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REHAU EVERLOC™ HEATING AND PLUMBING SYSTEMS TECHNICAL MANUAL

55

1 Introduction 6

2 Polymer Pipe – Cross Linked Polyethylene 82.1 Polymerisation 82.2 PE-Xa Characteristics 82.2.1 Chemical Resistance 82.2.2 Oxygen Permeability/Opacity 102.2.3 A Widely Used Engineering Polymer 10

3 Product Range 113.1 Pipe Range and Descriptions 113.1.1 Pipe Markings 113.2 Jointing Technology 123.2.1 Tooling 123.2.2 Jointing Method 123.3 Fittings and Ancillaries 133.3.1 Pipe-in-Pipe 133.3.2 Modular Manifolds 133.3.3 Heating Manifolds 133.3.4 Wall Plate Fittings and Brackets 143.3.5 Branch/Cross Fittings 14

4 Standards, Approvals and Performance 154.1 General Approvals 154.2 Water Quality Statement 154.3 Disinfection of REHAU Pipework 164.4 Approvals 164.5 Quality Systems 16

5 Applications – The System in Use 195.1 Principle Advantages 195.2 Typical Layouts 205.3 System Design Information 215.3.1 Flow Rates 215.3.2 Pipe Sizing 245.3.3 Pipe-in-Pipe 245.3.4 Fixing Distances – Concealed Pipework 245.3.5 Pipe Support 245.3.6 Corrosion Inhibitors 245.3.7 Anti Freeze 245.3.8 Connection to Boilers 245.3.9 Expansion and Contraction 255.3.10 Bending RAU PE-Xa 265.3.11 Pressure Testing 265.3.12 Insulation Requirements 265.3.13 Trace Heating 265.3.14 Storage Conditions 26

6 Summary 27

7 Appendix 28

THE REHAU EVERLOC™ HEATING AND PLUMBING SYSTEM IS AN INTEGRATED RANGE OF RELIABLE AND HIGH QUALITY FLEXIBLE POLYMER PIPES. THE TOTALLY RELIABLE, SLIM, NEAT BRASS FITTINGS ARE ALL DESIGNED SPECIFICALLY TO WORK TOGETHER.

Manufactured by REHAU since the early 1980’s, the system is used extensively worldwide and is considered to be one of the most effective systems available. From the Far East and Asia to Australia and the Americas, the system meets all performance standards and requirements. No other company comes close to REHAU fl exible pipework for quality, reliability and performance.

Removing the need for traditional copper pipework and fi xings, REHAU fl exible heating and plumbing pipework is proven to save time, money and effort. There is no heating or plumbing application that REHAU fl exible pipework can’t do more simply than traditional materials, bringing with it a host of benefi ts:

INTRODUCTION

6

1.

7

- One pipe serves all service applications from 16 to 32mm, with 40 to 63mm options available for mains, risers and other applications. Larger sizes are available on request.

- High quality system allows the discerning engineer to achieve an effective system, with features making it easy to conceal.

- Pipe fl exibility means easy routing, as long lengths of pipe (available as coils or straight lengths) can be threaded and pulled through walls and fl oors effortlessly.

- The extensive range of superbly engineered DZR brass compression sleeve fi ttings form part of the unique REHAU cold jointing system which allows assembly of joints quickly, securely and permanently.

- The REHAU Pipe-in-Pipe option offers even greater fl exibility by offering ‘in-fl oor’ pipe installations. The combined pipe and sleeve can be fi tted prior to laying the fl oor screed, removing the need to construct special ducts, thereby saving a considerable amount of time and money.

- Delivered on a roll, REHAU fl exible pipe maximises effi ciency by reducing the number of joints and minimising waste from cut-offs.

- No naked fl ames and no swarf, fl ux, grease or oil means a safer working environment. Also the absence of heavy pipework lying around a building means accidents are less likely.

- The durable fl exible pipework has a service life in excess of 50 years, due to its excellent heat age resistance, high tensile strength and resistance to deformation and impact damage.

- The jointing tools that work with REHAU fl exible pipe are available to contractors from REHAU and other outlets. Robust and easy to use, the tools are available in foot pump hydraulic and electrical versions.

- A REHAU manifold keeps the heart of the installation in one place, allowing services to be run from a central point out to radiators or sanitary fi xtures, and allowing for simple fault fi nding and maintenance. The ability to run all pipework out from a single point keeps installation simple and saves time.

- Ultra smooth inner lining minimises limescale build up, for long life and consistent fl ow rates. The pipework has an in-service pressure rating of 6 bar at 95˚C and 12 bar at 20˚C (BS7291:1990). Corrosion free, as EVAL polymer oxygen diffusion barrier prevents oxygen getting into the system to corrode ferrous components. The growth of micro-organisms within the pipe is inhibited by the opacity barrier which blocks out light.

- REHAU offers a full range of purpose made brackets enabling fi rm and secure fi xing of fi ttings, for all common heating and plumbing application, for example, showers and washbasins. The brackets provide convenient junctions for fi xture connections and can be concealed or left visible, according to preference and/or task. Support channeling and stainless steel radiator tails are available for specifi c tasks.

1 REHAU EVERLOC™ joint

2 Cut away

3 Pipe-in-Pipe

3

2

1

POLYMER PIPECROSS LINKED POLYETHYLENE

8

2.

2.1 PolymerisationREHAU Heating and Plumbing Pipes are based on RAU PE-Xa, high pressure cross-linked polyethylene. The base material is polyethylene, with a high molecular weight and a high density, which is then cross-linked by a special process which dramatically improves its physical properties.

The process used by REHAU is based on the Peroxide cross-linking process, giving an optimal and consistent level of cross-linking. The resulting pipes are designated RAU PE-Xa.

2.2 PE-Xa Characteristics- Optimally cross-linked for fl exibility and long-term heat

aged performance- Can tolerate short exposure to operating temperatures up to

110˚C at normal operating pressure- Resistant to abrasion and impact- Resistant to crack formation- Exhibits a memory effect, as once deformed it can be returned

undamaged to its extruded shape.- Chemically inert- Non corroding- Free of heavy metals and halogens

The smooth bore of RAU PE-Xa, the long radius made bends and fi tting design mean that fl ow rates are improved over copper and steel.

