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Home , Polybutylene

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Sl Title Page No No.

1 Flexalen Polybutylene Piping System from Thermaflex Page 1-2

2 Flexalen - Material Properties Page 3-8

Technical Details - Sound, Trace Heating, Insulation 3 Page 9-13 & Disinfection

4 Polybutylene Pipes and Fittings - Jointing Techniques Page 14-32

5 Flexalen Polybutylene - Chemical Resistance Page 33-39

6 Flexalen Polybutylene - Bracketing, Support and Page 40-43 Thermal Expansion

7 Flexalen Polybutylene - Approvals & Certification Page 44-48

8 Flexalen Tender Specifications Page 49-51

Flexalen Polybutylene Piping System from Thermaflex Polybutylene Piping System Thermaflex (Netherlands) FLEXALEN The System Profile

● With FLEXALEN from THERMAFLEX, The installation

remains lime free. The smooth surface of polybutylene

prevents deposits from forming in the system. Free

passageways ensure a high level of comfort.

The FLEXALEN system is made of the polyolefin polybutylene the ideal material for domestic water installations.It was specially developed for applications in building services. The Material Polybutylene has the least thermal expansion of all the plastics. The low expansion forces are (30 times less than steel and 10 times less than composite piping) means that the material can absorb the expansion in itself. This reduces on expansion flexible arms or fittings and makes it possible to use standard fasteners, so clean and aesthetically pleasing installations can be built, even where space is limited. ● space-saving installation - using prefabricated skids Noise reduction ● no maintenance - as it is inert to corrosion Of all the piping systems, polybutene has the lowest ● easy to install - as it is light in weight acoustic velocity, e.g. ten times lower than for steel. ● the flexibility of polybutene enables making smaller Thanks to this excellent sound insulation, a good night's changes in direction without the use of fittings.This sleep is practically guaranteed, even if the bedroom saves on parts and valuable on-site time. adjoins the bathroom. ● FLEXALEN retains its flexibility even at low temperatures Chilled water applications and high pressures ● pre-fabricated and pre-insulated riser pipes can be FLEZRLEN is available in a wide range of dimensions transported in coils and installed in shafts on site (d16 mm to d225 mm) for universal use from smallest to easily and quickly the biggest projects ● very durable due to its high resistance to chemicals The d16 to d25 mm pipes can also be supplied as a pipe Plastic pipes - the modern alternative to steel and in sleeve systems for concealed in walls applications & all copper sizes of polybutylene pipes can be pre-insulated, using Environment polyolefin direct extruded insulation with or without Polybutylene has an excellent life cycle assessment. For polyethylene corrugated jacket for buried applications example, it can be reused to build noise barriers. This Connection technology for a minimum of fuss ultimately conserves our natural resources. Prefabrication in the workshop with the proven z-dimension Compared to steel and copper, the manufacture of plastic method from Thermaflex-Netherlands is a time and cost- requires four times less energy. Another example of how saving option. Complete, pre-assembled units (e.g. a polybutylene protects our environment. basement manifold) are rapidly installed on building Free of deposits sites, so you can easily meet your deadlines. ● FLEXALEN is a completely corrosion-free drinking FLEXALEN offers an error free jointing technology for water installation. Even after lengthy periods of nonuse, every type of application: the water quality remains consistent.

● Socket fusion fitting d16 - d110 as an economical alternative of effortless jointing using heating tools for sizes d60 - d63 & bench level heating equipment Less is definitely more for sizes d75 - d110 Weight Another advantage of plastic is its low weight, which ● Electrofusion fitting d16 - d225 for fast and safe jointing obviously makes handling and transport much easier. In on free of human error as the machine is fully automatic contrast to metal systems, no cranes are needed. ● Butt fusion d125-d225 for end jointing without the use of coupling

Fusion process Electrofusion is a controlled fusion process. Thanks to the visible fusion indicators, it is always clear to see whether a fitting has been fused or not.

Comparison of system weights 1 Polybutylene 173 kg 2 Copper 519 kg 3 Steel 1268 kg

Energy

Energy consumption of the manufacturing process is also extremely low in terms of consumption per unit finished product, and compares favourably with the raw material production of competitive piping systems. When compared with the raw material of traditional metal piping, Polybutylene shows clear advantages in terms of kilograms oil equivalent Electrofusion jointing per litre of material Kilograms Oil - Equivalent/Litre Material

Fused joint Unfused joint

Hygiene Water is our most precious resource and the most strictly regulated food. In contrast to metals, which can give off copper ions, nickel or corrosion deposits to the water, polybutylene does not release any taste or harmful substances at all. FLEXALEN is, from a hygiene and health point of view, absolutely safe for use in drinking water systems. The electrofusion joints in particular provide beadless inner surface, facilitating smooth flow of media over it.

Flexalen - Material Properties

The Flexalen is a polybutylene (PB) Material properties material system Properties Val- Unit Test norm ues General Density 0.94 g/cm³ ISO 1183 the polyolefin group of polymers. Its high flexibility, Melt flow index 0.4 g/10 min EN ISO 1133 temperature resistance and creep rupture strength MFI 190/2.16 render this material ideal for use in hot and cold water pipes. Yield stress at 23 PB is created via polymerisation of 1- butylene (C H ), 20 MPa EN ISO 527-1 i.e chaining together the basic 4 8 °C molecules(monomers). PB is a non-polar material, as are polyethylene (PE) and Elongation at 300 % EN ISO 527-1 polypropylene (PP). break at 23 °C Flexural modu- 450 MPa ISO 178 The most suitable jointing method for PB is heat fusion. lus of elasticity at For pressure piping, electrofusion and socket fusion are 23 °C generally preferred. Notched impact 37 kJ/m² EN ISO test at 23 °C 179/1eA Notched impact 20 kJ/m² EN ISO test at 0 °C 179/1eA Ball indentation 43 MPa EN ISO 2039-1 hardness (132 N) Coefficient of 0.13 mm/mK ASTM D696 thermal expansion Thermal conduc- 0.19 W/mK ASTM E1530 tivity at 23 °C Moisture absorp- 0.01- % EN ISO 62 tion at 23 °C 0.04 Electrofusion Mechanical properties The crystallinity of polybutylene (PB) at approx. 50 % is low compared to other polyolefins, rendering it both flexible and robust. These properties are very advantageous for prefabricating riser pipes. The material has very good creep rupture strength at high temperatures and under permanent loads, thus permitting high pressures with relatively small wall thicknesses. The long-term behaviour under internal pressure is illustrated in the long-term diagram based on the standard EN ISO 15494. The threshold values for pipes and fittings, which are given in the pressure-temperature diagram for Socket fusion PB, are deduced from this.

All bigger sizes of the pipe work can be welded using butt Resistance to chemicals, weather and UV fusion joints. The creep strength is certified to MRS 14 radiation (minimum required strength) and according to EN ISO Polybutylene (PB) is non-polar and therefore easily 9080 in longterm testing. withstands chemical attack. The polybutylene used for building service applications For more information, please see the chapter on Chemical features the following qualities: Resistance or contact one of our sales companies. When ● High long-term creep strength stored or used outdoors, PB, like most natural and plastic materials, will become damaged, especially by the ultraviolet ● Good resistance to corrosion wavelengths of solar radiation in combination with atmospheric ● High flexibility oxygen (photo oxidation). ● High resistance to heat ageing Plastic pipes and plastic fittings must be protected from ● High resistance to stress cracking direct ultraviolet radiation. The pipes and fittings are best ● High noise insulation left in their packaging until ready to use. Do not store outdoors.

Thermal properties Glossary Impact resistance and rigidity Density Generally speaking, polybutylene (PB) may be used at The density of a body is the mass m per unit volume V. temperatures between -15 °C and 95 °C. Below 0 °C the Hardness material's impact resistance diminishes somewhat, The hardness refers to the material's resilience against although the rigidity will increase at low temperatures. penetration of a body. It is generally measured using the Just as for every other piping material, the medium depth of penetration left by a load with a specific geometry should be protected from freezing because this could in the material. damage the pipe system. Melt Flow Index (MFI) The Melt Flow Index (MFI) indicates how easily the Linear expansion melted polymer flows. It depends on the length of the Thermoplastics, including Polybutylene, have a Much higher molecular chains and the number of branches. The mass linear expansion, than metals, but due to the lower E-modulus pressed through a standard die with a 5 kg weight in 10 of 0.13 mm/mK, the resulting forces are, very much lower minutes at 190 °C is measured. for PB than for metals. Strength Strength is resistance of an elastic body to deformation. Thermal conductivity Thermal conductivity The thermal conductivity is 0.19 W/m K (ASTM C177). As Thermal conductivity means the energy transported within a result, the insulation of a Polybutylene piping system is a substance in relation to temperature and surface. much more energy efficient compared to metals, such as copper with a high thermal conductivity of 400 w/mk Coefficient of thermal expansion The coefficient of thermal expansion specifies the change of length of a rod, 1 meter in length, after increasing the Fire behaviour temperature by 1 °C; it is measured in millimetres. Polybutylene (PB) belongs to the flammable plastics. The Impact strength oxygen index is 19%. Below 21% a plastic is considered flammable. When the flame is removed, PB will continue The impact strength refers to a material's breaking resistance to form droplets and burn without sooting. When burned, upon impact stress. It is defined as the amount of energy PB produces primarily carbon dioxide, carbon monoxide that the material can absorb at its smallest cross-section and water. before it breaks. It is determined in the Charpy notched bar impact test. Persuant to UL94 (Test for Flammability of Plastic Mat rials), PB is rated as a slow burning plastic in the horizontal Flexural modulus of elasticity burn test. The flexural modulus of elasticity is an expression of a According to DIN 4102-1, PB is classified B2 (normal material's rigidity. It is defined as the slope of its combustibility) and is classified E-d2 according to EN 13501-1. stressstrain curve in the linear range. In the French classification of building materials, polybutylene falls in category M3 (small flame). According to ASTM D Tensile strength 1929, PB self ignites at 360 °C. In case of fire, this plastic Tensile strength is the highest tensile stress which a is extinguished with spray water, foam or carbon dioxide. material can withstand before it breaks. The elongation before it breaks is referred to as elongation at break or Electrical properties ultimate elongation. Due to the fact that polybutylene (PB) is non-polar, PB is an excellent isolator. External impurities, oxidation or weather conditions considerably reduce the isolating action. Otherwise, the electrical conductivity is practically not dependent on temperature and frequency. The specific contact resistance is >10x1016 Kxcm, the dielectric strength 75 kV/mm.

