 140 170 180 223 284 331 384 433
L 1200 1200 1200 1400 1500 1600 1600 1800 1800
600 800 H 140 170 215 229 289 336 390 439 546
L1 statically unfavourable 1200 1500 1500 1600 1800 1800 1800 1800 1900
700 900 H 170 215 280 290 337 391 440 572 688
L1 1500 1500 1800 1800 1800 1800 1800 1900 2000
800 1000 H 170 215 280 291 338 392 440 573 689 816
L1 1500 1500 1800 1800 1800 1800 1800 1900 2000
2100
8.1.2015 BRG
Parallel T-piece
200 mm* *DN 20 – DN 150: 150 mm
D2
d2
H
D1
d1
L L
L1

DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800
D2 110 110 125 125 140 160 180 225 250 280 355 450 500 560 630 670 800 900 1000 1100
L2 450 460 480 480 500 510 510 510 530 570 700 750 850 1000 1000 1100 1200 1300 1500 1700
DN D1
20 110 H 120
L1 1000
25 110 H 120 120
L1 1000 1000
L = 1 L1
32 125 H 120 120 120 2
L1 1000 1000 1000
40 125 H 120 120 120 120
L1 1000 1000 1000 1000
50 140 H 120 120 120 120 120
L1 1000 1000 1000 1000 1000
65 160 H 120 120 120 120 120 120
L1 1000 1000 1000 1000 1000 1000
80 180 H 120 120 120 120 120 120 120
L1 1000 1000 1000 1000 1000 1000
1000
100 225 H 120 120 120 120 120 120 120 120
L1 1000 1000 1000 1000 1000 1000 1000 1100
125 250 H 120 120 120 120 120 120 120 120 130
L1 1000 1000 1000 1000 1000 1000 1000 1100 1200
150 280 H 120 120 120 120 120 120 120 120 130 141
L1 1000 1000 1000 1000 1000 1000 1000 1100 1200 1200
200 355 H 120 120 120 120 120 120 120 120 130 140 178
L1 1000 1000 1000 1000 1000 1000 1000 1100 1200 1200 1200
250 450 H 120 120 120 120 120 120 120 130 140 160 200
L1 1000 1000 1000 1000 1000 1000 1100 1200 1200 1200 1400
300 500 H 120 120 120 120 120 130 140 160 197 261
L1 1000 1000 1000 1000 1100 1200 1200 1200 1400 1500
350 560 H 120 120 120 120 130 140 160 200 197 253
L1 1000 1000 1000 1100 1200 1200 1200 1400 1500 1600
400 630 H 120 120 130 140 160 200 237 294 285
L1 1000 1100 1200 1200 1200 1400 1500 1600 1600
450 670 H 120 130 140 160 200 243 300 340 359
L1 1100 1200 1200 1200 1400 1500 1600 1600 1800
500 800 H 130 140 160 200 198 255 296 364 433
L1 1200 1200 1200 1400 1500 1600 1600 1800 1800
600 900 H 140 160 200 204 260 301 320 389 446
700 1000 H 160 190 205 261 252 321 390 472 588
L1 1500 1500 1800 1800 1800 1800 1800 1900 2000
800 1100 H 160 190 204 247 253 322 390 473 589 716
L1 1500 1500 1800 1800 1800 1800 1800 1900 2000
2100
8.1.2015 BRG
Parallel T-piece
200 mm* *DN 20 – DN 150: 150 mm
D2
d2
H
D1
d1
L L
L1

DN 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800
D2 125 125 140 140 160 180 200 250 280 315 400 500 560 630 670 710 900 1000 1100 1200
L2 450 460 480 480 500 510 510 510 530 570 700 750 850 1000 1000 1100 1200 1300 1500 1700
DN D1
20 125 H 120
L1 1000
25 125 H 120 120
L1 1000 1000
L = 1 L1
32 140 H 120 120 120 2
L1 1000 1000 1000
40 140 H 120 120 120 120
L1 1000 1000 1000 1000
50 160 H 120 120 120 120 120
L1 1000 1000 1000 1000 1000
65 180 H 120 120 120 120 120 120
L1 1000 1000 1000 1000 1000 1000
80 200 H 120 120 120 120 120 120 120
L1 1000 1000 1000 1000 1000 1000
1000
100 250 H 120 120 120 120 120 120 120 130
L1 1000 1000 1000 1000 1000 1000 1000 1000
125 280 H 120 120 120 120 120 120 120 130 130
L1 1000 1000 1000 1000 1000 1000 1000 1000 1200
150 315 H 120 120 120 120 120 120 120 130 130 130
L1 1000 1000 1000 1000 1000 1000 1000 1000 1200 1200
200 400 H 120 120 120 120 120 120 120 130 130 130 133
L1 1000 1000 1000 1000 1000 1000 1000 1000 1200 1200 1200
250 500 H 120 120 120 120 120 120 130 130 130 130 147
L1 1000 1000 1000 1000 1000 1000 1000 1200 1200 1200 1400
300 560 H 120 120 120 120 130 130 130 130 142 151
L1 1000 1000 1000 1000 1000 1200 1200 1200 1400 1500
350 630 H 120 120 120 130 130 130 130 130 132 183
L1 1000 1000 1000 1000 1200 1200 1200 1400 1500 1600
400 670 H 120 130 130 130 130 130 137 189 245
L1 1000 1000 1200 1200 1200 1400 1500 1600 1600
450 710 H 130 130 130 130 130 143 194 250 319
L1 1000 1200 1200 1200 1400 1500 1600 1600 1800
500 900 H 130 130 130 130 173 175 231 299 343
L1 1200 1200 1200 1400 1500 1600 1600 1800 1800
600 1000 H 130 130 130 140 175 181 250 294 346
700 1100 H 130 130 140 176 182 251 295 372 488
L1 1500 1500 1800 1800 1800 1800 1800 1900 2000
800 1200 H 130 130 140 177 183 252 295 373 489 616
L1 1500 1500 1800 1800 1800 1800 1800 1900 2000
2100
8.1.2015 BRG
Fixed point
Thermally and electrically separated (all insulations)
D
d
Fr
a/b
200 mm
Fr = Friction force
Main pipe Ancor flanges

Nominal Steel pipe Insulation Insulation Insulation Nominal Insulation Insulation Insulation
width thickness 1 thickness 2 thickness 3 length thickness 1 thickness 2 thickness 3
DN d D D D L a/b x s a/b x s a/b x s
20 26.9 90 110 125 2000 200 x 15 200 x 15 200 x 15
25 33.7 90 110 125 2000 200 x 15 200 x 15 200 x 15
32 42.4 110 125 140 2000 200 x 15 200 x 15 200 x 15
40 48.3 110 125 140 2000 200 x 15 200 x 15 200 x 15
50 60.3 125 140 160 2000 250 x 20 250 x 20 250 x 20
65 76.1 140 160 180 2000 250 x 20 250 x 20 250 x 20
80 88.9 160 180 200 2000 250 x 20 250 x 20 250 x 20
100 114.3 200 225 250 2000 330 x 25 330 x 25 330 x 25
125 139.7 225 250 280 2000 330 x 25 330 x 25 330 x 25
150 168.3 250 280 315 2000 380 x 25 380 x 25 380 x 25
200 219.1 315 355 400 2000 500 x 25 500 x 25 500 x 25
250 273.0 400 450 500 2000 600 x 30 600 x 30 600 x 30
300 323.9 450 500 560 2000 700 x 30 700 x 30 700 x 30
350 355.6 500 560 630 2000 700 x 30 700 x 30 700 x 30
400 406.4 560 630 670 2000 800 x 30 800 x 30 800 x 30
450 457.2 630 670 710 2000 800 x 30 800 x 30 900 x 30
500 508.0 710 800 900 2000 900 x 30 900 x 30 1000 x 35
600 610.0 800 900 1000 2000 1000 x 35 1000 x 35 1100 x 40
For dimensions of the concrete block (foundation dimensions) and concrete quality, see sheet PRE 6.515. Figures in mm
Wall sealing rings (PRE 6.355) has to be ordered separately. As an option non thermal and electrically separated
fixing points are available on request.
8.1.2015 BRG
Reduction piece
Description
Reduction pieces are pre-insulated in the factory

in the same way as the plastic casing pipe, and
they conform to EN448. They are manufactured
with a concentric reduction piece to EN 10253 and
a welded-on pipe cylinder. For static reasons, pre-
insulated reduction pieces are designed to reduce
L the dimension by a maximum of two steps.
L = length of main pipe
Dimension 1 Dimension 2 Data

DN 1 d DS1 DS2 DS3 DN 1 DS1 DS2 DS3 Length Weight
mm mm mm mm mm mm mm mm kg
25 33.7 90 110 125 20 90 110 125 1500 3.6
32 42.4 110 125 140 20 90 110 125 1500 5.1
25 90 110 125 1500 5.5
40 48.3 110 125 140 25 90 110 125 1500 5.7
32 110 125 140 1500 5.8
50 60.3 125 140 160 32 110 125 140 1500 7.8
40 110 125 140 1500 8.1
65 76.1 140 160 180 40 110 125 140 1500 9.2
50 125 140 160 1500 10.2
80 88.9 160 180 200 50 125 140 160 1500 11.8
65 140 160 180 1500 12.8
100 114.3 200 225 250 65 140 160 180 1500 16.3
80 160 180 200 1500 17.8
125 139.7 225 250 280 80 160 180 200 1500 20.0
100 200 225 250 1500 22.9
150 168.3 250 280 315 100 200 225 250 1500 27.2
125 225 250 280 1500 29.2
200 219.1 315 355 400 125 225 250 280 1500 37.8
150 250 280 315 1500 41.3
250 273.0 400 450 500 150 250 280 315 1500 52.2
200 315 355 400 1500 59.3
300 323.9 450 500 560 200 315 355 400 1500 71.3
250 400 450 500 1500 79.7
350 355.6 500 560 630 250 400 450 500 1500 87.0
300 450 500 560 1500 95.4
400 406.4 560 630 670 300 450 500 560 1500 112.0
350 500 560 630 1500 117.0
450 457.2 630 670 710 350 500 560 630 1500 130.0
400 560 630 670 1500 140.0
500 508.0 710 800 900 400 560 630 670 1500 154.0
450 630 670 710 1500 162.0
600 610.0 800 900 1000 450 630 670 710 1500 190.0
500 710 800 900 1500 198.0
700 711.0 900 1000 1100 500 710 800 900 1500 296.0
600 800 900 1000 1500 311.0
800 813.0 1000 1100 1200 600 800 900 1000 1500 349.0
700 900 1000 1100 1500 374.0
8.1.2015 BRG
Vent
Description
Vents are pre-insulated in the factory in the same way as the plastic casing pipe, and they conform to EN448. The insula-
tion protection on the front of the vent nozzle is provided by a heat-shrunk end cap. The branch is made with a T-piece to
EN 10253 and welded-on pipe cylinders, or by extruding the base pipe.
The vent ball valve is manufactured from stainless steel 1.4301, and is supplied complete with plugs. The inner thread
corresponds to the nominal width of the vent. All the exposed parts of the valve are made of stainless steel. The nozzle
height (h) and the nominal width can be changed at the customer's request.
h
L
h = height of vent from axis of main pipe
Main pipe Vent Weight

DN d DS1 DS2 DS3 L DN D h DS1 DS2 DS3
mm mm mm mm mm mm mm kg kg kg
25 33.7 90 110 125 1000 25 90 650 5.3 5.6 5.8
32 42.4 110 125 140 1000 25 90 650 6.6 6.8 7.1
40 48.3 110 125 140 1000 25 90 660 7.1 7.3 7.5
50 60.3 125 140 160 1000 25 90 660 8.2 8.4 8.7
65 76.1 140 160 180 1000 32 110 670 10.6 11.0 11.3
80 88.9 160 180 200 1000 32 110 680 11.9 12.3 12.8
100 114.3 200 225 250 1000 32 110 690 15.6 16.3 17.0
125 139.7 225 250 280 1000 40 110 700 18.9 19.7 20.7
150 168.3 250 280 315 1000 40 110 720 23.5 24.5 25.9
200 219.1 315 355 400 1000 40 110 740 32.6 34.4 36.7
250 273.0 400 450 500 1000 50 125 840 47.5 50.2 53.3
300 323.9 450 500 560 1000 50 125 860 59.8 62.9 67.1
350 355.6 500 560 630 1000 50 125 880 66.5 70.7 76.0
400 406.4 560 630 670 1000 50 125 900 82.9 88.2 91.7
450 457.2 630 670 710 1000 50 125 930 94.4 97.9 101.4
500 508.0 710 800 900 1000 50 125 1000 107.8 116.6 126.0
600 610.0 800 900 1000 1200 50 125 1050 139.6 149.1 159.4
700 711.0 900 1000 1100 1200 50 125 1100 176.9 187.2 198.7
800 813.0 1000 1100 1200 1200 50 125 1150 216.8 228.3 241.3
8.1.2015 BRG
Drainer
Description
The end cap on the vent branch has to be ordered separately. Drainers are pre-insulated in the factory in the same way as
the plastic casing pipe, and they conform to EN 448. The branch is made with a T-piece to EN 10253 and welded-on pipe
cylinders, or by extruding the base pipe.
The nozzle height (h) and the nominal width can also be produced to the customer's requirements. Flanges, relief valves
and ball valves can also be used as closures for the nozzle.
h
L
h = height of drainer from axis of main pipe
The end cap on the vent branch has to be ordered separately.
Main pipe Drainer Weight

DN d DS1 DS2 DS3 L DN D h DS1 DS2 DS3
mm mm mm mm mm mm mm kg kg kg
25 33.7 90 110 125 1000 25 90 660 4.7 5.0 5.2
32 42.4 110 125 140 1000 25 90 660 6.0 6.2 6.5
40 48.3 110 125 140 1000 25 90 660 6.5 6.7 6.9
50 60.3 125 140 160 1000 32 110 670 8.7 8.9 9.3
65 76.1 140 160 180 1000 32 110 680 10.1 10.4 10.8
80 88.9 160 180 200 1000 40 110 690 11.7 12.1 12.6
100 114.3 200 225 250 1000 40 110 710 15.5 16.2 17.0
125 139.7 225 250 280 1000 50 125 730 19.1 19.9 20.9
150 168.3 250 280 315 1000 50 125 740 23.7 24.8 26.1
200 219.1 315 355 400 1000 80 160 780 35.4 37.2 39.4
250 273.0 400 450 500 1000 80 160 830 48.1 50.8 53.9
300 323.9 450 500 560 1000 80 160 850 60.6 63.7 67.9
350 355.6 500 560 630 1000 100 200 880 77.8 82.7 89.0
400 406.4 560 630 670 1000 100 200 920 96.6 103.0 107.0
450 457.2 630 670 710 1000 100 200 940 110.0 114.0 118.0
500 508.0 710 800 900 1000 100 200 1000 125.0 136.0 146.0
600 610.0 800 900 1000 1200 100 200 1050 176.0 189.0 203.0
700 711.0 900 1000 1100 1200 100 200 1100 222.0 236.0 251.0
800 813.0 1000 1100 1200 1200 100 200 1150 271.0 286.0 304.0
8.1.2015 BRG
Fittings installed in the ground