The fl exible nature of the pipe means that it absorbs fl uctuations in pressure, thereby signifi cantly reducing noise transmission through fl uid fl ow and water hammer compared to other pipe systems.

2.2.1 Chemical ResistanceThe pipes described in this brochure are designed for use in heating and plumbing applications. The base material has excellent chemical resistance due to the chemical bonding of the polymer chains. Contact with chemicals to which the polymer is not resistant, usually results in swelling or some dissolving of the polymer. The results of exposure tests are given below.

The data given here is general and cannot be taken as typical of the performance of a pipe fi lled with the chemical and placed under pressure. If non-standard pressurised applications are being considered, please contact the REHAU Technical Department for further details.

0

0 1 2 3 4 5

10

20

30

40

50

60

70

Flow rate (m/s)

Pre

ssur

e (b

ar)

PE-Xa:25 x 3,5

PVC-C:25 x 2,8

PP Typ 3:25 x 5,0 Steel/Copper

60bar

15bar

Steel/Copper

PVC-C

PP Typ 3

PE-Xa

Pre

ssur

e sh

ock

leve

l

Hydrogen

Carbon

HDPE Polymer prior tocrosslinking

Simplified Cross linkingPE-Xa

Physical Properties of RAUTHERM Universal Pipe (RAU PE-Xa)

Density

(to DIN 53497)

0.93g/cm3

Modulus of elasticity

(to DIN 53457)

600 N/mm approx.

Impact resistance

(to DIN)

at 20°C

at -20°C

No damage

No damage

Co effi cient of expansion

at 20°C

at100°C

1.4 x 10-4K-1

2.0 x 10-4K-1

Thermal conductivity 0.35 W/mK

Oxygen diffusion

at 40°C ≤ 0.1 mg/lxd

Pipe internal roughness 0.007mm

9

Chemical Resistance

Substance 20˚C 60˚C Substance 20˚C 60˚C Substance 20˚C 60˚C

Acetic acid + + Diethyl ether 0 Petroleum + 0

Acetone + Engine oil + 0 Phenol + 0

Acrylonitrile + + Ethyl acetate + 0 Phosphates, hydrous + +

Allyl alcohol + 0 Ethyl alcohol + + Phosphoric acid 95% + +

Aluminium chloride, anhydrous + + Ethylene glycol + + Phthalic acid 50% + +

Aluminium sulphate, hydrous + + Esters, aliphatic + 0 Plant protection agents + +

Ammonia, hydrous + + Esters, aromatic 0 0 Polyglycols + +

Ammonium chloride, hydrous + + Fluorine -- -- Potassium bichromate 40% + +

Ammonium sulphate, hydrous + + Formic acid + + Potassium chloride, hydrous + +

Aniline, pure + + Formaldehyde 40% + + Potassium hydroxide, 30% solution + +

Aqua regia -- -- Freon 0 -- Potassium permanganate, 20% solution

+ +

Beer + + Glycerine + + Propanol + +

Benzene 0 + Glycols + + Propionic acid, 50% + +

Benzoic acid, hydrous + + Heating fuel oil + 0 Propyl alcohol + +

Bitumen + + Hexane + + Pyridine + 0

Bleach + Hydrochloric acid, concentrated + + Silicon fl uid + +

Bromine + -- Hydrofl uoric acid 70% + 0

Butane diol + + Hydrogen peroxide 30% + +

Butanol + 0 Hydrogen peroxide 100% + -- Soap solution + +

Butanone + + Hydrogen sulphide + + Sodium hypochlorite + 0

Butter + + Linseed oil + + Styrene 0 --

Butyl acetate + 0 Liquid paraffi n + + Sulphuric acid, up to 50% + +

Butyric acid + 0 Magnesium salts, hydrous + + Sulphuric acid, up to 98% 0 --

Carbon tetrachloride 0 -- Maleic Acid + + Sulphur trioxide -- --

Carbonic acid + + Mercury + + Tetrahydrofurane 0 --

Chlorine, liquid -- -- Methanol + + Tetralin + 0

Chlorine gas, damp 0 -- Methylene chloride 0 -- Tincture of iodine + 0

Chloroform 0 -- Milk + + Toluene 0 --

Chromic acid 50% + -- Naphtha + 0 Transformer oil + 0

Chromic acid/sulphuric acid + -- Naphthalene + -- Trichloroethylene 0 --

Citric acid + + Natron + + Turpentine oil + 0

Cod liver oil + + Nitric acid, 30% + + Vaseline + 0

Cresols + 0 Nitric acid, 50% 0 -- Washing agents + +

Cyclohexane + 0 Nitrobenzene + 0 Water + +

Cyclohexanol + + Oils, essential + 0 Wine + +

Cyclohexanon + 0 Oils, vegetable + 0 Xylene 0 --

Dekalin + -- Oleum -- --

Key to symbols+ = resistant0 = partial resistance -- = not resistant

Detergents, synthetic + + Oxalic acid 50% + +

Dibutyl phthalate + 0 Ozone 0 --

Dichlorethylene 0 -- Ozone, hydrous <0.1% + --

Dichlorobenzene 0 -- Petrol + 0

Diesel oil + 0 Petroleum ether +

10

2.2.2 Oxygen Permeability/OpacityHeating applications demand that the pipe is impermeable to oxygen to prevent corrosion of ferrous components, such as radiators and heat exchangers. RAUTHERM pipes use an EVAL oxygen barrier tested to BS 7291:1990 and DIN 4726.

Water Regulations Advisory Scheme (WRAS) and BS7291:1990 requirements are that water contained in pipes be screened from UV light, to prevent microbiological growth in potable water systems. RAUTHERM Universal Pipe has a deep red coloured layer which performs this function (16 to 32mm sizes) and RAUHIS pipes (40 to 63mm sizes) have a silver coloured layer which blocks all light.

The EVAL and pigmented layers are co-extruded onto the pipe during manufacture.

2.2.3 A Widely Used Engineering PolymerAside from heating and plumbing applications, there are many other specialist applications served by REHAU pipes made in RAU PE-Xa. These including carrying water services and mains, district heating networks and compressed air systems. Please contact REHAU for further details.

1 The polyethylene pipe (REHAU VPE)

2 Deep red opacity barrier

3 The EVAL barrier coating

1

2

3

11

PRODUCT RANGE3.

