Handbook – products, design and installation · PDF fileThis LOGSTOR handbook is primarily directed at the community heating ... (If FlexPipes are to be connected to existing systems

Handbook– products, design and installation

Version 2016.06

LOGSTOR A/S · Tel. +45 99 66 10 00 FlexPipe · 2013.06

1.0.0.1

Introduction

LOGSTOR FlexPipe handbookGeneral

This section describes LOGSTOR’s solutions for heating and domestic water systems primarily for community heating projects.

Contents System description 1.1 Fields of application 1.2 Component solutions 1.3 Design 1.4

FlexPipe · 2013.06 LOGSTOR Fredericia A/S · Tel. +45 76 23 30 00

1.1.0.1

System descrip-tion

LOGSTOR FlexPipe handbookGeneral - system description

This LOGSTOR handbook is primarily directed at the community heating/low temperature (up to 95°C) market with the products:• PexFlex and AluFlex for heating • PEX DW for domestic water

Community heating as a concept does not differ essentially from district heating as regards the technical solutions, but primarily as regards the facts that:• the system is connected to a local energy source either by utilising:

- existing systems or - new community heating systems

• the ownership is rooted locally • the system, by its nature, has a limited size • the pipe dimensions are small, making flexible pipe systems an obvious choice • the temperatures are low, enabling optimisation of the product choice and thus reducing the

construction costs.

LOGSTOR FlexPipe systems contribute to this with:• good insulating properties.

Certified thermal conductivity, lambda = 0.022 W/mK• few buried joints• no welding or soldering. Only mechanical joints.• narrow trenches = minimise the excavation and restoration costs also due to:

- the possibility to use TwinPipe - the small bending radii - self-compensating systems. No expansion components

LOGSTOR FlexPipe handbook

This handbook is based on excerpts from LOGSTOR´s Product Catalogue, Design, and Handling & Installation manual.

Refer to these, if additional documentation and instructions are required.

All rights reserved. The English version on www.logstor.com is the original. All other language versions are made according to the best knowledge of the translators.


1.2.0.1

LOGSTOR FlexPipe handbookGeneral - fields of application

System types: Distribution: Consumers:

Biogas Horticultural farms

Landfill gas Terraced and cluster houses

Biomass (Wood chips/straw) Detached houses

Heat pump (Air/ground) LOGSTOR FlexPipes Schools

Industry Sports centres

Geothermal energy Small- and medium-sized enterprises

Solar system Villages

Typical fields of application for community heat-ing projects

BIO


1.3.0.1

LOGSTOR FlexPipe handbookGeneral - component solutions

Solution A A. Branching components: - Preinsulated T-pieces and straight casing joints - T-press couplings and T-casing joints

Illustration Components Component No.

T-piece straight with couplings fitted onto it

3400

FXJoint (single pipe) 5057

SXJoint (TwinPipe) for foaming

5012

T-coupling, press T-coupling, compression

6062 Pex/Alu 6160 PEX DW

T-straight (single pipe) 5140

T-straight (TwinPipe) for foaming

5140

Component solutions

In addition to choosing the pipe system there are only a few other choices to make. The pri-mary choices are:

A. Branching components B. Connection to the consumer C. Straight joint of two lengths of FlexPipe

A B C


1.3.0.2

LOGSTOR FlexPipe handbookGeneral - component solutions

Solution C C. Straight joint between two lengths of FlexPipe: - Jointing single pipes - Jointing TwinPipe/DoublePipe (PEX DW)


Press coupling6000 PexFlex 6001 AluFlex

Compression coupling6100 PEX DW and

PexFlex

FXJoint (insulated) 5057

Press coupling6000 PexFlex 6001 AluFlex

Compression coupling6100 PEX DW and

PexFlex

SXJoint (foamed) 5012

Solution B B. Connection to the consumer: - In the cellar - Tilted bore - Embedded inlet pipe


Wall entry sleeve 5800

End cap 5600

End cap 5600

or protective cap 1230

Inlet pipe 1236

End cap 5600

Protective cap 1230


1.4.1.1

Introduction

Design with FlexPipesGeneral

Design and piping

The design of the pipeline is very simple, because the pipes are self-compensating. That means that expansion movements in the soil shall not be taken into account.

in the design phase the following shall be decided upon: - The design of the trench, see page 3.2.0.1 - Bending radius of the relevant dimensions, see page 3.2.0.3 - Introduction in buildings, see section2.6.1.

(If FlexPipes are to be connected to existing systems with steel service pipes special rules apply! (see www.logstor.com/Design, section 11.3 and 13.1-2).

This section describes general and product specific rules for designing and dimensioning with PexFlex, AluFlex, and PEX DW.


1.4.2.1

Conditions

Design with FlexPipesHeat loss

PexFlex The heat loss is the total heat loss of flow and return pipe.

The tables in this section are based on the following and are consequently only guiding:

- Flow temperature 80°C - Return temperature 40°C - Soil temperature 10°C - Soil cover 0.6 m - Distance between pipes (in connection with single pipes) 0.15 m - Lambda value of the soil 1.6 W/mK

If exact calculations with other condistions are required, please refer to LOGSTOR Calculator at www.logstor.com (use the quick link).

Series 1

Service pipe ø mm

Outer casingø mm

Heat loss W/m

16 77 10.72

20 77 12.55

25 77 15.17

32 77 19.73

40 90 19.77

50 110 19.61

63 125 21.74

75 140 23.28

90 160 24.77

110 160 38.30

Series 2

Service pipeø mm

Outer casingø mm

Heat loss W/m

16 90 9.15

20 90 10.50

25 90 12.35

28 90 13.57

40 110 15.15

50 125 16.17

63 140 18.16

75 160 18.81

Series 2

Service pipe ø mm

Outer casing ø mm

Heat loss W/m

2x16 110 6.14

2x20 110 7.24

2x25 125 7.46

2x32 125 9.64

2x40 140 10.73

Series 1

Service pipe ø mm

Outer casing ø mm

Heat loss W/m

2x16 90 7.59

2x20 90 9.33

2x25 110 8.91

2x32 110 12.29

2x40 125 13.51

2x50 160 11.92

TwinPipes:

Pipe pair:


1.4.2.2

Design with FlexPipesHeat loss

AluFlex The heat loss is the total heat loss of flow and return pipe.

Series 1

Service pipe ø mm

Outer casingø mm

Heat loss W/m

16 77 8.64

20 77 10.03

26 77 12.40

32 90 12.70

Series 2

Service pipeø mm

Outer casingø mm

Heat loss W/m

16 90 7.76

20 90 8.87

26 90 10.67

Series 2

Service pipe ø mm

Outer casing ø mm

Heat loss W/m

2x16 110 5.40

2x20 110 6.33

2x26 125 6.90

2x32 125 8.54

Series 1

Service pipe ø mm

Outer casing ø mm

Heat loss W/m

2x16 90 6.38

2x20 90 7.76

2x26 110 8.06

2x32 110 10.49

TwinPipes:

Pipe pair:


1.4.3.1

Design with FlexPipesPressure loss charts

General In order to establish the correct pipe dimension it is necessary to know the water flow and the maximum allowable pressure loss.

Small pipelines are often dimensioned after the available pressure difference, thereby minimis-ing the dimension and the heat loss as much as possible as well as assuring the consumer the highest possible flow temperature.

In addition, it must be ensured that the water speed will not be too high.

For flexible pipelines it is recommended that the speed does not exceed 2 m/s in couplings and that the speed in house connections does not exceed 1 m/s to minimise the risk of noise.

It is recommended that the system is dimensioned after the available pressure difference. In case it is not known, a value corresponding to 150 Pa/m is often used.

As a dimensioning tool LOGSTOR Calculator can be used. It is available on: www.logstor.com/calculator.

As an alternative to a hand calculation the graphs in the following can be used.

Inter-related values between output (kW) and cooling as well as water flow (kg/h) appear from the graphs. The required output is found with the inter-related cooling, or the water flow can be found after the formula:

q = Mass flow [ kg/h] Q = Output [kW] DT = Cooling

The following graphs are based on: Water temperature of 80°C for heat pipes and 60° for domestic water pipes. Absolute PEX roughness = 0.01 mm

q ≅ Q ∙ 860∆T


1.4.3.2


AluFlex

10 20 200 300 400 50030 40 50 100 1000 2000

10000

1000

100

200

300400500

10

20

30

4050

40°C

33

5

10

20

304050

75

100

200

300

kW

5

10

20

30405075

100

200300

ΔT

30°C

kg/h

Pa/m

ø 40

0,25 m/s

0,50 m/s

1,0 m/s

2,0 m/s

ø 32

ø 26

ø 20

ø 16

PexFlex100000

10000

1000

100

200

300400500

10

20

304050

10 100

ø 110

ø 90

ø 75

ø 63

ø 50

ø 40

ø 32

ø 25

ø 20

ø 16

1000 Pa/m

kg/h

40°C

ΔT

30°C

20 200 300 400 50030 40 50

0,25 m/s

0,50 m/s

1,0 m/s

2,0 m/s

2000

3

5

10

2030

40

5075

100

200

300

500

2000

1000

3000

3

5

10

20

30

405075100

200

300

500

1000

2000

kW


1.4.3.3


PEX DW

10000

1000

100

200

300400500

10

20

304050

10 100 1000

kg/h

Pa/m20 200 300 400 50030 40 50

ø 63

ø 50

ø 40

ø 32

ø 28

ø 22

ø 16

0,25 m/s

0,50 m/s

1,0 m/s

2,0 m/s

2000


2.0.0.1

Introduction

FlexPipesProduct Catalogue

This section contains a presentation of the LOGSTOR products:

- pipes - fittings - casing joints - accessories - tools

available to the following systems:

- heating: PexFlex AluFlex

- domestic water: PEX DW

Contents Technical description of FlexPipes 2.1

PexFlex 2.2

AluFlex 2.3

PEX DW 2.4

Casing joint types 2.5

Terminations with FlexPipes 2.6 - General 2.6.1 - PexFlex 2.6.2 - AluFlex 2.6.3

Tools for FlexPipes 2.7


2.1.0.1

Overview

FlexPipesTechnical description

Materials, properties etc. for LOGSTOR FlexPipes

PexFlex AluFlex PEX DW

Service pipe (1)

PEXb ø 16-110 mm

EVOH diffusion barrier 3.1 certificate is available

PEX/Alu/PE (out.) ø 16-32 mm

PEX ø 22-63 mm

Insulation (2)Polyurethane foam, PU Blowing agent: CyclopentaneCertified thermal conductivity: l50 = 0.022 W/mK

Diffusion barrier (3) Multilayer polymer foil -

Outer casing (4) Polyethylene PELD

Standards/approvals EN 15632-2 EN 15632-2Service pipe: - EN 12318 - DVGW K 178 and 183

Pressure, Pbar

PN 6: ø 16 mmPN 10: ø 20-110 mm

PN 10 PN 10

Temperature, °C- Continuous max.- Max. at 100 h/year

8595

95105

8595

Delivered lengths: Standard lengthsFixed lengths min. 10 - max. 90 m

50 and 100 mmYes

50 and 100 mmYes

50 and 100 mm

Measurements of FlexPipe coilApply to series 1, 2, andTwinPipe

1

2

34

Di

H

De

Measure approx.

Outer casing, ø out. mm

77 90 110 125 140 160

Di 1600 1600 1800 1800 2000 2000

De 2200 2300 2200 2300 2300 2300

H50 300 350 500 650 1100 1300

H100 425 475 800 1150 2250 2400


2.2.0.1

Single pipe

FlexPipesPexFlex - pipes in coils

Component No. 2100.

Lengths: 50 or 100 m

PN 6, SDR 11.

Component No. 2190.

Lengths: 50 or 100 m

PN 6, SDR 11.

TwinPipe

PEXservice pipe

Series 1 Outer casing

Series 2Outer casing

ø out.mm

Wall t.mm

ø out. mm

Wall t.mm

ø out.mm

Wall t.mm

16** 2.2 77 2.2 90 2.5

20 2.0 77 2.2 90 2.5

25 2.5 77 2.2 90 2.5

32 2.9 77 2.2 90 2.5

40 3.7 90 2.5 110 2.5

50 4.6 110 2.5 125 2.5

63 5.8 125 2.5 140 3.0

75 6.9 140 3.0 160 3.0

90 8.2 160 3.0

110 10.0 160* 3.0

* Series 0. Note! Preinsulated components have casing pipes ø 180 mm. ** PN 10.

PEX service pipe

Series 1 Outer casing

Series 2Outer casing

ø out.mm

Wall t. mm

ø out. mm

Wall t.mm

ø out.mm

Wall t.mm

16/16* 2.2 90 2.5 110 2.5

20/20 2.0 90 2.5 110 2.5

25/25 2.5 110 2.5 125 2.5

32/32 2.9 110 2.5 125 2.5

40/40 3.7 125 2.5 140 3.0

50/50 4.6 160 3.0

* PN 10.

Order example System - Component - Component No. - Dim. service/casing pipe - Length:

PexFlex - pipe - 2100 - 25/77 - 50 m

PexFlex Twin - pipe - 2190 - 40x2/125 - 100 m


2.2.0.2

FlexPipesPexFlex - preinsulated bends

Component overview

Component No. 2500.

Application

90° preinsulated bend

PexFlex bends have PEX service pipes.

Do not shorten!

Are available without free ends.

PEX pipeø out. mm

Outer casing ø out. mm

Series 1 Series 2

20 77 90

25 77 90

32 77 90

40 90 110

50 110 125

63 125 140

75 140 160

90 160

110 *180

* PexFlex in coils is delivered as ø 110 mm in a ø 160 mm casing pipe.

Single pipe TwinPipe

PEX pipeø out. mm


Series 1 Series 2

20/20 90 110

25/25 110 125

32/32 110 125

40/40 125 140

50/50 160

Order example System - Component - Component No. - Dimension:

PexFlex - 90° bend - 2500 - 32/90

PexFlex 90° bends are used, when a sharper curvature than allowed by the minimum bending radius is required.


2.2.0.3

FlexPipesPexFlex - preinsulated branches

Single pipes Component No. 3400

605 mm

400

mm

Description Preinsulated branches for PexFlex are straight branches with steel service pipes.

They are delivered with press couplings already welded on to them. As an alternative they can be ordered with compression couplings.

PexFlex, main pipe, D1 Branch ø out. mm, D2

Dim. outer casing = main pipeService pipe Outer casing, ø out. mm

ø out. mm Series 1 Series 2 16 20 25 32 40 50 63 75 90 110

16 77 90 x

20 77 90 x x

25 77 90 x x x

32 77 90 x x x x

40 90 110 x x x x x

50 110 125 x x x x x x

63 125 140 x x x x x x x

75 140 160 x x x x x x x x

90 160 180 x x x x x x x x x

110 160 180 x x x x x x x x x x

TwinPipes Component No. 3490

605 mm

400

mm


2.2.0.4

FlexPipesPexFlex - preinsulated branches

PexFlex, main pipe, D1 Branch, ø out. mm, D2


ø out. mm Series 1 Series 2 16/16 20/20 25/25 32/32 40/40 50/50

16/16 90 110 x

20/20 90 110 x x

25/25 110 125 x x x

32/32 110 125 x x x x

40/40 125 140 x x x x x

50/50 160 x x x x x x

Order example System - Component - Component No. - D1 - D2:

PexFlex - Straight branch - 3490 - 32/32-125 - 25/25-125

TwinPipes,continued


2.2.0.5

FlexPipesPexFlex - transition pipes, TwinPipe - single pipe

Application Preinsulated transition pipes are used in connection with straight transition from a single pipe system to a TwinPipe system.

As a standard series 2 dimensions for single pipe ends and series 1 dimensons for TwinPipe ends are delivered for PexFlex.

As the flow pipe is always placed at the bottom, the transition is available in a “type 1” as well as a “type 2” version.

Description "Type 1" and "type 2" are defined by viewing the transition pipe from the single pipe end perspective.

Type 1

Type 2

C/C = 245 mm

1700 mm

Possible combi-nations

Component No. 3071

Single pipe ø out. mm

16/77 20/77 25/77 32/77 40/90 50/110

TwinPipe ø out. mm

16/90 20/90 25/110 32/110 40/125 50/160

Order example System - Component - Component No. - Dim. single - Dim. Twin - Type:

PexFlex - Overgangsrør - 3071 - 25/77 - 25/110 - 1


2.2.0.6

FlexPipesPexFlex - press couplings

Straight and reducing couplings

Component No. 6000

Dimension = PEX ø out. mm

ø1 ø2

ø1 ø1

Coupling types For PexFlex-systems the three most commonly used coupling types are: - Straight press coupling: Same dimension - Reducing press coupling: 1-3 dimensional offsets dependent on the dimension - Straight branch with press coupling

Press couplings ensure a permanent sealing at all temperature variations.

Alternative: Straight couplngs as well as T-couplings are also available as compression cou-plings, see page 2.2.0.8.

Order example System - Coupling type - ø1 - ø2:

PexFlex - Press/reducing - 40 - 32

Coupling end ø1 16 20 22 25 28 32 40 50 63 75 90 110

Coupling end ø2

16 x x

20 x x x

22 x x

25 x x x

28 x

32 x x

40 x x

50 x x

63 x x

75 x x

90 x x

110 x


2.2.0.7

FlexPipesPexFlex - press couplings

ø1 ø3

ø2

T-branch with press couplings

Component No. 6060

PEX main pipe ø1 = ø3

ø out. mm

PEX branch, ø2 ø out. mm

16 20 25 32 40 50 63 75 90 110

20 x

25 x x x

32 x x x x

40 x x x x

50 x x x x x

63 x x x x x x

75 x x x x x x x

90 x x x x x x x x

110 x x x x x x x x x

Order example System - Coupling type - Comp. No. - ø1 - ø2 - ø3:

PexFlex - T-branch - 6060 - 75 - 32 - 75 PexFlex - T-branch with reduction - 6060 - 75 - 50 - 63

Other coupling types

- Transition coupling for steel service pipe. From steel/PEX: ø 26.9/16 mm to ø 114.3/110 mm.

PEX main pipe with reduction

ø1 - ø3ø out. mm

PEX branch, ø2 ø out. mm

20 25 32 40 50 63 75

25-20 x

32-25 x

63-40 x

63-50 x x

75-50 x

75-63 x x

90-63 x

90-75 x x


2.2.0.8

FlexPipesPexFlex - compression couplings

Coupling types For PexFlex compression couplings can also be used. They are available as straight couplings and T-couplings.

Please note that in some countries special rules apply to the use of not visible compression couplings.