Long-term pressure test for Polybutylene Flexalen Standardized operating pressure of polybutene drinking water systems

Standardized operating pressure of Polybutene Drinking Water Systems

Service life 50 years Service life 50 years =25-30 years.

)

r 20

( 18

e 16 14 PN 16

pressur 12 PN 10 10 8

Operating 6 4

C C C C C C C C C

° ° ° ° ° ° ° ° °

10 20 30 30 50 60 70 80 90

100 Temparature ( °C )

For operational safety and a long lifetime (service life), All the pipe dimensions expressed in the standards are selecting the right material and pressure rating for the based on this calculation formula. According to DIN, EN and piping components is key. Other factors to be taken into ISO standards, the nominal pressure PN (Pressure Nominal) consideration are operating temperature, the medium indicates the permissible operating pressure in bar at 20 °C. conveyed and the operating pressure range. In accordance with the European standardization of systems, the new terms will be additionally used in future. The FLEXALEN d16 to d110 products have a nominal pressure of PN 16 while the pressure rating for FLEXALEN Example size d125 to d225 is PN 10. The pressure temperature Nominal pressure PN 16 means that a pipe in this pressure diagram has been calculated for a service life of 50 class can be subjected to a pressure of 16 bar at 20 °C. years in the drinking water sector. The diagram also In sanitary installations, the nominal pressure is not figures in a safety factor of SF = 1.5. decisive for the pipe and fitting technology, but rather the Example for FLEXALEN d16 to d110 (PN 16) building codes and test specifications in the respective Operating temperature: 70°C country. These ensure safety in the distribution of hot Pressure rating: PN 16 and cold drinking water. The operating pressure taken from the diagram: 10 bar The critical material requirements are not the nominal Determining the pipe wall thickness and the pressure, but the operating pressure and the service pressure class life. To calculate the wall thickness of polybutylene (PB) Example pipes bearing internal pressure the Kessel formula is At an operating pressure of 10 bar and a lifetime of 50 applied: years, the operating temperature may be maximum 70 °C. A safety factor of 1.5 has already been included.

s = pipe wall thickness [mm] p = operating pressure at 20 °C [bar] d = pipe outer diameter [mm]

ðB = comparative stress SF = safety factor of 1.5

Pipe data for FLEXALEN Polybutylene pipes

Nominal diame- Pipe outer diam- Pipe wall thick- Pipe inner diam- Weight Water volume ter DN eter ness eter d s d i [mm] [mm] [mm] [mm] [kg/m] [l/m] 12 16 2.2 11.6 0.088 0.10 15 20 2.8 14.4 0.141 0.16 20 25 2.3 20.4 0.152 0.33 25 32 2.9 26.2 0.254 0.53 32 40 3.7 32.6 0.392 0.83 40 50 4.6 40.8 0.610 1.31 50 63 5.8 51.4 0.969 2.07 65 75 6.8 61.4 1.354 2.96 80 90 8.2 73.6 1.960 4.25 100 110 10.0 90.0 2.920 6.36 125 125 11.4 102.2 3.950 8.20 160 160 14.6 130.8 6.460 13.40 225 225 20.5 184.0 12.700 26.60

Roughness factor k = 0.007 for polybutylene per DIN 1988 Range of application for FLEXALEN Polybutylene pipes and fittings d16 - d225 Sanitary FLEXALEN is used for the hot and cold water pipes in drinking water installations. International specifications are not just satisfied, they are exceeded.

Long-term operating pressure “bar”

2 4 6 8 10 12 14 16

110 Lifetime 1 years PB pipes and fittings cannot be used in this range 95 Lifetime 5 years

°C 90 Lifetime 10 years

80 Lifetime 25 years

temperature

g 70

operatin 60

m ter

- 50

Long

40 Lifetime 50 years

0 °C

(-) 15 °C

A safety factor of SF = 1.5 was used in the lifetime calculation

Pipe Flow Performance Calculated for 50 year life @ 70° C, including design factor

PP-R PP-R PE-X PVC-C PB-1 (1) (2)

Pipe OD, mm 40 40 40 40 40

Pipe ID, mm 32.6 26.6 24.0 29.0 31.0

Pipe wall thickness, mm 3.7 6.7 8.0 5.5 4.5

Standard Dimension Ratio (SDR) 11 6 5 7.3 9

2 Pipe inner section area mm 835 556 452 661 755

Flow speed @ 2 liters/second, m/s 2.4 3.6 4.4 3.0 2.6

Pressure loss @ 2 liters/second, mbar/m 18 50 81 33 24

PN 16 means Permissible operating pressure of 16 bar at 20°C and a lifetime of 50 years assuming a safety factor of 1.5 for all materials. Compressed air

FLEXALEN Polybutylene pipes has been designed for a temperature range of 0 to 80 °C for compressed air applications. The maximum permissible operating pressure at 20 °C is 16 bar with a calculated safety Plastic factor of 1.5. Under humid conditions, PB is better option then any metal, that would react with the water content in the compressed air.

PB in comparison to other plastics, e.g. PP-R, PEX and PVC-C as well as metals The density of a body is the ratio of its mass m to its Density «q» [g/cm³] volume V: [kg/dm³] q = mlV

Polybutylene (PB) 0.94

Polyethylene, cross-linked (PE-X) 0.94 Polypropylene, random (PP-R) 0.90

Polyvinyl chloride, postchlorinated (PVC- 1.55 C)

Water 1.00 Steel 7.85 Copper 8.89

Thermal conductivity «L» [W/mK] Determining the length of a flexible section PB 0.19 The required length of a flexible section is determined by means of the following formula: PE-X 0.41 PP-R 0.24 PVC-C 0.14 Composite 0.43

Water 0.58 Symbol definitions: Steel 42 to 53 da = pipe outer diameter (mm)

Copper 407.10 AL = change in length (mm)

Ecm = average flexural creep modulus

ob = permissible flexural stress ratio

Example: Determining the length of a flexible section

Thermal conductivity means the energy transported within a substance in relation to the difference of pipe inner to pipe outer temperature and the pipe wall thickness.

Thermal expansion «a» [mm/mK] PB 0.13 PE-X = 0.20 PP-R 0.18 PVC-C 0.08 Composite 0.026 Water - Steel 0.012 Copper 0.018 Stainless steel 0.017

Modulus of elasticity «E» [MPa] [N/mm²] PB 450 PE-X 600 PP-R 800 PVC-C 2500 Composite 70000 Water - Steel 210000 Copper 120000

The E-modulus is the relationship of stress to strain in the elastic range of a material. At = temperature difference [K] The smaller the E-modulus, the more flexible the materi- DN = nominal diameter [mm] al. Rs the E-modulus increases, the material becomes L = length of expansion leg [mm] more flexurally rigid. AL = thermally dependent change in length [mm]

Technical Details - Sound, Trace Heating, Insulation & Disinfection

Noise behaviour of FLEXALEN polybutylene Trace heating (PB) valves Self-regulating trace heaters whose surface temperature Noise emission from FLEZRLEN polybutylene valves is does not exceed 65 °C may be used on the pipes. The less than 20 dB (R). This complies with the DIN 52218 trace heater has to be adapted to the water temperature. requirements for low-noise valves in valve group I. For better heat transfer, the entire length of the trace heater should be attached with a wide aluminium tape Dimension Valve noise emission so that it covers as much of the medium conveying

DN/d [bar/mm] LAG [dB (A)] at 3 bar flow pressure pipe as possible. For pipes with carriers, the trace heater should be attached to the carrier. 15/20 over 10 20/25 over 10

25/32 12

32/40 over 10 40/50 12 50/63 13

Sound velocity in materials 1 FLEZRLEN pipe 2 Trace heater Densi- E-modu- Sound ve- 3 Aluminium tape 4 Insulation ty lus locity

[kg/ [N/mm²] [m/s] dm³] Steel 7.95 210000 6000 Copper 8.9 120000 3900 PB (Polybutylene) 0.94 450 620 PVC-C(Polyvinyl 1.56 3500 2350 chloride, postchlorinated) PE-X(Polyethy- 0.95 600 800 lene, crosslinked) 1 FLEXALEN pipe Soft rubber 0.90 90 320 2 Carrier 3 Trace heater 4 Insulation

6,000 1,000,000 When installing trace heaters on FLEXALEN pipes,

please follow the installation instructions of the heater )

5,000 100,000 a manufacturer. Do not double wrap the trace heater on

, s

/ us

m FLEXALEN pipes. This also applies to carriers.

