Construction

Automotive Industry

www.rehau.comValid from September 2010 Subject to technical modifications

PRE-INSULATED INDUSTRIAL PIPINg SYSTEM RAUfRIgo®

TECHNICAL INfoRMATIoN 877620 EN

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1 TABLE of CoNTENTS

1 . . . . . . . . TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . . . . INFORMATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . 3

3 . . . . . . . . PROGRAMME COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 53.1. . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.2. . . . . . . RAUFRIGO pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.2.1 . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.2.2 . . . . . Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.2.3 . . . . . Technical data RAUFRIGO® pipe . . . . . . . . . . . . . . . . . . . . . . 63.2.4 . . . . . Special solutions RAUFRIGO . . . . . . . . . . . . . . . . . . . . . . . . . 63.2.5 . . . . . Building material class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.2.6 . . . . . Chemical resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.2.7 . . . . . Long-time rupture strength . . . . . . . . . . . . . . . . . . . . . . . . . . 73.3. . . . . . . EFS Electrofusion fitting joint . . . . . . . . . . . . . . . . . . . . . . . . . 83.3.1 . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.3.2 . . . . . Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.3.3 . . . . . Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.3.4 . . . . . Limits of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.4. . . . . . . REHAU Insulation sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.4.1 . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.4.2 . . . . . Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.4.3 . . . . . Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.5. . . . . . . PUR polyurethane sleeve foam. . . . . . . . . . . . . . . . . . . . . . . . 93.5.1 . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.5.2 . . . . . Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.5.3 . . . . . Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.6. . . . . . . Installation tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.6.1 . . . . . Monomatic welding device . . . . . . . . . . . . . . . . . . . . . . . . . 103.6.2 . . . . . Pipe cutter and pipe scraper . . . . . . . . . . . . . . . . . . . . . . . . 11

4 . . . . . . . . ASSEMBLY AND INSTALLATION . . . . . . . . . . . . . . . . . . . . 124.1. . . . . . . Preparing the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 124.2. . . . . . . Trimming RAUFRIGO pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 124.3. . . . . . . Pretreating the pipe ends . . . . . . . . . . . . . . . . . . . . . . . . . . 134.4. . . . . . . Connecting the pipe ends using electrofusion fittings . . . . . . 134.4.1 . . . . . Notes on welding with electrofusion fittings (EFS) . . . . . . . . 144.5. . . . . . . Putting insulation sleeve in place . . . . . . . . . . . . . . . . . . . . . 154.6. . . . . . . Fitting insulation sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154.6.1 . . . . . Up to 3 m span with PUR sleeve foam . . . . . . . . . . . . . . . . . 154.6.2 . . . . . Up to 6 m span with PUR sleeve foam . . . . . . . . . . . . . . . . . 154.6.3 . . . . . Alternative for installation in tight spaces . . . . . . . . . . . . . . . 164.7. . . . . . . Insulating the joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164.7.1 . . . . . Safety and precautionary measures when using PUR foam . . 164.7.2 . . . . . Preparing PUR sleeve foam . . . . . . . . . . . . . . . . . . . . . . . . . 164.7.3 . . . . . Using PUR sleeve foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174.7.4 . . . . . Notes on using PUR sleeve foam . . . . . . . . . . . . . . . . . . . . . 184.7.5 . . . . . Alternative insulation without PUR sleeve foam . . . . . . . . . . 19

5 . . . . . . . . PRESSURE EQUIPMENT DIRECTIVE 97/23/EG . . . . . . . . . . 20

6 . . . . . . . . DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216.1. . . . . . . Dimensioning base pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 216.2. . . . . . . Determining heat loss and dew point . . . . . . . . . . . . . . . . . . 216.3. . . . . . . Deciding on spans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216.4. . . . . . . Pipe clamp load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216.5. . . . . . . Fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226.5.1 . . . . . Fire load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226.5.2 . . . . . Fireproofing collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7 . . . . . . . . STANDARDS, REGULATIONS, GUIDELINES . . . . . . . . . . . . . 23

8 . . . . . . . . PRACTICAL EXAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Notes on this Technical Information

ValidityThis technical information applies to [enter country].

NavigationAt the beginning of this technical information, you can find a detailed Table of contents with hierarchical titles and corresponding page numbers.

Pictograms and logos

Safety instructions

Legal information

Important information, which has to be observed

Information on the internet

The advantages for you

Up-to-dateness of the technical information For your own safety and for the correct application of our products please check at regular intervals whether a newer version of your technical informa-tion is available. The issue date of your technical information is always printed on the bottom left-hand side of the cover page. You can obtain the current technical information from your REHAU Sales Office, specialist distributor or you can download it from the internet at www.rehau.com or www.rehau.de/downloads.

Safety instructions and operating instructions For your own safety and the safety of other people, please read through all -safety instructions and operating instructions carefully and completely before commencing assembly. Keep the operating instructions safe and have them available -If you have not understood the safety instructions or the individual assembly -instructions or find them unclear, please contact your REHAU Sales Office

- Failure to comply with the safety instructions can result in damage to property or personal injury

Use in line with the specificationThe REHAU industrial pipe system RAUFRIGO may only be planned, installed and operated as described in this technical information. Any other use is not in accordance with the specification and is therefore not permitted.

Observe all applicable national and international regulations relating to laying, installation, safety and the prevention of accidents when installing pipe sys-tems, as well as the instructions in this technical information.

Also observe applicable legislation, standards, guidelines, regulations (e.g. DIN, EN, ISO, VDE, VDI) as well as regulations relating to the environmental protection, provisions of the Employer’s Liability Insurance Association and regulations of the local public utilities companies.

Areas of application not covered in this technical information (special applica-tions) require consultation with our technical applications department. Please contact your REHAU sales office for a comprehensive consultation.

The planning and assembly instructions relate directly to the corresponding REHAU product. Some sections refer to generally applicable standards and regulations. Observe the relevant valid version of the guidelines, standards and regulations. More specific standards, regulations and guidelines relating to the planning, installation and operation of industrial pipe systems must also be observed and do not form part of this Technical Information.

General precautions

Keep your workplace tidy and free of obstructions -Make sure there is always sufficient light in your workplace -Keep children, pets and unauthorised persons away from tools and the as- -sembly areas. This particularly applies to installations in the production plant Only use the components intended for that particular REHAU pipe system. -The use of components from other systems or the use of tools, which are -not part of the relevant REHAU installation system, can result in accidents or other risks.