PEX main pipe ø1 = ø 3

ø out. mm

PEX-branch, ø2 ø out. mm

20 25 32 40 50 63 75 90 110

20 x

25 x x

32 x x

40 x x x

50 x x x x x

63 x x x x x x

75 x x x x x x x

90 x x x x x x x

110 x x x x x x x

Straight connec-tions

Straight compression coupling:

Component No. 6100ø20-32

ø40-110

PEX pipe diameter d, mm 20 25 32

Component No. 6100

PEX pipe diameter d, mm

40 50 63 75 90 110

Order example:

System - Component - Component No. - Dim. service pipe:PexFlex - Straight compression coupling - 6100 - 63

ø1 ø3

ø2Compression-T-coupling, component No. 6160.

In principle ø2 and ø3 are optional, provided that they are ≤ ø1.

Branches

Order example:

System - Component - Component No. - Dimension from/to:PexFlex - Compression-T-coupling - 6160 - 50/28


2.3.0.1

FlexPipesAluFlex - pipes in coils

Single pipe Component No. 2100

Order example System - Component - Component No. - Dim. service pipe/outer casing - Length:

AluFlex - Single pipe - 2100 - 20/90 - 100 AluFlex - TwinPipe - 2190 - 26-26/110 - 50

TwinPipe Component No. 2190

16 2.2 77 2.2 90 2.5 20 2.5 77 2.2 90 2.5 26 3.0 77 2.2 90 2.5 32 3.0 90 2.5

AluPEX Series 1 Series 2 Casing pipe Casing pipe ø out. Wall t. ø out. Wall t. ø out. Wall t. mm mm mm mm mm mm

16/16 2.0 90 2.5 110 2.5 20/20 2.5 90 2.5 110 2.5 26/26 3.0 110 2.5 125 2.5 32/32 3.0 110 2.5 125 2.5

AluPEX Series 1 Series 2 Casing pipe Casing pipe ø out. Wall t. ø out. Wall t. ø out. Wall t. mm mm mm mm mm mm


2.3.0.2

FlexPipesAluFlex - preinsulated branches

Single pipe Component No. 3400

605 mm

400

mm

Description

AluFlex, main pipe, D1 Branch ø out. mm, D2


ø out. mm Series 1 Series 2 16 20 26 32

16 77 90 x

20 77 90 x x

26 77 90 x x x

32 90 x x x x

TwinPipes Component No. 3490

605 mm

400

mm

Preinsulated branches for AluFlex are straight branches with steel service pipes.

They are delivered with press couplings already welded on to them.

AluFlex, main pipe, D1 Branch, ø out. mm, D2


ø out. mm Series 1 Series 2 16/16 20/20 26/26 32/32

16/16 90 110 x

20/20 90 110 x x

26/26 110 125 x x x

32/32 110 125 x x x x

Order example System - Component - Component No. - D1 - D2:

AluFlex - Straight branch - 3490 - 32-32/125 - 26-26/125


2.3.0.3

FlexPipesAluFlex - press couplings

Straight and reducing couplings

Component No. 6001

Dimension = PEX ø out. mm

ø1 ø2

ø1 ø1

Coupling types For AluFlex systems the three most commonly used coupling types are: - Straight press coupling: Same dimension - Reducing press coupling: 1-3 dimensional offsets dependent on the dimension - Straight branch with press coupling

Press couplings ensure a permanent sealing at all temperature variations.

Please note that press couplings for AluFlex are equipped with O-rings and insulator rings. See "Installation of press couplings".

Order example System - Coupling type - ø1 - ø2:

AluFlex - Press/reducing - 32 - 26

Coupling end ø1 16 20 26 32

Coupling end ø2

16 x x

20 x x

26 x x

32 x

ø1 ø3

ø2

T-branch with press couplings

Component No. 6062

Order example System - Coupling type - ø1 - ø2 - ø3:

AluFlex - T-press coupling - 32 - 20 - 32

Other coupling types

- Transition coupling for steel service pipe. From steel/PEX: ø 26.9/16 mm to ø 33.7/32 mm.

- End coupling, closed press coupling. Also see "Terminations with AluFlex", page 2.6.3.

16 x 20 x x 26 x x x 32 x x x x

Main pipe Branch, ø 2 ø1 = ø3 AluFlex, ø mmAluFlex 16 20 26 32


2.4.0.1

FlexPipesPEX DW - pipes in coils

Single pipe, PN 10 SDR 7.4

Distribution pipe, component No. 2100


PEX DW - DoublePipe - 2190 - 32/22-90 - 50

DoublePipe, PN 10 SDR 7.4

Circulation pipe, component No. 2190

Application The FlexPipe system “PEX DW” for domestic water is a complete distribution and house entry system.

PEX service pipe Outer casing (series 1)

ø out. Wall thick. ø out. Wall thick.

mm mm mm mm

22 3.0 77 2.2

28 4.0 77 2.2

32 4.4 77 2.2

40 5.5 90 2.5

50 6.9 110 2.5

63 8.7 125 2.5

PEX service pipe Outer casing (series 1)

ø out. Wall thick. ø out. Wall thick.

mm mm mm mm

28/22 4.0/3.0 90 2.5

32/22 4.4/3.0 110 2.5

40/28 5.5/4.0 125 2.5

50/32 6.9/4.4 125 2.5


2.4.0.2

FlexPipesPEX DW - preinsulated bends

Preinsulated 90° bend

PEX DW bends have PEX service pipes.

Do not shorten them!

They are delivered without free ends.

Component No. 3500.Component overview


PEX DW - 90° bend - 3500 - 50/110

PEX pipeø out. mm

Outer casingø out. mm

22 77

28 77

32 77

40 90

50 110

63 125


2.4.0.3

FlexPipesPEX DW - compression couplings

Connection types

Straight connec-tions

PEX DW pipes are connected by means of compression couplings.

When ordering, please state 10 bar.

Straight compression coupling:

Component No. 6100ø22-32

ø40-63


Component No. 6100


PEX pipe Male thread

ø out. mm 3/4” 1” 11/4” 1½” 2”

22 x x

28 x x

32 x x

40 x x

50 x x

63 x

Compression coupling with male thread, component No. 6100.

PEX pipe Female thread

ø out. mm 3/4” 1” 11/4” 1½” 2”

22 x x

28 x x

32 x x

40 x x

50 x x

63 x

Compression coupling with female thread, component No. 6100.

Order example:

System - Component - Component No. - Dim. service pipe:PEX DW - Straight compression coupling, 10 bar - 6100 - 63

Order example:

System - Component - Component No. - Dimension (mm/"):PEX DW - Compression coupling, male, 10 bar - 6100 - 32/11/4


2.4.0.4

FlexPipesPEX DW - compression couplings


ø out. mm 3/4” 1” 11/4” 1½” 2”

22 x x

28 x x

32 x

40 x

50 x

63 x

Compression coupling. Union elbow with male thread, component No. 6100.

PEX pipe Female thread

ø out. mm 3/4” 1” 11/4” 1½” 2”

22 x x

28 x x

32 x

40 x

50 x

63 x

Compression coupling. Union elbow with female thread, component No. 6100.

Bends

Main pipeBranch

ø out. mm

ø out. mm 22 28 32 40 50 63

22 x

28 x x x

32 x x x

40 x x x x

50 x x x x x

63 x x x x x x

Compression-T-coupling, component No. 6160.Branches

Order example:

System - Component - Comp. No. - Dimension (mm/"):PEX DW - Compression coupling, 90° male, 10 bar - 6100 - 50/11/4

Order example:

System - Component - Component No. - Dimension from/to:PEX DW - Compression-T-coupling, 10 bar - 6160 - 50/28


2.5.0.1

FlexPipesCasing joint types

Casing joint types

From LOGSTOR’s casing joint assortment 4 types have been selected which ensure simple and efficient connections of FlexPipes.

For single pipes shrink joints with insulation shells are used. Alternatively, casing joints for foaming may be used.

For TwinPipe shrink joints for foaming with foam packs are used.

Overview Pipe type Straight connections Branches Insulation

Single pipe FXJoint T-joint, straight F Insulation shells

TwinPipe SXJoint T-joint, straight Foam packs


2.5.1.1

FlexPipesCasing joints for FlexPipes - FXJoint

Application The shrink joint FXJoint with insulation shells is used for connections on single pipe FlexPipes ø 77-160 mm.

The sleeve is pre-installed on the pipes, before they are connected.

FXJoints are installed by means of a soft gas flame. (See installation instructions section 3.5).

Description

1

2

3

The FXJoint set consists of:1. Insulation shells with flexible core for

couplings2. Shrink sleeve with integrated mastic3. Cleaning tissue

Materials Sleeve Cross-linked PE (PEX) with mastic, embedded in the ends

Insulation shells Hard PU, polyurethane, furnished with soft PU

Component overview

Component No. 5057

FXJoint is available in 2 dimensions, covering the following two intervals: - Dimension ø 77-125 mm - Dimension ø 125-160 mm

Order example Casing joint type - Component No. - Outer casing dimension:

FXJoint - 5057 - 125

(No distinction is made between series 1 and 2).


2.5.2.1

FlexPipesCasing joints for FlexPipes - T-joint, straight F

Application The shrink joint “T-joint, straight F” with insulation shells is used for straight connections on single pipe FlexPipes ø 77-160 mm.

Collar, shrink wrap and T-shoe are pre-installed on the branch prior to connection to the main pipe.