Description, installation and operating instructions
General Position indicator

We only provide systematic heat insulation for ball valves if they are • Milled-in notch on switch spindle square, and pointer
suitable for direct installation in the ground, with or without pre-
stressing, i.e.: Activation
• Close by turning to the right (clockwise) as far as the stop
A. if they fulfil the requirements acc. EN 488 (90° for ball valve)
B. if there are no screwed connectors in the insulated area.
Operation
Range of applications • Matching socket wrenches must be used for switching
• Up to 160 °C / 16 bar or 140 °C / 25 bar • Plug-on gears with matching receiver components can be supplied
• Processed, deminer alized, clean tap water with low oxygen content for ball valves (our recommendation for DN 200 and above)
• not suitable for installation in the area of bends and expansion limbs • Do not apply force to the switching shaft
• Do not overtighten the end stops
Material • Intermediate positions are not allowed for ball valves due to the
• Housing made of steel, forged and welded. possbility of wear on the ball seals
• Ball in stainless steel • The processed tapwater must not contain any solid particles
• Switching spindle in stainless steel because they could damage the sealing surfaces
• Seals in reinforced Teflon
• Ball seal, spring-supported Maintenance
• Spindle seal, multiple • Periodically clean the steel parts on the dome and grease them
• Monitoring wire, foamed in thoroughly
• Heat insulation made of rigid PUR foam • Switch between OPEN and CLOSED several times, at least every
• HDPE casing 3 months, until smooth running is achieved
• Check the freedom of movement of the dome
Delivery and storage • Check the groundwater level and condition
• Ball valves in open position
• Protective caps on both pipe ends
Important
Assembly / installation
• Only weld in the ball valves in the open position, and protect the It is essential to follow the above instructions. We and/or the
housing against overheating while doing so fittings manufacturer cannot provide any warranty for damage due
• Install expansion pads in the area of the dome, as per the instructions to incorrect installation, handling and maintenance.
• Pay special attention to ensure that the dome has sufficient freedom
of movement
• The upper uninsulated section of the spindle must not stand in the
groundwater/other water
• The first switching operation must only take place after the pipe has
been flushed through (open the gate valve first)
• If there is a risk of frost, uncovered fittings must be completely emptied
• Thoroughly grease the steel parts on the dome
• If there is a provisional pipe end, the free pipe end must be welded shut
8.1.2015 BRG
Ball valve
Width across flats
H
d1
D
Dimensions depending on type of ball valve
Nominal width Steel pipe Insulation thickness 1 Insulation thickness 2 Insulation thickness 3 Standard length* Height Wrench size**
DN d D D D L H WS
mm mm mm mm mm mm
20*** 26.9 90 110 125 1500 540 19
25 33.7 90 110 125 1500 540 19
32 42.4 110 125 140 1500 550 19
40 48.3 110 125 140 1500 560 19
50 60.3 125 140 160 1500 560 19
65 76.1 140 160 180 1500 570 19
80 88.9 160 180 200 1500 580 19
100 114.3 200 225 250 1500 580 27
125 139.7 225 250 280 1500 600 27
150 168.3 250 280 315 1500 620 27
200 219.1 315 355 400 1500 580 50
250 273.0 400 450 500 1500 610 50
300 323.9 450 500 560 1800 660 50
350 355.6 500 560 630 1800 660 80
400 406.4 560 630 670 1800 790 80
450 457.2 630 670 710 1800 950 80
500 508.0 710 800 900 1800 - 80
600 610.0 800 900 1000 on request -
700 711.0 900 1000 1100 on request -
800 813.0 1000 1100 1200 on request -
Instructions on installation, operation and maintenance as per sheet PRE 6.325
For accessories, see sheet PRE 6.335
* Length for standard ball valves
** Square socket key see sheet PRE 6.335
*** Ball valve DN 25 reduced to DN 20
8.1.2015 BRG
Ball valve with 2 vents
a a
WS
h
Da Da
D
L
h = high of vent
150 ≥ 200
Main pipe Wrench size Draining/venting valve

Nominal Steel Insulation Insulation Insulation Nominal Nominal
width pipe thickness 1 thickness 2 thickness 3 length width
DN d D D D L WS h DN Da a h
mm mm mm mm mm mm mm mm mm mm
25 33.7 90 110 125 1500 19 540 25 90 320 350
32 42.4 110 125 140 1500 19 550 25 90 320 350
40 48.3 110 125 140 1500 19 560 25 90 320 360
50 60.3 125 140 160 1500 19 560 25 90 320 360
65 76.1 140 160 180 1500 19 570 32 110 320 370
80 88.9 160 180 200 1500 19 580 32 110 320 380
100 114.3 200 225 250 1500 27 580 32 110 320 390
125 139.7 225 250 280 1500 27 600 40 110 320 500
150 168.3 250 280 315 1500 27 620 40 110 320 510
200 219.1 315 355 400 1500 50 580 40 110 320 540
250 273.0 400 450 500 2000 50 610 50 125 400 580
300 323.9 450 500 560 2000 50 660 50 125 500 610
The dimensioning of the venting fitting can be freely selected.

8.1.2015 BRG
Ball valve with 1 vents
a
SW
h
Da
d
D
150
Main pipe Wrench size Draining/venting valve

Nominal Steel Insulation Insulation Insulation Nominal Nominal
width pipe thickness 1 thickness 2 thickness 3 length width
DN d D D D L WS h DN Da a h
25 33.7 90 110 125 1500 19 540 25 90 320 350
32 42.4 110 125 140 1500 19 550 25 90 320 350
40 48.3 110 125 140 1500 19 560 25 90 320 360
50 60.3 125 140 160 1500 19 560 25 90 320 360
65 76.1 140 160 180 1500 19 570 32 110 320 370
80 88.9 160 180 200 1500 19 580 32 110 320 380
100 114.3 200 225 250 1500 27 580 32 110 320 390
125 139.7 225 250 280 1500 27 600 40 110 320 500
150 168.3 250 280 315 1500 27 620 40 110 320 510
200 219.1 315 355 400 1500 50 580 40 110 320 540
250 273.0 400 450 500 1750 50 610 50 125 400 580
300 323.9 450 500 560 1810 50 660 50 125 500 610
The dimensioning of the venting fitting can be freely selected.

8.1.2015 BRG
Ball valve for installation in the ground

Installation diagram
Road cap no. 2

DIN 3582 in cast iron
Secured surface
Sealing cap with seal
Concrete crown
Concrete plate
PE-HD protective pipe
Spindle extension
DPE
PREMANT ball valve

Shrink-on collar
DDOM
Expansion pad
Protective pipes for the spindle must be provided by the customer or others; see sheet PRE 6.520 - 6.525.
PE protective pipe
Ball valve DDOM* DPE*
DN
mm mm
20 ... 80 110 140
100 125 160
125 ... 200 140 180
250 200 225
300 200 225
* for standard ball valves
Delivery length: 1.0/1.5/2.0 m

Options of supply: – without sealing cap (standard)
– with sealing cap
8.1.2015 BRG
Accessories – shut-off fitting

Ball valve
Square wrench, 27/32
Square adapter
Square, 27/32 Square, 27/32
1100
for ball valve for ball valve
DN 25 - DN 80 DN 100 - DN 150
Hexagon; Width Hexagon; Width Ø 24

across flats 19 across flats 27
Square
27/32
Figures in mm
Ball valve
Gear can be supplied on request (for DN 200 or more, a gear is recommended)
8.1.2015 BRG
Sleeve joint
Shrink sleeve, non-cross-linked/cross-linked
1. PE shrink sleeve, non-cross-linked
The non-cross-linked shrink sleeve consists of a heat-shrunk PE sleeve

pipe and the following accessories:
- Shrink-on collars
- Permanently elastic sealing strip, butyl rubber
- Venting plug
- Welded-in PE plug
The shrink sleeves are pushed onto the casing pipe when the pipe is
being laid, before the medium pipe weld seams are made. The connec-
tion points are then fitted with additional insulation by trained fitting
staff who have been tested as per AGFW Worksheet FW 603.
This produces a watertight, non-positive connection between the

casing pipe and the sleeve. The sealing strip and the shrink-on collars
are used to double-seal the sleeve joint. Technical requirements as per
EN 489, AGFW Worksheet FW401, parts 6, 14, 16 and 17.
Nominal width: 90 ... 1200

Length: 700, 1000, 1400 mm
2. Shrink sleeve made of cross-linked PE
The cross-linked shrink sleeve consists of molecular cross-linked poly-

ethylene, so only limited welding is possible. The very high shrinkage
capacity of this material combined with the sealing strip inserted
between the casing pipe and the sleeve produce a very strong non-
positive connection.
Because this type of sleeve can withstand high mechanical loads, it

is especially suitable for plastic casing pipe sections that are subject
to higher stresses (e.g. frequent load alternation, pipes laid in the
groundwater zone).

Length: 700 mm
8.1.2015 BRG
Sleeve joint
Reduction sleeves, fitting sleeves and shrink-on end sleeves
3. Shrink-on reduction sleeves
For reasons related to statics, shrink-on reduction sleeves to insulate

steel reduction joints that are welded in by the pipelayer (provided
by the customer or others) are designed to reduce the dimension by
a maximum of three steps. Their structure corresponds to that of the
non-cross-linked PE shrink sleeve, and they must be pushed onto the
outer casing before the medium pipe is welded.
The non-cross-linked reduction shrink sleeve consists of a heat-shrunk

PE sleeve pipe and the following accessories:
- Shrink-on collars
- Permanently elastic sealing strip, butyl rubber
- Venting plug
- Welded-in PE plug
Nom. width Reduction sleeve Length Nom. width Reduction sleeve Length
D D D D L D D D D L
110 90 700 400 355 315 280 900
125 110 90 700 450 400 355 315 900
140 125 110 90 700 500 450 400 355 1200
160 140 125 110 700 560 500 450 400 1200
180 160 140 125 700 630 560 500 450 1200
200 180 160 140 900 670 630 560 500 1200
225 200 180 160 900 710 670 630 560 1200
250 225 200 180 900 800 710 670 630 1400
280 250 225 200 900 900 800 710 670 1400
315 280 250 225 900 1000 900 800 710 1400
355 315 280 250 900 1100 1000 900 800 1400
4. Fitting sleeve
Fitting sleeves made of non-cross-linked PE are used when it is not

possible to push the joint sleeves on due to shortage of space.
The fitting sleeve is separated in the axial direction and it can then
be moved into position over the points where the pipes are connected.
This separation point is welded to guarantee the tightness of
the sleeve.
Length: 700, 1000, 1400 mm
5. Shrink-on end sleeve
The shrink-on end sleeve is used to insulate pipe closures in the

ground and in buildings or shafts. It has the same structure as a non-
cross-linked PE shrink-on sleeve but is sealed on one side with a PE
end cover.

Length if end is:
dished end: 700 mm
one time ball valve: 1400 mm
8.1.2015 BRG
Brugg VISUCON
Brugg VISUCON is a connection technology which is fundamentally different from the processing
of other sleeve systems. VISUCON makes possible visual inspection of the polyurethane foam. This
means it is not necessary to destroy the sleeve or the foam.
With the VISUCON connection sleeve, the annular space for the external foaming process is not
limited by a polyethylene sleeve, but by reusable forming shells. With this technology, the external
sealing connection is not made until after the foaming process is complete. The result and quality of
the polyurethane foam can be reliably tested for every sleeve.
Sleeve system parts:
- Polyurethane foam, made of liquid components polyol and isocyanate (cf. PRE 6.410)
- Sealing shrink film
- Sealing tape
- VISUCON sleeve bodies made of integrated shrinkable HDPE
A cylindrical VISUCON shell is used for installation, which is then removed after the polyurethane
foam hardens. The two sealing systems are then installed. Due to the system design, no foaming
holes are necessary, meaning the plug welding process can also be omitted. The VISUCON sleeve
body shrinks across its entire length during installation, whereby the sleeve area does not expand.
This unchanging pipe diameter can be advantageous during pipe installation in empty tubes or
when driving over cable links.

Nominal size 160...710 mm
Length: 780 mm
Welding - Foaming - Sealing

Brugg VISUCON is only available as a straight connection sleeve. Non-integrated shrink sleeves
should be used for reducing sockets and stop ends.
Polyurethane half shells
The VISUCON connection sleeve can also be used together with the prefabricated polyurethane
half shells. In this case, forming VISUCON shells are not necessary. The remaining installation is
identical.
8.1.2015 BRG
EWELCON electro-welding joint

System description
The EWELCON electro-welding joint is the protected name for a welding joint from BRUGG Pipe Systems to produce joints
which transmit force, and are watertight and gastight, for plastic pipes - mainly PE-HD casing pipes (pre-insulated plastic
casing pipes (KMR)) in the district heating sector.
The EWELCON electro-welding joint is a fully prefabricated HD-PE plate which is only placed ('wrapped') around the two
ends of the plastic casing pipe immediately prior to welding. This simplifies the fitting procedrure and plays a key part in
the high and constant quality of the joint, even in difficult and confined installation locations. The weld seam area can
easily be cleaned and dried.
These properties make the EWELCON system especially suitable for repairs and refurbishments on existing pipes.
The 'inside' of the PE-HD plate in the EWELCON electro-welding joint is fitted with a thermal conductor and a tempera-
ture sensor. The thermal conductor, a meanderform copper wire, forms a heating spiral with a width of approx. 27 mm.
The position of the heating spiral is selected so that when the plate is placed around it, it completely surrounds the inte-
rior of the joint. During the welding process, the pipe and plate materials are plastified along the heating spiral, and are
homogeneously mixed due to the high expansive pressure of the melts. After the melts cool down, the interior is sealed
by a weld seam with a width of approx. 30 mm.
Together with the contact pressure for the weld surfaces, the weld bath temperature is the most important requirement
for plastic weld seams of high quality.
This fact is consistently implemented in the EWELCON system.
The required contact pressure is reliably applied by the clamping tool specially developed for this purpose.
The welding process is regulated by a microprocessor-controlled welding appliance. The temperatures of the weld bath
and the thermal conductor are monitored and stored throughout the entire welding process. This method ensures that the
weld bath temperature is largely independent of disruptive external influences (such as the weather) and thus compara-
ble from one welding operation to the next.
Every joint produced is subjected to a thorough visual inspection and a tightness test, after which it is foamed and the
filling and venting bores are sealed with weld plugs.
8.1.2015 BRG
EWELCON electro-welding joint

Technical data
Heating spiral Heating spiral Temperature sensor

connection wire
B1
Plattendicke: s
Heating spiral
connection wire
L
Casing pipe Ø Width Length Thickness Weight Packaging unit

D B1 L s B 700 B 850 B 700 B 850
mm mm mm mm kg kg Piece Piece
90 700 or 850 450 4 1.2 1.5 18 18
110 700 or 850 515 4 1.3 1.6 18 18
125 700 or 850 560 4 1.5 1.8 18 18
140 700 or 850 610 4 1.7 2.1 16 16
160 700 or 850 675 4 1.9 2.3 16 16
180 700 or 850 740 4 2.1 2.6 16 16
200a 700 or 850 805 4 2.3 2.8 15 15
225 700 or 850 885 4 2.4 2.9 15 15
250 700 or 850 950 4 2.5 3.0 20/40/80 20/40/80
280 700 or 850 1050 4 2.7 3.2 20/40/80 20/40/80
315 700 or 850 1160 4 3.0 3.6 20/40/80 20/40/80
355 700 or 850 1290 4 3.3 4.0 20/40/80 20/40/80
400 700 or 850 1440 4 3.7 4.5 20/40/80 20/40/80
450 700 or 850 1600 4 4.2 5.0 20/40/80 20/40/80
500 700 or 850 1830 6 7.0 8.5 20/40 20/40
560 700 or 850 2020 6 7.7 9.5 20/40 20/40
630 700 or 850 2250 6 8.7 10.5 20/40 20/40
710 700 or 850 2580 8 13.2 16.0 20 20
800 700 or 850 2870 8 14.7 17.8 20 20
900 700 or 850 3190 8 16.5 20.0 20 20
1000 700 or 850 3510 8 18.0 22.0 10/20 10/20
Material:  PE80 - DIN EN 32 162 (PE-HD)
Further dimensions on request.