, 4,000 10,000

odu

sound c

3,000 1,000

(

oc 2,000 100

h Ve

it r 1,000 10

Loga

- 1 PB-1 PP-R PVC-C Copper

Sound Velocity Elastic Modulus

Pipe surface temperature Polybutylene piping permits minimum energy dissipation through its surface temperatures on the pipe surfaces can be calculated using the formula below

Example: Polybutylene Flexalen pipe: 40 x 3.7 Water temperature: 16 °C Air temperature: 24 °C Air humidity: 60 % Minimum pipe surface temperature from h-x diagram15.5 °C The temperature of 17.5°C calculated with the formulas explained below, means that condensation will not form. Thermaflex will gladly provide you with data for other pipe dimensions and temperatures for the FLEXALEN system.

Calculation of pipe surface temperature

 T1  Tamb  Q   D ln  d 1    2 PB kD

Qln  D  d  T2  T1  2  PB Q = heat flow per meter pipe [W/m] T1 = water temperature [°C] T2 = outer pipe surface temperature [°C] Tamb = ambient air temperature [°C] aK = heat transfer coefficient [W/m² * K], calculated from measurements LPB = heat conductivity of the pipe material [W/m * K] d = pipe inner diameter [m] D = pipe outer diameter [m] Surface temperature of different pipes

PB Steel Copper Heat conductivityL [W/m * 0.19 67 372 K] Heat transfer coefficient 25 25 25 [W/m² * K] Air temperature Tamb [°C] 20 20 20 Water temperature T1 [°C] 10 60 10 60 10 60 Pipe dimension d40 x 3.7 d42 x 3.25 d35 x 1.5 Pipe surface temperature 13.5 46.0 10.0 59.9 10.0 60.0 T2 [°C]

Calculating heat emission from uninsulated Flexalen polybutene pipes

  kR  1 1 1 D   ln    d 2  d  i aD PB kR = overall heat transfer coefficient [W/mK] ai = heat transfer coefficient on inside (water-pipe)[W/m²K] aa = heat transfer coefficient on outside (pipe-air)[W/m²K] D = pipe outer diameter [m] d = pipe inner diameter [m] LPB = heat conductivity of polybutylene [W/mK]

T  T1  Tamb

AT = Temperature difference water in the pipe and air Ti= water temperature Tamb= ambient air temperature

Q  kR (T ) Q = energy loss per meter pipe AT = Temperature difference water in the pipe and air

Example: Uninsulated PB pipe d40 x 3.7 D = 40 mm d =32.6 mm ai= 6000 W/m²K aa= 10 W/m²K LPB = 0,19 W/mK Ti= 60 °C Tamb= 20 °C  W k   1.032 R. 1 1 1 mK   ln  0.040m  W W W  0.0326m 6000 0.0326m 10 0.040m 20.19 2 2 mK m K m K

T  60 °C  20 °C  40 K

W W Q  1.032 (40K)  41.3 mK m

Heat emission for FLEXALEN Polybutylene pipes, uninsulated

6T [K] 20 30 40 50 60 70 kR 16 11.6 8.836 13.254 17.673 22.091 26.509 30.927 0.442 20 14.4 10.693 16.039 21.386 26.732 32.079 37.425 0.435 25 20.4 13.830 20.744 27.659 34.574 41.489 48.404 0.691 32 26.2 17.178 25.768 34.357 42.946 51.535 60.124 0.859 40 32.6 20.645 30.967 41.290 51.612 61.935 72.257 1.032 50 40.8 24.745 37.117 49.490 61.862 74.234 86.607 1.237 63 51.4 29.553 44.330 59.106 73.883 88.660 103.436 1.478 75 61.4 33.734 50.601 67.468 84.335 101.202 118.069 1.687 90 73.6 38.248 57.372 76.496 95.620 114.743 133.867 1.912 110 90.0 43.663 65.494 87.326 109.157 130.989 152.82 2.183 D [mm] D [mm] Q [W/m] [W/mK]

Insulation thickness indication of chilled water polybutylene pipes

ai = 6000 W/m²k aa = 10 W/m²k (but varies with ambient and pipe temperature) LPB = 0.19 W/mK Lins = 0.038 W/mk

Room temperature with 75% 15 [°C] 20 [°C] 25 [°C] 30 [°C] 35 [°C] 40 [°C] RH

Minimal wall temperature 11.9[°C] 16.7[°C] 21.6[°C] 26.5[°C] 31.3[°C] 36.2[°C]

16 11.6 10 10 20 20 20 20 20 14.4 10 10 20 20 20 20 25 20.4 10 10 20 20 20 20 32 26.2 10 10 20 20 20 25 40 32.6 10 10 20 20 20 25 50 40.8 10 20 20 20 20 25 63 51.4 10 20 20 20 20 25 75 61.4 10 20 20 20 20 25 90 73.6 10 20 20 20 25 25 110 90.0 10 20 20 20 25 25 D [mm] D [mm] Minimal insulation thickness Tins [mm]

Thermaflex will gladly provide insulation advise for your specific circumstances.

Flushing drinking water pipelines Optional disinfectants According to EN 806, DIN 1988, as well as the other Sodium hypochlorite NaOCl European Associations for Water and gas Supplies. Drinking water pipelines must be flushed thoroughly in Hydrogen peroxide H2O2 order to remove residue, such as rust, shavings, Potassium permanganate KMnO4 traces of cutting oil and welding flux. Calcium hypochlorite Ca(ClO)2 For this reason the pipelines must be flushed intermitently with an air/water mixture and drinking water while Disinfection can take place either during the pressure under pressure. This type of flushing is mandatory for test or when the disinfectant solution is allowed to metal pipelines after its installation because of corrosion. stand for at least 12 hours in the pipeline. Due to the In the corrosion-proof drinking water distribution higher pressure during the pressure test, the water system FLEXALEN, where no auxiliary materials, e.g. containing disinfectant can penetrate into the pores cutting oil, welding flux or adhesives, are used for and gaps. fusion, compression or push-fit joining, this costly Following disinfection, the pipeline must be flushed method of flushing is not necessary. thoroughly, and prior to starting up the system again, However, flushing the lines is still advised for hygienic it must be ascertained that the threshold values for reasons. This is done by filling the system with drinking disinfectants in drinking water are not exceeded. water and then opening all the outlet valves.

Disinfection of drinking water systems In order to supply drinking water which is clean and pure, it is crucial that the water does not become contaminated on its way to the consumer. Correct disinfection of drinking water systems is an important prerequisite to ensure compliance with the strict microbiological threshold values and recommended values of drinking water ordinances. Disinfectants are hazardous substances for health and the environment, which is why their use must be carefully planned and executed according to the guidelines of occupational safety and environmentally compatible disposal

Recommended values for disinfection of drinking water according to the EU Guideline of 15th July 1980

No. Description Permissible Threshold val- Calculated as Reaction product added amount ue after treatment [mg/l] [mg/l] Threshold value calculated as after treatment

[mg/l] 1 Chlorine 1.2 (1.2%) 0.3 (0.3%) free 0.01 (0.01%) Trihaloge Sodium chlorine methane hypochlorite, Calcium hypochlorite, Magnesium hypochlorite Chloride of lime

2 Chlorine diox- 0.4 (0.4%) 0.2 (0.2%) ClO2 0.2 (0.2%) Chlorite ide

3 Ozone 10 0.05 O3 0.01 (0.01%) Trihalogen methane

Polybutylene Pipes and Fittings - Jointing Techniques

Socket fusion joints Hand-held fusion device Connecting by socket fusion of d16 to d110 The basics Building on several decades of experience in the fusion of plastics, Thermaflex has developed an ideal fusion method for polybutylene (PB) to create reliable, homogenous pipe joints in sanitary installations. Polybutylene fittings and pipes comply with the national standards and requirements specific to the respective country. Thermaflex pipes and polybutylene fittings are made of the same PB material, so a homogenous fusion joint is formed. Heating-element socket fusion In socket fusion the pipe and the fitting overlap and are fused without the use of auxiliary materials. Pipe ends and fitting sockets are heated with the help of a socket or spigot-shaped heating element to a specific fusion temperature and then joined. The pipe, socket and heating element are dimensioned so that a fusion pre sure The hand-held fusion device is heated electrically is built up during the fusion process. (230V/50 Hz), with a wattage of 800 W. The welding The fusion temperature is 255 ±10°C (240°C - 270°C). therostat is also available in a 110 V/60 Hz version as an Socket fusion may be done manually up to and including alternative The electronic temperature control ensures a d63 pipe outer diameter with chamfered pipe ends. consistent temperature on the heating tools. Tools required The tools and equipment required to create socket fusion joints, as well as for electrofusion, must comply with DVS Guideline 2208, Part 1. In addition to the plastic pipe cutter, a pipe chamfering tool is required for fusion prepping. For socket fusion an electrically heated and electronically controlled handheld fusion device and/or a fusion machine are necessary. Provided that the equipment, machines, heating bushes and spigots conform to DVS Guideline 2208, fusion may be performed with any commercially available tools.