Description

12

3

4

56

7

A complete set consists of:1. Closure patch2. Shrink wrap3. Insulation shells with marking for branch4. T-shoe5. Insulation shells6. Collar7. Cleaning tissue

Materials - T-shoe PE with hotmelt in the branch- Shrink wrap and collar PE with mastic- Closure patch Cross-linked polyolefin with fibreglass reinforcement- Insulation shells Hard PU, polyurethane with soft PU embedded

Order example Casing joint type - Component No. - From dimension - To dimension:

T-joint, straight F - 5140 - 160 - 125

No distinction is made between series 1 and 2.

Component overview

Component No. 5140Main pipe,

outer casingø mm

Branch, outer casing ø mm

77 90 110 125 140 160

77 x

90 x x

110 x x x

125 x x x x

140 x x x x x

160 x x x x x x


2.5.3.1

FlexPipesCasing joints for FlexPipes - SXJoint

Materials Shrink sleeve: Crosslinked PE (PEX) Venting plugs: LDPE Expansion plugs: PEX with a butyl mastic ring Wedge plugs: PEXPatches: PEX with water-resistant hotmelt

Application

Description

The shrink joint SXJoint for foaming is used for straight connections of Twin FlexPipes ø 77-160 mm.

The sleeve is pre-installed on the pipes prior to their connection.

The SXJoint is installed by means of a soft gas flame, see installation instructions section 3.7. The joint is for foaming and consequently shrinkable at the ends and not in the middle.

The SXJoint set consists of:1. Shrink sleeve

(The joint ends contain mastic)2. Venting plugs 3. Expansion plugs 4. Wedge plugs 5. Patches 6. Collars (to be ordered separately)

The joint set is wrapped in white PE foil on delivery.Store the shrink sleeve vertically.Max. temperature during transportation and storage: 80°C.

L1

2345 6

Component overview/data

Component No. 5012

90 77 650 110 90 650 125 110 650 140 125 650 160 140 650 180 160 650

Outer casing dim. Shrinkable to L ø mm ø mm mm

Accessories Foam packs are used for foaming.

When ordering, simply state the insulation series and that the casing joint must be delivered including foam packs, then the correct dosage will be delivered automatically.

The foam pack size appears from the table on page 3.12.0.1.

Order example Casing joint type - For outer casing dmension - Foam pack - Series:

SXJoint - ø 125 mm - incl. - 2

For outer casing dimension ø 77 mm a ø 90 mm sleeve is used.


2.5.4.1

FlexPipesCasing joints for FlexPipes - T-joint, straight branch

Materials T-shoe: PE with hotmelt in the branchShrink wrap and collar: PE with masticClosure patch: Cross-linked polyolefin with fibreglass reinforcementVenting plugs: LDPEExpansion plugs: PEX with masticWedge plugs: PEX

Application

Description

The shrink joint T-joint for foaming is used for branching single pipe FlexPipes ø 77-160 mm.

Collar, shrink wrap and T-shoe are pre-installed on the branch prior to connection to the main pipe.

A complete set consists of:

1. Closure patch2. Shrink wrap3. T-shoe4. Collar5. Venting, expansion, and wedge plugs

4

5

3

1

2

L1

L2

Component overview

Component No. 5140Main pipe,

outer casingø mm

Branch, outer casing ø mm

90 110 125 140 160

90 x

110 x x

125 x x x

140 x x x x

160 x x x x x

Accessories Foam packs are used for foaming.

When ordering, simply state the insulation series and that the casing joint must be delivered including foam packs, then the correct dosage will be delivered automatically.

The foam pack size appears from the table on page 3.12.0.1.

Order example Casing joint type - Comp. No. - From dim. - To dim. - Foam pack - Series:

T-joint, straight - 5140 - ø 160 mm - ø 125 mm - incl. - 1


2.6.1.1

Possible termina-tions. Description

Straight lead-in throug the base. Wall entry sleeve

Terminations with FlexPipesGeneral

Component No. 5800.

Dependent on whether bore or core has been used a wall entry sleeve may be required.

Outer casing Sealing ring ø out. mm

Is used by direct introduction into e.g. service space, cellar etc.

Tilted bore in the base

Is used in connection with existing buildings, where boring is preferred to cutting a hole.

A projected FlexPipe end may be covered by a tight-fitting protective cap.

Component No. 1230.

As for TwinPipes the conical connecting pieces are adjusted to the service pipe end.

In principle there are 4 methods to introduce FlexPipes through a wall:- Straight lead-in through the base- Tilted bore in the base- 90° lead-in through the base with embedded inlet pipe- External lead-in through the wall, covered by a cabinet

For internal use a number of possible mountings and valves, adjusted to the pipe type and expansion stress (see under the different FlexPipe types) are offered.Consequently, it is possible to find a solution which fits the specific task precisely.

77 x 90 x 110 x 125 x 140 x 160 x


- - Wall entry pipe - 5800 - 32/22-90 - 50


Lead in through base by means of embedded inlet pipe

1

2 / 3

2.6.1.2


Tilted bore in the base, component over-view for protec-tive cap

Component No. of protective cap for single pipe: 1230.

General for all FlexPipe types.

Is used in connection with new buildings to facilitate later introduction of FlexPipe without drawbacks for the building.

1. Inlet pipe2. Sealing reduction

or

3. End-cap

Use a special pulling tool to pull the pipe through the inlet pipe, see page 2.7.1.1.

Inlet pipe (1)

77 800 1050 900 125 90 800 1050 900 125 110 800 1050 900 140

FlexPipe R H L ø ø out. mm mm mm mm mm

HR

L

øComponent No. 1236.

SystemDimension internal/external mm

20/77 25/77 26/77 32/77 22/90 26/90 32/90 40/90 50/110

PexFlex x x x x x

AluFlex x x x x x x


AluFlex - Protective cap - 1230 - 26/77


FlexPipe - Inlet pipe - 1236 - 110/140


2.6.1.3

Protective cap (2)


The introduction may be terminated with a protective cap (see section about tilted introduc-tion) or an end-cap.

End-cap (3) Shrinkable end-cap for single pipe.Component No. 5600

16-32 77 2000 35-40 90 2100 42-50 110 2200 54-63 125 2300 70-75 140 2400 90 160 2500

Service pipe Outer casing DHEC ø out. mm ø out. mm No.

Shrinkable end-cap for Twin FlexPipe.Component No. 5600

16/16-20/20 90 3200 22/22-25/25 110 3200 28/28 125 3200 35/35 140 3280

Service ppe Outer casing DHEC ø out. mm ø out. mm No.


Twin FlexPipe - End-cap - 5600 - 28/28-125 or DHEC 3200

Description. Internal fixing. Connection to house installation

There are a lot of suitable individual solutions, but LOGSTOR offers a number of possibilities which make allowance for the material properties of the individual pipe type and the pure pipe-static influences.

Mounting type A Applicable for all types of introduction in con-nection with screw couplings.Used for: - PexFlex- AluFlex

Product No. 0005 0000 802 011.


2.6.1.5


Mounting type C If expansion movements occur in the FlexPipes through the wall, the pipe bend-ing must be ensured by means of a matrix (especially in connection with cooling of the pipes).

Primarily used for:- PexFlex (max. ø 28 mm)- AluFlex

18 - 20 0005 0000 202 023 22 - 26 8-41631 28 - 32 8-41632

Service pipe Product No. ø out. mm

Accessories for mounting type A

For installation on this mounting an adapter coupling with ex- and internal thread respec-tively is available for threaded couplings, screw couplings and loose ball valves.

Thread Product No.

In connection with mounting type A (or for individual solutions) a 3/4” ball valve with internal thread is available.

Component No. 4261

3/4” 0005 0000 202 021 1” 0005 0000 202 022

Design Flow (red) Return (blue)

All-welded steel x x

Nickeled brass x x


FlexPipe - Mounting type C - 0005 0000 202 023 - 18-20


2.6.2.1

Terminations with FlexPipesPexFlex

Termination in cabinet (relieved)

Press coupling with male thread. Material: Brass

Component No. 6000.

To be used relieved (in cabinet or indoors).

PEX pipe ø out. mm

Male thread1/2”

3/4” 1” 11/4” 11/2” 2” 3”

16 x

20 x

22 x

25 x x

28 x

32 x x

40 x

50 x

63 x

75 x

90 x

110 x

Internal wall installation (with relief)

Mounting type A is used for all introduc-tions where there is some kind of expansion absorption.

Product No. 0005 0000 202 011.

See ”Terminations, general”.


PexFlex - Press coupling with male thread - 6000 - 32/11/4”

Internal installation

Compression coupling with male thread can be used for internal installation.

Component No. 6100.

The coupling is made of brass.


2.6.2.2


Internal wall installation (without relief)ø 22 and 28 mm

Mounting type A combined with mounting type C is used, when the PexFlex pipe is installed directly through the wall without any absorption of the expansion movement.

See page 2.6.1.4.

A

C

Internal installation,continued


ø out. mm 3/4” 1” 1 1/4” 1 1/2” 2” 3”

20 x

22 x x

25 x x

28 x x

32 x x

40 x

50 x

63 x

75 x

90 x

110 x


PexFlex - compression coupling with male thread - 6100 - 50/11/2”

Internal wall installation (without relief), ø 32 and 40 mm

In connection with PexFlex ≥ ø 32 mm mounting type C cannot be used, as the radius will be too large.

Instead a 90° bend coupling is used. Component Nos. 6100, see page 2.4.0.4. (Naturally, this solution can also be used in cellars).