Sleeves up to Ø 225 are pre-rolled for delivery
Sleeve widths: Standard width: B = 700; repair width: B = 850
8.1.2015 BRG
EWELCON-S
System description
The EWELCON-S Electro-Welding Joint is a member of the "EWELCON family". It is the ideal match for our tried-and-
tested EWELCON welding joint for the smaller dimension range.
The shrink-on sleeve and the prefabricated heating elements for the EWELCON-S electro-welding joint are delivered in
separate packaging units. The shrink-on sleeve, which is fitted with solar protection foil, is pushed onto the casing pipe
before welding the inner pipes. The heating elements are delivered in handy packaging units which are protected against
contamination as appropriate for use on construction sites. The heating elements are only placed around the two ends
of the plastic casing pipe immediately before welding. The weld seam area can easily be cleaned and dried. This plays a
key part in the high and constant quality of the joint, even in difficult and confined installation locations. These properties
make the EWELCON-S system particularly suitable for new installations. Repairs and refurbishments on existing pipes are
carried out with the EWELCON welding joint using the wraparound method. For quality reasons, the installation is only
carried out by fitters who have acquired the necessary qualifications after thorough training from our training staff.
The shrink-on sleeve in the EWELCON electro-welding joint consists of bimodal PE-HD. This ensures optimal long-term
properties. The thermal conductor, a meanderform copper wire, is embedded in a PE-HD carrier strip. Each heating
element set is fitted with a temperature sensor. The heating elements are fixed onto the prepared casing pipe ends; they
adapt to the component tolerances. The special design in the area of the connecting ends ensures constant welding
conditions over the entire pipe circumference.
Following the usual on-site method, the shrink sleeve is shrunk down onto the casing pipe ends with a gentle propane
gas flame; the heating elements are optimally chambered as this is done. Together with the contact pressure for the weld
surfaces, the weld bath temperature is the most important requirement for plastic weld seams of high quality. This fact
is consistently implemented in the EWELCON-S system. The required contact pressure is reliably applied by the clamping
tool specially developed for this purpose.
The welding process is regulated by a microprocessor-controlled welding appliance. The temperatures of the weld bath
and the thermal conductor are monitored and stored throughout the entire welding process. This method ensures that
the weld bath temperature is largely independent of disruptive external influences (such as the weather) and thus
comparable from one welding operation to the next. The parameters for each welding operation are stored in the welding
computer so that they can be read out and documented at a later stage. Furthermore, every joint produced is subjected
to a thorough visual inspection and a tightness test, after which it is foamed and the filling and venting bores are sealed
with weld plugs.
8.1.2015 BRG
EWELCON-S
Technical data
Casing pipe PE-HD sleeve pipe Heating element

D Outer ø Thickness Length Length Width
mm mm mm mm mm mm
90 107 2.9 700 310 100
110 129 2.9 700 370 100
125 143 3.0 700 420 100
140 156 3.4 700 460 100
160 178 3.5 700 520 100
180 198 3.5 700 580 100
200 224 3.8 700 650 100
225 255 4.3 700 730 100
250 278 4.4 700 810 100
280 306 4.9 700 700 100
315 341 5.5 700 900 100
355 384 5.8 700 - 100
400 430 6.2 700 - 100
EWELCON-S can also be used for reduction sleeves and for shrink
sleeves of any desired length.
8.1.2015 BRG
Fitting bend
Fitting bends are used as additional insulation for medium pipe bends welded in at the building site
by the pipelayer. Fitting bends are made from non-shrinking HDPE pipe. Shrink-on collars are used
to seal the pipe on the face side.
The fitting bend comprises:

• Segment bend made from PE sleeve pipe
• Shrink-on collars
Fitting bends are made to measure depending on the bend design (radius, angle, length). The follo-
wing details are therefore required when placing an order:
• Nominal diameter of the medium pipe
• Nominal diameter of the PE casing
• Bend design or radius
• Angle of the fitting bend
Compliance with the minimum lengths defined in the following table is required if a prefabricated
welded bend as per EN 10253/2 is fitted between the adjacent free pipe rod ends.
Fitting bend, minimum lengths

Angle 5.....45° 46.....90°
design: 3 D 5 D 3D 5 D
L L L L
Da mm mm mm mm
90
110
125 500 500 500 500
125
140
160
180 500 500 500 700
200
225
250 500 500 700 700
280
315
355 500 700 700 1000
400
450 500 700 1000 1100
8.1.2015 BRG
Wall sealing ring, pipe warning tape

Wall sealing ring Data table: sealing ring
D Da
90 133
110 153
125 168
140 183
160 203
180 223
200 240
225 265
250 290
Da
315 355
D
355 395
400 440
450 490
500 540
560 600
630 670
710 750
800 840
Figures in mm
50
Pipe warning tape

Width Language Colour
mm
40 German blue
100 German/English/French/Italian blue
Standard roll length, 250 m
Installation depth; see sheet PRE 6.500
8.1.2015 BRG
Shrink-on closure
Shrink-on closure/end cap
PREMANT shrink-on closures protect the PUR insulation on the front of the PREMANT district heating pipes against
splashing water in buildings and shafts. The shrink-on closure is not necessarily watertight in contact with water (floo-
ding). The shrink-on closure also stops gas escaping from the PUR insulation at the end of the pipe.
Monitoring box Material: Important fitting note

Heat-shrunk cross- PREMANT shrink-on
linked polyolefin. closures must be pushed
Coated with sealing onto the end of the
adhesive. PREMANT district heating
pipe before welding the
inner pipes, and must be
protected against the action
of heat during welding.
min. 120 mm
Allocation of PREMANT dimensions to type of shrink-on closure

Nominal Insulation thickness 1 Insulation thickness 2 Insulation thickness 3
width Casing End cap Casing End cap Casing End cap
DN pipe Type pipe Type pipe Type
mm mm mm
20 90 20 110 20 125 20
25 90 30 110 40 125 50
32 110 40 125 50 140 70
40 110 50 125 50 140 70
50 125 70 140 70 160 80
65 140 70 160 80 180 80
80 160 80 180 80 200 90
100 200 90 225 90 250 100
125 225 100 250 100 280 110
150 250 110 280 110 315 120
200 315 120 355 120 400 130
250 400 130 450 130 500 140
300 450 140 500 140 560 -
8.1.2015 BRG
Rigid Foam Beams

Nominal Size Size Length
1 100 x 100 mm 1000 mm
Characteristics Value Unit

Material Polystyrol
Compressive strength 150 kPa
Density 30 kg/m3
Thermal conduction
group 040
Rigid foam beams serve as a support for preinsulated jacket pipes in the pipe trench. PU-rigid foam beams can remain in
the sand filled pipe trench.
For large pipelines rigid foam beams are only limited useable. They tend to break under the heavy load if they lay hollow.
The additional effort for a plane trench bottom is in most cases not justifiable. German Pipe suggests for pipelines from
DN 250 to use sandbags, sand beds or square timbers.
While aligning the pipeline using square timbers it is necessary to remove the square timbers after finishing the welding
works and before the sand back-filling. Otherwise the jacket pipe may be damaged due to the thermal expansion.
8.1.2015 BRG
Ring seal
Leak-proof sealing against pressurized water for building entries
Wall duct double-seal, Wall duct,

leak-proof for pressurized water leak-proof for non-pressurized water
3 3
1 1
D
D
R
R
2 2
1 PREMANT district heating pipe 1 PREMANT district heating pipe

2 Sealing-set, double seal 2 Sealing-set, single-seal
3 Liner pipe made of fibre cement or coated core bore 3 Liner pipe made of fibre cement or coated core bore
Casing pipe diameter Liner pipe Core bores

PE Core bore Perfect bores are required for installation. As hairline cracks may
ØR ØD be present in the concrete or could be caused by processing, it is
mm mm advisable to seal the entire length of the borehole wall with suitable
90 150 sealant (such as AQUAGARD).
110, 125, 140 200
160, 180 250 Tightness can only be guaranteed if this recommendation is fol-
200, 225 300 lowed.
250, 280 350
315 400 Installation / trench infill
355 450 To avoid deformations at the sealing point, it is especially important
400 500 during installation and when filling the trench to ensure that no subse-
450 600 quent sinking of the pipe can occur. We also recommend that the pipe
500 700 is supported or suspended inside the building. Tightness cannot be
guaranteed unless these recommendations are followed.
8.1.2015 BRG
Expansion pad
Description
In order to absorb expansion movements of the underground pipe system in bends, branches and reduction pieces, expansion pads must be
applied to the outer PE casing in these areas. Expansion pads are manufactured from cross-linked closed-cell polyethylene, are permanently
elastic, do not decay and are resistant to chemicals. The expansion zone is designed on the basis of pipe statics calculations.
Delivery
The delivery scope for an expansion zone of 1 m comprises 2 pieces of expansion pad strip, length 1000 mm, which are glued onto the outer
casing at the 3 o'clock and 9 o'clock positions. Laminate is then wrapped around the entire zone in order to prevent sand or soil particles from
penetrating between the expansion pad and the PE casing.
Material: Polyethylene particle foam

Properties Value Unit
Nominal width: Size I 120 mm Apparent (bulk) density 32 Kg/m³
Size II 240 mm Tensile strength 160 kPa
Size III 360 mm Compressive stress
50 % deformation at 23 °C 100 kPa
Nominal thickness: 40 mm Vibration fatigue test, 80 000 load changes
- Change in thickness 2,4 %
- Change in hardness number 2,4 %
Absorption of water (volume fraction)
- after 1d 2,0 %
- after 7d 3,0 %
Thermal conductivity at 10 °C 0,040 W/mK
120 240 360

1000
1000
1000
EP strip = 1 m
PUR insulation
Medium pipe
Laminate
Diameter of Nominal size Weight Volume

outer casing
mm Name existing kg/piece kg/m m³/piece m³/m
90 up to 160 Size 1 I 0.154 0.307 0.0048 0.0096
180 up to 280 Size 2 II 0.307 0.614 0.0096 0.0192
315 up to 355 Size 3 III 0.461 0.922 0.0144 0.0288
400 Size 4 II+II 0.614 1.229 0.0192 0.0384
500 up to 560 Size 5 II+III 0.768 1.536 0.0240 0.0480
630 up to 670 Size 6 III+III 0.922 1.843 0.0288 0.0576
710 Size 7 III+II+II 1.075 2.150 0.0336 0.0672
800 Size 8 III+III+II 1.229 2.458 0.0384 0.0768
900 Size 9 III+III+III 1.382 2.765 0.0432 0.0864
1000 Size 10 III+III+II+II 1.536 3.072 0.0480 0.0960
8.1.2015 BRG
Transport and storage

Transport
Pipes, preformed parts and accessories are usually delivered by truck 'free site' (as per our valid Conditions of Sale or
Delivery). Due to the transfer of risk on delivery, it is advisable for the client to nominate and provide a person responsible
for receiving the goods. To avoid costly waiting times, the unloading locations should be suitably prepared.
Unloading, handling
Unloading is the responsibility of the client/recipient.
Except for pipes up to about DN 80, which can be unloaded manually, lifting gear must be used for unloading. To prevent
damage, especially to the thermal insulation, the preformed parts and pipes must not be thrown or rolled.
Figure 1: Suspension gear for accident-proof protective handling
Traverse with textile belts, min. 100 mm wide Stay cables at adequate distance from casing pipe.
Only attach hooks to the steel pipe
Figure 2: Temporary storage on a levelled sand bed

max. 2.0 m
approx. 0.15 m
Levelled sand bed
Figure 3: Temporary storage on wooden planks

min. 0.06 m
max. 2.0 m
Level surface
Up to DN 150 min. 0.20 m

 DN 150 min. 0.25 m
max. 1.90 m 0.4 m
The pipes and preformed parts have been treated to protect them against moisture in the factory and where possible,
they must be stored in a dry, covered location on planks or wooden pallets in order to protect them.
8.1.2015 BRG
Storage of preformed parts

Caps at the ends of formed parts protect the medium pipe against external influences. These protective caps should not be removed until the pipe
is fitted on site.
Approved formed parts should be stored flat and dry.
Formed parts can also be stored on flat pallets and in mesh boxes in a pyramid formation. The parts should be stacked on top of one another in a
manner that ensures stability and an even distribution of weight. Where necessary, stacks on flat pallets should be secured with wedges.
Most importantly, the ends of formed parts should not face upwards. It is imperative to prevent the accumulation of water on the insulation layer
(between the medium pipe and casing pipe) to protect the pipe ends against corrosion.
In general, formed parts should be protected from frost and direct sunlight.
They should also be protected from improper handling such as the effects of impact, shock, bending, etc.
8.1.2015 BRG
Assembly Foam
Component A Polyol
Colour ocker
Density 1.04 kg/m3
Solubility in water yes
Component B Isocyanat
Colour brown
Density 1.23 kg/m3
Solubility in water no
Storage
The components of the foam system may only be stored and transported in the original canisters. The canisters have
to be stored in a dry environment. They should stay airtight closed and sealed. Direct solar radiation and frost have
to be avoided.
Are the foam components stored in a closed room, the room has to be ventilated. The minimum ventilation is an air
change twice in 24 h. The temperature ought to be between 10 and 25 ºC.
While storing together with other substances, these have to be basically compatible. Furthermore we refer to the
“VCI-Konzept zur Zusammenlagerung von Chemikalien” of the “Verband der chemischen Industrie”.
PUR-foam-components should not be stored for longer then 6 months.
Storage Value Unit