1 2 1 red 2 green

The temperature can be readjusted with a control screw. The status can be read from the yellow and green control lamps. ● yellow and green lights on device is heating up ● yellow light on, green blinking device is at fusion temperature ● yellow light on, green light off temperature too high, device lowers temperature automatically Fusion machine The use of a bench-mounted fusion machine has proved highly advantageous when prefabricating with FLEXALEN. The electric functions are identical with those of the handheld fusion device, the wattage is also 800 W. Easy handling and a special pick-up for fittings enable stress- free fusion, making this machine a valuable aid in the fusion process.

Fusion preparation d16 to d110 Fusion preparation Protect the fusion equipment and the work area from dampness and dirt.

Periodic temperature check Set the fusion temperature of the heating element at 260 °C. Cleaning The temperature required for socket fusion with FLEXALEN is between 245 °C and 270 °C. You can check the fusion temperature on the outside of the heating bush Attention: with tempil sticks. This temperature check should be Damaged or worn heating bushes can lead to faulty repeated periodically, especially if the weather conditions fusion. Replace damaged heating bushes or send are adverse. them back to Thermaflex for recoating. Fusion machine check Before beginning with the fusion, the machine adjustments should be checked, with particular attention given to:

● axial alignment of the fitting and pipe clamps with the heating bushes and spigots and ● the correct setting of the end stops.

Temperature check

The correct temperature of the heating element has been reached when the 253 °C stick melts on the outside of the heating bush and the 274 °C stick does not melt. Socket fusion can be performed at ambient temperatures down to -10 °C if the fusion parameters are maintained. Cut the pipe Cleaning the heating socket and spigot Cut the pipe squarely to length. Clean the heating bush and heating spigot after each fusion with a clean, dry, lint-free paper without a cleanser. Caution: Hot. Can cause burns. The heating tools are heated to 270 °C.

Cleaning the fitting and pipe Clean the jointing surfaces of the parts to be joined fitting and pipe end immediately before beginning with the fusion. Use an absorbent, lint-free paper and the plastic pipe cleaning fluid. Wipe off the cleaning fluid completely with cleaning paper.

Chamfer the pipe ends Chamfer the pipe ends of dimensions d25 and above. This ensures correct insertion of the pipe in the socket- shaped heating bush. The chamfering also reduces the force required to insert the cold pipe in the heating bush. Cleaning the pipe end Chamfer the pipe ends at a 15° angle to half of the wall thickness. Attention: Do not chamfer d16 and d20 pipes.

Cleaning the fitting

It is not necessary to mark for Polybutylene fitting and pipe alignment since the following markings have already been made in the factory: Pipe Pipe marking Fitting Marking every 45°

Chamfer

Fusion parameters

Pipe outer diame- Minimum Insertion depth Heat soak time Holding time Cooling time ter wall thickness and joining depth (fusion length) d s t t1 t2 [mm] [mm] [mm] [s] [s] [min] 16 2.0 15 5 15 2 20 2.0 15 6 15 2 25 2.3 18 6 15 2 32 2.9 20 10 20 4 40 3.7 22 14 20 4 50 4.6 25 18 30 4 63 5.8 28 22 30 6 75 6.8 31 26 60 6 90 8.2 36 30 75 6 110 10 42 35 90 6

Fusion check Manual fusion of d16 to d63 Check the outer bead of the fusion weld. The fusion bead must go around the entire circumference. Clean the fitting and pipe Clean the jointing surfaces of the parts to be joined - fitting and pipe end - immediately before beginning the fusion. Use an absorbent, lint-free paper and the plastic pipe cleaning fluid. Wipe off the cleaning fluid completely with cleaning paper.

Cleaning the pipe end

1 fusion bead

Pressure test All the fusion joints must be completely cooled before beginning with the pressure test. Wait at least one hour after the last fusion has been made. Welder requirements Rll welders must be trained to perform fusion. In order to qualify, certification of attendance for plastic fusion may be obtained upon completion of a jointing technique training Cleaning the fitting conducted by Thermaflex staff on work site for project piping installer personnel Mark the insertion depth Mark the insertion and joining depth according to the pipe. For obligatory handling and safety instructions, Make sure the mark stays visible when heating and joining. please see the «lnstructions for PB Socket Fusion».

Pipe dimension Insertion and joining Pipe dimension d Heat soak time t d depth (fusion length) [mm] [mm] [mm] [s] 16 15 16 5 20 15 20 6 25 18 25 6 32 20 32 10 40 22 40 14 50 25 50 18 63 28 63 22

Joining the pipe and fitting Join the fitting and the pipe immediately after heat soaking and without axial rotation. The holding and cooling times must be observed. Do not twist the parts during and after joining. The marking must always be visible!

Mark the insertion and joining depth

The insertion depth is also marked on the fitting for all Polybutylene fittings. Heat soak the pipe end and socket fitting Slide the pipe end and fitting onto the heating socket or spigot without twisting and not too quickly. (Material melts slowly). Joining the fitting and pipe The heat soak time begins when the pipe and fitting are completely inserted in the heating socket or on the heating spigot. Rfter the heat soak period, pull the fitting and Pipe dimension d Holding time Cooling time pipe slowly off the heating tools and without twisting or Minimum turning. [mm] [s] [min] 16 15 2 20 15 2 25 15 2 32 20 4 40 20 4 50 30 4 63 30 6

Holding time: During this time the joined parts (fitting and pipe) must be held securely without twisting or turning. Cooling time: The fused parts (fitting and pipe) may only be subjected to further installation loads when the cooling time has elapsed.

Weld-in saddles d50 to d110 Assembly instructions for weld-in saddles in dimensions d50 to d110

Drill through pipe wall with the drill with custom made holesaw. Use a speed-controlled drill with 300-350 rpm. Important: Select the drill dimension: The hole must be drilled at a right angle. ● One drill for outlets: 20, 25, 32 ● One drill for outlets: 40, 50

Chamfering the drill hole makes it easier to insert the heating bush in the next step.

The heating bushes for the corresponding dimension

Clean the pipe and the drill hole with plastic pipe cleaning fluid. Wipe off all the cleaning fluid with the cleaning paper. Mark the drilling point

Mount a pipe bracket about 15 to 20 cm next to the Clean the weld-in saddle with plastic pipe cleaning fluid. drilling point to prevent the pipe from bending out dur- Check that the saddle dimension corresponds to the pipe ing assembly. dimension.

The heating bushes must be cleaned after each fusion Mount heating bush on the welding blade. joint. There must be no polybutene material left on the heating bushes.

Slide both the weld-in saddle and the pipe onto the heating bushes at the same time. Result: the saddle is welded in the pipe.

Heat soak time, see Table 1

Various connections can be mounted on the saddle.

1 Melt bead

Rfter heat soaking the pipe and saddle, an even bead must have formed around the drill hole.

Immediately after pulling off the heating bush, push the weld-in saddle into the pipe. Do not twist or turn the saddle. Holding and cooling time, see Table 1

Weld-in saddles d125 to d225 Assembly instructions for weld-in saddles in dimensions d125 to d225

Chamfer 3 to 4 mm of the drill hole, which makes it easier to insert the heating bush in the next step.

Select the drill dimension: ● One drill for outlets: 20, 25, 32 ● One drill for outlets: 40, 50

Clean the pipe and the drill hole with plastic pipe cleaning fluid. Wipe off all the cleaning fluid with the cleaning paper.

The corresponding heating bushes for the dimension.

Clean the weld-in saddle with plastic pipe cleaning fluid. Check that the saddle dimension corresponds to the pipe dimension.

Mark the drilling hole

Mount the heating bushes on the welding blade.

Drill a hole through the pipe wall. Use a speed-controlled drill with 300-350 rpm. Important: The hole must be drilled at a right angle.

The heating bushes must be cleaned after each fusion joint. There must be no polybutene material left on the heating bushes.

Slide both the weld-in saddle and the pipe onto the heating bushes at the same time. Heat soak time, see Table 2

Result: the saddle is welded in the pipe.

Various connections can be mounted on the saddle.

1 Melt bead

After heat soaking the pipe and saddle, an even bead must have formed around the drill hole.

Immediately after pulling off the heating bush, push the weld-in saddle into the pipe. Do not twist or turn the saddle. Holding and cooling time, see Table 2.