THE COMPREHENSIVE RANGE OF PIPES AND FITTINGS MEANS THAT ANY HEATING OR PLUMBING APPLICATION CAN BE SUCCESSFULLY TACKLED WITH THE SYSTEM. THE VARIOUS ADAPTERS MAKE INTEGRATION POSSIBLE WITH COPPER AND STEEL, AS WELL AS OTHER MATERIALS.

For sizes up to 32mm, a single type of pipe is suitable for both heating and plumbing applications. From 32mm to 63mm, there are two types of pipe for each diameter, one for heating and one for plumbing applications.

3.1 Pipe Range and DescriptionsTo select the correct pipe size, reference should be made to the fl ow rate required (rather than by comparing to equivalent copper pipe size). The inherent properties of the RAU PE-Xa Pipe (smooth bore, reduced friction through fi ttings and reduced furring) means that pipe sizes can normally be reduced compared to traditional pipe materials. Information on fl ow rates and head loss for the various pipes is given under Section 5.3 Design Information page 21.

3.1.1 Pipe MarkingsREHAU pipes are marked with the following information repeated at regular intervals along the pipe:- Manufacturers name: REHAU- Commercial name: REHAU RAU PE-Xa- Pipe diameter- Wall thickness- Temperature classifi cation and maximum

operating pressure- Production location reference and batch number- Production date reference- Metre markings for registering usage

Description Application Size-OD/wall thickness (mm)

I.D. (mm)

Supply Format

RAUTHERM Universal PipeWith EVAL and Opacity layer

Heating andPlumbing

16 x 1.520 x 1.925 x 2.332 x 2.9

13.016.220.426.2

6m Straight lengths and coils6m Straight lengths and coils6m Straight lengths and coils6m Straight lengths and coils

RAUTHERM FWWith EVAL layer

Heating only 40 x 3.750 x 4.663 x 5.8

32.640.851.4

Straight lengths Coils to special orderStraight lengthsCoils to special order

RAU HISWith silver coloured layer

Plumbing 40 x 3.750 x 4.663 x 5.8

32.640.851.4

Straight lengthsCoils to special order Straight lengthsCoils to special order

12

3.2 Jointing TechnologyWith the development of the REHAU EVERLOC System, the use of PE-Xa in heating and plumbing applications has increased dramatically. This system gives totally secure, reliable joints, in seconds. Manufactured in traditional brass, with some in stainless steel, the fi ttings are neat, slim and attractive to the eye. Most of all, they are permanent, meaning that callbacks to projects to repair leaking connections are eliminated.

3.2.1 ToolingCentral to the jointing method are the REHAU Compression Sleeve Tools. These are available as mechanical, mechanical hydraulic, electric hydraulic and rechargeable electric variants. Tooling is available to contractors working with the REHAU system.

1 to 7 Making a joint with RAUTOOL

G1, 40 - 63mm pipe sizes

1 32

7

4

65

321 4

3.2.2 Jointing MethodJoints are simple to make and the system can be learnt in minutes. The photo sequence shows how simple the process is. During the creation of a joint, the installer can hear and feel a very fi rm and secure connection being made. The joints are permanent.

The pipe must be cut square and without burrs. This is achieved quickly and easily by using REHAU pipe cutters.

The compression sleeve is slid over the pipe with the square end of the sleeve fi rst (the other side of the sleeve has an internal chamfer).

The end of the pipe is opened up using the expander pliers, expanding twice, offsetting by 45˚ for the second expansion.

The lining spigot of the fi tting is inserted into the fi tting and the compression sleeve clamped home.

Due to the memory effect of the pipe, the pipe will start to return to its original size after expansion and start to grip the fi tting shortly after it has been pushed into the pipe. During this time, fi ttings can be lined up before fi nally securing them.

Making a joint - 32mm pipe sizes

3.3 Fittings and Ancillaries The full fi ttings range is shown in the REHAU EVERLOC™ Heating and Plumbing Parts List 886:300.

There is an extensive range of fi ttings for all heating and plumbing applications, manufactured mainly in brass, with stainless steel radiator tees and elbows. Brass fi ttings are dezincifi cation resistant and the stainless steel fi ttings are made from DIN 2463 stainless steel.

The extensive range includes copper adapters and male / female connectors making it easy to integrate REHAU pipework with traditional plumbing materials. Attractive stainless steel radiator tails are part of the range and should only be used for connecting radiators. They are not to be used in plumbing applications.

The Pipe-in-Pipe is run in a continuous length without joints, for example, between the manifold and a radiator. The Pipe-in-Pipe is fi xed directly to the fl oor slab. At the manifold, the sleeve is taken out above the fi nished fl oor level. At the radiator end, a fl oor access box (available from REHAU) should be fi tted. The fl oor can then be screeded.

Should access be needed to the pipe, it can be cut at either end and a new length of pipe connected to the old, using a simple device fi tted within the pipe. The old pipe can be withdrawn, pulling in the new pipe in one operation.

3.3.2 Modular ManifoldsThese are simple DZR manifolds in two or three port formats which can be screwed together to make up headers of any size. Pipe connection to the manifold is made using 16mm compression sleeves which are ideal for plumbing or heating applications.

3.3.3 Heating ManifoldsThese are brass headers with threaded connections, to which control valves may be connected. Controls may be fi tted to the manifold (sited in a secure place) making it possible to supply and control radiators in situations where radiator mounted controls may be tampered with.

13

3.3.1 Pipe-in-PipeThis is essentially a corrugated pipe sleeve within which the pipe is held. It can be supplied separately to the pipe or with the pipe already in the sleeve.

The system complies with current water regulations and signifi cantly reduces duct costs, both the costs of constructing the ducting and the costs associated with fi tting pipework into ducts.

3.3.4 Wall Plate Fittings and BracketsIt is always a problem when installing appliances to fi nd fi rm, secure fi xing points. REHAU offer a range of brackets punched with holes for screws and tapped to take M5 fi xings as used on wall plate elbows. These brackets facilitate installation in partition walls and timber frame construction. Carpentry work is minimised, installation is quick and easy.

One of the principle benefi ts of the bracketing system is that it enables pipework to be kept out of sight, and with the REHAU system it is possible to have a system with just female iron threaded fi ttings fi nishing fl ush with the wall fi nish.