A


2.6.2.3


Inlet pipe

R = 6 × øD

Component No. 1236.

For casing øD, mm 77 90 110 125

Pipe K, mm 110 125 140 160

End fitting

500

100

2

1

Component No. 5700.

The outmost 100 mm of the end fitting is shrinkable.

1. End fitting 2. Shrink sleeve

PEX pipe ø out. mm


20 77

22 77

25 77

28 77

32 77

40 90

50 110

63 125

75 140

90 160


PexFlex - Inlet pipe - 1236 - 90/125


PexFlex - End fitting - 5700 - 32/77


2.6.3.1

Internal wall installation (partial relief)

Internal wall installation (with relief)

Terminations with FlexPipesAluFlex

In connection with introduction with partial absorption of the expansion movement

- Tilted bore - Embedded inlet pipe

mounting type A is used.

If the AluFlex pipe is installed through the wall after the expansion movement has been absorbed, mounting type A can be used.

Product No. 0005 0000 202 011.

See ”Terminations, general”.

Internal wall installation (with-out relief)

Mounting type A combined with mounting type C is used, when the AluFlex pipe is installed directly through the wall without any absorption of the expansion movement.

min.300 mm

A

C

Straight screw couplings(with relief)

When the lead-in has been relieved, straight couplings can be used to connect to internal installations. 1

2


AluFlex - Screw coupling - 6001 0032 043 000 - 32/1”

Dimension ø out. mm

Product No.

20 6001 0020 043 000 (3/4”)

26 6001 0026 043 000 (3/4”)

32 6001 0032 043 000 (1”)


2.7.1.1

FlexPipesTools for FlexPipes, general

Pulling tool If concrete cast pipes or tilted bore in the base is used, then pulling tool and pulling sleeve are used.

LOGSTOR Service Department can refer to a supplier.

Introduction This section describes the tools which can be used generally for:- PexFlex- AluFlex

Transport and uncoiling

To transport or uncoil FlexPipes it is possible to hire or buy special FlexPipe trailers from various suppliers.

Especially for major dimensions of AluFlex and major numbers of house entries, the FlexPipe wagon with motorized straightener and remote control are recommended.

Please contact our Service Department.


2.7.2.1

FlexPipesTools for PexFlex

Installation equip-mentJoints

Introduction This section describes the tools which are used especially in connection with Pexflex pipes.

12

3

4

6 7

8

5

When installing compression couplings for PexFlex pipes a tool set, containing com-pression tool and accessories for PEX-service pipe dimensions ø 16, 22, 25, 28, 32, 40 and 50 mm, is used. Available in a sturdy carrying case, product No. 0500 0000 002 006.

1. Compression tool2. Exchangeable compression inserts3. Saw4. Plastic pipe cutter for ≤ ø 40 mm5. Plastic pipe cutter for ≤ ø 63 mm6. Stripping knife7. Deburring tool8. Special lubricating grease

For the installation a hydraulic pump must also be used.

Product No. 0520 0000 008 100.

Stripping toolsA B

Stripping tools

TypePEX dimension

ø mmProduct No.

A 20-25 9000 0000 006 001

32-40 9000 0000 006 011

40-50 9000 0000 006 003

B 63 9000 0000 006 004

75 9000 0000 006 005

90 9000 0000 006 006

110 9000 0000 006 007


2.7.3.1

FlexPipesTools for AluFlex

Introduction This section describes the tools which are used in connection with AluFlex pipes.

Hydraulic pump

1

2

Carrying case for hydraulic pump, product No. 0520 0000 008 100.

Contents: 1. Hydraulic pump, complete2. Bottle with reserve oil

Compression tool for service pipe dimensions ø 20-32 mm

Sturdy carrying case for compression tool and accessories for service pipe dimensions ø 20, ø 26 and ø 32 mm.

Available in sturdy carrying case, product No. 0500 0000 002 005.

Contents: 1. Compression tool2. Exchangeable compression inserts3. Hacksaw4. Pipe cutter5. Stripping knife6. Deburring tool, internal7. Deburring tool, external8. Special lubricating agent

12

3

4

6

78

5

Alternative stripping tool

Alu-PEX ø mm

Product No.

16-20 9000 0000 006 020

26-32 9000 0000 006 021


2.7.3.2

FlexPipesTools for AluFlex

Alternatively compression tool for service pipe dim. ø 20 - 32 mm

Complete tool set in carrying case with all necessary tools and accessories for service pipe dimensions ø 20, ø 26 and ø 32 mm. Part no. 18266.

LOGSTOR Service Department sells this tool set or can refer to suppliers of it.

REMS

REMS


2.7.4.1

FlexPipesTools for shrink joints

Burner set for shrinking

Introduction This section describes the tools and accessories to use, when installing shrink joints and other shrink materials: end-caps, shrink sleeves, and shrink wrap for repairs.

Burner set for propane gas with 10 m hose and 50 mm burner head and union for regu-lator: Product No. 9000 0000 001 943.

Burner set for propane gas with 10 m hose and hose union with ½” thread: Product No. 9000 0000 001 944.

Also used to dry joint locations and preheat joints.

Roller Used to compress overlap etc. on shrink joints and shrink sleeves.

Component No. 9000.

Heat protection LOGSTOR Heat Shield is wrapped around the outer casings, when shrinking joints.

Product No. 9050 0150 031 000.

Dimension: L x W = 120 x 15 cm


3.0.0.1

Introduction

FlexPipesHandling & Installation

This section describes the most important requirements to and instructions for handling, adapting and installing the FlexPipe system.

Contents Storage and transport 3.1 Installation, general 3.2 Installing press couplings 3.3 Installing compression couplings 3.4

Installing casing joints: - FXJoint 3.5

- T-joint, straight F 3.6 - SXJoint 3.7 - T-joint, straight 3.8

Insulating joints with foam packs: - Foam packs, general 3.9

- Storage and handling 3.10 - Foam packs for shrink joints 3.11 - Foam pack numbers 3.12


3.1.0.1

Delivery

Storage

Unloading

GeneralStorage and transport

Delivery takes place in accordance with the sales and delivery terms of the supplier, see www.logstor.com/District Heating/Sales & Delivery.

• Stock pipes in such a way that they are not damaged. Stack the pipes on a level surface of stoneless sand with cushions of sand as it appears from the illustration. Stack the FlexPipe coils so the maximum height is 2 m.

• Store pallets with foam liquids indoors at 16-22°.

• Likewise store shrink materials indoors or under cover.

• All casing joints of plastic materials must be stored vertically, resting on one end in order to avoid ovalization.

Do not throw or roll pipes and other components directly on to the ground. They must be lifted into place and NOT dragged - neither on the truck bed nor on the ground.

max

. 2 m

100 mmOnly use lifting straps with a width of min. 100 mm.

When using a truck protect the forks with casing pipe, rubber pads etc.

Handling, FlexPipes


3.2.0.1

Installation methods

FlexPipesInstallation, general

FlexPipes are installed in trenches either horizontally or vertically in accordance with the mini-mum trench dimensions in the illustration below.

This sectional view of the trench shows the minimum dimensions for:- The sand layer

The pipes must be surrounded by min. 50 mm sand or other stonefree backfill mate-rial.

- The distance between outer casing pipes, 50 mm

- The cover H1 = In areas with heavy traffic min. 400

mm from the top of the pipe to the bottom of the asphalt or concrete layer

H2 = In areas with no or only light traffic min. 300 mm ! = Warning tape or netThe cross section of the trench must allow sufficient space for proper installation of pipes and casing joints and compacting of backfilling. Note! The minimum cover also applies to branching, if any, from the illustrated cross section.

Trench installa-tion

50 mm

50 mm

50 mm

50 mm

50 mm

50 mm

50 mm

5050

50

D

D

D

D

D

D

H1H2

! !

50 mm

50 mm

50 mm

50 D

D

!

Shortening FlexPipes are delivered in coils.

The required length is cut perpendicularly, using a suitable saw.

The casing of the FlexPipe has a metre indi-cation, facilitating the cutting of exact lengths.

Example of marking: LOGSTOR PEXFLEX :: VARME - HEAT - HEIZUNG :: EN 15632 :: 20x20/77 MM :: MAX 95°C :: 6 BAR :: PELD :: MADE IN DK :: 198 m

LOGSTOR PEXFLEX :: VARME-HEAT-HEIZUNG :: EN 15632 :: 20x20/77 MM :: MAX 95°C :: 6 BAR :: PELD :: MADE IN DK :: 198 m

LOGSTOR PEXFLEX :: VARME-HEAT-HEIZUNG :: EN 15632 :: 20x20/77 MM :: MAX 95°C :: 6 BAR :: PELD :: MADE IN DK :: 199 m

0198

0199


3.2.0.2


In case of major tasks and very large dimen-sions it is advantageous to use a waggon with motorized straightener (not obligatory).

The LOGSTOR Service Department can refer to relevant suppliers of the FlexPipe-waggon.

NOTE! 1. At temperatures below +5°C the outer

casing must be preheated to lukewarm, immediately before it is inserted in the straightener head (soft gas flame during the entire straightening process).

2. It is recommended to store the coil in a heated room at least 24 hours before use - this does not however exclude item 1, if the coil becomes cold again.

Auxiliary tools

Straightening

500L

Adapt the FlexPipe end, so that min. 500 mm of it is straight and plane-parallel with the welded branch pipe piece or the adjoin-ing pipe end.

This adaptation is important and necessary to ensure that subsequent installation of the casing joint can be carried out according to instructions.