Temperature 10 ... 25 °C
Ventilation twice each 24 h
Period < 180 days
Disposal
Basically a disposal of the fluent components should be avoided. The disposal of this product hat to occur at all times
in compliance with the standards of environmental protection and laws of waste disposal as well as the requirements
of the local authorities. It is recommended to clarify the details with the responsible waste management company.
Classification
Substance ADR/RID-class Water hazard class Storage class Waste class EAK Code
Component A (Polyol) 3 1 Class 3 08 04 09
Component B (Isocaynat) – 1 Class 10 08 05 01
8.1.2015 BRG
Underground construction work, installation

Pipe installation
• It is essential to ensure that the outer PE casing is not damaged.
• Before welding, the PE sleeve pipes must each be pushed over one side of the pipe ends. Then they must be pulled
back over the connection points to protect the insulation.
• The detection wires must always be on top when installing the pipes.
• Make sure that sufficient space is available to apply the supplementary insulation on the sleeves
(at least 15 or 20 cm below and between the sleeves).
Underground work
• The general construction regulations must be observed when excavating the pipe trenches.
• Please ask us for an installation suggestion in case of difficult soil conditions or subsidence, etc.
• The pipe trench must be kept clear of water throughout the installation period.
• PREMANT district heating pipes must be installed on foam pipe supports (sand bags), each at a distance of approx.
1 m from the weld points.
• After installation, the pipe must be filled in on all sides, following the trench profile, with friable, round-edged sand
(particle size 0 - 8 mm).
• Fill the pipe to 30 cm below the upper edge of the terrain with excavation material, and compact.
• Install the pipe warning tape, finish filling in the trench and compact.
Trench profile according to DIN 4124 Trench dimensions

PE outer pipe Gap Width
Sand, washed
D A B
Pipe warning tape Particle size 0 - 8 mm
mm m m
90 0.23 0.9
110 0.23 0.9
125 0.23 0.9
140 0.28 1.2
min. 0.60
160 0.28 1.2

0.40
180 0.28 1.2

0.10
200 0.28 1.2

225 0.28 1.2
250 0.28 1.4
min. 0.10
280 0.28 1.4

315 0.38 1.8
355 0.38 1.8
400 0.38 1.8
450 0.48 2.4
A D A D A
500 0.48 2.4
B 560 0.48 2.6
630 0.48 2.6
Polystyrene pipe support Figures in m
670 0.58 3.1
or sand bags
710 0.58 3.1
800 0.58 3.1
EWELCON electro-welding joints

• Every joint requires a top hole (sheet PRE 6.501)
• In the pipe zone, clearance of at least 23 cm is required (sheet PRE 6.501)
8.1.2015 BRG
Underground construction work, installation

Trench widening in the area of the expansion pads
The trench must be widened and deepened by at least 0.1 m on both sides in the area of the expansion pads.
0.10
0.10
0.10
Expansion pad
2.00 - 4.00
Figures in m
Trench profile with top hole
To allow the steel pipes to be welded together perfectly, and so that the sleeve joints can be executed neatly, top holes
must be made on each weld seam for larger dimensions, but as a minimum on bends and T-branches. This can reduce the
width of the normal trench profile.
0.20
1.80
0.35
B + 0.40
Figures in m
8.1.2015 BRG
Filling in the pipe trenches

Surrounding material (sand)
• Compactable washed sand, max. particle size 8 mm (0 - 8 mm)

• Finest particle component ≤ 0.25 mm, not more than 8% if possible
• Friable or smallest possible loam component
As an alternative, so-called cyclone sand/sludge sand, particle size 0 - 1 mm, is permitted (the 'waste' from washed
sand). Crushed glass is not permitted as a substitute for sand with PREMANT district heating pipe (it is allowed for
FLEXWELL).
Embedding the pipe in sand (as per Trench Profile sheet)
• Coverage over crown of pipe - at least 10 cm.

• Compaction – very important!
• The sand must be compactly bedded in or compacted by hand, with suitable implements (such as a spade or
pick-axe handle) in layers between, below and next to the pipes. No cavities must be created.
Important: Do not damage the sealing strips and pipes!
Residual infill of the pipe trench
• The rest of the trench must be filled in with layers of compactable material, such as excavated material and/or fine
gravel which must be well compacted. Local regulations govern the use of excavated material and the minimum
thickness of the fine gravel layer.
• To compact the material, use a vibrator providing max. 100 kPa pressure/unit of area. Earliest compaction: from 30 cm
coverage of pipe crown. Remember: install pipe warning tape and any protective pipes (not over the pipes)
(approx. 30 cm above pipe crown).
• Top layer: use humus or HMT according to regulations.
If coverage is insufficient (< 60 cm) and in zones with heavy traffic loads, pressure distribution plates must be installed
over the sand layer to relieve pressure on the pipes.
In general, all construction and safety regulations must be followed.
8.1.2015 BRG
House lead-in
Wall seal – neoprene rubber
Wall leadthrough
Wall sealing ring made of

profiled neoprene rubber; Basement/shaft
see sheet PRE 6.355
Monitoring box
PREMANT
Shrink closure
see sheet PRE 6.345
60 50 min. 120
Wall opening
B
H
90 D 200 Figures in mm
Wall opening dimensions

D 90 110 125 140 160 180 200 225 250 280 315 355 400 450 500 560 630 710 800
B 540 580 640 640 680 720 760 810 860 920 990 1070 1160 1260 1360 1480 1620 1780 1960
H 250 300 300 350 350 350 350 400 400 450 450 500 550 600 650 750 800 900 990
Figures in mm
8.1.2015 BRG
Installation instructions
Failure:
Sleeve can't be
moved.
min. 150 mm
min. 150 mm min. 750
Failure:
Wall sealing ring
and end cap
can't be installed.
Failure:
Sleeve can't be
installed.
< 300 mm
min. 300 mm min. 120 mm
Failure:
Overlaping area
for the sleeve is
too short.
min. 200 mm
Failure:
Overlaping area
for the sleeve is
too short.
8.1.2015 BRG
Concrete block for fixed point

For maximum fixed point forces
H
A
a

A1
B L*
L* max. width
For divergent fixed point forces and soil conditions, the foundation dimensions must be calculated.
Steel pipe Fixed point force Concrete block dimensions Pipe distance
DN d Fs max B A1 A L* a
mm kN m m m m mm
20 26.9 66.5 0.8 0.40 0.8 0.8 270
25 33.7 83.7 0.8 0.40 0.8 0.8 270
32 42.4 107.2 1.0 0.40 0.8 0.8 280
40 48.3 123.1 1.0 0.45 0.9 0.8 280
50 60.3 172.4 1.2 0.55 1.1 1.0 295
65 76.1 219.9 1.4 0.65 1.2 1.0 320
80 88.9 284.1 1.6 0.80 1.3 1.0 340
100 114.3 412.9 2.0 0.95 1.6 1.0 390
125 139.7 507.6 2.2 1.15 1.7 1.0 415
150 168.3 680.9 2.5 1.40 2.0 1.3 450
200 219.1 1000.6 3.0 1.70 2.4 1.3 550
250 273.0 1388.5 3.5 2.10 2.9 1.3 680
300 323.9 1847.0 4.2 2.25 3.2 1.5 745
350 355.6 2052.0 4.5 2.40 3.3 1.5 810
400 406.4 2592.0 5.2 2.40 3.5 1.8 890
450 457.2 2920.0 5.6 2.60 3.6 2.0 890
500 508.0 3240.0 5.6 2.60 3.8 2.0 980
Calculation basis for the size of the concrete block

• Max. thrust for 2 pipes: Fs max = 2 · As · dT, [ dT = 165 N/mm², ∆T = 70 °K ]
• Coverage height H = 0.8 m
• Foundation dimensions are based on a frictional angle of  = 32.5° for friable soils (coefficient of friction m = 0.40)
• Apparent density g = 18 kN/m³
• Ground specification acc. DVGW GW 310
Concrete quality
• P 350 to DIN 1045, impermeable to water with armouring
8.1.2015 BRG
Sectional drainage, sectional venting
min.
120 150
3 2
1
500
6
150 4
L as stated
Special version
2
3
L as stated
min. 100
4
1000 Figures in mm
1 Valve, supplied by customer or others

2 Shrink-on closure, delivered loose
3 Expansion pad
4 Sand
5 Lean concrete
6 Soakaway gravel
8.1.2015 BRG
Underground construction for ball valve

Shafts with drive-over cast cover
D2 D2
1
3
4
H
>D2
6
200 D1 200 D1 200 Figures in mm
DN D1 H D2 1 Cast cover, drive-over (e.g. Von Roll)

mm mm mm 2 Cement pipe
20 125 470 3 Ball valve
25 125 470 4 Expansion pad
32 140 470 5 Support plate
40 140 490 6 Sand filling (particle size 0 - 8 mm)
50 160 500 250
65 180 510 250
80 200 520 250
100 250 560
125 280 570
150 315 590
200 355 630 300
250 450 670 300
8.1.2015 BRG
Tapping technology
System description
m
40 c
Important: Tapping technology must only be processed by specialist staff.
Tapping systems are designed to produce pipe branches under pressure. Today's equipment and components are the
results of a product development process which has combined proven solutions with new findings. This tapping method
achieves major cost savings thanks to simple and cost-effective working procedures, and fitting work which can be car-
ried out quickly and reliably without interruptions to operation.
The tapping device for weldable joints on steel pipes and containers can be used for branch dimensions of DN 25 to
DN 100, up to 25 bar and 140 °C. On branches, the tapping block is welded to the part to be tapped, either directly or
with a weld ring if necessary.
The tapping blocks are designed with a reduced opening. They can be used in district heating pipes and various process
pipes.
Tapping pipe branches under pressure has the advantage that they can always be produced in the desired location at a
later stage.
Larger dimensions can be executed with another system on request.
8.1.2015 BRG
Tapping technology
Dimensions and measurements
Fittings with reduced through passage

Hexagon screw
H
A2
A1
B
L
Tapping ball valve with fully welded housing in St 37

Ball in nickel chromium steel with PTFE seals
Dimension DN 25* DN 32 DN 40* DN 50 DN 65 DN 80 DN 100

Ball opening 25 25 40 40 50 65 80
Bore diameter 24 24 40 40 48 65 79
Flow value (KVS) [m³/h] 26 41 68 112 200 380 620
A1 (house connection branch) 33.7 x 2.9 42.4 x 2.9 48.3 x 2.9 60.3 x 3.1 76.1 x 3.1 88.9 x 3.2 114.3 x 3.6
A2 (connecting branch to main pipe) 37.0 x 5.8 37.0 x 5.8 54.0 x 6.7 54.0 x 6.7 63.0 x 7.0 82.0 x 8.0 100.0 x 9.0
B 60.3 60.3 88.9 88.9 114.3 133.0 159.0
H 46.0 46.0 57.0 57.0 70.0 80.0 92.0
L 145.0 145.0 200.0 200.0 260.0 265.0 275.0
Sealing screw, hexagon socket 10 10 10 10 14 14 14
Weight [kg] 1.3 1.2 3.5 3.4 5.1 6.7 11.3
Min. main pipe Ø DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 DN 125
Min. casing pipe Ø (branch) 110 125 125 140 160 180 225
* Dimensions with full through passage Figures in mm

Larger dimensions with different tapping systems on request
8.1.2015 BRG
Tapping technology
Preparation of weld seam and seam structure
Weld-on end with seam preparation
Thread for tapping tool
Imbus screw
Tighten after the connecting pipe is commissioned (block the ball) and
weld to the housing all the way round.
60°
Place the tapping fitting directly on

the base pipe, without a gap.
Make sure that no welding deposit

penetrates the inside of the tapping
fitting. Bevelling of weld-on end as per
DIN 2559, joint type 22
Weld seam structure:

E-weld (2 - 3 layers) with Kb electrodes, basic (alkaline)
Type E5155B10 DIN 1913 Ø 2.5 mm
Important during welding!

• Ball must be exactly in the open position.
• Avoid excessive temperature stress on the Teflon seals by cooling the fitting between the individual
weld seam layers (cool the fitting with a wet cloth / waiting time between individual weld seam layers)
8.1.2015 BRG
Tapping technology
Junction branch at top with 45° PRE bend
Bend, 45°, vertical, may be shortened
Tapping fitting with thread
Protect end of insulation

against overheating
min 150
30 in.
m
0
45°
D1
min. D1
+ 300
mi 00
n.
2
mi 50
n.
1
500 500
Joint/sleeve
1200
min. 200
Without braces
min. D2
+ 200
1500
200
200
Joint/sleeve
1200
min. 200
Figures in mm
8.1.2015 BRG
Tapping technology
Junction branch at top with 45° welded bend
Welded bend
Adapter
min. 60
min. 150
46°
D1
min. D1 + 300
500 500
1200
min. 200
D2
1500
500
200
200
1200
min. 200
Figures in mm
8.1.2015 BRG
Tapping technology
Junction branch at bottom with 45° PRE bend

Protect end of insulation Tapping fitting with thread
against overheating
46°
L
0
15
0
20
1200
min. 150
1500
500 500
Joint/sleeve
1200
min. 200
Without braces
D2
1500
min. D2
+ 200
200
200
Joint/sleeve
1200
min. 200
Figures in mm
8.1.2015 BRG
Tapping technology
Junction branch at bottom with 45° welded bend
Welded bend, 5d
Adapter
45°
min 60
1200
min. 150
1500
500 700
1200
min. 200
Without braces
D2
1500
min. D2
+ 200
200
200
1200
min. 200
Figures in mm
8.1.2015 BRG
Tapping technology
Junction branch at top with 90° PRE bend
min. 150 min. 150
min. 150
D1
Protect end of insulation
against overheating
min. D1
+ 300
Same side as branch
500 500
1200
Joint/sleeve
min.
200
D2
Without braces
min. D2
+ 200
1500
200
200
1200
Joint/sleeve
min. 200
Parallel branch: limb length: max. 2.5 m

Figures in mm
8.1.2015 BRG
PREMANT DUO district heating pipe PRE DUO 7.0
Table of contents
7.0 Table of contents