3.3.5 Branch/Cross Fittings16 x 16 x 16 fi ttings for branching off to appliances, in one slim unit, useful in areas of poor access. (Not to be used as part of the Pipe-in-Pipe system).

Number of Ports 2 3 4 5 6 7 8 9 10 11 12Length in mm 190 245 300 355 410 465 520 575 630 685 740Overall width 295 350 405 460 515 570 625 680 735 790 845

14

ß

500

700-

800 22

013

0

110 75

Number of Ports 2-3 4-6 7-9 10- 2 12

Width (B) 400 550 750 950 1150

1 Radaitor bends not to be used in plumbing applications

1

STANDARDS, APPROVALS AND PERFORMANCE

4.

4.1 GeneralPolymer pipe systems are covered by BS 7291: 1990 Thermoplastics pipes and associated fi ttings for use in hot and cold water systems.The REHAU Heating and Plumbing System conforms to BS 7291 Class S, for sealed systems, the highest level of specifi cation under this standard.

BS 7291:1990 categorises different system types and according to this standard, it is suitable for maximum operating pressures and temperatures of:

- 12 Bar 20˚C for direct mains fed cold water- 6 Bar 95˚C for open vented systems- 3 Bar 105˚C for sealed systems

The REHAU system also conforms to the French Avis Technique 15/95-217 issued by CSTB (The French Agrément Authority).

4.2 Water Quality Statement

CAUTION Danger of corrosion!

All REHAU plumbing fi ttings are made of dezincifi cation-resistant brass, REHAU fulfi ls the highest level of requirements in accordance with WRAS, BS EN 12164, BS EN 12165 and BS EN 12168 and we continuing to develop this product further to fulfi l ever greater quality requirements.

Irrespective of the material used in the manufacture of fi ttings, corrosion can occur in the drinking water installation as a result of various infl uencing factors.

In isolated cases, corrosion can even occur when water quality levels are within the permissible range set out by the Drinking Water inspectorate. The chloride content and the hydrogen carbonate content of the water have a considerable infl uence on this. A high chloride content in combination with a low hydrogen carbonate content may have a negative impact of the corrosion behaviour.

15

16

However, the interactions under the following factors in accordance with BS EN 12502-1:2005 (En) also affect corrosion resistance:

- Material properties (chemical composition, surface condition)- Water condition (physical and chemical properties, solids)- Planning and execution (geometry, mixed installation, connections)- Leakage test and commissioning (rinsing, emptying, disinfection)- Operating conditions (temperature, temperature changes, fl ow ratios)

The use of a water after-treatment system, for example water softening, will, in principle, lead to a change in the chemical corrosion behaviour of the water. To avoid corrosion damage due to incorrect use and operation of a water after-treatment system, we expressly recommend that you arrange for an expert, for example the system manufacturer, to check your individual situation in advance.

To evaluate the probability of corrosion, practical experience of the intended area of use should also be called on for the distribution of the incoming water.

Within the area of responsibility of system planning, the factors and infl uencing variables mentioned above with regard to corrosion protection and stone formation for specifi c application should be taken into consideration.

If necessary, you may contact our technical department for support purposes in the area of use.

If the drinking water quality is outside the limit values of the Drinking Water Ordinance, testing and approval by our technical department is necessary in all cases for the use of REHAU pipework systems

Please contact your REHAU Sales Offi ce regarding this matter.

4.3 Disinfection of REHAU Pipework

DisinfectionREHAU drinking water and universal pipes and REHAU compression sleeve joint provide support during drinking water installation in line with hygiene regulations. They comply with the recommendations of the Drinking Water Inspectorate and the WRAS fi ttings directory.

They are therefore also suitable for areas of application with special hygiene requirements in the area of drinking water. When the pipes are used the domestic, commercial and industrial plumbing system they have been proven not to lead to any increase in micro-organisms on the surface and therefore do not promote bacterial contamination or the growth of legionella bacteria.

Due to errors in planning, construction and operation, due to stagnation or water of inadequate quality (e.g. dirty water, fl ood water or maintenance work on the pipe network), impurity can occur. Damage in the pipe network, e.g. supply line with infi ltration water penetration, is a cause of possible contamination.

Disinfection of a drinking water installation is only necessary in exceptional cases (in the event of contamination) and the priority is to eliminate all operating and technical system defi ciencies. Repeated or continuous bacterial exposure of the water in the domestic plumbing system is often caused as a result of incorrect installation methods (e.g. dead leg pipelines) or the operating methods (e.g. long periods of inactivity causing stagnation periods) and, as such, does not justify continuous disinfection.

4.3.1 Thermal disinfection in the event of contaminationIn the case of well designed drinking water installations (no dead legs, etc.), most impurities can be removed by suffi cient rinsing with water, as long as they remain water-soluble or dissolved in water.

If contamination is suspected, then procedures for disinfection of water supply pipelines detailed in the UK Drinking Water Inspectorate Regulations must be followed. At water temperatures of at least 70°C, according to the current status of technology, it can be assumed that bacteria found freely in the water, even legionella, will be destroyed. Guidance from the water supply company must be obtained before using this method of disinfection in the UK It is important to prevent persons from being scalded by employing suitable safety measures.

All pipes of REHAU’s Universal and RAU HIS domestic plumbing systems are suitable for thermal disinfection at 70°C. It is necessary to ensure that, during thermal disinfection, the permissible operating pressures are not exceeded.

17

4.3.2 Chemical disinfection in the event of contaminationFor decontamination, in addition to thermal disinfection, chemical disinfection is also being increasingly used. Chemical and thermal disinfection measures always put stress on the materials used in the drinking water installation. According to current knowledge, a number of disinfection measures are also unsuitable for modern materials of installation technology. Among other things, this also affects materials that were previously assumed to be suffi ciently corrosion-resistant, for example rust-proof steel, copper and some plastics.

Before such procedural measures are introduced, it is necessary to ensure that all parts of the installation system are thermally and chemically suitable for the relevant measure. If necessary, ask the manufacturer of the disinfectant about its suitability for all system parts of the installation.

4.3.2.1 Chemical “standing disinfection”For chemical short-term disinfection (“standing disinfection”), only special active substances that are stipulated in the relevant regulations can be used.