Weld-in saddles fusion times Fusion times

Table 1 Weld-in saddle on pipe Pipe in weld-in saddle Dim. Temp. Fusion time Fusion time d - d1 °C Heat soak Holding Cooling time Heat soak Holding time Cooling time time time time sec. sec. min. sec. sec. min. 50 - 20 260 22 - 24 30 4 6 15 2 50 - 25 260 22 - 24 30 4 6 15 2 50 - 32 260 22 - 24 30 4 10 20 4 63 - 20 260 22 - 24 30 4 6 15 2 63 - 25 260 22 - 24 30 4 6 15 2 63 - 32 260 22 - 24 30 4 10 20 4 75 - 20 260 24 - 26 30 4 6 15 2 75 - 25 260 24 - 26 30 4 6 15 2 75 - 32 260 24 - 26 30 4 10 20 4 90 - 20 260 26 - 28 30 4 6 15 2 90 - 25 260 26 - 28 30 4 6 15 2 90 - 32 260 26 - 28 30 4 10 20 4 110 - 20 260 28 - 32 30 4 6 15 2 110 - 25 260 28 - 32 30 4 6 15 2 110 - 32 260 28 - 32 30 4 10 20 4

Table 2

125 - 32 260 29 - 33 30 4 10 20 4 125 - 40 260 31 - 35 30 4 14 20 4 125 - 50 260 31 - 35 30 4 18 30 4 160 - 32 260 28 - 30 120 4 10 20 4 160 - 40 260 42 - 45 120 4 14 20 4 160 - 50 260 42 - 45 120 4 18 30 4 225 - 32 260 25 - 30 120 4 10 20 4 225 - 40 260 45 - 50 120 4 14 20 4 225 - 50 260 45 - 50 120 4 18 30 4

Pipes d125 to d225: drill hole with 3 to 4 mm chamfer

Weld-in saddles and spacing

Spacing weld-in saddles When positioning the weld-in saddles on the FLEXALEN pipe, the following distances are important: ● distance between two weld-in saddles ● distance of the weld-in saddle across the circumference ● distance between weld-in saddle and fitting

It is also imperative to check that the saddle dimension Allowed on the pipe side corresponds to the pipe dimension. Pipe dimension d110 to d225 Distance between two weld-in saddles If a weld-in saddle has been welded into a d110 to d225 The minimum distance X between two weld-in saddles pipe, it is allowed to weld in another weld-in saddle must be at least 30 mm . This distance applies to pipe across the circumference. The minimum distance of Z = dimensions 50 to 225 mm with all outlets. Burst and pul- 30 mm from saddle to saddle must be observed in this sation tests were conducted on welded-in saddles to de- case as well. termine this distance. It is not allowed to weld in more than 2 saddles across the circumference.

Allowed

Distance of weld-in saddle across circumference Pipe dimensions d50 to d90 If a weld-in saddle has been welded into the pipe, another or more weld-in saddles may not be welded in Allowed across the circumference at this point. Rlternatively, another saddle may be welded in with a minimum dis- Distance between weld-in saddle and fitting tance Z of 30 mm across the circumference. This applies to pipe dimensions 50 to 90 mm with outlets d20, The minimum distance X between weld-in saddle and d25 and d32 mm. fitting must be at least 30 mm. This applies to dimensions 50 to 225 mm irrespective of the outlet dimension.

Not allowed! Allowed

Electrofusion joints HWSG-3 Polyfusion Device

FLEXALEN electrofusion joints for d16 to d110 The same polybutylene (PB) material is used for FLEXALEN pipes and PB fittings, which guarantees a homogenous fusion joint. General requirements Polybutylene electrofusion fittings are suitable for operating pressures up to 16 bar at 20 °C and 10 bar at 70 °C. The guidelines of the respective countries and the specifications for a homogenous joint are illustrated as below.

The electrofusion process In electrofusion the pipe and the fitting overlap and are fused without auxiliary materials. The heat required to fuse the pipe and fitting is supplied with the help of the resistance wires embedded in the socket. The electrical energy supply is controlled by the thermostat on the Electrofusion device. The required fusion pressure is achieved via the dimensionally adapted FLEXALEN pipes Features of the Polyfusion HWSG-3 fusion device are: and Polybutylene electrofusion fittings.

● the dimension connected is identified by measuring the electrical resistance ● no errors due to incorrectly set parameters ● fully automated fusion process ● start and finish of fusion process is signalled acoustically and visually ● interruptions in the fusion process are indicated ● simultaneous fusion of three different dimensions is possible

Polybutylene electrofusion fittings In developing the Polybutylene electrofusion sockets, the special requirements of building services piping systems were taken into consideration:

● no support fixtures ● minimal pipe end prepping as possible

● no axial displacement of pipes during assembly

● simple cable connections for functional and safe operation clearly visible product identification and fusion indicator ● Electrofusion fittings ● easy transition from electrofusion to socket fusion All these requirements, as well as the benefits of the socket fusion fittings, were the basis for development of the electrofusion fittings.

Fusion parameters

Pipe outer di- Insertion depth I Fusion time ameter d Socket Fitting t [mm] [mm] [mm] [s] 16 38 38 37 20 40 40 47 25 42 42 55 32 42 42 70 40 47 47 120 50 49 49 145 63 51 51 180 75 67 67 185 90 74 74 200 110 80 80 210 CIeaning the fitting

Cleaning the pipe end

Cut the pipe squareIy and deburr the inside of the pipe. Do not chamfer the pipe end! Use a pIastic pipe cutter. Marking the insertion depth on the Flexalen pipe

Mark the insertion and joining length accordingly on both pipes. Make sure the marking stays visible during fusion.

Use plastic marker

Clean the jointing surfaces of the parts to be joined - fitting and pipe end - immediately before starting. Use an absorbent, lint-free paper and the plastic pipe cleaning fluid Wipe off all the cleaning fluid with the cleaning paper.

Push the pipes into the fitting up to the marking. Make sure the pipe faces butt against each other in the mid- Pipe dimension Fusion time Cooling time dle of the socket. Tighten the screws alternately on the d t t1 integrated pipe attachment. [mm] [s] [min] Note: 16 37 2 With a pipe surface temperature above 40 °C and the related expansion, it is difficult to push the fitting onto 20 47 2 the pipe because of the required tight tolerances. 25 55 2 32 70 4

40 120 4 50 145 4 63 180 6

75 150 6 90 200 6 110 210 6

During the fusion process the parts to be joined - fitting and pipe - may only be subjected to the forces which normally occur in installation (pipe fastening) according to the guidelines.

Cooling time: The joined parts - fitting and pipe - may only be exposed to further installation forces when the cooling time Pipes must butt in the middle of the socket has elapsed.

«Start» fusion Fusion check Check the fusion with the optical fusion indicator. R Connect the fusion device to the mains. fused socket can be identified by means of the emerg- ing material pin. Plug the fusion cable into the fitting. You can perform up to three fusion welds at the same time.

Start fusion with the button:

Operation

1. Connect the device to the mains. All the control lamps will light up for two seconds. The mains indicator goes on:

2. Connect the fusion cable to the respective fitting. The "Ready" light goes on.

Each fusion channel is able to identify the fitting Pressure test connected and its dimension independently. Up Before starting the pressure test, all the fusion welds to three fusion welds can be performed in differ- must be fully cooled. Observe the minimum waiting time ent dimensions simultaneously. Fusion chan- of one hour after finishing the last fusion. nels which are not connected are blocked during the fusion process (no current).

Functions of the Polyfusion device The following conditions must be met for the fusion device to function accurately:

Mains voltage min. 185 V max. 264 V Mains frequency min. 47 Hz max. 65 Hz Temperature min. -15°C max. 40°C

These values are continuously checked by the fusion device during the process. The fusion process is inter- rupted if there are deviations and the control lamp indicates an error.

3. Start the fusion process with the button:

The fusion indicator blinks and a beep signals the beginning of the fusion process:

The "Ready" light of the connected fusion channel goes on:

To stop the fusion push:

Attention: The process cannot be resumed afterwards and the fusion is not complete.

5. Remove the fusion cable from the fitting. The Mains indicator lights up:

All three fusion channels are free for the next fusion.

4. The fusion is completed after the longest fusion time has elapsed. You will hear a beep and the control lamp "End" will light up.

The "Ready" indicator for channels with shorter fusion times (different dimensions) will go out when the fusion has been completed:

Assembly instructions for Polybutylene electrofusion joints d125 to d225 Assembly of electrofusion sockets

Cut the pipe squarely to length

Plane the top layer in one pass with the peeling tool.

Peeling lengths for electro-socket fusion

Dimension Peeling length Total required length (with peel- Width of peeling tool ing tool)

[mm] [mm] [mm] [mm] d125 90 190 360 d160 95 190 380 d225 110 210 450

Cleaning the socket Fasten the socket to the pipe with the strap Clean the jointing surfaces of the socket and retainer. the pipe end. Use an absorbent, lint free paper and plastic pipe cleaning fluid. Wipe off all the cleaning fluid with the cleaning paper

Connect the fusion cable of the EF machine to the electrofusion socket.

Cleaning the pipe end Clean the jointing surfaces of the socket and the pipe end. Use an absorbent, lint free paper and plastic pipe cleaning fluid . Wipe off all the cleaning fluid with the cleaning paper.

Scan the coding with the barcode reader. This transmits the fusion data to the fusion device.

Mark the insertion and joining depth accordingly. Make sure the marking stays visible during fusion.

Start the fusion process.

Slide the socket on the pipe.

Butt fusion

Heating element for butt fusion

The fusion surface is the circular ring area of the pipe. The stability of the pipe is equivalent to the stability of the fusion weld. However, the pipe loses stability if there is the slightest deviation in the fusion parameters.

Fusion may only be performed by persons trained by THERMAFLEX staff or persons with the respective certification. Each fusion must be documented in a fusion protocol.