7.105 Medium pipe
7.106 Heat insulation, casing pipe, monitoring wires
7.300 Components
7.300 District heating pipe – DUO
7.304 Elbow pipe
7.305 Bend, with equal limbs, 90°
7.307 Bend, with equal limbs, 45°
7.312 T-piece, 90°
7.316 Y-pipe, type G; straight, insulation thickness 1
7.319 Y-pipe, type W; angled, insulation thickness 1
7.325 Fixed point
7.327 Vent
7.330 Ball valve
7.340 Sleeve joint: Shrink sleeve, non-cross-linked/cross-linked
7.342 Sleeve joint: Reduction sleeves, fitting sleeves and shrink-on end sleeves
7.345 Brugg VISUCON
7.356 Shrink-on closure/end cap
7.357 Rigid foam bar
7.360 Ring seal
7.365 Expansion pad
7.410 Assembly foam
8.1.2015
System description
PREMANT is the registered name for a pre-insulated plastic casing pipe system used to trans-
Max. continuous operating temperature
port district heat, and PREMANT DUO is a special version of this system. It is a pipe system for
TBmax: 130 °C
direct installation in the ground, without channels.
Max. temperature difference
PREMANT DUO district heating pipe is available with a medium pipe made of welded or between flow and return
seamless steel, as specified by the customer. It is suitable to transport heating water, domestic tBmax: 100 K
hot water, water/glycol mixtures and other fluids. Due to the connected pipes and the limited Max. permitted operating pressure
maximum temperature, the use of this system for steam or condensate is restricted. p: 25 bar
Heat insulation for PREMANT DUO district heating pipe is provided by a rigid polyurethane
foam that can withstand temperatures of up to 144 °C. A PE-HD casing pipe provides external
protection. All three components form one fixed unit, so this pipe system is a member of the
composite pipe family.
PREMANT DUO district heating pipe is available in two categories of insulation thickness. De-
pending on the dimensions, it can be supplied in lengths of 6 m, 12 m and (16 m). The construc-
tion units and all the relevant preformed parts such as bends, T-pieces and fixed points, etc.,
are prefabricated in the factory. The result is a modular system that is correspondingly simple to
plan and install.
All the components are connected together on site with circumferential seams. Supplementary
insulation of the weld seam and the weld-on ends is provided by means of joint sleeves. The
supplementary insulation work is usually carried out by BRUGG / GERMAN PIPE itself or by
qualified specialist companies on our behalf. During the planning phase, we offer support based
on our system experience to system users who request this.
PREMANT DUO district heating pipe, and the preformed parts and fittings, are manufactured
according to the latest standards (EN 15698, EN 448 and EN 488).
Important note on statics and stability:
PREMANT DUO district heating pipe is designed for a temperature difference of 100 Kelvin
between the flow and the return. When planning double pipe systems, it must be ensured that
this value is not exceeded. In particular, the stated value must not be exceeded when starting
up plants that have been cooled down.
In order to compensate for the difference in expansion between the flow and return pipes, both
pipes must be permanently connected to each other. This is especially important:
– on free pipe ends in buildings, shafts and other structures
– on free pipe ends in end sleeves
– in/ahead of bends, branches, reductions, drainers, vents and
– in/ahead of shut-offs.
With PREMANT DUO district heating pipes, these fixing plates are installed in the factory on
all DUO preformed parts and fittings. No further joints to absorb forces are required in straight
sections of pipe between two bends. For reasons related to production, welded spacers are used
in pipe rods, but these spacers do not perform any static functions.
When installing PREMANT DUO pipes, fixing plates must be installed on site in the following
situations:
– at the end of house lead-ins
– on all ends of fitting bends and branches
– on the larger side of reduction pieces (except for pre-insulated reduction pieces)
Please contact your BRUGG partner for information on design and execution.
All the illustrations are schematic representations, and they do not correspond to the origi-
nal components in every detail.
8.1.2015
System description
1. Medium pipe
Bars: steel pipes with longitudinal or helical seam welds

Quality: P235TR1 or P235GH as per (EN 10220/ EN 10217-1) or EN 10217-2
Standard: EN 15698-1
Test certificate: EN 10204-3.1
Welding bevel: From wall thickness > 3.2 mm, as per DIN 2559-1 codes 21 and 22
Preformed parts: T-pieces are flared, or are produced with a welded T-piece as per EN 10253 (formerly DIN 2615);
material as appropriate to the straight welded pipes.
Quality: P235TR1 or P235GH as per EN 10220/ EN 10217
Standard: EN 448
Test certificate: EN 10204-3.1
Welding bevel: From wall thickness > 3.2 mm, as per DIN 2559-1, codes 21 and 22
Bends are made from cold-bent (seamless or welded) steel pipes, or with welded bends
as per EN 10253 (formerly DIN 2605).
Quality: P235TR1 or P235GH as per EN 10220/ EN 10217
Standard: EN 448
Welding bevel: From wall thickness > 3.2 mm, as per DIN 2559-1, codes 21 and 22
Note:
To ensure a long service life for the PREMANT plastic jacket pipe system, it is important to
observe the correct heating water quality. The requirements of VDI 2035 (standard of the
Association of German Engineers), AGFW FW 510 (worksheet of the German District Heating
Association) and European standard EN 12953-10 must be complied with, in particular with
respect to preventing magnetite (iron(II,III) oxide) and scale formation.
Before commissioning, a newly installed heat distribution network should be run without a
heat exchanger, if possible, and the particulate matter should be removed using a suitable filter
system. If possible, this procedure should also be repeated each time the network is extended or
repairs are made.
8.1.2015
System description
Material: Polyurethane foam (pentane-blown), manufactured from 3 components:

polyol, isocyanate and cyclopentane
High-pressure plants are used for mixing and metering.
PUR insulation Reference temperature °C PREMANT value Test standard

Pressure resistance - ≥ 0.3 MPa EN 253
Percentage of closed cells - ≥ 96 %
Water absorption after 24 hours - ≤ 10 %
2.1 Supplementary insulation
Standard: EN 489
Execution: – Executed by trained installation staff
– Polyurethane foam is used to foam and seal the sleeve joints
– Sealing with shrink-on sleeve or electro-welding joint
– Connecting the monitoring wires
– Installing the expansion pads, consisting of an elastic foam material which is resistant to ageing
3. Casing pipe
Quality: PE-HD, GM 5010 T3 or equivalent

Standard: EN 15698-1
Dimensions of PE-HD casing pipes Dimensions of PE-HD casing pipes

Outer Ø Pipe Preformed parts Outer Ø Pipe/Preformed parts
mm mm mm mm mm
125 3.0 4.0 355 5.1
140 3.0 4.0 400 5.3
160 3.0 4.0 450 5.6
180 3.0 4.0 500 6.3
200 3.2 4.0 560 7.0
225 3.5 4.0 630 7.6
250 3.6 5.0 670 8.0
280 4.4 5.0
315 4.5 6.3
4. Monitoring wires
Brandes system: 1 x CrNi, red, insulated and perforated, Ø 0.8 mm / 0.5 mm2

1 x Cu, green, insulated, Ø 1.0 mm / 0.8 mm2
Nordic system: 1 x Cu, bare: 1.5 mm2
1 x Cu, tinned: 1.5 mm2
Task: Identification and location of moisture by means of resistance or pulse measurements
8.1.2015
Heat loss
Heat loss q [W/m] for VL and RL together

PREMANT DUO U-value Average operating temperature TB [°C]
W/mK 50 °C 60 °C 70 °C 80 °C 90 °C 100 °C 110 °C 120 °C 130 °C
26.9/ 26.9 - 125 0.174 7.0 8.7 10.5 12.2 13.9 15.7 17.4 19.2 20.9
33.7/ 33.7 - 140 0.195 7.8 9.7 11.7 13.6 15.6 17.5 19.5 21.4 23.3
42.4/ 42.4 - 160 0.216 8.6 10.8 12.9 15.1 17.2 19.4 21.6 23.7 25.9
48.3/ 48.3 - 160 0.263 10.5 13.2 15.8 18.4 21.1 23.7 26.3 29.0 31.6
60.3/ 60.3 - 200 0.254 10.2 12.7 15.2 17.8 20.3 22.8 25.4 27.9 30.5
76.1/ 76.1 - 225 0.312 12.5 15.6 18.7 21.8 24.9 28.1 31.2 34.3 37.4
88.9/ 88.9 - 250 0.363 14.5 18.1 21.8 25.4 29.0 32.6 36.3 39.9 43.5
114.3/114.3 - 315 0.362 14.6 18.3 21.9 25.6 29.2 32.9 36.5 40.2 43.8
139.7/139.7 - 400 0.331 13.4 16.7 20.1 23.4 26.8 30.1 33.5 36.8 40.2
168.3/168.3 - 450 0.413 16.6 20.8 25.0 29.1 33.3 37.4 41.6 45.7 49.9
219.3/219.3 - 560 0.473 18.9 23.6 28.3 33.0 37.7 42.4 47.1 51.8 56.6
Caution: In contrast to the single pipes heat losses the losses for both pipes listed together here.
RL
VL
H = 0.8 m

TE
lE
8.1.2015
Heat loss

W/mK 50 °C 60 °C 70 °C 80 °C 90 °C 100 °C 110 °C 120 °C 130 °C
26.9/ 26.9 - 140 0.154 6.1 7.7 9.2 10.8 12.3 13.8 15.4 16.9 18.4
33.7/ 33.7 - 160 0.165 6.6 8.3 9.9 11.6 13.2 14.9 16.5 18.2 19.8
42.4/ 42.4 - 180 0.184 7.3 9.2 11.0 12.9 14.7 16.5 18.4 20.2 22.0
48.3/ 48.3 - 180 0.216 8.6 10.8 12.9 15.1 17.3 19.4 21.6 23.7 25.9
60.3/ 60.3 - 225 0.211 8.4 10.5 12.6 14.8 16.9 19.0 21.1 23.2 25.3
76.1/ 76.1 - 250 0.253 10.1 12.6 15.2 17.7 20.2 22.8 25.3 27.8 30.3
88.9/ 88.9 - 280 0.278 11.1 13.9 16.7 19.5 22.2 25.0 27.8 30.6 33.4
114.3/114.3 - 355 0.275 11.1 13.8 16.6 19.4 22.1 24.9 27.7 30.4 33.2
139.7/139.7 - 450 0.258 10.4 13.0 15.5 18.1 20.7 23.3 25.9 28.5 31.1
168.3/168.3 - 500 0.310 12.4 15.5 18.7 21.8 24.9 28.0 31.1 34.2 37.3
219.3/219.3 - 630 0.328 13.0 16.3 19.6 22.8 26.1 29.3 32.6 35.8 39.1
RL
VL
H = 0.8 m

TE
lE
8.1.2015
Heat loss

W/mK 50 °C 60 °C 70 °C 80 °C 90 °C 100 °C 110 °C 120 °C 130 °C
26.9/ 26.9 - 140 0.135 5.4 6.8 8.1 9.5 10.8 12.2 13.5 14.9 16.2
33.7/ 33.7 - 160 0.147 5.9 7.4 8.8 10.3 11.8 13.2 14.7 16.2 17.6
42.4/ 42.4 - 180 0.163 6.5 8.2 9.8 11.4 13.0 14.7 16.3 17.9 19.6
48.3/ 48.3 - 180 0.187 7.5 9.4 11.2 13.1 15.0 16.8 18.7 20.6 22.4
60.3/ 60.3 - 225 0.184 7.4 9.2 11.0 12.9 14.7 16.6 18.4 20.2 22.1
76.1/ 76.1 - 250 0.212 8.5 10.6 12.7 14.8 17.0 19.1 21.2 23.3 25.4
88.9/ 88.9 - 280 0.226 9.0 11.3 13.6 15.8 18.1 20.3 22.6 24.9 27.1
114.3/114.3 - 355 0.224 9.0 11.2 13.4 15.7 17.9 20.2 22.4 24.6 26.9
139.7/139.7 - 450 0.218 8.7 10.9 13.1 15.3 17.4 19.6 21.8 24.0 26.2
168.3/168.3 - 500 0.248 9.9 12.4 14.9 17.4 19.8 22.3 24.8 27.3 29.8
219.3/219.3 - 630 0.257 10.3 12.9 15.4 18.0 20.6 23.1 25.7 28.3 30.8
RL
VL
H = 0.8 m

TE
lE
8.1.2015
District heating pipe – DUO

Medium pipes, pre-insulated in the factory, with plastic casing pipe and 200 mm free pipe ends.
Key features of double pipes are: reduced heat loss, less outlay on underground construction work and faster completion
times than single pipes. The temperature difference between the medium pipes causes stresses within the system. This
results in additional static requirements which must be considered during installation.
Nominal Steel pipe Wall thickness Distance PE casing pipe delivery lengths Volume
width d s x D D D 6 m 12 m 16 m Inner pipe
DS1 DS2 DS3
DN mm mm mm mm kg/m mm kg/m mm kg/m l/m
20 26.9 2.6 19 125 4.9 140 5.3 160 5.7 • 2 x 0.37
25 33.7 2.6 19 140 6.1 160 6.6 180 7.1 • 2 x 0.64
32 42.4 2.6 19 160 7.6 180 8.2 200 8.8 • • 2 x 1.02
40 48.3 2.6 19 160 8.3 180 8.9 200 9.5 • • 2 x 1.38
50 60.3 2.9 20 200 11.8 225 12.6 250 13.7 • • 2 x 2.28
65 76.1 2.9 20 225 14.8 250 15.7 280 17.5 • • 2 x 3.82
80 88.9 3.2 25 250 18.5 280 19.7 315 22.0 • • 2 x 5.35
100 114.3 3.6 25 315 27.5 355 29.5 400 32.8 • • • 2 x 9.01
125 139.7 3.6 30 400 36.6 450 39.7 500 44.4 • • • 2 x 13.8
150 168.3 4.0 40 450 47.3 500 50.7 560 57.2 • • • 2 x 20.2
200 219.1 4.5 45 560 70.3 630 76.2 710 86.9 • • • 2 x 34.7
x = clear distance between medium pipes
8.1.2015
Elbow pipe
Elbow pipes are plastic casing pipes made to customer specifications and pre-insulated at the factory. Elbow pipes
are produced as curved plastic casing pipes with a large radius and serve to optimise pipe routing when the direction
changes.
Elbow pipes behave in the same way as straight pipes; in other words, heat expansion does not cause any bending mo-
ment. The deflection angle "a" of the pipe routing or the bend radius "R" must be known in order to produce elbow pipes.
All elbow pipes have straight ends between 1.2 and 2.0 m due to machine-based production.
The PUR foam is subject to lateral pressure as a consequence of heat expansion and the curve of the pipe. The magnitu-
de of this pressure must not exceed the permissible force of 0.15 MPa. The outcome of this is a maximum permissible
deflection angle "a" or a minimum bend radius "R".
The permissible values are contained in the following table.
Deflection angle for elbow pipes à 12m

Nominal Deflection angle min.perm.
width minimum maximal radius
DN a [°] a R [m]
32 10 33 20.8
40 8 31 22.2
50 6 29 23.7
65 5 24 28.6
80 3 20 34.4
100 3 18 38.2
125 3 16 43.0
150 3 11 62.5
200 on request
8.1.2015
Bend, with equal limbs, 90°