Personnel requirements Our systems should only be assembled by people who are authorised to do -so and have received training in this Work on electrical installations or pipework components should only be -carried out by qualified and authorised persons

Working clothing Wear protective goggles, suitable working clothing, safety shoes, a hard hat -and a hairnet if you have long hair Do not wear loosely fitting clothes or jewellery as they may get caught in -moving parts Wear a hard hat when carrying out assembly work at head height or above -your head

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2 INfoRMATIoN AND SAfETY INSTRUCTIoNS

During assembly Always read and follow the operating instructions for the REHAU assembly -tool usedImproper handling of tools can result in severe cuts, trapped or severed -limbs Improper handling of tools can damage the jointing components and result -in leaks The REHAU pipe shears have a sharp blade. Store and handle them in such -a way that there is no risk of injury from the pipe shears When trimming the pipes, maintain a safe distance between the hand -holding the pipe and the cutting tool Never put your hand in the tool‘s cutting zone or on moving parts during the -cutting process Following the expansion process, the expanded pipe shrinks back to its -original shape (memory effect). Do not insert any foreign objects into the expanded pipe during this stage Never put your hand in the tool‘s compression zone or on moving parts -during the compression process Until the connection is established following the compression process, the -fitting can fall out of the pipe. There is a risk of injury! During maintenance or retooling work and when changing the assembly -area, always unplug the tool and prevent it from being switched on acciden-tally

Operating parameters If the operating parameters are exceeded, excessive stress is placed on -the pipes and connections. It is therefore not permissible to exceed the operating parameters It is to be ensured that the operating parameters are adhered to by means -of safety / regulation devices (e.g. reducing regulator, safety valves or similar equipment)

System-specific safety instructions Deburring or removing sharp metal edges on the folded spiral-seam tube or -insulation sleeve to prevent possible injuries When working with PUR sleeve foam (polyol and isocyanate components), -the safety datasheets are to be heeded (see point 4.7.1) When working with PUR sleeve foam (polyol and isocyanate components), -chemically resistant protective gloves and goggles are to be worn at all times (see point 4.7.1) Wear a dust mask when sawing or grinding rigid PUR foam -During the welding of electrofusion fittings and foaming with PUR sleeve -foam, the component heats up Working with tightening straps to fix the insulation sleeve in place entails a -risk of trapping fingers Remember that the edges of the aluminium adhesive tape used for sealing -the insulation sleeve can result in cuts

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5

3 PRogRAMME CoMPoNENTS

RAUFRIGO is a pre-insulated pipe system for transporting coolants, cooling brines and process media. The base pipe is made of polymer material, insulated with high-density poly-urethane foam and finally coated with a rigid folded spiral-seam tube. This system is used, for instance, in:

Production -Industrial cooling -Air-conditioning -Freezing plants -Cold stores -Solar power plants -Exposed installation indoors and outdoors -And much more -

Broad spans can be achieved due to the low weight and the rigid design of the RAUFRIGO pipe.

The REHAU electrofusion fitting is used for making joints. As soon as the connection is made and the pressure is tested, they can be in-sulated using REHAU insulation sleeve and REHAU polyurethane sleeve foam.

Fig.1 RAUFRIGO

3.1 Overview

RAUFRIGO pipe Pre-insulated industrial pipes for transporting coolants, cooling brines and other industrial media

Jointing system electrofusion fittings made from PE Extensive range of fittings for joining RAUFRIGO pipes

Insulation sleeve Pre-fabricated insulation sleeve subsequently insulate the electro-fusion fitting joint quickly using PUR sleeve foam

PUR sleeve foam Polyurethane sleeve foam, water-blown 2-component systems for filling the insulation sleeve with foam

AccessoriesMeasuring beakers and funnels for processing PUR sleeve foam

ToolsIn addition to the REHAU monomatic welding device shown, pipe scrapers, rotary scrapers, pipe shears and pipe cutters are also available

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3.2 RAUFRIGO pipe

3.2.1 DescriptionRAUFRIGO consists of a base pipe made of PE 100 to DIN 8074/75 in black, a high-density polyurethane foam insulation and a galvanised folded spiral-seam tube as a rigid outer casing. The folded spiral-seam tube has an additional vapour barrier incorporated into the fold.

Fig. 2: RAUFRIGO pipe cross section

Fig. 4: RAUFRIGO pipe with base pipe made of PE-Xa and an oxygen barrier coating

connected with a FUSAPEX electrofusion fitting.

Fig. 5: RAUFRIGO pipe with outer casing made of PE Fig. 3: RAUFRIGO pipe structure

Depending on the dimension, SDR 11 or SDR 17 base pipes are used. The term SDR stands for „Standard Dimension Ratio” and states the ratio of the outer diameter to the wall thickness.

d ____SDR = s

d: outer diameter of the base pipe [mm] s: wall thickness of the base pipe [mm]

3.2.2 PropertiesRAUFRIGO provides the following properties with its combination of materials used:

Installation and insulation from a single source -Low weight, therefore low load -Rigid pipe for large spans -Low linear expansion compared to plastic pipes -High degree of mechanical strength -Normal pipe clamps can be used (low temperature clamps are not required) -Low heat conductivity -Simple jointing technique -Extremely corrosion resistant -UV resistant -Quick installation -Visually appealing -Good aging behaviour -Low sound transmission -Excellent pressure resistance -Toxicologically and physiologically harmless -

3.2.3 Technical data RAUFRIGO® pipe Temperature resistance: -40 °C to +50 °CMean linear expansion coefficient: 0.15 x 10-4 K-1

= 0.015 mm/mKBuilding material class: B2(see point 3.2.5)

Base pipe:PE 100: DIN 8074/75Length: 6000 mmTolerance: +5/-20 mmColour: blackDensity: 0.95 g/cm3

Thermal conductivity: 0.41 W/mKMin.modulus of elasticity: 480 N/mm2

Pipe roughness: 0.007 mm

Insulation:High-density polyurethane foam Pipe density: ≥ 65 kg/m3

Pressure resistance: ≥ 0.3 N/mm2

Flexural strength: 0.3 N/mm2

Shearing resistance: ≥ 0.2 N/mm2

Thermal conductivity λ 10tr To DIN 52612 part 1+2: 0.018-0.024 W/mKClosed-cell factor: ≥ 90 %Water vapour diffusion resistance coefficient μ: ≥ 100GWP (greenhouse warming potential): ≤ 0.01ODP (ozone depletion potential): 0(no CFCs or HCFCs)

Outer casing:Folded spiral-seam tube zinc coating: 275 g/m2

Both sides hot-dip galvanised Impermeable double fold achieved with Integrated polyamide tape: PA6

3.2.4 Special solutions RAUFRIGO RAUFRIGO pipes can also be supplied with an outer casing made of stainless steel or PE or a base pipe made of PE-Xa for special requirements. It is also possible to vary the insulation thickness or the pipe length.

The use of base pipes made from PE-Xa may require the jointing techniques compression sleeve or FUSAPEX electrofusion fitting.

Contact your local sales office in such cases.