Please keep the bounce effect of the free pipe ends in mind when cutting.

Unwinding Do not cut all fixation strings at the same time.

Place the coil at the start of the trench. Cut the first string. Unwind the pipe till the next string and then cut that etc.

123


Bending Winter measures

Unrolling and straightening do not normally require preheating, only common caution.

Preheating is however recommended, if the material (FlexPipe) has a temperature below 5°C, see page 3.2.0.2 “Auxiliary tools”.

Ordinarily bending of the outer casing at temperatures below 5°C, requires preheat-ing of the section which is influenced by the bending to lukewarm, The preheating rule also applies to tilted bores in the base or inlet pipes.

Bend the pipe slowly and smoothly, not jerkily.

Avoid to bend the utmost 25-30 cm of the pipe because of the bounce effect.

3.2.0.3


Bending radius

R min.

The minimum radius of the curve is deter-mined by the dimension (see table below).

Do not bend the pipes over a sharp edge.

Outer casing Bending radius ø out. mm R min. m

77 0.6 90 0.8 110 1.1 125 1.2 140 1.4 160 1.6 180 1.8

The rigidity of PexFlex pipes depends on the temperature of the pipe. On installation it may be necessary to ensure the pipe position e.g. by partial backfilling.

Prior to bending/installation in the pipe trench it is advantageous to preheat the casing pipe in order to reduce the stresses.


Preskoblinger, PexFlex(tra) and SaniFlextra

1 3

46 75

2

12

The service pipe of PexFlex(tra) and SaniFlextra are joined by means of press cou-plings, ensuring a permanent tightness of all joints made at all temperature viariations.

1. Coupling nipple2. Compression ring

Note! For PexFlex(tra) and SaniFlextra compres-sion couplings can be used as an alternative. For AluFlex(tra) press couplings, type MP, are used.

LOGSTOR recommends press couplings for Flex(tra) systems in the ground.

Press couplings are installed by means of compressing tools, which typically are activated mechanically or electrohydraulically.

Prior to installation of the coupling nipple the service pipe must be expanded by means of an expander pliers.

Typical tools for compression of press cou-plings, type JT are:

1. Compression tool, incl. inserts*2. Expander pliers, incl. expanders*3. Saw4. Plastic pipe cutter for ≤ ø 32 mm

Product No. 9000 0000 005 002 Plastic pipe cutter for ≤ ø 63 mm Product No. 9000 0000 005 003

5. Pipe cutter > ø 63 mm6. Stripping tool

See p. 2.7.2.1 for product Nos.7. Deburring tool

Product No. 9050 0000 043 001

* Not supplied by LOGSTOR

Tools

3.3.1.1

FlexPipesInstalling press couplings, type JT


Foam removal

L 30

L + 30

Remove L + 30 mm of the insulation from the FlexPipe end, using the stripping tool.

The 30 mm is a general addition, ensuring that the service pipe end can be shortened in a clean and perpendicular cut to the L length.

The L length appears from below table.

After shortening check that the pipe end is not damaged.

L

Deburr the inside and outside of the perpendi cularly cut service pipe end, using the deburring tool.

Remove foam remnants on the service pipe with emery cloth, grain size 150.

If closed shrink joints/collars are used, install them on the pipe end.

L-measurementsCoupling types

Service pipe, ø mm

Lmm

Straight and reducing* 16-110 140

90° 16-110 140

With transition to thread and weld end 16-110 200

T-coupling:

Main pipe 16-110 140

Branch 16-110 200

* In case of more than 1 dimensional offset on the service ppe, two successive casing joints (FXJoint) must be installed. This is not necessary, when using SXJoint.

3.3.1.2


Preparing pipe ends


Expanding the pipe end

Push the compression ring on to one of the pipe ends.

Place the compression ring minimum 2 x compression ring length from the pipe end.

Expand the pipe ends with the expander pli-ers as described in the user instructions of the tool supplier.

Note! The pipe end is typically expanded twice in a row, rotating the expander pliers 30°.

Immediately after using the expander pliers the coupling nipple is inserted as far as pos-sible into the pipe.

Check that all the ribs of the coupling nip-ple as a minimum are covered by the pipe. If this is not the case, repeat the expansion process.

Before compressing the coupling check again that none of the ribs of the coupling nipple pipe end are visible.

3.3.1.3



Compressing the coupling

Activate the compressing tool, until the com-pression ring is flush with the nipple flange.

Avoid excessive compression.

Make sure the compression is even around the flanges of the coupling (perpendicular to the pipe).

Check Ensure that the compression ring on the finished joint is flush with the nipple flange and that the joint is evenly compressed all around.

(A minimal gap may occur).

Note! A press coupling cannot be disassem-bled after installation is complete.

The other pipe end is prepared and compressed according to the same guidelines and method.

Compressing the 2nd pipe end

On transition from steel to PexFlex(tra) the coupling must first be installed on the steel part.

The compression part of the coupling is then installted after the instructions in the precedings.

Weld coupling and transition to thread

Preparing com-pression tool

Place the compression tool so the jaws presses against the nipple flange and the compression ring as described in the user instructions from the tool supplier.

Check that the tool is correctly placed, before compressing.

3.3.1.4



3.3.2.1

FlexPipesInstalling press couplings, type MP

Press couplingsPexFlex(tra) og AluFlex(tra) 12 3

4 5

The service pipe of PexFlex(tra) and AluFlex(tra) are joined by means of press cou-plings, ensuring a permanent tightness of all joints made at all temperature variations.

1. Coupling nipple2. Compression ring3. Squeezing ring

AluFlex(tra) only:4. O-ring5. Insulating ring

PexFlex(tra):

Service pipe dimensions ø 16, ø 20, ø 22, ø 25, ø 28, ø 32, ø 40, ø 50 and 63 mm.

1. Compression tool2. Exchangeable compression inserts3. Hydraulic pump4. Saw5. Plastic pipe cutter for ≤ ø 32 mm

Product No. 9000 0000 005 002Plastic pipe cutter ≤ ø 63 mmProduct No. 9000 0000 005 003

6. Pipe cutter for > ø 63 mm7. Stripping tool

See p. 2.7.2.1 for product Nos8. Deburring tool

Product No. 9050 0000 043 001

Note!For the domestic water system SaniFlextra press couplings, type JT, are used or alternatively, 10 bar compression couplings.

LOGSTOR recommends the use of press couplings in buried Flex(tra) systems.

For PexFlex(tra) service pipe dimensions ø 75, ø 90 and ø 110 mm a special tool set with a compression tool which is universal for all three dimensions is available.

Contact LOGSTOR Service department for further information.

1 2

4

576

8

3

Press couplings are installed with compression tools which are typically hydraulically activated. All tools can be rented from LOGSTOR Service department.

Typical tools for press couplings, type MP, are:

Tools


3.3.2.2


Tools continued

AluFlex(tra):

Service pipe dimensions ø 16, ø 20, ø 26, and ø 32 mm.

1. Compression tool2. Exchangeable compression inserts3. Hydraulic pump4. Hacksaw5. Stripping tool

See p. 2.7.2.1 for product Nos.6. Deburring tool, internal

Product No. 9050 0000 043 0017. Deburring tool, external

4 5 6

7

1 2

3


3.3.2.3

Foam removal


L 30

a b

Remove L + 30 mm of the insulation from the FlexPipe end.

The 30 mm is a general addition, ensuring that the service pipe end can be shortened in a clean and perpendicular cut to the L length.

The L length appears from below table.

Cut the pipe perpendicularly, using:a. PexFlex(tra) plastic cutterb. AluFlex(tra) hacksaw

After shortening check that the pipe end is not damaged.

Place shrink joint and collar on one of the pipe ends.

L

Deburr the inside and outside of the perpendi cularly cut service pipe end, using the deburring tool.

Remove foam remnants on the service pipe with emery cloth, grain size 150.

If closed shrink joints/collars are used, place them on the pipe end.

L-measurements Service pipe, ø mm

Lmm

16-40 90

50 105

63-110 125

L + 30

Preparing pipe ends


3.3.2.4


Preparing first pipe end

Preparing second pipe end

1

2

1

2

Push the compression ring and the squeez-ing ring on to one of the pipe ends.

Push the compression ring and the squeez-ing ring on to the other pipe end.

Thrust the nipple into the pipe, until the pipe end is flush with the nipple flange. Use a rubber hammer, if necessary.

AluFlex(tra) only: Make sure that the insulating ring (1) and the O-ring (2) are placed correctly.

Push the other pipe end on to the coupling nipple, so it is flush with the nipple flange.

AluFlex only: Make sure that the insulating ring (1) and the O-ring (2) are placed correctly.


3.3.2.5


Preparing com-pression tool

Connecting hydraulic pump

General: Follow the instructions in the tool box.

Fit compression inserts, corresponding to the service pipe dimension, on to the compres-sion tool.

General: Follow the instructions in the tool box.

Connect the hydraulic pump to the compres-sion tool.

Place the pipe joint in the compression tool. Prior to compression make sure that the joint is placed correctly.


Compressing coupling

Activate the compression tool, until the com-pression ring is flush with the nipple flange.

Avoid excessive compression.

Compress the other end of the coupling by following the same directions and method.

3.3.2.6


Check Ensure that both compression rings on the finished joint are compressed, so they are flush with the nipple flanges.

(A minimal gap may occur).