Design versions
Two versions are offered for double pipe bends. When installing normal pipelines,
"horizontal" bends are used whereas for house lead-ins and vertical projections,
"vertical" bends are required.
The sketches on the right illustrate the design versions.
Horizontal Vertical
Nominal Diameter Limb length PE casing pipe

width d L D D D
DS1 DS2 DS3
DN mm mm mm mm mm
20 26.9 1000 125 140 160
25 33.7 1000 140 160 180
32 42.4 1000 160 180 200
40 48.3 1000 160 180 200
50 60.3 1000 200 225 250
65 76.1 1000 225 250 280
80 88.9 1000 250 280 315
100 114.3 1000 315 355 400
125 139.7 1000 400 450 500
150 168.3 1000 450 500 560
200 219.1 1300 560 630 710
8.1.2015
Bend, with equal limbs, 45°
Nominal Diameter Limb length PE casing pipe

width d L D D D
DS1 DS2 DS3
DN mm mm mm mm mm
20 26.9 1000 125 140 160
25 33.7 1000 140 160 180
32 42.4 1000 160 180 200
40 48.3 1000 160 180 200
50 60.3 1000 200 225 250
65 76.1 1000 225 250 280
80 88.9 1000 250 280 315
100 114.3 1000 315 355 400
125 139.7 1000 400 450 500
150 168.3 1000 450 500 560
200 219.1 1300 560 630 710
8.1.2015
T-piece, 90°
L1
L2
Main pipe Branch

DN 20 25 32 40 50 65 80 100 125 150 200
D 125 140 160 160 200 225 250 315 400 450 560
(DS1)
D 140 160 180 180 225 250 280 355 450 500 630
(DS2)
D 160 180 200 200 250 280 315 400 500 560 710
(DS3)
DN D D D
(DS1) (DS2) (DS3)
20 125 140 160 L2 600
L1 1000
25 140 160 180 L2 600 600
L1 1000 1000
32 160 180 200 L2 600 600 600
L1 1000 1000 1000
40 160 180 200 L2 600 600 600 600
L1 1000 1000 1000 1000
50 200 225 250 L2 700 700 700 700 700
L1 1000 1000 1000 1100 1100
65 225 250 280 L2 700 700 700 700 700 700
L1 1000 1000 1000 1000 1200 1200
80 250 280 315 L2 700 700 700 700 700 700 700
L1 1000 1000 1000 1000 1100 1300 1300
100 315 355 400 L2 800 800 800 800 800 800 800 800
L1 1000 1000 1000 1000 1100 1100 1400 1400
125 400 450 500 L2 900 900 900 900 900 900 900 900 900
L1 1000 1000 1000 1000 1100 1100 1200 1500 1500
150 450 500 560 L2 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
L1 1000 1000 1000 1000 1100 1100 1200 1200 1600 1600
200 560 630 710 L2 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
L1 1000 1000 1000 1000 1100 1100 1200 1200 1800 1800 1800

Figures in mm
8.1.2015
Y-pipe, type G
straight, insulation thickness 1
Y-pipes are used to produce a transition from conventional installation with two single pipes to the space-saving
PREMANT DUO system.
The upper pipe (preferably the return) runs straight through the Y-pipe, whereas the lower pipe is angled outwards
at 90°. With type G, the double and single pipes have parallel axes. Fixing plates are positioned on the side of the
double pipe connection.
Design versions
Two different design versions are offered for Y-pipes. The relevant type must be stated
when ordering. The arrows in the sketch show the direction of flow in the forward flow pipe.
Combine Separate
L2
L1
A reducing sleeve must be used on single pipe side, to connect the pipe that passes straight
through.
Nominal Diameter Overall Junction Distance PE casing pipe

width (installed) length
d L1 L2 a D1 D2
DN mm mm mm mm mm mm
20 26.9 1000 450 250 125 90
25 33.7 1000 460 250 140 90
32 42.4 1000 480 300 160 110
40 48.3 1200 480 300 160 110
50 60.3 1200 500 300 200 125
65 76.1 1200 510 350 225 140
80 88.9 1400 510 400 250 160
100 114.3 1400 510 450 315 200
125 139.7 1400 530 500 400 225
150 168.3 1500 570 550 450 250
200 219.1 1800 700 660 560 315
8.1.2015
Y-pipe, type G
PREMANT DUO system.
at 90°. With type G, the double and single pipes have parallel axes. Fixing plates are positioned on the double pipe
connection side.
Design versions
Combine Separate
L2
L1
through.

d L1 L2 a D1 D2
20 26.9 1000 450 250 140 110
25 33.7 1000 460 250 160 110
32 42.4 1000 480 300 180 125
40 48.3 1200 480 300 180 125
50 60.3 1200 500 300 225 140
65 76.1 1200 510 350 250 160
80 88.9 1400 510 400 280 180
100 114.3 1400 510 450 355 225
125 139.7 1400 530 500 450 250
150 168.3 1500 570 550 500 280
200 219.1 1800 700 660 630 355
8.1.2015
Y-pipe, type G
PREMANT DUO system.
at 90°. With type G, the double and single pipes have parallel axes. Fixing plates are positioned on the double pipe
connection side.
Design versions
Combine Separate
L2
L1
through.

d L1 L2 a D1 D2
20 26.9 1000 450 270 160 125
25 33.7 1000 460 280 180 125
32 42.4 1000 480 300 200 140
40 48.3 1200 480 300 200 140
50 60.3 1200 500 330 250 160
65 76.1 1200 510 350 280 180
80 88.9 1400 510 400 315 200
100 114.3 1400 510 460 400 250
125 139.7 1400 530 540 500 280
150 168.3 1500 570 580 500 315
200 219.1 1800 700 740 710 400
8.1.2015
Y-pipe, type W
angled, insulation thickness 1
Y-pipes are used to make a transition from a conventional installation with two single pipes to
the space-saving PREMANT DUO system.
With type W, the double and single pipes run at an angle of 90°. Fixing plates are positioned on
the double pipe connection side.
Design versions
Combine Separate
b
L

d L b a D1 D2
20 26.9 1000 500 320 125 90
25 33.7 1000 500 320 140 90
32 42.4 1000 500 340 160 110
40 48.3 1000 500 340 160 110
50 60.3 1000 550 355 200 125
65 76.1 1100 550 420 225 140
80 88.9 1200 600 440 250 160
100 114.3 1350 600 480 315 200
125 139.7 1450 650 505 400 225
150 168.3 1600 700 530 450 250
200 219.1 2000 750 700 560 315

8.1.2015
Y-pipe, type W
Design versions
Combine Separate
b
L

d L b a D1 D2
20 26.9 1000 500 320 140 110
25 33.7 1000 500 320 160 110
32 42.4 1000 500 340 180 125
40 48.3 1000 500 340 180 125
50 60.3 1000 550 355 225 140
65 76.1 1100 550 420 250 160
80 88.9 1200 550 440 280 180
100 114.3 1350 600 480 355 225
125 139.7 1450 600 505 450 250
150 168.3 1600 700 530 500 280
200 219.1 2000 750 700 630 355

8.1.2015
Y-pipe, type W
Design versions
Combine Separate
b
L

d L b a D1 D2
20 26.9 1000 500 320 160 125
25 33.7 1000 500 320 180 125
32 42.4 1000 500 340 200 140
40 48.3 1000 500 340 200 140
50 60.3 1000 550 355 250 160
65 76.1 1100 550 420 280 180
80 88.9 1200 550 440 315 200
100 114.3 1350 600 480 400 250
125 139.7 1450 600 505 500 280
150 168.3 1600 700 530 560 315
200 219.1 2000 750 700 710 400
8.1.2015
Fixed point
Pre-insulated in the factory, design as per EN 448, steel quality and dimensions of steel pipe
and PE outer casing correspond to those of the straight pipe.
The anchor is a square steel plate that is designed according to the load it must take.
The medium pipe and the anchor plate are thermally and electrically separated from each other.
Nominal Diameter Overall (installed) length PE casing pipe

width d L D D D
DS1* DS2 DS3
DN mm mm mm mm mm
20 26.9 2000 140 160
25 33.7 2000 160 180
32 42.4 2000 180 200
40 48.3 2000 180 200
50 60.3 2000 225 250
65 76.1 2000 250 280
80 88.9 2000 280 315
100 114.3 2000 355 400
125 139.7 2000 450 500
150 168.3 2000 500 560
200 219.1 2000 630 710
* Due to the internal structure of the electrical isolation, DUO fixed points only in DS2 are
available. When DUO fixed points in DS1 systems be installed, so shrink-on sleeves (7.342) are
necessary to connect the jacket pipes.
8.1.2015
Vent
Pre-insulated in the factory, design as per EN 448, produced with a T-piece as per DIN 2615-1.
With inbound and outbound venting ball valves made of stainless steel. A heat-shrunk end cap
is used for frontal insulation protection on the vent nozzle. The nozzle height is 600 mm above
the top of the base pipe.
The standard design for this vent fitting is as follows:

– non-insulated stainless steel ball valve with inner thread and plug
– reduced through passage
– for key operation
b
a
h
Nominal Diameter Overall Distance Offset Height PE casing pipe Vent

width d L a b h D D D D
DS1 DS2 DS3
DN mm mm mm mm mm mm mm mm DN mm
25 33.7 1200 200 100 600 140 160 180 25 90
32 42.4 1200 200 100 600 160 180 200 25 90
40 48.3 1200 200 100 600 160 180 200 25 90
50 60.3 1200 200 140 600 200 225 250 25 90
65 76.1 1200 200 140 600 225 250 280 32 110
80 88.9 1200 200 140 600 250 280 315 32 110
100 114.3 1400 200 100 600 315 355 400 32 110
125 139.7 1400 200 100 600 400 450 500 40 110
150 168.3 1400 200 100 600 450 500 560 40 110
200 219.1 1400 200 175 600 560 630 710 40 110
8.1.2015
Ball valve
Pre-insulated shut-off fittings for direct installation in the ground, design as per EN 488, pre-insulated in the factory,
frontal insulation protection on the dome with heat-shrunk end cap, ball valve with fully welded housing, yield strength
fitting, version for max. axial stress up to 300 N/mm2.
Ball valves can be supplied with reduced or full-size through passages. The stem height depends on the desired brand
of ball valve. A socket wrench or plug-on gear is used for operation. Fixing plates are installed on both sides of the
connection.

width d L a b D D D
DS1 DS2 DS3
DN mm mm mm mm mm mm mm
20 26.9 2000 225 50 125 140 160
25 33.7 2000 225 55 140 160 180
32 42.4 2000 225 65 160 180 200
40 48.3 2000 225 85 160 180 200
50 60.3 2000 225 110 200 225 250
65 76.1 2000 225 145 225 250 280
80 88.9 2100 225 165 250 280 315
100 114.3 2300 225 225 315 355 400
125 139.7 2500 225 275 400 450 500
150 168.3 2800 300 315 450 500 560
200 219.1 not available*
* will be integrated into subsequent UNO pipes
8.1.2015
Sleeve joints
Shrink sleeve, non-cross-linked/cross-linked
1. PE shrink sleeve, non-cross-linked
The non-cross-linked shrink sleeve consists of a heat-shrunk PE sleeve

pipe and the following accessories:
– Shrink-on collars
– Permanently elastic sealing strip, butyl rubber
– Venting plug
– Welded-in PE plug
The shrink sleeves are pushed onto the casing pipe when the pipe is
being laid, before the medium pipe weld seams are made. The connec-
tion points are then fitted with additional insulation by trained fitting
staff who have been tested as per AGFW Worksheet FW 603.
This produces a watertight, non-positive connection between the cas-

ing pipe and the sleeve. The sealing strip and the shrink-on collars are
used to double-seal the sleeve joint. Technical requirements as per
EN 489, AGFW Worksheet FW401, parts 6, 14, 16 and 17.

Length: 700, 1000, 1400 mm
2. Shrink sleeve made of cross-linked PE
The cross-linked shrink sleeve consists of molecular cross-linked

polyethylene, so only limited welding is possible. The very high shrink-
age capacity of this material, combined with the sealing strip inserted
between the casing pipe and the sleeve, produces a very strong non-
positive connection.
Because this type of sleeve can withstand high mechanical loads, it

is especially suitable for plastic casing pipe sections that are subject
to higher stresses (e.g. frequent load alternation, pipes laid in the
groundwater zone).

Length: 700 mm
8.1.2015
Sleeve joints
Reduction sleeves, fitting sleeves and shrink-on end sleeves
3. Shrink-on reduction sleeves
For reasons related to statics, shrink-on reduction sleeves to insulate

steel reduction joints that are welded in by the pipelayer (provided
by the customer or others) are designed to reduce the dimension by
a maximum of three steps. Their structure corresponds to that of the
non-cross-linked PE shrink sleeve, and they must be pushed onto the
outer casing before the medium pipe is welded.
The non-cross-linked reduction shrink sleeve consists of a heat-shrunk

PE sleeve pipe and the following accessories:
– Shrink-on collars
– Permanently elastic sealing strip, butyl rubber
– Venting plug
– Welded-in PE plug
Nominal Reduction joint Length Nominal Reduction joint Length

D D D D L D D D D L
140 125 700 355 315 280 250 900
160 140 125 700 400 355 315 280 900
180 160 140 125 700 450 400 355 315 900
200 180 160 140 900 500 450 400 355 1200
225 200 180 160 900 560 500 450 400 1200
250 225 200 180 900 630 560 500 450 1200
280 250 225 200 900 710 630 560 500 1200
315 280 250 225 900
4. Fitting sleeve
Fitting sleeves made of non-cross-linked PE are used when lack of

space makes it impossible to push the joint sleeves on. The fitting
sleeve is separated in the axial direction and it can then be moved into
position over the points where the pipes are connected. This separa-
tion point is welded to guarantee the tightness of the sleeve.

Length: 700, 1000, 1400 mm
5. Shrink-on end sleeve
The shrink-on end sleeve is used to insulate pipe closures

in the ground and in buildings or shafts. It has the same structure as a
non-cross-linked PE shrink-on sleeve, but is sealed on one side with a
PE end cover.

Length with closure
with cap: 700 mm
with 1x ball valve: 1200 mm
In Switzerland, it is preferable not to use shrinkable end sleeves.
8.1.2015
Brugg VISUCON
Brugg VISUCON is a connection technology which is fundamentally different from the processing
of other sleeve systems. VISUCON makes possible visual inspection of the polyurethane foam. This
means it is not necessary to destroy the sleeve or the foam.
With the VISUCON connection sleeve, the annular space for the external foaming process is not
limited by a polyethylene sleeve, but by reusable forming shells. With this technology, the external
sealing connection is not made until after the foaming process is complete. The result and quality of
the polyurethane foam can be reliably tested for every sleeve.
Sleeve system parts:
- Polyurethane foam, made of liquid components polyol and isocyanate (cf. PRE 7.410)
- Sealing shrink film
- Sealing tape
- VISUCON sleeve bodies made of integrated shrinkable HDPE
A cylindrical VISUCON shell is used for installation, which is then removed after the polyurethane
foam hardens. The two sealing systems are then installed. Due to the system design, no foaming
holes are necessary, meaning the plug welding process can also be omitted. The VISUCON sleeve
body shrinks across its entire length during installation, whereby the sleeve area does not expand.
This unchanging pipe diameter can be advantageous during pipe installation in empty tubes or
when driving over cable links.