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Fig. 6: RAUFRIGO pipe end

Fig. 7: RAUFRIGO pipes

3.2.5 Building material class The building materials are divided into building material classes to DIN 4102 according to their resistance in the case of exposure to fire. The building material class of RAUFRIGO pipes was determined in a trial by the Materials Testing Office and documented in a general Building Inspectora-te test certificate. Building material class upon delivery: RAUFRIGO pipe: B2 (normal flammability) The pipe foam used only conforms to building material class B2 in combina-tion with the outer steel casing. The PE-100 base pipe is also classified as building material class B2. Upon delivery, the foam is coated with a fire protection coating at the ends of the pipes. This is the reason for the RAUFRIGO pipe being classified as building material class B2. Prior to foaming the sleeve, the fire protection coating must be removed to achieve a better adhesion of the foam. The requirements of the building material class B2 are met again by subse-quently applying the REHAU insulation sleeve or insulating the visible rigid PUR foam areas with AF / Armaflex – 10 mm (synthetic rubber conforming to building material class B2 to DIN 4102 part 1).

Temperature [°C]

Years of operation

Permissible operating pressure p [bar] SDR 17 SDR 11

- 40 5 12.6 20.210 12.4 19.825 12.1 19.350 11.9 19.0

- 30 5 12.6 20.210 12.4 19.825 12.1 19.350 11.9 19.0

- 20 5 12.6 20.210 12.4 19.825 12.1 19.350 11.9 19.0

- 10 5 12.6 20.210 12.4 19.825 12.1 19.350 11.9 19.0

0 5 12.6 20.210 12.4 19.825 12.1 19.350 11.9 19.0

+ 10 5 12.6 20.210 12.4 19.825 12.1 19.350 11.9 19.0

+ 20 5 10.6 16.910 10.4 16.625 10.1 16.250 10.0 16.0

+ 30 5 9.0 14.410 8.8 14.125 8.6 13.850 8.4 13.5

+ 40 5 7.7 12.310 7.6 12.125 7.4 11.850 7.2 11.6

+ 50 5 6.7 10.710 6.5 10.415 5.9 9.5

Permissible operating pressures to DIN 8075 Flow medium water, safety factor (SF) = 1.25 Tab. 1: permissible excess operating pressures for PE 100 pipes

3.2.7 Long-time rupture strength The long-time internal rupture strength of RAUFRIGO depends on the interplay between pressure, temperature and time. Different combinations of these produce a max. permissible pressure for particular temperatures and years of operation. This technical data has been determined to DIN 8075 and can only represent a general information about the long-time rupture strength as the maximum temperature and pressure values in their practical application can fluctuate significantly.

3.2.6 Chemical resistance RAUFRIGO demonstrates excellent resistance to chemicals due to the PE-100 carrier pipe. Safety factors and temperature resistance depend on the media being trans-ported, which may differ from the values for water. If RAUFRIGO is to be used for the transport of chemicals, the REHAU Technical Applications Department can offer technical assistance. As regards chemical resistance of the pipe and joint, the following antifreeze agents can be used in the concentrations stated by the manufacturer:

TYFOCOR -TYFOCOR L -TYFOCOR LS -TYFOXIT -TYFOXIT F -Antifrogen N -Antifrogen L -Antifrogen KF -Antifrogen SOL -And many more -

Further information about the compatibility and long-time rupture strength is also available in the guideline DVS 2205 part 1.

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3.3 EFS Electrofusion fitting joint

3.3.1 Description REHAU electrofusion fittings (EFS) are fittings with an integrated resistance wire. By means of electric currents, this wire is heated to the required fusion temperature, at which fusion is carried out. Each fitting has an integrated recognition resistor, which ensures the automa-tic setting of the welding parameters in the REHAU welding device (article 244762-001). The barcode on all REHAU electrofusion fittings permits the use of all commercially available welding devices with a barcode reader.

3.3.2 Properties Built-in pins, which project during the welding process, enable you to visually check that the weld in every fitting has been accomplished. For pipes made of polymer materials, oxidisation can occur on the edges of the walls caused by environmental influences. Due to this reason, the outer layer must be removed immediately prior to the welding process by means of scraping.

3.3.3 Technical data REHAU electrofusion fittings are made of black UV stabilised polyethylene (PE 100).

Density: >0,93 g/cm - 3 (to DIN EN ISO 1183) Melt index MFR 190/5: 0.3 – 1.7 g/10 min (to DIN EN ISO 1133) -

Temp. [°C]

SDR 11 Max.operating pressure [bar]

Years of operation [a]

SDR 17 Max.operating pressure [bar]

Years of operation[a]

- 40 °C 19.0 bar 50 Years 11.9 bar 50 Years

- 30 °C 19.0 bar 50 Years 11.9 bar 50 Years

- 20 °C 19.0 bar 50 Years 11.9 bar 50 Years

- 10 °C 19.0 bar 50 Years 11.9 bar 50 Years

0 °C 19.0 bar 50 Years 11.9 bar 50 Years

+ 10 °C 19.0 bar 50 Years 11.9 bar 50 Years

+ 20 °C 16.0 bar 50 Years 10.0 bar 50 Years

+ 30 °C 13.5 bar 50 Years 8.4 bar 50 Years

+ 40 °C 11.6 bar 50 Years 7.2 bar 50 Years

+ 50 °C 9.5 bar 15 Years 5.9 bar 15 Years

Safety factor 1.25 Medium: Water or air Tab. 2: Limits of use electrofusion fittings

Fig. 8: REHAU electrofusion fitting cross section

Fig. 9: Projecting pin, visual check of weld Fig. 10: Integrated welding wires

3.3.4 Limits of use

3.4 REHAU Insulation sleeve

3.4.1 DescriptionThe REHAU insulation sleeve is required for insulating RAUFRIGO pipes once a joint has been made on site. The insulation sleeve protects the joint and its insulation and provides the pipe with added stability.

3.4.2 Properties The REHAU insulation sleeve is designed to be self-sealing. Therefore, no ex-tra seal is required between the pipe and insulation sleeve during installation. The insulation sleeve can be foamed immediately following the installation without having to wait any longer.

3.4.3 Technical data Insulation sleeve: Thin sheet steel, hot-dip galvanised on both sides in machine fold quality (cold-rolled) with a surface-specific zinc coating of at least 275 g/m2 (total of both sides) and a small flower of zinc.

Sheet thickness: 0.75 mmDiameter filling hole: 30 mmRivet option (heavy duty)Hole diameter: 4.1 mmDrilling depth: 10 mmMultirange blind rivet: 4.0 x 10 mm (see price list)

Seal:Prefabricated, synthetic rubber tape (closed-cell elastomer foam) For use in temperature range: -40 °C to +105 °CWater vapour permeability μ: ≥ 7000

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Fig. 11: REHAU insulation sleeve

1 1

2

Holes:

Axial holes: Pre-drilled holes on one side for sealing. Self-tapping screws are included in the scope of delivery.

