Table of Contents 2.0 EIGERFLEX CPE. 2.0 Table of Contents
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1 Table of Contents Table of Contents 2.1 System description System description (general) System description (data) DN 20 - DN 40 with frost protection strip, Ø carrier pipe mm DN 50 - DN 100 with frost protection strip in the frost protection strip channel, Ø carrier pipe mm 2.2 Planning, design engineering Pressure loss chart, DN 20 - DN 100 (SDR 11) Heat loss 2.3 Components L-shell, dimension Ø mm Big-L-shell, dimension Ø 162 mm Joint (PE-HD shrink sleeve), dimension Ø mm I-shell, dimension Ø mm Big-I-shell, dimension Ø 162 mm T-shell, dimension Ø mm Big-T-shell, dimension Ø 162 mm Insulation material, PUR-foam containers / PE-Isolation PE-jointing methods 1, screwed connectors (external thread, weld end, coupling) PE-jointing methods 2, screwed connectors / T-pieces PE-jointing methods 3, fusion-welded and alternative connections End closure, shrink-type closure Wall sealing ring, pipe warning tape Building entry, wall opening/core bore Building entry, core bores/cement pipe liners 2.4 Underground construction, installation Trench dimensions Sleeve joint - frost protection strip T-piece, frost protection strip Connection to end of frost protection strip
2 System description General is Brugg Pipe Systems protected name for a flexible, pre-insulated cold water pipe featuring an integrated frost protection strip (FPC). This pipe system is especially suitable for cold water and waste water pipes which cannot be installed at depths that are safe from frost. The cold water pipe features a medium pipe produced from high-density polyethylene (PE100) as per standard EN 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 electrowelded fittings or by means of polyfusion welding technology. 2. Range of applications Max. continuous operating temperature T Bmax: 20 to +20 C Max. permitted operating pressure p: max. 16 bar The heat insulation consists of CFC-free flexible rigid polyurethane foam with excellent insulating properties. The bending capacity of the flexible 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 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) is used with different power capacities (11 or 18 W/m), regardless of the thickness of the medium pipe or the insulation. cold water pipe is prefabricated 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 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.
3 System description Medium pipe Material: Polyethylene class PE100 with high density, to DIN EN ISO 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 Density Heat conductivity Ultimate tensile strength (tearing resistance) Modulus of elasticity Linear expansion coefficient Crystallite melting range Ref. temp. C Value kg/m³ 0.40 W/mK 32 N/mm³ 1000 N/mm³ E-4 1/K C Test standard DIN DIN DIN DIN DIN Frost protection strip Material: Outer casing Screened protective braiding Insulation Conductive heating element Copper conductor Frost protection strip, selfregulating mm power output Power delivery 11 W/m Dimensions Width 7.7 mm, Thickness 5.3 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: 128 m / 16 A at 10 C 100 m / 10 A at 10 C Power delivery (W/m bei 10 C) 11 W/m To protect people and equipment, we basically specify a 30 ma residual current-operated device (FI) mm Power delivery 18 W/m Width 7.7 mm, Thickness 5.3 mm 20 mm 230 V AC 50 Hz Continuous operation 65 C, short periods 85 C, to 30 C 102 m / 16 A at 10 C 60 m / 10 A at 10 C 18 W/m 3. Heat insulation Material: CFC-free, 100% CO 2-driven polyurethane foam (PUR) PUR-insulation Density Heat conductivity Closed cellular structure Water absorption after 24 hrs. Ref. temperature C 30 Value > 60 kg/m³ W/mK 90 % 10 % Test standard ISO 845 EN 253 and ISO 8497 EN Enveloppe de protection Material: Purpose: PE-LLD-protective casing Density Heat conductivity Crystallite melting range Polyethylene of low density, PE-LLD, extruded seamless Protection against mechanical effects and moisture Ref. temperature C Value kg/m³ 0.33 W/mK 122 C Test standard ISO 1183 DIN ISO