The disinfection measures can be carried out without impairing the functionality of a REHAU drinking water installation if the active substances, concentrations, application durations and maximum temperatures listed in table 1 are adhered to.

It should be noted that combined thermal-chemical disinfection at temperatures greater than 25°C and permanent or regular disinfection cycles (e.g. monthly) are not permissible. In relation to the service life of the pipes, the overall number of disinfection cycles is limited to fi ve “standing disinfection” cycles. Otherwise it is not possible to ensure that the specifi ed service lives can be realised.

The person carrying out the disinfection process must ensure that no drinking water is drawn during the disinfection phase, including the subsequent rinsing phase.

TABLE 1

Chemical “standing“ disinfection (active substances and concentrations in accordance withe.g. DVGW W 291)Name Commercial form Storage Safety information1 Max. application

concentration2

Application duration and temperature in the pipeline

Hydrogen peroxideH

2O

2

Aqueous solution in various concentrations

Light-protected, cool, dirt must be avoided

For solutions >5%, safety gear essential

150mg/l H2O

2

Max. 12hTmax ≤ 25°C

Sodium hypochloriteNaOCl

Aqueous solution with maximum 150g/l chlorine

Light-protected, cool, enclosed and in a collecting tray

Alkaline, caustic, poisonous, safety gear essential

50 mg/l chlorineMax. 12hTmax ≤ 25°C

Calcium hypochloriteCa(OCl)

2

Granulate or tablets approx. 70% Ca(OCl)

2

Cool, dry andenclosed

Alkaline, caustic, poisonous, safety gear essential

50 mg/l chlorineMax. 12 hTmax ≤ 25°C

Chlorine dioxideClO

2

Two components (sodium chlorite, sodium peroxodisulphate)

Light-protected, cool, enclosed

Has oxidising effect, do not breathe in chlorine dioxide gas, safety gear

6 mg/l ClO2

Max. 12hTmax ≤ 25°C

1) The relevant information in the safety datasheets of the manufacturer is to be observed.

2) Approval of REHAU; this value must not be exceeded anywhere in the installation over the entire application duration.

4.3.2.2 Continuous chemical disinfectionDue to possible material damage on installation components, we do not recommend the use of systems operating without any time limits for chemical disinfection in the domestic plumbing installation, particularly as a measure for legionella prophylaxis. In such cases, no guarantee can be given.

In a number of cases, chemical disinfection may be necessary over an extended period but for a limited time until complete structural renovation is carried out. These kinds of disinfection measures may only be carried out with permissible procedures. The parameters given in table 2 must be monitored by means of measurements over the entire duration of the disinfection measure directly downstream of the active substance feed and documented. If the active substances, concentration, application durations and maximum temperatures listed in table 2 are adhered to, it is possible to carry out disinfection without impairing the functionality of a REHAU drinking water installation.

In relation to the service life of the pipes, the entire application duration is limited to four months. Otherwise it is not possible to ensure that the specifi ed service lives can be achieved.

We generally exclude the use of any other disinfectants not listed here, particularly strong oxidising agents (e.g. ozone).

Chemical and thermal disinfection measures that are carried out incorrectly may cause sustained damage to the components of a drinking water installation.

Before any such procedural measures are introduced, it is necessary to ensure that all parts of the installation system are thermally and chemically suitable for the relevant measure. If necessary, please contact the manufacturer of the disinfectant about this.

In the case of thermal disinfection, it is essential to prevent persons from being scalded by the appropriate measures.

In the case of chemical “standing disinfection”, it is necessary to ensure that no drinking water is drawn during the disinfection phase, including the subsequent rinsing phase.

The safety information of the disinfectant manufacturer should be observed.

4.4 ApprovalsThe system is approved by the Water Regulations Advisory Scheme (WRAS) for connection to the UK potable water supply system.

4.5 Quality SystemsAll REHAU Heating and Plumbing products are manufactured to ISO 9001 quality management procedures approved by TUV management services Certifi cate Nos ISO 9001-12 100 10634 /ISO 14001-12 104 19288 ensuring the products are manufactured to the highest standards.

18

TABLE 2

Chemical disinfection with a time limit (active substances and concentrations in accordance with TrinkwV 2001)

Name3 Max. applicationconcentration4

Max. application duration in the pipeline5

Application temperature in the pipeline

ChlorineCl

2

Max. 0.3 mg/l free chlorine

4 months 60°C

Calcium hypochloriteCa(OCl)

2

Max. 0.3 mg/l free chlorine

4 months 60°C

Chlorine dioxideClO

2

Max. 0.2 mg/l CLO

2

4 months 60°C

3) The relevant information in the safety datasheets of the manufacturer is to be observed.

4) Approval of REHAU; this value must not be exceeded anywhere in the installation

over the entire application duration.

5) Maximum application duration accumulated over the entire service life of the system

THE PHYSICAL PROPERTIES OF RAU PE-XA, ITS TOUGHNESS, FLEXIBILITY AND THE FACT THAT IT IS CONTINUOUSLY EXTRUDED AND CAN BE SUPPLIED IN LONG COILS, MAKES IT THE IDEAL CHOICE FOR HEATING AND PLUMBING APPLICATIONS.

These characteristics mean that a new approach has to be taken to the layout and design of installations. In particular, the system lends itself to the concealment of pipework.

APPLICATIONS THE SYSTEM IN USE

5.

5.1 Principle AdvantagesInherent characteristics:Long life – Pressure stability across the temperature range gives a projected life in excess of 50 years – BS 7291:1990.

Corrosion free – Chemically inert, there is no risk of corrosion, (often a problem with copper pipe in soft water areas).

Non furring – The smooth internal walls and chemically inert nature of the pipework prevent scale build up.

Reduced Theft – The pipe has no scrap value.

Application advantages:Overall ease of installation is one of the obvious reasons for using REHAU Universal Pipe.

Pipe-in-Pipe – The pipe in sleeve installation method signifi cantly reduces duct costs, both the costs of ducting and the costs associated with fi tting pipework into ducts.

Long pipe coils – Long lengths reduce the number of joints and allow the pipe to be pulled through awkward areas.

Flexibility – When passing through joists.