2 Radial holes: In addition to this, there is an option to rivet the insulation sleeve to the RAUFRIGO pipes The radial holes are intended for this purpose.

3.5 PUR polyurethane sleeve foam

3.5.1 Description REHAU polyurethane sleeve foam normally takes the shape of a closed-cell, rigid foam produced by the chemical reaction of two components. These two components are mixed and poured into the designated cavity of the REHAU insulation sleeve. Once inside, the mixture foams and then hardens. Once the foam has finished its hardening process in the REHAU insulation sleeve, it provides the joint with the required degree of rigidity.

Fig. 12: In-situ PUR foam components A and B

Fig. 13: Reaction mixture, freely foamed.

3.5.2 Properties The reaction mixture is composed of components A and B:Component A: Elastopor EXH (polyol) 2100/1Component B: Lupranat M 20 S(isocyanate) The in-situ PUR foam used by REHAU is a water-blown system, which can be used indoors or outdoors without any special safety precautions..

3.5.3 Technical data

Component A: Elastopor EXH 2100/1 Form: liquidColour: yellowishSmell: Amine-likePh value: > 7Solidification temperature: < 0 °CBoiling point: > 110 °CFlash point: > 110 °CVapour pressure: < 10 mbar (20 °C)Measured density: 1,07 g/cm3 (20 °C)Measured viscosity: 1740 mPas (20 °C)

Component B: Lupranat M 20 SForm: liquidColour: brown Smell: Earty, mustyMelting point: < 10 °CBoiling range: 330 °C (1.013 mbar)Flash point: > 204 °CInflamation point: > 600 °CVapour pressure: < 0,01 Pa (25 °C)Measured density: 1,23 g/cm3 (20 °C)Measured viscosity: 300 mPas (20 °C)

Foam system:Foaming behaviour (readings), beaker test to ultrasound method (20 °C, mixing ration 100 : 160) Start time: 69 seconds Stringing time (hypothetical): 183 seconds Expansion time: 265 seconds Apparent density, freely foamed: 54 kg/m3

Laboratory readings, Test specimen prepared using a turbo mixer.Apparent density (core): 63 kg/m3

Pressure resistance: 0.43 N/mm2

Compression set: 7 %Closed-cell percentage: 94 %

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3.6 Installation tools

3.6.1 Monomatic welding device

Fig. 14: Monomatic welding device

Cable length Cross section

Up to 20 m 3 x 1.5 mm²

20 – 50 m 3 x 2.5 mm²

50 – 100 m 3 x 4.0 mm²

Diameter Output power

20-75 mm 2 kW

90-160 mm 3.2 kW

160-355 mm 4.5 kW (regulated mechanically)5 kW (regulated electronically)

Input voltage (AC) 230 V (185-300 V)

Feed frequency 50 Hz (40-70 Hz)

Input strength of current 16 A

Output voltage 40 V

Output strength of current max. 60 A

Capacity 2600 VA / 80 % ED

Temperature range -10 °C to +50 °C

Safety of equipment CE, IP 54

Weight approx. 18 kg

Length of electricity cable 4.5 m

Length of welding cable 4.7 m

Display 2 x 20 characters,backlit

Dimension 440 x 380 x 320 mm

Automatic parameter input automatically

Electr. Input control Voltage / Strength of current / Frequency

Electr. Output control Voltage, contact, resistance, short circui-ting, welding time, working temperature, strength of current curve, system check

Error message Continuous warning signal, indication in the display

Tab. 4: Technical data welding device electrofusion fitting

Tab. 3: Cable length and cross section for extension cables

The REHAU monomatic welding device is fully automatic in operation. It has a stable housing and a backlit display. The menu navigation can be switched to other languages. The welding device is connected to the fitting with two differently coloured welding cables (black and red). The red cable should be plugged into the red contact on the fitting. The resistor installed in the elecrofusion fitting is used to automatically set the welding parameters in the welding device. An automatic monitoring system controls the welding process based on the electrical current curve. In the event of a fault, the operator is informed by means of a warning signal and indication on the display. The processing company has to ensure that the equipment used is maintained in accordance with instructions.

Information on use

MaintenanceThe monomatic welding device has to be serviced every 12 months or every 200 operating hours (whichever comes first).

Extension cable The following rules are to be used for the extension of the power cable:

The welding cable must not be extended!

Using generators First start the generator, then plug in the device. -No other users may be connected to the generator -No-load voltage should be adjusted to around 260 volts -Disconnect the welding device before the generator is switched off -

The useful generator power output decreases by 10% per 1000m height of -location Check the contents of the tank prior to starting the welding process -

In order to avoid damage to the welding device and to ensure that the internal monitoring functions of the welding process are not interrupted, the genera-tors used must meet the following requirements:

Suitability for phase-control and inductive loads -No-load voltage can be adjusted to 245 V-260 V -18 A output current in one phase -Stable output voltage or motor speed, even with quickly changing load -Synchronous generators with mechanical speed control are preferred -Voltage peaks may not exceed 800 V -

Generator nominal output power: 1 phase 230/240 V, 50/60 Hz

In the case of generators with poor regulating capability or poorly voltage stabilised generators, the guaranteed output must be 3 – 3.5 times the load in order to ensure error-free operation. In the case of electronically regulated generators, their suitability should be tested beforehand as different devices tend towards speed oscillations here and this produces extreme peaks in voltage.

11

If you use the 110 V version of the welding device, the generator used may have to fulfil different requirements. Contact your local sales office if this is the case.

3.6.2 Pipe cutter and pipe scraper Various tools are available to trim REHAU pipes and to prepare the pipe ends for connection with the electrofusion fitting. Further details on this can be found in the current valid price list.

12

4.1 Preparing the assembly

Bring the tools required for assembly to your place of work and check that they are in working order. Please follow the operating instruction and only use the tools for the intended purpose. If the operating instructions are not enclosed with the tool or are not available, they are to be requested prior to using the tool.

The base pipes are delivered without insulation for 200 mm on both sides. When joining pipes, these 200 mm should always be adhered to because the foam quantity lists and the length of the insulation sleeves are designed with this in mind. If a pipe is cut to a particular length, the insulation is to be removed from both pipe ends as shown in order to join the pipes.

Fig. 13: Pipe end as delivered

Fig. 14: RAUFRIGO pipe end diagram

Fig. 15: 1.Cut pipe square to the desired

length and deburr base pipe

Fig. 16: 2. Mark length of insulation to be

removed 1 from cut end 2

Fig. 17: 3. Cut open the folded spiral-

seam tube.

Fig. 18: 4. Remove cut section of folded

spiral-seam tube.

Fig. 19: 5. Once the folded spiral-seam

tube has been removed, remove the high-

density polyurethane foam.