Compression couplings ø 16-32 mm PexFlex(tra) and SaniFlextra

75 mm

1 2 3 4

The service pipes of PexFlex(tra) and SaniFlextra can be joined by means of com-pression coup lings, cf. local regulations.

1. Clutch casing2. Supporting bush3. Squeeze ring4. Union nut

Please note! LOGSTOR recommends press coupling for systems in the ground.

Remove 75 mm insulation from the FlexPipe end with a stripping tool.

3.4.1.1

FlexPipesInstalling compression couplings ø 16-32 mm

Preparing pipe ends

45 mm

Cut the PEX pipe at right angles, using a pair of PEX scissors or a pipe cutter.

Free end: 45 mm.

Remove any external burrs and foam rem-nants.

If closed shrink joints/collars are used, install them on the pipe end.

Disassemble the coupling:

Place the union nut and the squeeze ring on the pipe.

Push the supporting bush into the pipe to full stop. Use a rubber hammer, if necessary.

The pipe end must be in the dish-shaped part.

Installing coupling


Installing coupling, continued

Push the supporting bush into the body of the coupling - to the bottom.

Tighten the union nut hard. The body must not turn.

By correct installation of the union nut the squeeze ring must be visible between the union nut and the PEX pipe.

Use a ring spanner or an adjustable spanner, NOT a PIPE WRENCH.

If the union nut can be tightened to its bot-tom, the coupling must be dismantled.

Then shorten the PEX pipe at least 100 mm and install a new coupling.

3.4.1.2



Compressioncouplings ø 40-110 mm PexFlex(tra) and SaniFlextra

110 mm

1 2 34

The service pipes of PexFlex(tra) and SaniFlextra can be joined by means of com-pression coup lings, cf. local regulations.

1. Clutch casing2. Supporting bush3. Clamp4. Allen screw

Please note! LOGSTOR recommends press couplings for systems in the ground.

Remove 110 mm insulation from the FlexPipe end with a stripping tool.

3.4.2.1


Preparing pipe ends

80 mm

Cut the PEX pipe at right angles, using a pair of PEX scissors or a pipe cutter.

Free end: 80 mm.

Remove any external burrs and foam rem-nants.

If closed shrink joint/collars are used, place them onto the pipe end.

Disassemble the coupling:

Push the supporting bush into the pipe, using a drift and a hammer

The PEX end must reach the lock ring of the union nut.

Installing coupling


Installing coupling, continued

Install the two clamps so the union nut flange fits the track in the clamps.

Tighten the two clamps with the screws.

Allen wrench, width = 6 for dimension 40 mm and width = 10 for dimensions 50 and 63 mm.

Tighten the screws so that there is no gap between the two clamps.

Check that the union nut can be turned.

3.4.2.2


Install the union nut to the body.

Use a ring spanner or an adjustable spanner, NOT a PIPE WRENCH.


3.5.0.1

FlexPipesInstalling FXJoints

Application FXJoints are used to join FlexPipes with outer casing dimensions ø 77-200 mm.

1. Insulation shells with flexible core for couplings

2. Shrink sleeve with integrated mastic3. Cleaning tissue

1

2

3

1. Coupling Cut off the insulation with a suitable strip-ping tool. L depends on the type of coupling: - press couplings, see page 3.3.0.3

- compression couplings, see pages 3.4.0.1 and 3.4.0.3

Install the coupling as shown in the relevant instructions.

2. Place the shrink sleeve with packing on one of the pipes, before the service pipes are joined by means of a press or compres-sion coupling.

The total free pipe length must not exceed 300 mm regardless of the couplings length.

440 mm

L

Removing insula-tion from pipe ends

Tools Use the following tools when installing FXJoints:

Type: Application:

1. Saw Adjusting insulation shells 2. Alcohol, min. 94% Cleaning the surface 3. Emery cloth, Surface activation grain size 804. Gas burner, Surface activation,

ø 50 mm Shrinking sleeve5. Heat shield Heat protecing the

outer casing

2 31

4 5

Preinstalling casing joint


3.5.0.2


Cleaning

4. Shorten the insulation shells to size, so that they fit tightly between the casing pipes.

As for couplings, it is normally not neces-sary to cut away insulation foam to make room for the coupling, when insulation shells with flexible core are used.

5. Fit the insulation shells tightly between the casing pipes, using adhesive tape if neces-sary. All surfaces must be CLEAN and DRY at least 150 mm from both casing ends.

Reduction: See at the end of this instruc-tion.

3. All surfaces in the mounting area must be CLEAN and DRY. Clean the outer casing at least 150 mm from both casing ends with alcohol.

Adjusting insulation shells

6. Activate the casing pipe with emery cloth grain size 80 at least 150 mm from both casing ends.

150

Activation


8. Remove the packing from the shrink sleeve. Check that the sleeve is CLEAN and DRY inside and out and that the internal mastic has not been damaged. Centre the shrink sleeve over the joint.

3.5.0.3


Installing shrink sleeve

7. Activate the casing pipes with a soft gas flame at least 150 mm from both casing ends, until the surface has a matt, silky look. Surface temperature: Approx. 65°C.

Activation,continued

9. First, shrink from the middle towards one end, then from the middle towards the other end. Hold the burner head at an angle of ap-prox. 30° against the sleeve to avoid unin-tended heating of the casings. NB! Avoid heating directly on the casing.

Shrinkage

If necessary, use a LOGSTOR heat shield as illustrated.

10. The joint is complete.


3.5.0.4

FlexPipesInstalling FXJoints, reduction

Reduction

12. 2-3 offsets. Use 2 different insulation shells, which fit the pipe ends in question. Bevel the inside of the smaller insulation shell, so that it is placed planely against the reduction and the service pipe. Bevel the outside of the larger insulation shell to obtain a plane shape of the insula-tion, see figure. Fasten the insulation shells with canvas tape.

11. 1 offset. Use an insulation shell, which fits the larg-est pipe end. Bevel the insulation shell so that the insu-lation obtains a plane shape, see figure.

max. 300 mm

max. 300 mm

When applied as a reduction, the sleeve may shrink up to 2 dimensions more than the minimum diameter listed. (Example: FX dimension 125-200 mm is able to shrink to dimension 90 mm).

Max. covering length is 300 mm.

D1 77 90 110 125 140

D2 90 110 125 140 160

Joint 77-125 77-125 125-200 125-200 125-200

D1 77 90 110

D2 110 125-140 140-160

Joint 77-125 125-200 125-200


Application

3.6.0.1

FlexPipesT-joint straight F

Straight T-joints are used to branch with FlexPipes from outer casing dimensions ø 77-180 mm, using couplings.

Max. branch dimension: ø 160 mm.

1. Closure patch2. Shrink wrap3. Insulation shells with marking for branch4. T-shoe5. Insulation shells6. Collar7. Cleaning tissue

12

3

4

56

7

1. Cut off the insulation with suitable stripping tool. L depends on the type of coupling: - press couplings, see page 3.3.0.3

- compression couplings, see pages 3.4.0.1 and 3.4.0.3

2. Place the collar, wrap and T-shoe on the branch pipe. Install the coupling according to the rele-vant instructions. The total free pipe length must not exceed 300 mm regardless of couplings.


Use the following tools to install T-joint straight F:Type Application1. Saw Adjusting insulation

shells2. Alcohol, min. 94% Cleaning the surface3. Emery cloth, Surface activation grain size 804. Gas burner, Surface activation

ø 50 mm Shrinking T-shoe, clo - sure patch, wrap and collar

5. Roller Securing mastic in overlap

4 5

1 2 3Tools

Preinstalling joint parts

L

300 mm


3.6.0.2


5. Fit the insulation shells tightly between the casing pipes, using adhesive tape if required. All surfaces must be CLEAN and DRY.

6. Heat the T-shoe to 50-60°C. Pull the T-shoe over the main pipe and fasten it with tape.

Cleaning

4. Shorten the insulation shells to make them fit tightly between the casing pipes. It can be necessary to remove insulation foam around the coupling. Use the marking for the position of the branch, when removing insulation for the branch pipe.

3. Clean all surfaces in the mounting area. Clean min. 200 mm of the 3 outer casing ends with alcohol.

Adjusting insula-tion shells

Preinstalling T-shoe


3.6.0.3


10. Centre the closure patch on the wrap joint with the hotmelt facing down. The side with the hotmelt has visible rein-forcement. Heat the closure patch until the structure of reinforcement becomes visible on the topside. Press down the closure patch.

Activation

8. Activate the casing pipes with a soft gas flame at least 150 mm from the casing ends, until the surface has a matt, silky look. Surface temperature: Approx. 65°C.

7. Activate the outer casings with emery cloth, grain size 80, at least 150 mm from the casing ends.

9. Remove the paper, while pulling the wrap into position. Turn the wrap so that the text goes around the pipe and closes at the top.

150 mm

Installing shrink wrap


3.6.0.4


Installing shrink wrap,continued

13. Shrink the outermost 200 mm on the branch of the T-shoe. Activate the casing 150 mm onto the branch. Surface temperature: Approx. 65°C.

11. Shrink the wrap from the centre towards both ends ensuring that the mastic becomes visible at both ends and the full shrinking effect has been utilised.

NB! Avoid heating directly on the cas-ing.

12. Roll along the overlapping edge, ensuring that any tunnel at the edge is sealed with mastic.

14. Remove the packing and paper from the collar. Check that the paper has been removed. Shrink while centering the collar on the end of the T-shoe.

NB! Avoid heating directly on the cas-ing.