19

20

accessible metal luminaire

plastic pipe

plastic pipes

plastic pipes

metal heater

metal waterradiator

plastic soil pipe metal shower

metal hand rail

taps

bathwaste

waste

accessible metal luminaire

metal pipe

metal pipesmetal waste

metal soil pipes to be main bonded

heater

water radiator

metal soil pipe shower

metal hand rail

taps

bath

waste

1 2

Speed of installation – Flexible pipe can be installed quicker than rigid materials. Joints are made extremely quickly.Safe – No naked fl ames needed for jointing. Coils of pipe are safer to move around busy sites or occupied premises.

Manifold systems – The location of the distribution centre in one central position simplifi es maintenance and speeds up installation.Earth Bonding – According to IEE 16th Edition Regulations, earth bonding of PE-Xa pipes is unnecessary which further simplifi es installation.

5.2 Typical LayoutsManifold Options Illustrated. Two pipe ring systems also possible.

1 Stainless steel or copper radiator tails with access to joints.

2 Manifolds of brass construction with fl ow and return sections.

3 Continuous lengths of Pipe-in-Pipe – no joints.

4 Pipes should be laid as shown and not direct between radiator to appliance.

5 Pipe-in-Pipe sleeve holding fl ow and return pipes.

6 Pipes can be completely concealed in fl oors or walls.

7 Floor screed placed after pipe installation.

3

54

6

7

1 Plastic Pipe Installation 2 Metal Pipe Installation Supplementary bonding in a bathroom

1 2

21

1 Typical surface mounted

plumbing application

Ø25Ø16

Ø20

Ø16Ø25 Ø16

Ø16

Ø16

Ø16

Ø16

Ø20

Ø16

321

5.3 System Design Information5.3.1 Flow RatesREHAU fi ttings are designed to give minimum restriction to fl ow rates and the pipes themselves have a smooth internal fi nish for maximised fl ow.

The smooth internal bore of polymer pipes does not pick up scale, a common problem with metallic pipes. As a result, fl ow characteristics are maintained over the life of the pipe.

Flow rates are higher than for the same ID size for copper pipe, due to the bore smoothness, the reduced number of fi ttings and the long radius made bends.