Fig. 20: 6. Remove polyurethane residues

Risk of injury from sharp edges.

Wear a dust mask when sawing or grinding high-density PUR foam.

Risk of injury from sharp edges.

200 mm

200 mm

200 mm

1

2

4 ASSEMBLY AND INSTALLATIoN

4.2 Trimming RAUFRIGO pipe

13

4.3 Pretreating the pipe ends 4.4 Connecting the pipe ends using electrofusion fittings

Fig. 21: 1. Prepare the pipe ends as set

out in point 4.2.

Fig. 23: 3. Machine down both ends of

the pipe with a rotary scraper or manual

scraper (depth of cut ≈ 2 mm)

Fig. 25: 5. Mark insertion depth as per

tab. 6.

Fig. 22: 2. Mark the scraping zone on the

base pipe as per tab. 5.

Fig. 24: 4. The scraping area (welding

zone) must be free of grease and dust.

If absolutely required, clean with tangit

cleaning agent for PE. Allow the cleaning

agent to entirely evaporate.

Dimension Min. scraping area 63 63 mm 75 67 mm 90 78 mm110 85 mm125 90 mm160 101 mm180 109 mm225 124 mm250 132 mm280 141 mm315 146 mm355 134 mm

Dimension Insertion depth 63 57.5 mm 75 61.5 mm 90 72.5 mm110 80.0 mm125 85.0 mm160 95.5 mm180 104.0 mm225 118.5 mm250 126.5 mm280 136.0 mm315 140.5 mm355 128.5 mm

Tab. 5: Electrofusion fitting scraping zone

Tab. 6: Electrofusion fitting insertion depth

200 mm

Fig. 26: 6. Remove electrofusion fittings

from the PE bag.

Fig. 30: 10. Connect welding device, red

cable to red contact.

Fig. 34: 14. An acoustic signal will be

sounded after the welding process

has been completed. The plugs can be

removed.

Fig. 27: 7. Push electrofusion fitting onto

the first pipe end. The insertion depth

mark must still be just visible.

Fig. 31: 11. Compare the welding time

shown on the display with the information

on the fitting.

Press the start button on the welding

device and check instructions as follows.

Fig. 28: 8. Push the second pipe end into

the fitting. The two insertion depth marks

must still be just visible.

Fig. 32: 12. Check alignment and inser-

tion depth.

Fig. 29: 9. The joint must be flush and

may not be under tension, if necessary

temporarily disconnect.

Fig. 33: 13. Press the start button once

more.

The electrofusion fitting heats up during welding

14

Dimension Cooling-down times 63 20 min 75 30 min 90 30 min110 30 min125 45 min160 70 min180 70 min225 80 min250 80 min280 90 min315 90 min355 90 min

Tab. 7: Electrofusion fittings cooling down times

The full operating pressure may only be applied once the cooling periods as per tab. 7 have expired!

Note information in chapter 4.4.1.

4.4.1 Notes on welding with electrofusion fittings (EFS)

Fig. 35: Use a PE-pen in a contrasting colour to mark the pipe.

Fig. 39: Do not touch the inside of the

electrofusion fitting.

Fig. 43: The welding devices’ master

switch is on the back.

Fig. 45: If electrofusion fittings are difficult

to slide on, use a diameter tape measure

as per tab.8 to check the outer diameter

and, if necessary, repeat the scraping

process using a rotary scraper.

Fig. 36: Do not use fitting for marking.

Fig. 40: If the coupler is to be used as a

sleeve coupler, the stop nipples have to

be removed.

Fig. 44: The indicator pins project on each

pipe end when the electrofusion fittings‘

weld is complete.

Fig. 37: The welding surface must not be

wet or soiled.

Fig. 41: Do not use a used cloth for

cleaning. Only use waterproof, unused

cellulose cloths.

Fig. 38: Do not touch the welding surface.

Fig. 42: Do not weld any pipes which

have not been fully inserted.

Dimension Under-allowance 63 -0.4 mm 75 -0.4 mm 90 -0.4 mm110 -0.4 mm125 -0.4 mm160 -0.4 mm180 -0.4 mm225 -0.4 mm250 -0.4 mm280 -0.4 mm315 -0.4 mm355 -0.4 mm

Tab. 8: Min. outer diameter

The weld must be achieved without tension -Rounding clamps and holding devices are to be used if necessary -When the time stated in the fittings has elapsed (cool:...min.), the auxiliary -attachments or temporary supports can be removed Do not move the pipes during the welding process and the cooling time -Do not pull the plug out of the mains socket during the welding process -If the welding device generates an error message, the electrofusion fittings are -to be removed and disposed of The pipe and fitting must be processed and assembled between -10 °C to -+45 °C. Otherwise appropriate precautions are to be taken All welding process work steps must be carried out immediately following -each other

15

4.6 Fitting insulation sleeve 4.6.1 Up to 3 m span with PUR sleeve foam 4.6.2 Up to 6 m span with PUR sleeve foam

4.5 Putting insulation sleeve in place

Fig. 47: 2. Break off front face of the

high-density PUR foam at a depth of

approx. 10 mm on both sides.

Fig. 51: 6. Attach the second lashing

strap next to the opposite hole and pull

both tight.

The axial sealing strip must at least

entirely overlap.

Fig. 46: 1. Slide the insulation sleeve onto

the pipe before the joint is made or

clip over the pipe on the required spot.

Fig. 48: 3. Saw off the connection nipple

protruding from the electrofusion fitting.

Fig. 52: 7. Bolt down the insulation sleeve

along the axial overlap using the

self-tapping screws provided.

Use holes provided.

Fig. 49: 4. Clean the joint (it must not be

damp).

Fig. 53: 8. Loosen and remove both

lashing straps.

Fig. 50: 5. Slide the insulation sleeve over

the centre of the joint and fix in place

with the first lashing straps next to the

outermost hole.The filling hole must face

straight upwards.

Fig. 54: 9. The insulation sleeve can be

immediately foamed with polyurethane

sleeve foam.

Fig. 55: 1. Fix the insulation sleeve in place using tightening straps (see fig. 46 to 51).

Fig. 59: 5. Bolt down the insulation sleeve along the axial overlap with the self-tapping

screws and remove lashing straps (see fig. 52 and 53).

Fig. 56: 2. Starting from the axial sealing

strip, drill the first hole left and right

through the outer casing of the pipe.

Hole diameter 4.1 mm, drilling depth

max.10 mm.

Fig. 60: 6. The insulation sleeve can be

immediately foamed (see point 4.7).

Fig. 58:4. Tighten insulation sleeve once

more and rivet second hole on the left

and right. Continue until all rivets are in

place.

Fig. 57: 3. Rivet insulation sleeve to outer

casing of the pipe on the left and right.