4 range (with frost protection strip) Dimensions DN 20 - DN Aluminium foil, 50 mm wide Frost protection strip; Power delivery 11 W/m Aluminium foil, 50 mm wide s d D s1 PE-Medium pipe PUR-foam PE-foil LLD-PE casing, corrugated Frost protection strip; Power delivery 11 W/m Dimensions DN 20 - DN 40 Type 25/76 32/76 40/91 50/91 DN Inches ¾ 1 1 ¼ 1 ½ Medium pipe PE d x s mm 25 x x x x 4.6 Outer casing D x s1 mm 78 x x x x 2.2 Min. bending radius m Medium pipe Volume I/m Weight kg/m max. delivery length* Jumbo coil Maxi coil m m * 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)
5 range (with frost protection strip) Dimensions DN 50 - DN Aluminium foil, 102 mm wide Frost protection strip; Power delivery 17 W/m Plastic channel Aluminium foil, 102 mm wide d D s1 s PE-Medium pipe PUR-foam PE-foil LLD-PE casing, corrugated 18 Frost protection strip channel Frost protection strip; Power delivery 17 W/m Dimensions DN 50 - DN 100 Type 63/126 75/126 90/ /162 DN Inches 2 2½ 3 4 Medium pipe PE d x s mm 63 x x x x 10.0 Outer casing D x s1 mm 128 x x x x 3.2 Min. bending radius m Medium pipe Volume I/m Weight kg/m max.delivery length* Jumbo coil Maxi coil m m * 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)
6 Pressure loss DN 20 - DN 100 (SDR 11) Water temperature 20 C Roughness = 0.01 mm (PE100) (1 mmws = 9.81 Pa) Water velocity /90 mm (DN 100) 90/73.6 mm (DN 80) 3.0 m/s 75/61.4 mm (DN 65) 63/51.4 mm (DN 50) Mass flow rate ṁ [kg/h] m/s 1.5 m/s 2.0 m/s 50/40.8 mm (DN 40) 40/32.6 mm (DN 32) m/s 32/26.2 mm 4000 (DN 25) 0.5 m/s m/s 0.3 m/s 25/20.4 mm (DN 20) Pressure loss p [Pa/m]
7 Heat loss Heat losses at different external temperatures or surface temperatures of the casing pipe. surface temperatures Medium temperature: 2 C The frost protection strip can no longer compensate for a heat loss of more than 10 W/m, and there is a danger of freezing. If the pipes are laid underground (covered height of 0.6 m), the heat losses are reduced by at least 20%. Tmed = 2 C surface temperature of the outher casing C / / pipe dimensions 40/91 50/91 63/126 75/126 q W/m Medium temperature: 2 C Danger of freezing 90/ /
8 L-shell Dimension DN 20 - DN 65 (Ø mm) d d2 376 Figures in mm L-shell Outer casing Ø d2 Ø d x 91 x 126 x PE-jointing methods; see Structure of the half-shell 1 ABS-half-shells 2 Electro-fusion-joints; see Sealing clamps (14 pcs.) 4 Insulation material; see Glued surface 6 Reducer ring or sealing ring 7 Frost protection strip
9 Big-L-shell Dimension DN 80 - DN 100 (Ø 162 mm) d d2 Figures in mm 508 Big-L-shell Outer casing Ø d2 Ø d x 182 x CALPEX Big-shells are freely reducible from Ø 162 mm to Ø 76 mm PE-jointing methods; see Structure of the half-shell 1 ABS half shells 2 PE-fusion welded joints; see Sealing clamps (22 pcs.) 4 Insulation material; see Glued surface 6 Reducer ring or sealing ring 7 Frost protection strip
10 Joint using PE-HD shrink sleeve Dimension Ø mm joints and reduction joints d1 d2 1 PE fusion welded joints; see Insulation material, PUR or PE; see Shrink sleeve pipe 4 Shrink hose Ø d Ø d1 76 x 91 x x 126 x x x 162 x x PE-jointing methods; see