Radiator connection options

1 Top, bottom, opposite ends

2 Bottom, bottom, opposite ends

3 Combined fl ow/return valve

1

22

TABLE 1

Pressure Loss Chart 16 X 1.5 mm RAUTHERM Universal PipeWater at 80˚C - T = 10˚K

Heat Output

Mass Flow

Velocity PressureDrop

QW

ml/h

Vm/s

Rpa/m

300 25.80 0.05 5.5

400 34.40 0.07 8.9

500 43.00 0.09 13

600 51.60 0.11 17.8

23.2 60.20 0.13 23.2

800 68.80 0.14 29.1

900 77.40 0.16 35.7

1,000 86.00 0.18 42.9

1,200 103.20 0.22 58.9

1,400 120.40 0.25 77.1

1,600 137.60 0.29 97.4

1,800 154.80 0.32 119.8

2,000 172.00 0.36 144.3

2,200 189.20 0.40 170.7

2,400 206.40 0.43 199.2

2,600 223.60 0.47 229.6

2,800 240.80 0.50 262

3,000 258.00 0.54 296.3

3,200 275.20 0.58 332.5

3,400 292.40 0.61 370.6

3,600 309.60 0.65 410.5

3,800 326.80 0.68 452.4

4,000 344.00 0.72 496.1

4,200 361.20 0.76 541.6

4,400 378.40 0.79 588.9

4,600 395.60 0.83 638.1

4,800 412.80 0.86 689.1

5,000 430.00 0.90 741.9

5,200 447.20 0.94 796.5

5,400 464.40 0.97 852.9

TABLE 2

Pressure Loss Chart 20 x 1.9mm RAUTHERM Universal Pipe Water at 80˚C - T = 10˚K

Heat Output

MassFlow

Velocity PressureDrop

QW

ml/h

Vm/s

Rpa/m

1,000 86.00 0.12 15.1

1,200 103.20 0.14 20.7

1,400 120.40 0.16 27

1,600 137.60 0.19 34.1

1,800 154.80 0.21 41.9

2,000 172.00 0.23 50.3

2,200 189.20 0.25 59.5

2,400 206.40 0.28 69.3

2,600 223.60 0.30 79.8

2,800 240.80 0.32 91

3,000 258.00 0.35 102.8

3,200 275.20 0.37 115.2

3,500 301.00 0.41 135.1

3,800 326.80 0.44 156.4

4,100 352.60 0.48 179

4,400 378.40 0.51 203.1

4,700 404.20 0.54 228.5

5,000 430.00 0.58 2.553

5,300 455.80 0.61 283.4

5,600 481.60 0.65 312.9

5,900 507.40 0.68 343.6

6,200 533.20 0.72 375.8

6,500 559.00 0.75 409.2

6,800 584.80 0.79 443.9

7,100 610.60 0.82 479.9

7,400 636.40 0.86 517.3

7,700 662.20 0.89 555.9

8,000 688.00 0.93 595.8

8,300 713.80 0.96 637

8,600 739.60 1.00 679.4

TABLE 3

Pressure Loss Chart 25 x 2.3 mm RAUTHERM Universal PipeWater at 80˚C - T = 10˚K

Heat Output

MassFlow

Velocity PressureDrop

QW

ml/h

Vm/s

Rpa/m

4,000 344.00 0.29 56.6

4,300 369.80 0.31 64.3

4,600 395.60 0.34 72.5

5,000 430.00 0.37 84.1

5,400 464.40 0.39 96.4

5,800 498.80 0.42 109.5

6,200 533.20 0.45 123.3

6,600 567.60 0.48 137.9

7,000 602.00 0.51 153.2

7,400 636.40 0.54 169.3

7,800 670.80 0.57 186.1

8,200 705.20 0.60 203.5

8,600 739.60 0.63 221.8

9,000 774.00 0.66 240.7

9,400 808.40 0.69 260.3

9,800 842.80 0.72 280.7

10,200 877.20 0.75 301.7

10,600 911.60 0.77 323.4

11,000 946.00 0.80 345.9

11,400 980.40 0.83 369

11,800 1014.80 0.86 392.8

12,200 1049.20 0.89 417.3

12,600 1083.60 0.92 442.5

13,000 1118.00 0.95 468.4

13,400 1152.40 0.98 495

TABLE 4

Pressure Loss Chart32 x 2.9 mm RAUTHERM Universal PipeWater at 80˚C - T = 10˚K

Heat Output

MassFlow

Velocity PressureDrop

QW

ml/h

Vm/s

Rpa/m

8,000 688.00 0.35 58.3

8,500 731.00 0.38 64.9

9,000 774.00 0.40 71.9

9,500 817.00 0.42 79.2

10,000 860.00 0.44 86.8

10,500 903.00 0.47 94.7

11,000 946.00 0.49 103

11,500 989.00 0.51 111.5

12,000 1032.00 0.53 120.4

12,500 1075.00 0.55 129.6

13,000 1118.00 0.58 139

13,500 1161.00 0.60 148.8

14,000 1204.00 0.62 158.9

14,500 1247.00 0.64 169.3

15,000 1290.00 0.66 180

15,500 1333.00 0.69 191

16,000 1376.00 0.71 202.3

16,500 1419.00 0.73 213.9

17,000 1462.00 0.75 225.8

17,500 1505.00 0.78 237.9

18,000 1548.00 0.80 250.4

18,500 1591.00 0.82 263.2

19,000 1634.00 0.84 276.3

19,500 1677.00 0.86 289.6

20,000 1720.00 0.89 303.3

20,500 1763.00 0.91 317.2

21,000 1806.00 0.93 331.4

21,500 1849.00 0.95 346

22,000 1892.00 0.97 360.8

22,500 1935.00 1.00 375.9

23

24

5.3.2 Pipe SizingMethods for calculating pipe size are given by CIBSE and other bodies. The methods for RAU PE-Xa are similar to those for conventional pipes.

Reference should be made to Section B4 of the CIBSE Guide, for information on the loading of different appliances and demand loading.

5.3.3 Pipe-in-Pipe In order to comply with pipe accessibility regulations, pipes within sleeving run within fl oor screed, must have accessible ends. At the manifold end, the sleeve should be run above the screed, leaving the pipe accessible.

At the radiator end, the sleeve should terminate in a REHAU Floor Box or other termination giving accessibility.

5.3.4 Fixing Distances - Concealed PipeworkThe fl exibility of RAUTHERM Universal Pipes makes installation within suspended ceilings and partition walls very easy. Normal clips or pipe hangers can be used to fi x the pipes. The recommended fi xing distances within BS 5955 Part 8 shown in the table below are recommended – note different distances for supported and unsupported pipe.

5.3.5 Pipe SupportIn situations where the pipe will be visible, REHAU Pipe Support Channel can be used to hold the pipe straight. It may be used in both horizontal and vertical runs of pipe. The sequence of drawings shows how to use the channel.

Cable ties at the recommended centres should be used to hold the pipe fi rmly in the channel.

Fixing Centres

Pipe Diameter Horizontal Vertical

16 0.3 0.5

20 0.5 0.8

25 0.5 0.8

32 0.9 1.2

40 1 1.5

50 1 1.5

Pipe Diameter Fixing Centres Cable Tie Centres

mm m m

16 and 20 1.5 0.3

25 and 32 1.5 0.4

40 2 0.5

50, 63 2 0.5

max. 0.5mmax. 2.0m

5.3.6 Corrosion Inhibitors (Heating systems only)Although RAUTHERM pipes will not themselves corrode, it is sensible to include a corrosion inhibitor into the heating system. RAUTHERM pipes are unaffected by the leading brands of corrosion inhibitor.

5.3.7 Anti FreezeAnti freeze as used in heating circuits will not affect the pipework. Please refer to the table of chemical resistances. REHAU EVERLOC™ Plumbing and Heating systems are susceptible to the same freezing conditions as all plumbing and heating systems and should be protected against freezing. Note: Anti freeze not to be used in Plumbing systems.

5.3.8 Connection to BoilersRAUTHERM pipework must be installed in accordance with BS 5955 Part 8 and not connected directly to any boiler. Metallic pipe has to be used for the boiler connection and the transfer to polymer must be no closer than 350mm from the boiler.

5.3.9 Expansion and Contraction Cross-linked PE-Xa responds to changes in temperature, in common with other materials. With increases of temperature, expansion will cause slight distortion over the length of the pipe in long runs. RAUTHERM pipe work is designed to be fi xed out of sight, it is therefore recommended that REHAU clip channel be used where the pipe will be visible.

Where expansion is likely to have an impact, the pipework should be installed with fi xed points and pipe clamps with low friction linings or mineral wool sheathing. It may also be necessary to include an expansion loop in some circumstances. Generally, the pipe absorbs the movement itself, but some care should be taken against shrinkage, particularly in corners.

These graphs determine thermal linear expansion of RAUTHERM PE-Xa Pipes. Refer to the graphs for guidance on the amount of expansion for run lengths and temperature differentials.

The use of REHAU pipe support channel, by restraining natural movement, reduces the normal co effi cient of thermal expansion by approximately 50%.

FP SC

GS

LSFP = Fixed Point

SC = Slip Clip

− Δλ1 + Δλ2

L = Pipe length

LS

FP = Fixed Point

+ Δλ2 + λ1 − Δλ2

Deflection leg length

− Δλ1 /2 /2 /2 /2

1/2 x Ls

L

FP FP

FP

0

0 2 4 6 8 10 10

20

40

60

80

100

120

140

160

Line

ar e

xpan

sion

(mm

)

Pipe length (m) Deflection leg length

Temperature difference ?T

80

70

60

50

40

30

20

10

α = 1.5* 104 C = 120

0

20

20 25 32 40 50 63 75 90 11016D

40

60

80

100

120

140

160

200 400 600 800 1,000 1,200 1,400 1,600

Line

ar e

xpan

sion

(mm

)

Pipe length (m)

Temperature difference ΔT

0

20

40

60

80

100

120

140

160

0 2 4 6 8 10 12

70 K 60 K

50 K 40 K

30 K20 K

10 K

α = 0,15 mm/m K

25

1 432

26

5.3.10 Bending RAU PE-XaRAU PE-Xa in sizes to 32mm is easily bent, even when cold. Bend formers can be supplied to form tight bends for certain applications.