Type multirange blind rivet, 4,0 x 10 mm

(see price list)

16

4.6.3 Alternative for installation in tight spaces

Fig. 61: 1. If it is not possible to put

screws in place from above, the insulation

sleeve can be turned 90° in order to be

bolted down from below.

Fig. 62: 2. Seal open filling hole and all 6

ventilation holes with adhesive aluminium

tape of the length required. Also seal the

filling hole from the inside.

Fig. 63: 3. Remove the aluminium tape

from the sealed filling hole and add

ventilation holes (diameter 1 mm).

Beware of cuts: adhesive aluminium tape has sharp edges.

4.7 Insulating the joint 4.7.1 Safety and precautionary measures when using PUR foam

Before using PUR sleeve foam, please adhere to the safety datasheets for component A (polyol, yellowish colour) and component B (isocyanate, brown colour), the technical datasheet as well as the safety and precautionary measures.

These documents can be downloaded from the internet at www.rehau.de. If you haven‘t got internet access, please contact your local REAHU sales office. We will be happy to send the documents to you. The following generally applies when working with PUR sleeve foam: Always wear protective gloves and goggles!

Fig. 64: Work safety.

Respiratory equipment is required wherever insufficient ventilation or increa-sed temperatures are encountered.

In the event of accidents with PUR sleeve foam proceed as follows:

Splashes in the eyes:Immediately rinse with eyewash or with water for an extended period of time. Following this, seek medical attention if liquid components have contacted the eyes.

Splashes on the skin:Immediately wipe off and thoroughly wash with soap and water. Change clothing splashed with component B (isocyanate, brown colour).

Breathing difficulties, shortness of breath, chest pains:Go out into the fresh air immediately, keep calm and don’t smoke. If the pro-blem was caused by component B (isocyanate, brown colour), seek medical advice.

4.7.2 Preparing PUR sleeve foamPlease adhere to the safety instructions in the above point. Determine the required quantities of components A and B using table 9 and heed the instructions for using sleeve foam. Following this, select a suitable beaker size.

Percentage of component A and B for foaming the insulation sleeve:Processing temperature: 20 °CMixing ratio: A : B = 100 : 160Pipe density: 80 [kg/m3]

Percentages can be calculated as follows in order to foam other sizes: Component A [ml] = empty volume (dm3) x 30.55 Component B [ml] = empty volume (dm3) x 42.53

17

RAUFRIGOBase pipe [mm]

Outer jacket [mm]

Component A Elastopor EXH 2100/1,yellowish [ml]

Component B Lupranat M 20 S,brown [ml]

A + B[ml]

140/63x5.8 63 x 5.8 - SDR11 140 165 229 394150/75x6.8 75 x 6.8 - SDR11 150 174 243 417160/90x5.4 90 x 5.4 - SDR17 160 173 241 415180/110x6.6 110 x 6.6 - SDR17 180 195 271 466200/125x7.4 125 x 7.4 - SDR17 200 232 322 554250/160x9.5 160 x 9.5 - SDR17 250 340 474 814280/180x10.7 180 x 10.7 - SDR17 280 420 585 1.005315/225x13.4 225 x 13.4 - SDR17 315 377 524 901355/250x14.8 250 x 14.8 - SDR17 355 495 689 1.184400/280x16.6 280 x 16.6 - SDR17 400 660 918 1.578450/315x18.7 315 x 18.7 - SDR17 450 827 1.151 1.978560/355x21.1 355 x 21.1 - SDR17 560 1.400 1.948 3.348Variation in ambient temperature may make it necessary to use up to 30 % more foam (see point 4.7.4)

Tab. 9: Foam quantities for REHAU insulation sleeve

4.7.3 Using PUR sleeve foam

Fig. 65: 1. Select beaker size, remember

to allow enough space for stirring.

Fig. 66: 2. Pour component A (yellowish)

into the beaker as set out in table 9.

Fig. 67: 3. Add component B (brown) as

set out in tab. 9. reaction time (start time)

is now approx. 50 seconds.

Fig. 69: 5. Pour reaction mixture into the

insulation sleeve, use funnel if necessary.

Abb. 73: 9. Seal ventilation holes with the

adhesive aluminium tape provided.

The foam will have completely hardened

after approx. 24 hours and will have

obtained its mechanical properties.

Fig. 70: 6. Seal the filling hole immedia-

tely using the adhesive aluminium tape

provided (100 x 150 mm).

Fig. 71: 7. Once the expansion time (approx.

265 seconds) has expired, the foam

reaches the ventilation holes, hardens and

seals them.

Beware: The insulation sleeve gets very

warm.

Fig. 72: 8. Remove any hardened foam,

which has emerged. Check if the insulati-

on sleeve is completely filled with foam.

Fig. 68: 4. Stir reaction mixture well,

homogeneity achieves good quality.

05

10

15

20

2530

35

40

45

50

55

0 5

10

15

20

25 30

35

40

45

50

55

Wear protective gloves and goggles!

Beware of cuts: adhesive aluminium tape has sharp edges.

The insulation sleeve heats up during foaming.

18

Fig. 74: Temperature/humidity range

4.7.4 Notes on using PUR sleeve foam

Storage Components A and B are sensitive to moisture. Therefore, they are always to be stored in sealed containers. It is advisable that components are stored on wooden pallets in order to avoid cooling from direct contact with the floor. The storage temperature should be +15 to +23 °C. The date the components were filled is printed on the containers of both components. The storage stability is 22 weeks from this date. If the storage stability of 22 weeks is exceeded, the quality of the components can be checked by conducting a foaming test, after which, the component quantities may have to be increased.

Foaming test:Component A: 42ml (= 44.9 g)Component B: 58ml (= 71.8 g)Temperature: approx. 20 °CSize of beaker: 2 litres

Stir the components quantities stated above in the beaker and allow to foam (free foaming). The foam, when rigid, must have a volume of >1.5 dm3 . The component quantities must be increased if a volume of <1.5 dm3 is obtained. If the foaming test is carried at the location of the joint, the same ambient influences exist (temperature of all materials, rel. air humidity). Depending on the ambient conditions, it may be determined that the foaming components have to be increased.

Using the foama.) Always wear protective gloves and goggles when working with polyol and isocyanate components! b.) The elements to be joined (pipes, fitting, inside of insulation sleeve) must

be free of moisturec.) Foaming work should be carried out at a temperature of +20 °C i.e. the elements to be joined (pipes, fittings, insulation sleeve) and the foam

components A and B must be at this temperature. Controlled foaming is possible in humidity of 20 to 60 %.

d.) Foaming must generally be carried out at a temperature between +15 °C to +45 °C . This temperature applies to foaming components as well as the elements of the joint (pipes, fitting, sheet metal sleeve).