Nominal size: 160...710 mm
Length: 780 mm
Welding - Foaming - Sealing
Brugg VISUCON is only available as a straight connection sleeve. Non-integrated shrink sleeves
should be used for reducing sockets and stop ends.
Polyurethane half shells
The VISUCON connection sleeve can also be used together with the prefabricated polyurethane
half shells. In this case, forming VISUCON shells are not necessary. The remaining installation is
identical.
8.1.2015
Wall sealing ring, pipe warning tape

Wall sealing ring Data table: sealing ring
D Da
90 133
110 153
125 168
140 183
160 203
180 223
200 240
225 265
250 290
Da
315 355
355 395
400 440
450 490
500 540
560 600
630 670
710 750
Figures in mm
50
Pipe warning tape

Material width Language Print colour
mm
40 German blue
100 German/English/French/Italian blue
Standard roll length, 250 m
Installation depth; see sheet PRE 6.500
8.1.2015
Shrink-on closure
Shrink-on closure/end cap
PREMANT DUO shrink-on closures protect the PUR insulation on the front of the PREMANT district heating pipes against
splashing water in buildings and shafts. The shrink-on closure is not necessarily watertight in contact with water (flood-
ing). The shrink-on closure also stops gas escaping from the PUR insulation at the end of the pipe.
Material: Important fitting note

Heat-shrunk, PREMANT DUO shrink-on
cross-linked polyolefin. closures must be pushed
Coated with onto the end of the
sealing adhesive PREMANT DUO district
heating pipe before
welding the inner pipes,
and must be protected
against the action of heat
min. 120 mm during welding.
Allocation of PREMANT DUO dimensions to type of shrink-on closure

Nominal Insulation thickness, DS1 Insulation thickness, DS2 Insulation thickness, DS3
width Casing End cap Mantel- End cap Casing End cap
DN pipe Type rohr Type pipe Type
mm mm mm
20- 20 125 2-30 140 2-50 160 2-50
25- 25 140 2-30 160 2-60 180 2-60
32- 32 160 2-70 180 2-70 200 2-70
40- 40 160 2-70 180 2-70 200 2-70
50- 50 200 2-90 225 2-90 250 2-110
65- 65 225 2-90 250 D-110 280 D-120
80- 80 250 D-110 280 D-120 315 D-120
100-100 315 D-120 355 D-130 400 D-130
125-125 400 D-130 450 D-140 500 D-140
150-150 450 D-140 500 D-140 560 D-355
200-200 560 D-355 630 D-355 710 D-355
8.1.2015
Rigid foam bar

Nominal size Thickness Length
1 100 x 100 mm 1000 mm

Material Polystyrene
Pressure resistance 150 kPa
Apparent (bulk) density 30 kg/m3
Thermal conductivity group 040
Rigid foam bars are used as supports for plastic casing pipes in the pipe trench. Rigid foam bars can remain sanded into
the pipe trench.
Rigid foam bars are only partially suitable for large pipes. They tend to break under high loads if they are not properly
supported. In most cases, the additional outlay for a flat trench floor is not justified. For PREMANT DUO district pipe from
DN 100 upwards, GERMAN PIPE recommends sandbags, sand beds or timber strips.
If timber strips are used for alignment, it must be ensured that they are removed again after the welding work is com-
pleted, prior to sanding-in. Otherwise, the casing may be damaged due to thermal expansion.
8.1.2015
Ring seal
Seal against water (exerting pressure/not exerting pressure) in water-impermeable components
Wall leadthrough with double seal, Wall leadthrough,

impermeable to water exerting pressure impermeable to water not exerting pressure
3 3
1 1
D
D
R
R
2 2
1 PREMANT DUO district heating pipe 1 PREMANT DUO district heating pipe
2 Sealing kit, double seal 2 Sealing kit, single seal
3 Liner pipe made of fibre cement or coated core bore 3 Liner pipe made of fibre cement or coated core bore
Casing pipe diameter Liner pipe Core bores

PE Core bore Perfect bores are required for installation. As hairline cracks may
ØR ØD be present in the concrete or could be caused by processing, it is
mm mm advisable to seal the entire length of the borehole wall with suitable
125, 140 200 sealant (such as AQUAGARD).
160, 180 250
200, 225 300 Tightness can only be guaranteed if this recommendation is fol-
250, 280 350 lowed.
315 400
355 450 Installation / trench infill
400 500 To avoid deformations at the sealing point, it is especially important
450 600 during installation and when filling the trench to ensure that no subse-
500 700 quent sinking of the pipe can occur. We also recommend that the pipe
560 700 is supported or suspended inside the building. Tightness cannot be
630 800 guaranteed unless these recommendations are followed.
710 800
8.1.2015
Expansion pad
Description
In order to absorb expansion movements of the underground pipe system in bends, branches and reduction pieces, expansion pads must be
applied to the outer PE casing in these areas. Expansion pads are manufactured from cross-linked closed-cell polyethylene, are permanently
elastic, do not decay and are resistant to chemicals. The expansion zone is designed on the basis of pipe statics calculations.
Delivery
The delivery scope for an expansion zone of 1 m comprises 2 pieces of expansion pad strip, length 1000 mm, which are glued onto the outer
casing at the 3 o'clock and 9 o'clock positions. Laminate is then wrapped around the entire zone in order to prevent sand or soil particles from
penetrating between the expansion pad and the PE casing.
Material: Polyethylene particle foam

Nominal width: Size I 120mm Apparent (bulk) density 32 Kg/m³
Size II 240mm Tensile strength 160 kPa
Size III 360mm Compressive stress
50 % deformation at 23 °C 100 kPa
Nominal thickness: 40 mm Vibration fatigue test, 80,000 load changes
- Change in thickness 2,4 %
- Change in hardness number 2,4 %
Absorption of water (volume fraction)
- after 1d 2,0 %
- after 7d 3,0 %
Thermal conductivity at 10 °C 0,040 W/mK
120 240 360

1000
1000
1000
EP strip = 1 m
PUR insulation
Medium pipe
Laminate
Diameter Nominal size Weight Volume

Outer casing Name Existing
mm designation kg/unit kg/m m³/pce m³/m
125 to 160 Size 1 I 0.154 0.307 0.0048 0.0096
180 to 280 Size 2 II 0.307 0.614 0.0096 0.0192
315 to 355 Size 3 III 0.461 0.922 0.0144 0.0288
400 to 450 Size 4 II+II 0.614 1.229 0.0192 0.0384
500 to 560 Size 5 II+ III 0.768 1.536 0.0240 0.0480
630 Size 6 IIl+ III 0.922 1.843 0.0288 0.0576
710 Size 7 IIl+ II+II 1.075 2.151 0.0336 0.0672
8.1.2015
Assembly Foam
Component A Polyol
Colour ocker
Density 1.04 kg/m3
Solubility in water yes
Component B Isocyanat
Colour brown
Density 1.23 kg/m3
Solubility in water no
Storage
The components of the foam system may only be stored and transported in the original canisters. The canisters have
to be stored in a dry environment. They should stay airtight closed and sealed. Direct solar radiation and frost have
to be avoided.
Are the foam components stored in a closed room, the room has to be ventilated. The minimum ventilation is an air
change twice in 24 h. The temperature ought to be between 10 and 25 ºC.
While storing together with other substances, these have to be basically compatible. Furthermore we refer to the
“VCI-Konzept zur Zusammenlagerung von Chemikalien” of the “Verband der chemischen Industrie”.
PUR-foam-components should not be stored for longer then 6 months.
Storage Value Unit

Temperature 10 ... 25 °C
Ventilation twice each 24 h
Period < 180 days
Disposal
Basically a disposal of the fluent components should be avoided. The disposal of this product hat to occur at all times
in compliance with the standards of environmental protection and laws of waste disposal as well as the requirements
of the local authorities. It is recommended to clarify the details with the responsible waste management company.
Classification
Substance ADR/RID-class Water hazard class Storage class Waste class EAK Code
Component A (Polyol) 3 1 Class 3 08 04 09
Component B (Isocaynat) – 1 Class 10 08 05 01
8.1.2015
PREMANT DUO-Fernwärmeleitung PRE DUO 7.410
Montageschaum
Eigenschaften Wert Einheit
Komponente A Polyol
Farbe ocker
Dichte 1.04 kg/m3
Löslichkeit in Wasser ja
Komponente B Isocyanat
Farbe braun
Dichte 1.23 kg/m3
Löslichkeit in Wasser nein
Lagerung
Die Komponenten des Schaumsystems dürfen nur in Originalbehältern gelagert und transportiert werden. Die Behälter
müssen trocken und vor Feuchtigkeit gut geschützt abgestellt werden. Sie sollten bis zur Verwendung dicht verschlossen
und versiegelt bleiben. Bei der Lagerung muss direkte Sonneneinstrahlung sowie Frost unbedingt vermieden werden.
Werden die Schaumkomponenten in geschlossenen Räumen aufbewahrt, so müssen diese gut belüftet sein. Als mini-
maler Luftwechsel wird ein 2-facher Austausch in 24 h angesehen. Die Lagertemperatur sollte zwischen 10 und 25°C
betragen.
Bei der Zusammenlagerung mit anderen Stoffen müssen diese grundsätzlich verträglich sein. Nahrungsmitteln und Ge-
tränke sollten nicht gemeinsam mit den Komponenten des Schaums gelagert werden. Weiterhin sei auf das „VCI-Konzept
zur Zusammenlagerung von Chemikalien“ des Verbandes der chemischen Industrie hingewiesen.
PUR-Schaum-Komponenten sollten nicht länger als 6 Monate gelagert werden.
Lagerung Wert Einheit

Temperatur 10 ... 25 °C
Raumluftwechsel 2-fach pro 24 h
Dauer < 180 Tage
Entsorgung
Grundsätzlich sollte eine Entsorgung der flüssigen Komponenten weitgehend vermieden werden. Die Entsorgung dieses
Produkts sowie seiner Lösungen und Nebenprodukte muss jederzeit unter Einhaltung der Umweltschutzanforderungen
und Abfallbeseitigungsgesetze sowie den Anforderungen der örtlichen Behörden erfolgen. Es wird empfohlen, die Einzel-
heiten mit dem verantwortlichen Entsorgungsunternehmen zu klären.
Einstufung Wasser-
Stoff ADR/RID-Klasse gefährdungsklasse Lagerklasse Abfallklasse EAK Code
Komponente A (Polyol) 3 1 Klasse 3 08 04 09
Komponente B (Isocaynat) – 1 Klasse 10 08 05 01
8.1.2015
Technische Änderungen vorbehalten.
Monitoring technology/Visileak VSL 8.0
Table of Contents

8.100 General system description
8.110 Principle of operation
8.120 Measurement principle
8.2 Planning, inspection plans

8.200 Planning, sensor loop plan
8.210 Inspection plans, weld seam plans
8.3 LMS 120 monitoring device

8.300 Description of device, technical data
8.310 Description of device, sheet 2
8.320 Description of device, sheet 3
8.1.2015
General system description

In the majority of cases, district heat pipes laid underground are now equipped with operational monitoring systems. The
benefits are that damage can be detected at an early stage and easily located. Together with the appropriate monitoring
devices, monitoring wires foamed into the heat insulation at the factory perform a wide variety of tasks. Operational re-
liability and safety are increased, and costs of damage are limited.
The following BRUGG pipe systems are factory-equipped for monitoring with the resistance reference measuring method
(WIREM) as standard: FLEXWELL district heating cables, PREMANT district heating pipe and CASAFLEX district heating
pipe; BRUGG STEEL CASING PIPE can also be equipped for this purpose on request. (On request, PREMANT district hea-
ting pipe can be supplied with different monitoring wires).
WIREM and BRANDES are compatible systems.
The WIREM technology makes it possible to carry out a large number of functions with the help of the monitoring wires
and devices:
• Monitoring heat insulation for moisture - already possible when the pipe is being installed. Supply of informative
measurement data on the condition of the heat insulation.
• Contact between monitoring wires and inner pipe, break-offs or interruptions anywhere in the circuit are differentiated
and displayed.
• During operation, the entry of moisture - for example through weld seam faults, non-tight joints or external damage -
can be measured, signalled and located, not only in the area of the joint but continuously throughout the entire length
of the pipe.
• Short circuit detection
• Alarm signals are passed on via outputs for external alarm devices.
Depending on the requirements for network size and data availability, a suitable system can be selected from the range
of measurement, monitoring and locating equipment based on the modular principle.
Device combinations range from manual entry of measurement data about the status of the heat insulation and manual
fault location (device LMS 120) through to fully automated monitoring and fault location (devices available on the market)
with remote signalling, test inquiries via dialog electronics, storage of measurement data and electronic data transmitters
to computers and printers in central management systems.
8.1.2015
Principle of operation
Monitoring wires
The monitoring wires (sensor wire and feedback wire) are positioned continuously in the heat insulation of the pipe,
between the outer and inner pipes. On PREMANT and CASAFLEX, the wires are positioned parallel to the inner pipe, ap-
proximately in the middle of the heat insulation, but in FLEXWELL district heating cable, they are positioned parallel and
next to one another in a helical configuration, at a defined distance from and around the inner pipe.
Structure of sensor wires 1 2 3

1. Perforations at
regular intervals
for moisture contact
2. PTFE insulation, colour: red
3. NiCr wire 2 1
Structure of feedback wires

1. Copper wire
2. FEP insulation, colour:
green
Measuring principle for monitoring
The technical basis for measurement, both for monitoring and location, In addition to the sensor wire, another FEP-insulated copper wire
is the resistance reference measuring system (WIREM) which operates known as the 'feedback wire' is used for the actual monitoring.
according to the principle of the unloaded voltage distributor.
A defined voltage is applied between the sensor wire positioned paral- The two wires make up a sensor loop (see the picture) which can be
lel with the pipe in the heat insulation, and the pipe (see picture). If a maximum of 1000 meters in length, enabling 1000 meters of pipe to
the insulation resistance that is present there drops due to the entry of be monitored. Branch lines starting from the sensor wire in the main
moisture, an increase in voltage is measured on the comparator resist- pipe are 'looped in', i.e. sensor wires 'in' and feedback wires 'back' (see
ance in the upstream monitoring device, thereby triggering a signal. picture).
Structure of sensor loop

Monitoring principle Sensor wire [red]
Sensor wire [red]
Feedback wire [green] Pipe axis

Sensor loop including branch
S Loop
Feedback wire [green]
I Insulation
Monitoring device
The comparator resistance defines the signalling threshold at the same

time.
Monitoring of the heat insulation is handled by a special sensor wire For monitored pipe networks with a pipe length of over 1000 meters,
(see the picture). This wire is protected against direct metallic contact the network is subdivided (for example, using the wire model) into
by a temperature-resistant PTFE insulation. The moisture contact monitoring sections of a maximum of 1000 meters, and individual sen-
with the NiCr wire is established through perforations in the PTFE sor loops are formed from them. An appropriate monitoring device can
insulation, thereby enabling continuous monitoring of the entire pipe be assigned to each monitoring section.
section.
In addition, the perforations allow a differentiated evaluation of the in-

tensity of moisture faults, across the entire monitorable spectrum from
'dry' at over 50 MΩ to 'wet' at less than 10 kΩ insulation resistance.
8.1.2015
Measurement principle
Measurement principle for location Location of an interruption in the sensor loop
In order to locate the moisture or contact faults (insulation faults), a Where as the interruption of the sensor loop as such is signalled im-
location voltage (U) is applied to the sensor loop. mediately on automatic systems, the location of the fault point must be
carried out manually, using different methods.
At the start of the sensor loop, between the sensor wire and the pipe,
a measurement is taken of voltage component U1; this is measured The most widespread measuring method is the runtime method,which
over the insulation fault on the sensor wire. However, the voltage has proven its merits in these cases. If a wire is broken off, recourse
component is not measured in volts but as a percentage of the total can be had to a simple capacitance measurement method.
voltage, so it represents the result of the location.
In order to prevent subsequent fault sources, the integrity of the
Since the sensor wire has a very high series resistance of 5.7 Ω/m sensor loop should be ensured during the installation stage through
and the feedback wire is close to zero ohms, the following relation is continuous control measurements and manual checks on the strength
obtained: and stability of wire connections.
A measurement expert will do the positioning.