Flexalen Polybutylene - Chemical Resistance

Raw Material - Polybutylene-1 Chemical Resistance The information provided in the following pages is confined to the effects that various products have on Polybutylene-1, not the other way round. Whilst indicative of the general resistance of Polybutylene-1 to various products, the data were obtained by laboratory methods which may or may not be representative of the actual conditions of use encountered in specific end-use applications. For any application where the intention is to use products made from Polybutylene-1, it is recommended that further tests to simulate the end-use application are carried out. In the assessment presented here, chemical resistance has been evaluated through several observations on a test sample: 1) the surface is visually analysed for evidence of oxidative attack, environmental stress cracking, staining and dimensional distortion 2) any weight gain in the sample is evidence of swelling caused by solvent absorption 3) the sample is tested for signs of physical deterioration, such as embrittlement, softening, decreased yield stress and increased yield elongation. In the following tables, overall chemical resistance is evaluated through the use of three rating symbols, S, M and U, which have the following significance: S - Satisfactory Little or no noticeable effect with no indication that serviceability has been impaired M - Marginal Noticeable effect, but not necessarily indicating a lack of serviceability or useful life. Further testing is strongly recommended to determine suitability in a specific application U - Unsatisfactory Severe effect and not recommended for service applications

Chemical exposure performance Reagent Temp. (Solids in saturated solution unless indicated otherwise) 23°C 60°C

Acetaldehyde M U Acetate solvents - crude S M Acetate solvents - pure S M Acetic acid 0-10% S S Acetic acid 10-20% S S Acetic acid 20-30% S S Acetic acid 30-60% S M Acetic acid 80% S - Acetic acid - glacial M U Acetic acid vapours S M Acetic anhydride U U Acetone S S Acetylene M U Adipic acid S M Alcohol (see type) - - Allyl alcohol 96% S S Allyl chloride S S Alum M U Aluminium chloride S S Aluminium fluoride S S Aluminium hydroxide S S Aluminium oxychloride S S Aluminium nitrate S S Aluminium sulphate M U Ammonia - dry gas S S Ammonia - liquid S M

Chemical exposure performance Reagent Temp. (Solids in saturated solution unless indicated otherwise) 23°C 60°C

Ammonium bifluoride S S Ammonium carbonate S S Ammonium chloride S S Ammonium fluoride 25% S M Ammonium hydroxide 28% S S Ammonium metaphosphate S S Ammonium nitrate S S Ammonium persulphate S S Ammonium phosphate (ammoniacal) S S Ammonium phosphate neutral S S Ammonium sulphate S S Ammonium sulphide S S Ammonium thiocyanate S S Amyl acetate S - Amyl alcohol S S Amyl chloride M M Aniline M M Aniline chlorohydrate U U Aniline hydrochloride U U Anthraquinone M U Anthraquinonesulphonic acid M U Antimony trichloride S S Aqua regia U U Arsenic acid 80% S S Asphalt S S Barium carbonate S S Barium chloride S S Barium hydroxide S S Barium sulphate S S Barium sulphide S S Beer S S Beet - sugar liquor S S Benzaldehyde M U Benzene U U Benzoic acid S S Benzol U U Bismouth carbonate S S Black liquor (paper industry) S S Bleach - 12,5% active Cl S S Borax S S Boric acid S S Boron trifluoride S S Breeder pellets - deriv. fish S S Brine U S Bromic acid M S Bromine - liquid U U Bromine - water M U Butane U U Butanol - primary S - Butanol - secondary S - Butyl acetate M U Butyl alcohol S S Butyric acid 20% S M Calcium bisulphite S S Calcium carbonate S S Calcium chlorate S S

Chemical exposure performance Reagent Temp. (Solids in saturated solution unless indicated otherwise) 23°C 60°C

Calcium chloride S S Calcium hydroxide S S Calcium hypochlorite S S Calcium nitrate S S Calcium sulphate S S Cane sugar liquors S S Carbon bisulphide U U Carbon dioxide (aqueous sol’n) S S Carbon dioxide gas (wet) S S Carbon monoxide S S Carbon tetrachloride U U Carbonic acid S S Casein S S Castor oil S S Caustic potash S M Caustic soda S M Cellosolve S S Chloracetic acid U U Chloral hydrate U U Chlorine gas (dry) U U Chlorine gas (moist) S U Chlorine water U S Chlorobenzene M U Chloroform U U Chlorosulphonic acid S U Chrome alum S S Chromic acid 10% S S Chromic acid 25% S S Chromic acid 30 % S S Chromic acid 40% S - Chromic acid 50% S - Citric acid S S Coconut oil S S Copper chloride S S Copper cyanide S S Copper fluoride 2% S S Copper nitrate S S Copper sulphate S S Core oils S S Cottonseed oil S S Cresol U U Cresylic acid 50% U U Crude oil - sour M U Crude oil - sweet M U Cyclohexanol S M Cyclohexanon U U Demineralized water S S Dextrin S S Dextrose S S Diazo salts S S Diglycolic acid S S Dimethylamine U U Dioctylphthalate M U Disodium phosphate S S Distilled water S S Ethers U U

Chemical exposure performance Reagent Temp. (Solids in saturated solution unless indicated otherwise) 23°C 60°C

Ethyl acetate M U Ethyl alcohol 0-50% S S Ethyl alcohol 50-98% S S Ethyl ether M U Ethylene bromide U U Ethylene chlorohydrin U U Ethylene dichloride S S Ethylene glycol S S Fatty acids S S Ferric chloride S S Ferric nitrate S S Ferric sulphate S S Ferrous chloride S S Ferrous sulphate S S Fish solubles S S Fluorine gas - dry M U Fluorine gas - wet M U Fluoroboric acid S S Fluorosilicic acid S S Food products such as milk,molasses,salad oils S S Formaldehyde S S Formic acid S S Freon-12 S S Fructose S S Fruit pulps and juices S S Fuel oil (containing H2SO4) U U Gallic acid S S Gas - coke oven S S Gas - manufactured S S Gas - natural (dry) S S Gas - natural (wet) S S Gasoline - refined U U Gasoline - sour U U Gelatine S S Glucose S S Glycerine (glycerol) S S Glycol S S Glycolic acid 30% S S Green liquor (paper industry) S S Heptane U U Hexane U U Hexanol, tertiary S S Hydrobromic acid 20% S S Hydrochloric acid 0-25% S S Hydrochloric acid 25-40% S S Hydrocyanic acid or hydrogen cyanide S S Hydrofluoric acid 4% S S Hydrofluoric acid 10% S S Hydrofluoric acid 48% S S Hydrofluoric acid 60% S S Hydrofluorosilicic acid S S Hydrogen S S Hydrogen peroxide 30% S S Hydrogen peroxide 50% U U Hydrogen peroxide 90% U U Hydrogen phosphide S S

Chemical exposure performance Reagent Temp. (Solids in saturated solution unless indicated otherwise) 23°C 60°C

Hydrogen sulphide - aqueous sol’n S S Hydrogen sulphide - dry S S Hydroquinone S S Hypochlorous acid S S Iodine (in alcohol) S U Isopropylalcohol S S Kerosene M U Kraft liquor (paper industry) S S Lactic acid 28% S S Lard oil S M Lauryl chloride S M Lead acetate S S Lime sulphur S S Linoleic acid S M Linseed oil S S Liquors S S Lubricating oils S S Magnesium carbonate S S Magnesium chloride S S Magnesium hydroxide S S Magnesium nitrate S S Magnesium sulphate S S Maleic acid S S Malic acid S S Mercuric chloride S S Mercuric cyanide S S Mercurous nitrate S S Mercury S S Methyl alcohol S S Methyl chloride U U Methyl ethyl ketone S M Methyl sulphuric acid S S Methylene chloride S M Milk S S Mineral oils M U Molasses S S Naphthalene M U Nickel acetate S S Nickel chloride S S Nickel nitrate S S Nickel sulphate S S Nicotine S S Nicotine acid S S Nitric acid 10% M U Nitric acid 20% U U Nitric acid 35% U U Nitric acid 40% U U Nitric acid 60% U U Nitric acid 68% U U Nitric acid (anhydrous) U U Oils and fats S S Oleum U U Oxalic acid S S Perchloric acid 10% M U Perchloric acid 70% U U Phenol S M

Chemical exposure performance Reagent Temp. (Solids in saturated solution unless indicated otherwise) 23°C 60°C

Phosphoric acid - 0-25% S S Phosphoric acid - 25-50% S S Phosphoric acid - 50-75% S M Photographic chemicals S S Picric acid S M Potassium acid sulphate S S Potassium bicarbonate S S Potassium bichromate M U Potassium borate 1% S S Potassium bromate 10% S S Potassium bromide S S Potassium carbonate S S Potassium chlorate S S Potassium chloride S S Potassium chromate 40% S S Potassium cuprocyanide S S Potassium cyanide S S Potassium dichromate 40% S S Potassium ferricyanide S S Potassium fluoride S S Potassium hydroxide 10% S S Potassium hydroxide 20% S S Potassium nitrate S S Potassium perborate S S Potassium perchlorite S S Potassium permanganate 10% S S Potassium persulphate S S Potassium sulphate S S Potassium sulphide S S Potassium thiosulphate S S Propane S - Propyl alcohol S S Rayon coagulating bath S S Salt water S S Selenic acid S S Silicic acid S S Silver cyanide S S Silver nitrate M U Silver plating solutions S S Soaps S S Sodium acetate S S Sodium acid sulphate S S Sodium antimonate S S Sodium arsenite S S Sodium benzoate S S Sodium bicarbonate S S Sodium bisulphate S S Sodium bisulphite S S Sodium bromide S S Sodium carbonate (soda ash) S S Sodium chlorate S S Sodium chloride S S Sodium cyanide S S Sodium dichromate S S Sodium ferricyanide S S Sodium ferrocyanide S S

Chemical exposure performance Reagent Temp. (Solids in saturated solution unless indicated otherwise) 23°C 60°C