11 I-shell Dimension DN 20 - DN 65 (Ø mm) d1 d2 578 Figures in mm 1 ABS half-shells 2 PE jusion welded joints; see Sealing clamps (12 pcs.) 4 Insulation material; see Glued surface 6 Reducer ring or sealing ring 7 Frost protection strip I-shell Outer casing Ø d2 Ø d x 91 x x 126 x x x PE-jointing methods; see
12 Big-I-shell Dimension DN 80 - DN 100 (Ø 162 mm) d1 d2 Figures in mm 752 Big-I-shell Outer casing Ø d2 Ø d x 162 x x CALPEX Big-shells are freely reducible from Ø 162 mm to Ø 76 mm PE-jointing methods; see Structure of the half-shell 1 ABS half-shells 2 PE jusion welded joints; see Sealing clamps (22 pcs.) 4 Insulation material; see Glued surface 6 Reducer ring or sealing ring 7 Frost protection strip
13 T-shell Dimension DN 20 - DN 65 (Ø mm) d d1 d3 Angaben in mm 578 Figures in mm T-shell Outer casing Branch, Ø d2 Ø d1 - Ø d x x x x x x x x x x x x x x x x x x Structure of the half-shell 1 ABS half-shells 2 PE T-piece; see Sealing clamps (16 pcs.) 4 Insulation material; see Glued surface 6 Reducer ring or sealing ring 7 Frost protection strip PE jointing methods; see
14 Big-T-shell Dimension DN 80 - DN 100 (Ø 162 mm) d2 d1 d Figures in mm Big-T-shell Outer casing Branch, Ø d2 Ø d1 - Ø d x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x CALPEX Big-shells are freely reducible from Ø 162 mm to Ø 76 mm PE jointing methods; see Structure of the half-shell 1 ABS half-shells 2 PE T-piece; see Sealing clamps (27 pcs.) 4 Insulation material; see Glued surface 6 Reducer ring or sealing ring 7 Frost protection strip
15 Insulation material PUR foam containers, PE-Insulation PUR foam containers CFC-free PUR foam in plastic bottles Safety regulations 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 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
16 PE jointing methods Screwed connectors (outer thread, weld end, coupling) Connection with outer thread/weld end L L St 37.0 L St 37.0 L Heating, 6 bar Material: brass PE-pipe Screwed connector L Weld end L mm mm mm mm mm 25 x x 2.3-¾ x x x x x x 3.7-1¼ x x x 4.6-1½ x x x x x x 6.8-2½ x x x x x x x angle coupling z z a a Heating, 6 bar Material: brass PE-pipe PE-pipe a z mm mm mm mm 25 x x x x x x x x x x x x x x x x 10.0 Coupling, equal L L PE PE Heating, 6 bar Material: brass PE-pipe PE-pipe L mm mm mm 25 x x x x x x x x x x x x x x x x Coupling, reduced L L PE PE Heating, 6 bar Material: brass PE-pipe PE-pipe L mm mm mm 32 x x x x x x x x x x x x x x
17 2.355 PE jointing methods Screwed connectors, T-pieces d2 d2 d1 d3 d1 d3 PE PE Material: brass Ø d1 Ø d3 Branch, Ø d2 mm mm 25 x x x x x x x x x x x x 2.3 x 28 x x 4.0 x 32 x x 2.9 x x 32 x x 4.0 x 32 x x 2.3 x 40 x x 3.7 x x x 40 x x 2.9 x x 50 x x 4.6 x x x x 50 x x 3.7 x x x 63 x x 5.8 x x x x x 63 x x 4.6 x x x x 75 x x 6.8 x x x x x x 75 x x 5.8 x x x x x 90 x x 8.2 x x x x x x x 90 x x 6.8 x x x x x x 110 x x 10.0 x x x x x x x x 110 x x 8.2 x x x x x x x Any other T-pieces that may be required can be supplied on request.
18 PE jointing methods Fusion welded and alternative joints PE100 electro fusion-welded fittings SDR 11/SDR 17 Sleeves Ø mm Reduction sleeves Ø mm Angle piece, 90 equal Ø mm Angle piece, 90 equal (without fusion joint) Ø mm T-piece, equal/reduced Ø mm T-piece, equal/reduced (without fusion joint) Ø mm (Source: Georg Fischer Rohrleitungssysteme AG) Mechanical pipe couplings Butt-fusion To join: plastic to plastic, or plastic to metal pipes Ø mm (Source: Straub Werke AG) (Source: PF-Schweisstechnologie GmbH) All jointing methods listed on this sheet are available on request.