For 40, 50 and 63mm pipe sizes, we recommend the use of elbow and other fi ttings. A hot air gun can be used.

Kinking of the pipe is to be avoided but, should this accidentally happen, it is possible to restore the pipe to its former shape by removing any stress from the pipe and then gently heating the pipe to its extrusion temperature of 135˚C, taking care not to overheat and damage the surface of the pipe. Due to the memory effect, the pipe will return to its original shape. Allow to cool before using.

Thermal Conductivity W/(m.k) of insulating material not exceeding:

0.035 0.04 0.055 0.07

Pipe Diameter OD

Thickness of Insulation

mm mm

16 and 20 22 32 50 75

25 and 32 22 32 50 75

RAUTHERM Universal Pipe Radius Bend

mm mm

16 x 1.5 80mm

20 x 1.9 100mm

25 x 2.3 125mm

32 x 2.9 160mm

barAfter pumping

180 min120 min60 min

∆ P1< 0,6 bar

302010

∆P2< 0,2 bar

Preliminary test Main test

1,5

x W

orki

ng p

ress

ure

5.3.11 Pressure TestingIn accordance with good working practices, systems should be pressure tested to 6 bar or 2.5 x Maximum Working Pressure. Due to the expansion of the pipe, the pressure will drop slightly during pressure testing, shortly after reaching test pressure. The pressure will stabilise after re-pressurising the system up to test pressure two or three times.

5.3.12 Insulation RequirementsThe treatment of RAUTHERM pipes is no different to other pipe systems. Pipe work should be insulated in exposed locations (as recommended by BS 6700 and BS 5422).

5.3.13 Trace HeatingRAUTHERM Pipes are suitable for trace heating.

5.3.14 Storage ConditionsThere are no special requirements. Pipes should be stored free of oil and grease. Once removed from its packaging, the pipe should not be left in direct sunlight.

max. 0.5mmax. 2.0m

6 7

ca. 2mm

5

1 Pipe support channel – Cutting

2 De-burring

3 Fitting

4 Joint clip rail

5 Distance from fi tting

6 Pipe clip spacing

7 Assembly detail in rising main

– distance from fi tting

SUMMARY6.

As a market leader in the fi eld of polymer processing, REHAU are involved in many diversifi ed industries – for example medical, automotive, electrical and furniture to name a few. As an organisation one of its overriding philosophies is to provide full support in every market in which it operates – for the Flexible Pipework market this is provided in a number of ways.

The UK market is serviced by a network of fi ve regional sales offi ces strategically located to ensure a rapid, local response and to build long term partnerships. The Heating and Plumbing Area Sales Managers based at each of these offi ces form the fi rst point of contact when assistance is required. They are backed by a dedicated Technical Applications Department based at the UK Headquarters in Ross-on-Wye, who provide technical support.

A full range of support literature in the form of sales brochures, technical bulletins, installation guides and parts lists is available. This manual has been produced as a vital component of this package to provide concise technical information on all aspects of our Flexible Pipework System.

To complete the support package offered, the REHAU EVERLOC™ Heating and Plumbing System is backed by a comprehensive warranty. This covers both products and consequential damage amounting to a total claim sum of £100,000 for a period of 10 years subsequent to putting a system into operation. Full details of our warranty are available on request – address details for our Sales Offi ces are provided on the back of this manual.

27

1.0

0.01

0.10

0.1

m/s

16 x

1.5

mm

25 x

2.3

mm

20 x

1.9

mm

32 x

2.9

mm

40 x

3.7

mm

50 x

4.6

mm

63 x

5.7

mm

0.3

m/s

0.4

m/s

0.5

m/s0.

6 m

/s0.7

m/s0.

8 m

/s0.9

m/s

1.0

m/s

1.1

m/s

1.2

m/s

1.3

m/s

1.4

m/s

1.5

m/s

1.6

m/s

1.7

m/s

1.8

m/s

1.9

m/s

2.0

m/s

Flow

rat

e l/s

Pressure loss Pa/m

1.00

10.0

0

10.0

100.

0

1 00

0.0

10 0

00.0

Wat

er T

emp

erat

ure:

30˚

C

Hea

d lo

ss d

iagr

am fo

r R

EH

AU

PE

-Xa

Pip

es

0.2

m/s

APPENDIX7.

1.0

0.01

0.10

0.1

m/s

16 x

1.5

mm

25 x

2.3

mm

20 x

1.9

mm

32 x

2.9

mm

40 x

3.7

mm

50 x

4.6

mm

63 x

5.7

mm

0.3

m/s

0.4

m/s

0.5

m/s0.

6 m

/s0.7

m/s0.

8 m

/s0.9

m/s

1.0

m/s

1.1

m/s

1.2

m/s

1.3

m/s

1.4

m/s

1.5

m/s

1.6

m/s

1.7

m/s

1.8

m/s

1.9

m/s

2.0

m/s

Flow

rat

e l/s

Pressure loss Pa/m

1.00

10.0

0

10.0

100.

0

1 00

0.0

10 0

00.0

Wat

er T

emp

erat

ure:

60˚

C

Hea

d lo

ss d

iagr

am fo

r R

EH

AU

PE

-Xa

Pip

es

0.2

m/s

1.0

0.01

0.10

0.1

m/s

16 x

1.5

mm

25 x

2.3

mm

20 x

1.9

mm

32 x

2.9

mm

40 x

3.7

mm

50 x

4.6

mm

63 x

5.7

mm

0.3

m/s

0.4

m/s

0.5

m/s0.

6 m

/s0.7

m/s0.

8 m

/s0.9

m/s

1.0

m/s

1.1

m/s

1.2

m/s

1.3

m/s

1.4

m/s

1.5

m/s

1.6

m/s

1.7

m/s

1.8

m/s

1.9

m/s

2.0

m/s

Flow

rat

e l/s

Pressure loss Pa/m

1.00

10.0

0

10.0

100.

0

1 00

0.0

10 0

00.0

Wat

er T

emp

erat

ure:

80˚

C

Hea

d lo

ss d

iagr

am fo

r R

EH

AU

PE

-Xa

Pip

es

0.2

m/s

www.rehau.co.uk 890.610EN/927/DAIR/04.08