Sodium fluoride S S Sodium hydroxide 10% S S Sodium hydroxide 35% S S Sodium hydroxide saturated S S Sodium hypochlorite S S Sodium nitrate S S Sodium nitrite S S Sodium phosphate - acid S S Sodium silicate S S Sodium sulphate S S Sodium sulphide S S Sodium sulphite S S Sodium thiosulphate (hypo) S S Stannic chloride S S Stannous chloride S S Stoddards solvent S S Stearic acid S S Sulphur S S Sulphur dioxide gas - wet S M Sulphuric acid 0-10% S S Sulphuric acid 10-30% S S Sulphuric acid 30-50% S S Sulphuric acid 50-75% M U Sulphuric acid 75-90% M U Sulphuric acid 95% U U Sulphurous acid S S Sulphyr trioxide M U Tannic acid S S Tanning liquors S S Tartaric acid S S Tetrahydrofurane M U Thionyl chloride S S Toluol or toluene U U Trichloroethylene U U Triethanolamine S M Trisodium phosphate S S Turpentine U U Urea S S Urine S S Vinegar S S Water - acid mine water S S Water - distilled S S Water - fresh S S Water - salt S S Whiskey S S White gasoline U U Wines (still) S S Xylene or xylol U U Zinc chromate S S Zinc cyanide S S Zinc nitrate S S Zinc sulphate S S

Flexalen Polybutylene - Bracketing, Support and Thermal Expansion

FLEXALEN PB pipe Calculating the flexible section length Temperature-related changes in length A l are deter- Calculating the change in length 6L mined from the temperature difference A 9 and the expansion loop length L . The temperature-related change in length is calculated DS with the following formula: The flexible section length LBS is determined from the change in length A l and the pipe outer diameter d. AL = a x L x 6T Example:

LDS = 5 m AL = Temperature-related change in length [mm] A 9 = 50 K a = Coefficient of linear expansion [mm/mK] da = 63 mm L = 45 cm BS L = Length of pipeline [m] See diagram below. AT = Temperature difference [K] Diagram to determine length of flexible section FLEXALEN pipes a = 0.13 mmlmK corresponds to 1.3 x 10 -4 mm/mmK Calculating the flexible section length Calculate the minimum length of the flexible section using the following formula:

Definition of symbols:

da = pipe outer diameter (mm) AL = change in length (mm)

Ecm = average bend-creep module

ob = permissible bending stress Calculation example: The length of the pipeline is 5 m. The temperature-related change in length of this pipe section has to be taken up with a flexible section. The temperature difference between the installation temperature and the maximum operating temperature is 50 K. For this calculatation, PB pipe 63 x 5.8 mm with an outer diameter of 63 mm is used. Determining the flexible section length: AL = a x L x AT AL = 0.13 (mm/mK) x 5 m x 50 K AL = 32.5 mm change in length To determine the required length of the flexible section more easily, the diagram for flexible section length de- termination can be used.

L BS = 45 cm length of flexible section If we compare this data with the data for a metal pipe in the same dimension, we see that the flexible section for the metal pipe must be much larger. The reason for this is the significantly higher material constant C for metal pipes than for a polybutene pipe.

Temperature-related change in length 6L [cm] for FLEXALEN POLYBUTYLENE pipe

Pipeline Temperature difference 6 [K] [m] 10 20 30 40 50 60 70 80 90 100 0.1 0.01 0.03 0.04 0.05 0.07 0.08 0.09 0.10 0.12 0.13 0.2 0.03 0.05 0.08 0.10 0.13 0.16 0.18 0.20 0.23 0.26 0.3 0.04 0.08 0.12 0.16 0.20 0.23 0.27 0.31 0.35 0.39 0.4 0.05 0.10 0.16 0.21 0.26 0.31 0.36 0.42 0.47 0.52 0.5 0.06 0.13 0.20 0.26 0.33 0.39 0.46 0.52 0.59 0.65 0.6 0.08 0.16 0.23 0.31 0.39 0.47 0.55 0.62 0.70 0.78 0.7 0.09 0.18 0.27 0.36 0.46 0.55 0.64 0.73 0.82 0.91 0.8 0.10 0.21 0.31 0.42 0.52 0.62 0.73 0.83 0.94 1.04 0.9 0.12 0.23 0.35 0.47 0.59 0.70 0.82 0.94 1.05 1.17 1.0 0.13 0.26 0.39 0.52 0.65 0.78 0.91 1.04 1.17 1.30 2.0 0.26 0.52 0.78 1.04 1.30 1.56 1.82 2.08 2.34 2.60 3.0 0.39 0.78 1.17 1.56 1.95 2.34 2.73 3.12 3.51 3.90 4.0 0.52 1.04 1.56 2.08 2.60 3.12 3.64 4.16 4.68 5.20 5.0 0.65 1.30 1.95 2.60 3.25 3.90 4.55 5.20 5.85 6.50 6.0 0.78 1.56 2.34 3.12 3.90 4.68 5.46 6.24 7.02 7.80 7.0 0.91 1.82 2.73 3.64 4.55 5.46 6.37 7.28 8.19 9.10 8.0 1.04 2.08 3.12 4.16 5.20 6.24 7.28 8.32 9.36 10.40 9.0 1.17 2.34 3.51 4.68 5.85 7.02 8.19 9.36 10.53 11.70 10.0 1.30 2.60 3.90 5.20 6.50 7.80 9.10 10.40 11.70 13.00

Change in length due to thermal effects in AL in cm for FLEXALEN POLYBUTYLENE PIPES

Arrangement and spacing of pipe brackets in flexible section installation Place the pipe brackets so that the changes in length are not hindered. Make sure that the pipes can rebound in holes through walls and floors. For longer pipelines you can divide up the length changes with fixed points in order to absorb them better.

Table to determine pipe bracket spacing

Polybutylene pipe Pipe dim. Cold water pipeline under 20 °C Hot water pipeline over 20 °C without with carriers without with carriers carriers carriers

d x s L 1 [cm] L 2 [m] Pipe L 1 [cm] L 2 [m] Pipe bracket bracket 16 x 2.2 50 35 20 x 2.8 60 ca. 1.5 - 2 m 0.5 m 40 ca. 1.5 - 2 m 0.25 m 25 x 2.3 70 45 32 x 3.0 80 50 40 x 3.7 80 ca. 1.5 - 2 m 0.75 m 50 ca. 1.5 - 2 m 0.5 m 50 x 4.6 100 60 63 x 5.8 125 75 75 x 6.8 150 90 90 x 8.2 180 ca. 1.5 - 2 m 0.75 m 110 ca. 1.5 - 2 m 0.5 m 110 x 10.0 200 130 125 x 11.4 200 150 160 x 14.6 200 2 m 0.75 m 190 ca. 2 m 0.5 m 225 x 20.5 200 190

Individual fixed point spacing depending on pipe layout Fastening technology for riser pipes in shafts and building situation. There are no carriers for d90 to d110 in the FLEXALEN product range.

PB drinking water pipeline with PB pipe and carrier FB = Fixed point GB = Sliding fastener

As illustrated above, carriers are not used in the area of the flexible section so that the deflection is not hindered.

Requirements: Rigid installation - laying pipelines without pipe ● Use suitable pipe fastening to ensure that a fixed expansion point is created at the bottom and top T-piece (floor outlet). A rigid installation is a straight pipeline between two fixed Definition of fixed point: points in which the pipe cannot move laterally. The Fastening which prevents axial movement of the pipe temperature-related change in length is absorbed in the and the pipe bracket in any direction (traction forces). FELXALEN pipe. The thermal expansion forces of the pipe are transferred via the fixed point to the structure. ● Position the pipe fastening directly at each floor outlet

(above or below the T-piece). For FLEXALEN pipes rigid installation is only possible ● If the floor outlet is at midway height of the with pipe carriers. The forces which act on the fixed point room (ca. 0.4 m), one pipe fastening per floor is depend on the pipe cross-section, the temperature difference enough. and the pipe material. They are however much higher ● If the T-piece is located at the height of the top edge than for installations with flexible sections, which is why of floor, a second fastening is required. you need additional support fixtures at greater wall and ● Only use flexible polyolefin direct extruded insulation floor spacing. from Thermaflex for hot water riser pipes.

Typical Fixed Support Experience (based on testing and practice): Thanks to their flexibility, hot water FLEXALEN pipes bend out freely without large axial thrust forces. You can support this free movement by using flexible insulation wherever possible. The insulation also protects against mechanical damage. Basic principle: Riser pipes in shafts enable absorbing the thermal expansion by letting the FLEXALEN pipes «bend out» at the floor height. This lateral bending has no negative effects on the polybutylene material, regardless whether one, two or more pipe fastenings are used.

