INDEX 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. 01 ● 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. 02 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 expan- sion 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 advanta- geous for prefabricating riser pipes. The material has very good creep rupture strength at high temperatures and under permanent loads, thus permitting high pres- sures 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. 03 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.