If this is not the case or if humidity exceeds 90 % or if it is raining, foaming can only be carried out if additional measures are put in place e.g.

protection from the weather or pre-heating. e.) If foaming is conducted in winter, for instance, at less than +20 °C, the

start time is longer because the foam will take longer to react. In this case, the quantities of components A and B have to be increased by

up to 30 %. If the foam is used at temperatures of +20 °C, in summer for example, the

quantities of components A and B as set out in the below foam quantities list, are to be applied. In this case, the start time is shorter as the foam reacts quicker.

f.) Prior to usage, component A (Elastopor EXH 2100/1, yellowish) should be homogenised for 10-15 minutes. This can be achieved by rolling or shaking the container or with a stirrer, which submerges to within 10 cm from the base of the container.

g.) The foam will have completely hardened after approx. 24 hours and will have obtained its mechanical properties.

rel F

C

C

C

19

4.7.5 Alternative insulation without PUR sleeve foam

Fittings used for connecting RAUFRIGO pipes i.e. sleeves, bends, T-pieces, reducers, etc. can also be insulated with standard insulation materials used in the cooling and air-conditioning sectors.These have to be bonded water diffusion-proof in accordance with the manufacturer’s instructions and fitted with a sheet metal casing such as, for example, the REHAU insulation sleeve.

Fig. 75: 1. Seal the dug-out face of the

simulation foam surfaces of the RAUFRI-

GO pipes with cut-to-measure insulation

strips.

Fig. 79: 5. Slide the insulation sleeve over

the centre of the joint and fix in place

with the first lashing strap next to the

outermost hole. The filling hole must face

straight upwards.

Fig. 83: 9. Tighten insulation sleeve once

more and rivet second hole left and right.

Continue until all rivets are in place.

Fig. 76: 2. Encase the entire surface of

the joint (RAUFRIGO pipe and electrofusi-

on fitting) with insulation material.

Fig. 80: 6. Attach the second lashing

strap next to the opposite hole and pull

both tight. The axial sealing strip must at

least entirely overlap.

Fig. 84: 10. Bolt down the insulation

sleeve along the axial overlap using the

holes provided.

Fig. 77: 3. Apply glue to any gaps.

Fig. 81: 7. Starting from the axial sealing

strip, drill the first hole left and right

through the outer casing of the pipe.

Hole diameter 4.1 mm, drilling depth

max.10 mm.

Fig. 85: 11. Loosen and remove both

lashing straps.

Fig. 78: 4. Slide insulation sleeve onto pipe

before the joint is made or for installation,

clip onto the pipe over the required spot.

Fig. 82: 8. Rivet insulation sleeve to outer

casing of the pipe on the left and right.

Type multirange blind rivet, 4.0 x 10 mm

(see price list)

Fig. 86: 12. Seal ventilation holes and

filling hole with the adhesive aluminium

tape provided.

Risk of trapping fingers.

Beware of cuts: adhesive aluminium tape has sharp edges.

For transporting cold media, we recommend using synthetic rubber made of closed-cell elastomer foam with a water vapour permeability of μ ≥ 7000.

20

5 PRESSURE EQUIPMENT DIRECTIVE 97/23/Eg

With effect from 29.5.1997, the pressure equipment directive 97/23/EG exclusively applies for trading with pressure equipment in the European Union area.

The pressure equipment directive acts as a law and is obligatory throughout the European Union. From that date, differing national legislation for the trade with equipment pressure is no longer valid. Pressure equipment within the context of the directive are vessels, pipes, equipment with a safety function or for maintaining the pressure and its components with a maximum permissible pressure of >0.5 bar. As also pipes are subject to the regulations of the pressure equipment direc-tive, a CE marking has to be applied by the manufacturer of the pipes (see below legal information) and a conformity declaration has to be issued.

Within the context of this pressure equipment directive, the manufacturer of the pipes is the installer, fabricator and system builder, who assembles pipes from their individual components (such as the pipe, electrofusion fittings). The pressure equipment directive refers to these individual components as “materials”. Therefore, the articles of the industrial pipe system RAUFRIGO such as the pipes, elecrofusion fittings as well accessories are to be referred to as “mate-rial“ in line with the pressure equipment directive.

Since the system builder as the „manufacturer of the pipe“ has the duty to is-sue a conformity declaration and to apply a CE marking on the equipment, he has to provide proof that all components and materials meet the requirements of the systems limits of the pipes. In practise, the documents relating to the limits of use of the components utilised may have to be stored and test reports 2.2. or inspection certificates 3.1. to DIN EN 10204 have to be provided.

Please contact your REHAU contact person to obtain a test report 2.2. to DIN EN 10204 or an inspection certificate 3.1. to DIN EN 10204.

The text of the pressure equipment directive can be found on the internet on the Official pages of the European Union.

21

6 DESIgN

RAUFRIGO pipes can be installed, openly visible, inside buildings or outdoors.

6.1 Dimensioning base pipe The dimensions of the base pipes are chosen in line with the existing volume flow. A REHAU calculation programme is available for download from the internet at (www.rehau.com).

6.2 Determining heat loss and dew point The REHAU calculation programme is useful for determining the energy loss associated with RAUFRIGO pipes. A dew point analysis can also be carried out. A REHAU calculation programme is available for download from the internet at (www.rehau.com).

6.3 Deciding on spans The various REHAU insulation sleeve fixing systems make the following maxi-mum spans possible.

Insulation sleeve installation method Max.span

Standard insulation using PUR sleeve foam

3 m

Reinforced insulation with PUR sleeve foam (riveted)

6 m

Insulation without PUR sleeve foam (riveted)

3 m

Tab. 11: Maximum spans.

6.4 Pipe clamp load

Fig. 87: Suspended from ceiling

RAUFRIGO Base pipe

[mm]

Outer jacket

[mm]

Pipe weight

empty

[kg/m]

Volume

[l/m]

Pipe weight

filled with

water

[kg/m]

Pipe clamp

load at

3 m span

[N]*

Pipe clamp

load at

6 m span

[N]*

140/63x5.8 63 x 5.8 - SDR11 140 4.33 2.07 6.40 207.23 414.45150/75x6.8 75 x 6.8 - SDR11 150 5.00 2.96 7.96 257.65 515.29160/90x5.4 90 x 5.4 - SDR17 160 5.15 4.93 10.08 326.28 652.55180/110x6.6 110 x 6.6 - SDR17 180 6.36 7.36 13.72 444.01 888.02200/125x7.4 125 x 7.4 - SDR17 200 7.51 9.54 17.05 551.89 1103.79250/160x9.5 160 x 9.5 - SDR17 250 10.81 15.61 26.42 855.40 1710.80280/180x10.7 180 x 10.7 - SDR17 280 13.02 19.76 32.77 1061.02 2122.04315/225x13.4 225 x 13.4 - SDR17 315 16.98 30.85 47.83 1548.56 3097.12355/250x14.8 250 x 14.8 - SDR17 355 20.55 38.15 58.70 1900.43 3800.86400/280x16.6 280 x 16.6 - SDR17 400 25.02 47.84 72.85 2358.53 4717.07450/315x18.7 315 x 18.7 - SDR17 450 30.76 60.52 91.28 2955.07 5910.14560/355x21.1 355 x 21.1 - SDR17 560 41.96 76.85 118.81 3846.20 7692.40

* Safety factor: 1.1 for pipe filled with water

Tab. 12: RAUFRIGO pipe weights

RAUFRIGO pipes can be fixed in place using standard pipe clamps attaching to the folded spiral-seam tube (outer casing). The maximum span is 6 metres. Select the pipe clamps according to the weights listed in tab. 12.