Flexalen Polybutylene - Approvals & Certification

Flexalen Tender Specification

FLEXALEN Polybutylene (PB) Pipe work (03) Only pipe cleaner and sealant specifically System from THERMAFLEX Netherlands approved by the pipe end fittings manufacturer should Pipe Fittings end Valves be used, Tangit is a preferred brand, but if unavailable, General an equal or approved make could be used. The Polybutylene system shall be made by Thermaflex The above valves should be used for balancing and is PB 1 4237 grey and branded as FLEXALEN regulations purposes. Unless otherwise indicated on the drawings, draw-off isolating valves should be of Requirements specific to the design of PB pipe work approved construction with female threaded ends systems are contained in this section. Polybutylene (PB) suitable for PB threaded adapters. pipe work fittings shall be used for the conveyance of potable cold water, for use in all domestic cold water Selection of PB Pipe Systems services, chilled water (pre-insulated also), Central hot and very hot water services and compressed air should The selection is based on the following diameters: comply with there quirements specified in (BS 7291 The installed system shall be the Polybutylene pipe work (Parts 1 and 2) class 'S'.) system and shall have the following diameter

The whole of the PB pipe work installations should be Outer Diameter in MM Inner Diameter in MM installed and tested in accordance with the requirements as with the relevant manufacturer's instructions. 16 11.6 0 Care should be exercised whilst off-Loading, storing, 20 14.4 0 transporting about the site and whilst installing the 25 20.4 0 pipes and fittings to ensure that no accidental damage 32 26.0 0 occurs to the pipes or fittings. Also, the pipes and 40 32.6 0 fittings should not be stored where they may be 50 40.8 0 exposed to the effects of ultra violet radiation. 63 51.4 0 75 61.4 0 Pipes 90 73.6 0 All PB piping should be to EN ISO 15876-1,2,3 110 90.0 0 (BS 7291: Part 182 or DIN 16968/DIN 16969.) 125 102.20 Pipe Fittings and Valves 160 130.80 225 184.00 Unless specified otherwise, all associated pipe fittings (viz. Manifolds, unions and flanges) should be of Polybutylene All Polybutylene pipe work sizes stated on the drawings matererial manufacture generally in accordance with refer to outside diameters. (BS 7291: Parts 1 and 2) and brass fittings manufactured Workmanship, Finish and Appearance generally in accordance with EN ISO 15876-1,2,3 (BS 864, Part 2,) and be fully compatible with the pipe The finished tube shall be smooth, free of internal end system they are to be installed with either of same external mechanical imperfections and internally shall make or any brand manufactured to above specifications. have a smooth appearance. Valves for PB pipe work should be fully compatible with Packaging and Transportation the pipe system to which they are to be connected, The pipes should be delivered in coils or straight comprising variously: lengths, and the tubes shall be bundled by size in 1) PB gate valves for pipe sizes up to and including suitable bags or cardboard boxes, clearly marked with 63mm outside diameter, allowing bi-directional flow the purchase order number, material designation, size, with direct sealing of slide in valve body operating at 90° total length or piece count and name of supplier. to direction of pump flow with non raising valves spindle. Jointed either using socket fusion or electrofusion Pipe Joints ends The pipes and fittings should be entirely compatible 2) PVC-C ball valves, for pipe sizes up to and includ- with each other and the jointing should be carried out in ing 63mm outside diameter, meeting the resistance to strict accordance with the manufacturer's printed pressure requirement of DIN 3441, allowing bi-direc- instructions. tional flow with floating ball, and complete with double Unless indicated otherwise, the pipe joints in PB pipe socket disconnecting ends and removable seals. work should be made by socket fusion, electro fusion, 3) Brass valves should be suitable for connection with push fit, or compression. The assembly of these should PB pipe with adapters to flanged or threaded connectors. be carried out in strict accordance with the manufacturer's instructions.

Socket fusion It is essential that cleaners are correctly applied to the pipe ends and sockets prior to fusion and electro fusion Utilising the correct tools for assembly, heating end joints jointing with cleaning pads changed regularly in accordance in accordance with the manufacturer's instructions. This with manufacturer's instructions. After fusion jointing, a shall be carried out only on a workbench, with the heating ring of Polybutylene will be visible on the outside of the element securely fixed to the workbench. pipe as evidence that a joint has been completed. After Only fully trained installers should be used electro fusion an indicator pip will raise above the surface for assembling Flexalen Polybutylene pipe of the fitting as evidence that a joint has been completed. systems. Trained and Certified by Thermaflex Great care should be taken to ensure that only the representative. manufacturer's installation procedures are followed and, in particular, that the full cooling period is maintained Fire Sleeves before any joint is considered to be complete. No pipe work, or section thereof, shall have water pressure Fire sleeves should be used where single PB pipes of applied until the manufacturer's stipulated setting period 32mm outside diameter and above or multiple banks of has elapsed (a minimum of at least one hour after the last pipes penetrate fire barriers. They should generally fusion point). comply with the requirements of the local fire authority. Where an existing heat source has to be maintained, with (j) They should be constructed with an in tumescent pipes either running parallel or crossing each ether, lining. thermal insulation should be applied. (ij) Casings should accommodate the expansion of in On no account should ladders scaffold or ether building tumescent linings during fire conditions. items be propped up against the PB pipe work installation. (jjj) In tumescent linings should expand inwards at a Changes in direction can be achieved using the pipes temperature of about 150°C and completely seal the flexibility, in accordance with the manufacturer's instructions. openings against the passage of flames, fumes and No thermally induced bending of Polybutylene pipes smoke. Such linings should also be in accordance with through the application of local heating should be permitted. the pipe manufacturer's requirements. All Polybutylene pipes should be supported by pipe clips Note: The pressure of the expanding in tumescent lining or support brackets, the spacing of which should not may crush PB pipes. exceed the maximum intervals as advised end confirmed !iv) Individual sleeves mounted on vertical pipe work by the pipe manufacturer. should: Where a pipe clip or support bracket is being used to - be of construction suitable for surface mounting support a number of pipes, of different materials and - be installed on the pipe immediately below the barrier sizes, the spacing interval between such clips end brackets (the collar should be securely fixed to the sleeves, the should not exceed the smallest of the 'maximum intervals' sleeve and the flanged collar butted up against the fire stated or advised for each of the pipes being supported. barrier and the flange bolted into position) or similar. Polybutylene pipe work in exposed positions (or where distortion is likely to occur should be supported using the Installing the pipe work system piping manufacturer's standard pipe clip or support pipe carriers or also locally available products permitted is The contractor should: checked and confirmed by Thermaflex representative. (j) Check that the exterior of the piping is marked at intervals Where PB piping is supported using clamps and not exceeding one metre with the manufacturer's name, supports, the supports should comprise steel split pipe type of material, pipe size and standard with which it rings with rubber insert, nippling rod nuts and washers complies. with back plate as required, either fixed to rail support or (jj) Check that all the piping and fittings supplied are building fabric. uniform in colour density. The test pressure should be maintained throughout the (iij) Exercise particular care in their storage, handling and period of time of not less than three hours and not less installation to avoid deterioration due to ultraviolet light than one and a half times working pressure. and impact damage. The procedure detailed in the technical brochure should The piping manufacturer's printed instructions should be be adhered while performing the pressure tests and the rigidly adhered to in all respects of storage, stacking, sequences to allow for the expansion and the setting-in handling and installation. The pipe work should be period of PB pipes, during the time, the test is being supported as indicated upon the drawings and as carried out. The results of the pressure test should be detailed within the contract documents. recorded on a log sheet.

Expansion Prior to the dosing process commencing, the Contractor Expansion Loops or changes in pipe direction should is to submit details of the company it is proposing to be allowed for at regular intervals in accordance with engage to perform the operation, complete with all manufacturer's guidelines.Where expansion Loops and relevant information regarding the type of chemicals to changes in direction are impractical, fixed point assembly be used and the method. may be used on pipes up to 75mm diameter to prevent the Dosing by the mechanical contractor or any other PB pipes from expanding or contracting, in accordance organisation not a specialist will not be permitted. with manufacturer's guidelines. Only installers carrying a Thermaflex training If fixed point brackets are being used to avoid longitudinal expansion of PB pipes, the installation instructions of certificate shall be used for assembling the both the pipe and bracket manufacturer's should be Flexalen plain or pre-insulated polybutylene adhered to. Fixed point brackets should be located at pipe systems fittings and must grip the pipe on both sides of the fittings, or according to manufacturer's instructions. Fixed point supports should be located at fusion or electro fusion fittings and meet with the manufacturer's requirements, to absorb forces and transfer them to the structure. Fixed points should not be located more than a maximum of 6m apart. Pipe support carriers must be used to support the pipes between fixed points, to prevent buckling. Normal supports for the pipes and carrier, between fixed points should not be more thon 1.5m apart, in accordance with the manufacturer's guide lines. Pipe support carriers shall be of semi¬circular shape to closely match the pipes outside diameter. Manufactured from galvanised or size plated steel. The coating inside and outside are to be of the same standard. The finish is to be smooth along the surfaces and edges to prevent damage to the pipes. When cut the edges of the carrier are to be filed smooth. The carrier is to be attached to the pipe by approved cable ties suitable to support the forces, at intervals recommended by the manufacturer (never more thon 500mmJ. The carrier is not to be run over fittings, but to terminate 10-15 mm short both sides with adequate support through cable ties and brackets. Water Treatment On completion of installation, the whole of the heating and primary hot water system is to be filled and after a satisfactory pressure and heat test is achieved emptied and flushed clean of all foreign matter. When a clean water condition is proven, the system is to be dosed with an approved and recognised chemical scale and corrosion inhibiting agent. The dosing operation is to be carried out by an approved specialist and on completion, certificates are to be submitted indicating the chemical used (and its charac- teristics) the percentage dosage introduced and all other relevant details required to maintain satisfactory protection. Immediately upon completion of the dosing process, notices are to be posted in plant rooms indicating that the system has been treated, the chemical used, the percentage concentration, etc and particularly relevant information required by the Health and Safety at Work regulations.