U1 R1 x % L1 The accuracy of positioning is 1%.
= = =
U R 100 % L
It is therefore necessary that the measuring loop have an access point
at regular intervals (usually house connections).
If the sections bewteen two house connections are longer than 200 m,
U = total voltage we recommend installing a wire model.
U1 = voltage component
R = total loop resistance
R1 = loop resistance component
x % = location result
L = total pipe length
L1 = fault distance
The intensity of the insulation fault (insulation resistance) has no

influence on the accuracy of the location; this is because the device
concept takes account of the intensity.
Measurement principle for location
x% Moisture sensor
Sensor wire [red]
Location unit
U U1
Feedback wire [green]
100 %
8.1.2015
Planning
Sensor loop plan
Planning Sensor loop plan
Planning of the monitoring system is carried out in parallel with plan-

ning of the pipe network. Attention should be paid to the length of a
monitoring circuit (max. 1000 m pipe per device) and the division into Central
individual monitoring circuits. The devices may be placed centrally in heating system
a building. Bloc 1
For subsequent planned network extensions, consideration may be

given to accompanying (parallel) cables which can be laid in the pipe
trenches at the same time.
BRANDES monitoring system TT 1.5 mm2, or U 72 0.8 mm

Length ≥ 9 m: screened cable Wiring by
CrNi wire (red) electrician
Cu wire (green)
Provide wire model for sections longer than 300 m without

Wire model
house connection
Bloc 3
Monitoring boxes
T-Piece Wiring between

(downwards) BRUGG boxes in the building
by electrician
Bloc 4 T-Piece Bloc 2

(downwards)
Measurements taken (results)

Current flow (contact) Insulation resistance (IR)
resistance (DR) R = 5.7 Ω/m Stage BS-MH-2
Flow Return Flow Return
2219 Ω 2220 Ω 0=^ > 50 MΩ ^ > 50 MΩ
0=
8.1.2015
Inspection plans, weld seam plans

Inspection plans are required so that faults can also be measured above ground after location. Accurate plans make it
easier to locate and diagnose the error message. Weld seam plans have proven to be best for this purpose.
View A
Inspection plan
Weld seam plan Central
heating system
Bloc 1
Measurements taken (results)

Pipe Standard L Bend [m]
PRE 60.3-140 6 m 0.5 x 0.5
PRE 76.1-160 6 m 0.65 x 0.65 Venting
PRE 88.9-180 12 m 0.65 x 0.65
Bloc 3
Bloc 4
T-Piece
(downwards) Bloc 2
Drainage, DN 32
8.1.2015
Device description LMS 120

Technical data
Device description
General
The monitoring device is suitable for controlling sensor wires in district heating pipelines.
The system is based on measuring resistances between the connecting contacts.
With the LMS 120, it is possible to control various monitoring systems permanently.
The measurement interval can be set. An error memory is also installed in the device.
The technical design allows monitoring of two different system types at the same time. As such,
it is possible to connect one line with the NORDIC system on measurement channel 1 and one
line with the BRANDES system on measurement channel 2, for instance.
The system is based on measuring resistances between monitoring conductors and the metal
medium pipe or the resistances of measurement loops. All measured values can be read from
the display.
Technical data
Info display and LED

Free parameter setting
Operating voltage 110....230 V AC
Monitoring cycles 2 channels
Length of pipeline per channel:
Brandes ( 1 x Cu, 1 x CrNi) 1.000 m
EMS (nordic, 2 x Cu blank) 2.500 m
Swiss ( each 1 x Cu blank/isolated) 2.500 m
Fault (pot.-free converter) 2 A/30 V
Dimensions 182 x 180 x 90 mm
Permissible ambient temperature 0...50 °C
Protection category IP 65
System design
The LMS 120 has measurement channels operating free of potential to increase measurement precision and minimise the
influence of parasitic current measurements in the pipe.
Relay Display Keys CPU

Voltage 1
Voltage 2
Measurement Measurement
module module
1 2
Ext. alarm
Sensor
Return
Sensor
Return
Pipe
Pipe
Fig. 1 (System design)
8.1.2015

Mechanical installation
The mechanical installation of the LMS 120 monitoring device can be car-
ried out on an even dry wall (drilling template) or alternatively in a control
cabinet.
At the place of installation, the device must be protected against humidity
(formation of condensation), strong dust and strong electromagnetic fields.
The safety notes, protection measures and notes stated in these operating
instructions must be observed (see Safety notes; page 3). The housing lid
must be removed for fastening.
The installation must be carried out with fasteners that are suitable for the
respective substrate.
Electrical connection Fig. 3 (Wall installation)
3.2. Electrical connection

3.2.1. Connection
Connection terminals terminals
Terminal Description
12V Low voltage
+ 12V + (optional)
- 12V -
Alarm
NO Make cont’t External fault
COM Root message
NC Break cont’t
Channel 1
S1 Sensor Channel 1
Pipe Pipe
S2 Return
conductor
Channel 2
S1 Sensor Channel 2
Pipe Pipe
S2 Return
conductor
Tab. 1 (Terminals)
Note:
The 12V terminal is reserved for a special
version of the LMS 120. It must not be used.
The Alarm terminal can be charged with an

ohmic load of up to 2A/ 30V.
Fig. 4 (Wiring diagram)
Earth connection
To ensure smooth operation, the earth contact (pipe) of every measurement circuit must be connected with the associa-
ted pipeline. When replacing existing leakage measurement systems, it is mandatory to check whether an effective earth
connection to the relevant pipe exists. Each measurement channel requires its own connection with the pipeline.
Power
Finally, the device plug has to be inserted into a socket. The LMS 120 can be operated with an alternating current of
90…240 V AC.
8.1.2015

Technical data
7. Accessories
Item name Item number Description
LMS 120 DE 21000076 LMS 120 with mains plug for Germany
LMS 120 CH LMS 120 with mains plug for Switzerland
Socket AD2 21000083 Socket for LMS 120
Monitoring end piece 21000081 Loop end plug
Tab. 6
(Accessories)
8. Technical data
Requirements for voltage supply
Voltage 100 – 240 VAC
Power consumption max. 100 mA
Max. power consumption on
6A
activation
Output 6W
Housing specification:
Dimensions (width x height x depth) 182 x 180 x 90 mm
Installation Wall instillation, control cabinet installation, screws
Materials and colour Housing: Polystyrene, grey (similar to RAL 7035)
Lid: Polycarbonate, transparent
Protection category IP 65 in accordance with EN 60529
Weight (excl. packaging) 1.1 kg
Measurement inputs specification:

Wire standards / measurement Nordic, 2 copper blank
wires Brandes, NiCr 5,7 Ω/m copper isolated
Swiss, copper blank – copper isolated
Potential separation Yes
Alarm output specification

Type of the alarm output: Relay
Max. contact voltage: 24 VDC
Max. switching current: 2A
Min. switching current: 1 mA (at 10 mVDC)
Ambient conditions
Ambient temperature 0 to + 50° C
Transport and storage temperature -20 to + 60° C
Humidity: < 90 %, not condensing
Tests and certificates

EC Declaration of Conformity Yes
Conformity standards EN 61000-6-2 (2006-05-01)
EN 61000-6-4 (01/11/2007)
8.1.2015
Certifications RLS
Quality management system

IQ-Net
CERTIFICATE IQNet and SQS

hereby certify that the organisation
Brugg Rohrsystem AG
5314 Kleindöttingen
Switzerland
Certied area
Whole Company
Field of activity
Products and system packages for the efcient transport

of uids in the elds of district heating, industrial plants,
fuelling stations and plants using renewable energy technology
has implemented and maintains a
Management System
which fullls the requirements of the following standard(s)
ISO 9001:2008 / ISO 14001:2004 / OHSAS 18001:2007

Scope No(s): 14
Issued on: 2015-02-01
Validity date: 2018-01-31
Registration Number: CH-10350
Michael Drechsel Roland Glauser

President of IQNet CEO SQS
IQNet Partners*:
AENOR Spain AFNOR Certication France AIB-Vinçotte International Belgium ANCE-SIGE Mexico APCER Portugal CCC Cyprus
CISQ Italy CQC China CQM China CQS Czech Republic Cro Cert Croatia DQS Holding GmbH Germany
FCAV Brazil FONDONORMA Venezuela ICONTEC Colombia IMNC Mexico Inspecta Certication Finland IRAM Argentina
JQA Japan KFQ Korea MIRTEC Greece MSZT Hungary Nemko AS Norway NSAI Ireland PCBC Poland
Quality Austria Austria RR Russia SII Israel SIQ Slovenia SIRIM QAS International Malaysia
SQS Switzerland SRAC Romania TEST St Petersburg Russia TSE Turkey YUQS Serbia
IQNet is represented in the USA by: AFNOR Certication, CISQ, DQS Holding GmbH and NSAI Inc.
* The list of IQNet partners is valid at the time of issue of this certicate. Updated information is available under www.iqnet-certication.com
20.5.2015
Certifications RLS

ISO 9001 / ISO 14001
Certificate
SQS herewith certifies that the company named below has a management system which meets the
requirements of the standard specified below.
Brugg Rohrsystem AG
Switzerland
Certified area
Whole Company
e m ent Sy
st
Field of activity
g
na e
Products and system packages for the efficient transport
of fluids in the fields of district heating, industrial plants,
a
m
Cer t i f i ed M
Standard
by
ONR 49001:2008 Risk Management
including evaluation of the principles and guidelines
for risk management, ISO 31000:2009
a n d
ze rl
w i t
S
Swiss Association for Quality and
Management Systems SQS
Bernstrasse 103, CH-3052 Zollikofen
This SQS Certificate is valid up to
and including January 31, 2018
Scope number 14
Issue date: February 1, 2015 Registration number 37886
X. Edelmann, President SQS R. Glauser, CEO SQS
Trusted Cert Swiss Made
20.5.2015
Certifications RLS

ONR 49001
Certificate
SQS herewith certifies that the company named below has a management system which meets the
requirements of the standards specified below.
Brugg Rohrsystem AG
Switzerland
Certified area
Whole Company
e m ent Sy
st
Field of activity
g
na e
Products and system packages for the efficient transport
of fluids in the fields of district heating, industrial plants,
a

m
Cer t i f i ed M
Standards
by
ISO 9001:2008 Quality Management System
ISO 14001:2004 Environmental Management System
OHSAS Occupational Health and
18001:2007 Safety Management System
a n d
ze rl
w i t
S
Swiss Association for Quality and
Management Systems SQS
Bernstrasse 103, CH-3052 Zollikofen
This SQS Certificate is valid up to
and including January 31, 2018
Scope number 14
Issue date: February 1, 2015 Registration number 10350
X. Edelmann, President SQS R. Glauser, CEO SQS
Trusted Cert Swiss Made
20.5.2015

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07 / 10 / 5000 ex. / pictures by Key

Requirements: Factory insulated, flexible pipe systems according EN 15632-1/-2

PEXa carrier pipe Reference temperature °C Value Test standard

Materials: CALPEX heating

Materials: linear polyethylene, low density (LLD-PE), seamlessly extruded

LLD-PE protective casing Reference temperature °C Value Test standard

Long-term behaviour: (table)

CALPEX UNO range

CALPEX in straight lengths:

PE-HD casing pipe

CALPEX heating, 6 bar, UNO

CALPEX DUO range

DUO PUR foam

CALPEX heating, 6 bar, DUO

CALPEX UNO/DUO range

Heating strip channel (HBK)

CALPEX sanitary, 10 bar, UNO

CALPEX sanitary, 10 bar, DUO

CALPEX QUADRIGA range

CALPEX, heating 6 bar, sanitary 10 bar, QUADRIGA

Pressure loss chart

Water temperature 80 °C ṁ = Flow rate in kg/h

Q [kW] 160/130,8 mm 140/114,6 mm

Pressure loss ∆p [Pa/m]

Pressure loss chart

Water temperature 60 °C ṁ = Flow rate in kg/h

Pressure loss ∆p [Pa/m]

CALPEX DUO (flow and return in one pipe)

CALPEX QUADRIGA - heat loss during operation

Example of calculation for average operating temperature TB [°C]

70° + 40° + 60° + 50°

Planning and connection technology

1. Requirements for heating strip

1.1 Minimum power

In relation to a maintained temperature of:

1.2 Recommendations for heating strip

Hot water: Frost protection:

Max. heating circuit length in relation to a cut-in temperature of 12 °C (HWAT) or 0 °C (FS-B-2X)

Fuse protection using automatic cutouts with characteristic C

Supply Through connection Supply End closure Supply

3. T-branch End closure

Through connection Supply Through connection

House entry bend, 90°

House entry bend, 90°

Bend, 90° DN 16 - DN 50 (PEXa)

1100 UNO DUO

House entry bend, 90°

CALPEX L-shell, UNO/DUO Structure of the half-shell

Note: CALPEX shells are not suggested to be installed UV exposed!

CALPEX Big L-shell

CALPEX Big L-shell, UNO/DUO Structure of the half-shell

Note: CALPEX shells are not suggested to be installed UV exposed!

Joint using PE-HD shrink sleeve

CALPEX reduction joint

CALPEX – Insulated steel pipe 1 2

Insulated steel pipe

1 PEX coupling; see sheet 1.390 Installation note:

CALPEX Insulated steel pipe

CALPEX-CALPEX CALPEX to insulated steel pipe

CALPEX I-shell, UNO/DUO Structure of the half-shell

Note: CALPEX shells are not suggested to be installed UV exposed!

CALPEX Big I-shell

CALPEX Big I-shell, UNO/DUO/QUADRIGA Structure of the half-shell