22

6.5 Fire protection

6.5.1 Fire load Fire load refers to the energy released when a RAUFRIGO pipe burns. The fire load value is normally expressed in MJ/m. The fire loads of RAUFRIGO pipes are a product of the calorific value of the combustible materials used. This results in the following fire loads:

RAUFRIGO base pipe [mm]

Outer jacket [mm]

Weight of base pipe [kg/m]

Fire load base pipe [kWh/m]

PUR weight [kg/m]

PUR fire load [kWh/m]

RAUFRIGO fire load [kWh/m] ]

RAUFRIGO fire load [MJ/m]

140/63x5.8 63 x 5.8 - SDR11 140 1.05 12.8 0.86 5.8 18.6 66.8150/75x6.8 75 x 6.8 - SDR11 150 1.47 17.9 0.93 6.2 24.1 86.9160/90x5.4 90 x 5.4 - SDR17 160 1.46 17.8 0.96 6.4 24.3 87.3180/110x6.6 110 x 6.6 - SDR17 180 2.17 26.5 1.12 7.5 34.0 122.2200/125x7.4 125 x 7.4 - SDR17 200 2.76 33.7 1.34 9.0 42.7 153.5250/160x9.5 160 x 9.5 - SDR17 250 4.52 55.1 2.03 13.6 68.7 247.5280/180x10.7 180 x 10.7 - SDR17 280 5.71 69.7 2.53 16.9 86.6 311.8315/225x13.4 225 x 13.4 - SDR17 315 8.93 108.9 2.67 17.9 126.8 456.7355/250x14.8 250 x 14.8 - SDR17 355 11.00 134.2 3.49 23.4 157.6 567.4400/280x16.6 280 x 16.6 - SDR17 400 13.70 167.1 4.49 30.1 197.2 709.9450/315x18.7 315 x 18.7 - SDR17 450 17.40 212.3 5.68 38.0 250.3 901.2560/355x21.1 355 x 21.1 - SDR17 560 22.10 269.6 10.31 69.1 338.7 1.219.4

Calculation using calorific values for rigid PUR foam =6.7 kWh/kg and polyethylene = 12.2 kWh/kg – according to supplementary sheet 1 to DIN V 18230 part 1Tab. 13: RAUFRIGO fire loads

6.5.2 Fireproofing collars If RAUFRIGO pipes are led through a fire wall, the pipe is directly insulated on the RAUFRIGO base pipe. To achieve this, completely remove the folded spiral-seam casing and the high-density PUR foam from the RAUFRIGO basis pipe in the area of the insu-lated pipe and fit the exposed pipe with an approved fireproofing collar. Please observe point 3.2.5 building material class. It can be identified with the help of the ambient conditions around the insu-lated pipe, if any condensation is to be expected on the exposed base pipe.

If there is no condensation:If there is no condensation on the exposed RAUFRIGO base pipe, approved fireproofing collars for PE (polyethylene) pipes can be used to insulate pipes. The specifications of the general Building Inspectorate accreditation are to be observed.

If there is condensation:If there is condensation on the exposed RAUFRIGO base pipe, fireproofing collars for insulated PE (polyethylene) approved for the insulation of pipes can be used. To achieve this, depending on the type of fireproofing collar, the PE pipe can be insulated using foam strips / foam tubing (e.g. AF/Armaflex). When carrying out this work, always observe the general Building Inspectora-te accreditation.

23

7 STANDARDS, REgULATIoNS, gUIDELINES

Observe all applicable national and international regulations relating to laying, installation, safety and the prevention of accidents when installing pipe sys-tems, as well as the instructions in this technical information.

Also adhere to the applicable laws, standards, guidelines, regulations (e.g. DIN, EN, ISO, DVGW, TRGI, VDE and VDI) as well as the regulations on the protection of the environment, the regulations of the Employer’s Liability Insu-rance Associations and regulations of the public utilities companies.

Areas of application not covered in this technical information (special applica-tions) require consultation with our technical applications department. Please contact your REHAU sales office for a comprehensive consultation.

The planning and assembly instructions relate directly to the corresponding REHAU product. Some sections refer to generally applicable standards and guidelines.

Observe the relevant valid version of the guidelines, standards and regulations.

More specific standards, regulations and guidelines relating to the planning, installation and operation of building and industrial systems must also be observed and do not form part of this technical information.

DIN 4102Fire behaviour of building materials and building components

DIN 8074Polyethylene (PE) pipes – PE 63, PE 80, PE 100, PE-HD - Dimensions

DIN 8075Polyethylene (PE) pipes – PE 63, PE 80, PE 100, PE-HD - General quality requirements, testing

DIN 52612Testing of thermal insulation materials; determination of the thermal conducti-vity by means of the guarded hot plate apparatus;

DIN EN ISO 1133Plastics – Determination of the melt flow rate (MFR) and the melt volume rate (MVR) of thermoplastics

DIN EN ISO 1183Plastics – processes to determine the density of un-foamed plastics

DVS 2205-1Calculations of vessels and equipment made of thermoplastics

877620 EN 09.2010

This document is protected by copyright. All rights based on this are reserved. No part of this publication may betranslated, reproduced or transmitted in any form or by any similar means, electronic or mechanical, photocopying,recording or otherwise, or stored in a data retrieval system.

Urheberrecht Englisch

Insofar as the intended application deviates from that described in the relevant Technical Information brochure, theuser must consult REHAU and must receive express written consent from REHAU before commencing this utilization.If the user fails to do so, the sole responsibility for the utilization shall lie with the individual user. In this case, theapplication, use and processing of products are beyond our control. Should a case of liability arise, however, thisshall be limited to the value of the goods delivered by us and used by you in all cases of damage.Claims arising from granted guarantees shall become invalid in the case of intended applications that are not described in the Technical Information brochures.

Englisch HIS TI Prospekt

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8 PRACTICAL EXAMPLES

Fig. 89: Installed on the hall’s ceiling

Fig. 88: Special RAUFRIGO design with outer casing made of stainless steel

Fig. 90: Bends, subsequently insulated

Fig. 91: Expansion bend outdoors Fig. 92: Large spans outdoors