19 End closure Shrink-on closure Shrink-on closure shrink-on closures protect the PUR insulation on the front of the 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: shrink-on closures must be pushed onto the end of the 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
20 Wall sealing ring Pipe warning tape Wall sealing ring Type Da 25/ / / / / / / Da D 110/ Pipe warning tape To be laid in the ground Standard roll length: 250 m Installation depth: see sheet 2.505
21 Building entry Wall opening Wall leadthrough ca. 80 mm 60 mm 80 mm Wall opening D PE connection piece: see sheet pipe: see sheets 2.115, End cap; see sheet Wall seal: see sheet Core bores Outer A Outer D casing casing Ø D Ø D mm mm mm mm A D D A Figures in mm
22 Building entry Core bores/cement pipe liners Wall leadthrough PE connection piece: see sheet mm pipe: see sheet 2.115, D End cap: see sheet Core bores min. 30 D1 Outer casing D1 A Ø D mm mm mm A Figures in mm Core bores Perfect bores are required for installation. As hairline cracks may be present in the concrete or result from drilling, it is advisable to seal the entire length of the borehole wall with suitable sealant (such as AQUAGARD). Tightness can only be guaranteed if this recommendation is followed. Key 1 2 Sealing set, single-seal, width 1 x 40 mm, Shore hardness D35 3 Sealing set, double-seal*, width 2 x 40 mm, Shore hardness D35 4 Liner pipe: made of fiber cement or coated core bore * Suitable for pressure from water up to 0.5 bar
23 Trench dimensions Trench profile, 1 pipe D 10 T min D B 10 Figures in cm 1 Pipe warning tape; see sheet Excavated material 3 Sand, washed, max. grain size 8 mm Casing pipe Width Depth Minimum Ø D B T Bending radius mm cm cm m Installation depth: max. installation depth: 2.6 m Our approval is required for installation at greater depths. 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.
24 Frost protection strip Sleeve joint 1. Planning L 100 m Continous joint Connection frost protection strip/ frost protection strip V-H/H L > 100 m Separation End closure EA-H Supply End closure EA-H Supply Supply max. 100 m max. 100 m max. 100 m 2. Preparation 40 cm Figure 1 Figure 2 Shorten as shown in illustration 2 frost protection strip/ frost protection strip V-H/H 15 cm 15 cm Remove 40 cm of insulation at the ends and carefully expose the strip. Then shorten the inner pipe to length as shown in illustration Sleeve joint Continuous joint L 100 m Connection frost protection strip/frost protection strip V-H/H Separation L > 100 m Screwed joint or welded sleeve 30 cm 30 cm 30 cm Protect heating strip against moisture Connect the cables according to the installation instructions
25 Frost protection strip T-Piece Planning End closure EA-H T-piece Micro Uni Clip MUC Supply Supply (using connection A-H/K) End closure EA-H Connection V-H/H End closure EA-H L 100 m Example 1: Total lenght 100 m Example 2: Total lenght 100 m Supply Connection V-H/H End closure EA-H End closure EA-H L 100 m Protect heating strip against moisture 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 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
26 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. 80 m Regulation: Thermostat UTR15 Adjustment range: 5 C to +15 C pipe contact thermostat 2. Preparation Remove cm of insulation at the ends and carefully expose the strip. Then shorten the inner pipe to length according to the fitting instructions cm Shorten as described in fitting instructions 3. Installation procedure 230 V Protect the heating strip against moisture Thermostat UTR 15 with temperature sensor Frost protection strip Sensor cable length 3 m; can be extended to a max. of 100 m with screened cable, 1.5 mm Connection box (provided by the customer) Connection: Heating strip/cold lead A-H/K max. 100 m Electrical installation according to local regulations Only to be connected by an authorised electrical installer 30 ma residual current-operated device (FI)-required by regulations! Automatic fuse, C-characteristic Temperature sensor on pipe End closure EA-H 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 Temperature sensor cable ca. 7 cm Shrinkdown tube Filling adhesive S1113, 80 mm long Shrinkdown tube Temperature sensor
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