Shrinking and activating branch

Shrinking collar

200

150


Tools

3.7.0.1

Installing straight jointsSXJoints

Application

12

SXJoints are used for joints on FlexPipes with outer casing dimensions ø 90-200 mm.

They are primarily used in connection with flexible TwinPipes.

1. Shrink sleeve with plugs and patches 2. Collars (to be ordered separately)

Preinstallation of casing joint

440 mm

1. Place the shrink sleeve with packing on one of the pipes before the service pipes are joined by means of a press or compres-sion coupling.

The total free pipe length must not exceed 440 mm regardless of the coupling length.

Use the following tools when installing SXJoints:

Type: Application:

1. Emery cloth, Surface activation grain size 80 2. Alcohol, min. 94% Cleaning the surface3. Gas burner, Surface activation

ø 50 mm Shrinking joint Heating patch

4. Leakage test Leakage test equipment prior to foaming

5. Hammer Installing wedge plugs6. Foam pads Insulating joint7. Screw driver Dismounting venting plugs8. Patch-spoon Heating and placing

patch9. Patch-press Securing patch 10. Heat shield Heat protecting the

outer casing

1 3 4 5

6 79

8

2

10


3.7.0.2


5. Remove the packing from the shrink sle-eve, but leave the packing on the pipe as it may be useful later.

6. Do not use cutting tools with sharp edges. Make sure that the sleeve is CLEAN and DRY inside and out.

7 Centre the sleeve on the joint. Remove the mastic covering. Make sure that all the foil has been removed.

4. Activate the casing pipes with a soft gas flame at least 150 mm from both casing ends, until the surface has a matt, silky look. Surface temperature: Approx. 65°C.

2. Clean all surfaces in the mounting area.

Use alcohol on at least 150 mm of the two casing ends.

3. Activate the casing pipes with emery cloth, grain size 80, at least 150 mm from both casing ends.

Cleaning

Activation

Positioning shrink sleeve

150

150


3.7.0.3


Shrinkage

12. Install a venting plug in one of the holes and foam the sleeve through the other hole. Install the other venting plug.

13. Wait min. 30 min. for degassing to com-plete. Remove the venting plugs by turning and lifting them. Remove excess foam or spillage, if any.

14. Activate the whole surface of the reces-sed area around the holes with emery cloth, grain size 80, and clean the area with alcohol.

9. Shrink until all expansion marks have va-nished and the end of the sleeve forms an almost straight encircling edge.

8. Shrink the ends of the sleeve.

NB! Avoid heating directly on the casing.

Use a heat shield for heat protection of the casing.

Shrink the sleeve starting at the top to en-sure centering.

Hold the flame perpendicular to the joint.

11. Wait until the sleeve has cooled off. Lea-kage test at 0.2 bar.

Test the ends with a soap solution.

Leakage test

Venting and foaming

0,2 bar

1

2

30 min.

10. Shrink the collars over the casing joint end and the outer casing. Follow previous instructions.


3.7.0.4


Expansion plugs 15. Remove the protective foil from the ex-pansion plugs and check the mastic.

16. Activate briefly the recessed area with a hard flame.

1

1-2 sec.

2

17. Mount the expansion plugs in the ho-les and press until the mastic is spread smoothly under the collar of the plug.

Wedge plugs 18. Centre the wedge plugs in the leading edge of the expansion plugs and drive them completely into the plugs with a hammer.

Patch installation 19. Activate the area where the patch must be placed by grinding it with emery cloth, grain size 80, and remove grind dust, if any and clean with alcohol.

20. Place the patch on a patch-spoon, the hotmelt side facing up. Heat the hotmelt side, until the mastic begins to bubble.


3.7.0.5


21. Activate briefly, 1-2 sec., the recessed area with a hard flame. Place the patch over the plug in the recessed area, the hotmelt side facing down.

22. Press it at once hard with the patch-press for approx. 20 sec. The patch must fit tightly to the joint in the recessed area.If the patch does not fit tightly or the co-lored spots, if any, of the patch do not turn black, it must be heated again for a short while with a hard flame and pressed with the patch-press for approx. 10 sec. Repeat the process at the other patch.

The joint is complete.

NOTE! Do not touch the patch, before it has cooled.

Patch installation, continued

20 sec.


3.8.0.1

TwinPipesT-joint straight

Application T-joints straight are used to branch from TwinPipes to TwinPipes, primarily FlexPipes.

TwinPipe outer casing: ø 90-200 mm.

1. Closure patch2. Shrink wrap3. T-shoe4. Collar5. Venting, expansion and wedge plugs

Use extra closure patches, filament tape or straps for the T-shoe.

4

5

3

12

Tools Use the following tools when installing T-joint straight:Type: Application:1. Emery cloth, Surface activation grain size 80 2. Alcohol, min. 94% Cleaning the surface3. Gas burner, Surface activation

ø 50 mm Shrinking T-shoe, shrink wrap, closure patch and collars

4. Drill Venting and filling holes5. Hammer Installing wedge plugs6. Roller Securing mastic overlap

1 3

54

6

2

Preinstalling shrink wrap and T-shoe

2. Cut the T-shoe open in the middle of the bevelled area.

1. Cut off the insulation with a suitable strip-ping tool. L depends on the type of coupling, press or compression coupling L



3.8.0.2


7. Clean all surfaces in the mounting area. Use alcohol to clean at least 150 mm of the casing pipe ends.

8. Pull the T-shoe over the main pipes. Fasten the T- shoe tightly around the pipe with tape, max 60 mm from the edge.

Max. 60 mm

440 mm

250 mm

4. Join the main pipes with the couplings ac-cording to the relevant instructions.

5. Mount the branch pipes in the couplings on the main pipes.

6. The total free pipe length must not exceed 440 and 250 mm, respectively, regardless of coupling lengths.

Connecting ser-vice pipes

Cleaning

Installing T-shoe

3. Place the collar, wrap and T-shoe on the branch pipe.

440 mm

Preinstalling shrink wrap and T-shoe, continued


3.8.0.3


9. Shrink the outer 200 mm of the branch pipe.

10. Drill a hole ø25 mm in the branch pipe.

11. Foam the T-shoe and install a venting plug in the hole. Wait min. 30 min. for degassing. Remove the venting plug by turning and lifting it. Remove excess foam, if any. Activate the area around the hole with emery cloth, grain size 80.

Shrinking branch Drilling holes

Venting and foaming

Expansion plug 12. Remove the protective foil from the ex-pansion plug and check the mastic.

13. Activate briefly the area around the hole with a hard flame.

2

200

1

1-2 sec.

14. Mount the expansion plug in the hole and press until the mastic is spread smoothly under the collar of the plug.


3.8.0.4


15. Centre the wedge plug in the expansion plug and drive it completely into the plug with a hammer.

150 mm

16. Activate the casing on the main pipe with emery cloth grain size 80 at least 150 mm from both pipe ends.

150 mm

17. Activate the casing on the main pipe with gas burner at least 150 mm from both pipe ends, until the surface has a matt, silky look. Surface temperature: Approx. 65°C.

Wedge plug

Activation, main pipe

Installing shrink wrap

18. Place the shrink wrap around the main pipe. Remove the protective paper as the wrap is pulled into place. Make sure that the text on the wrap goes around the pipe and that the wrap is joined on the upper side.


3.8.0.5


Installing shrink wrap, continued

19. Centre the closure patch over the ends of the shrink wrap with the glue side facing down. The glue side has a visible net. Heat closure patch with a strong flame, until the net structure is faintly visible on the upper side. Press the closure patch in place.

20. Shrink the wrap from the centre towards both ends ensuring that the mastic becomes visible at both ends and the full shrinking effect has been utilised.

21. Roll along the overlapping edge, ensuring that any tunnel at the edge is sealed with mastic.

Activation, branch

22. Activate the branch pipe and casing with emery cloth grain 80 starting at least 150 mm from both pipe ends.

150 mm


3.8.0.6


Activation, branch, continued


150 mm

23. Activate the shoe and the casing with the gas burner starting at least 150 mm from the end of the branch pipe. Surface temperature: Approx. 65°C.

24. Remove wrapping and paper from the collar. Check that all paper is removed. Shrink the collar so that it is centred over the end of the shoe.

Shrinking the collar


3.9.0.1

Application

Foam packs

Insulating jointsGeneral and foam packs

There are two ways of insulating joints on FlexPipes:

- FXJoints and T-joints straight F for single pipes are insulated with insulation shells, see the relevant installation instructions.

- SXJoints and T-joints straight for TwinPipes are insulated with foam packs as described in this section.

Foam packs are supplied in insulation boxes with information about contents and storage.

81132x1323.96

5

0700000000815 4809

5

5

5102 SX

ø 160 mm

SX

It is an easy-to-apply method according to which a two-component foam liquid, after mixing and filling, forms an effective insulation with the same properties as in the rest of the pipe sys-tem.

Foam packs which are stored in accordance with stated rules have a time limit for use of 12 months counting from the stated production week.

Foam packs comply with the requirements to materials in EN 253.

The cartons in the insulation box contain pre-dosed packings with a number correspond-ing to the table in this section and the foam pack folder in the box.

The key is the information on the label on the casing joint.

Each carton is marked with installation instructions, information about contents and storage as well as safety data.

Cartons


3.9.0.2

Insulating jointsGeneral and foam packs

The carton contains a multi-ply plastic bag, divided into two sections which are sepa-rated by a clip bairrier.The brown liquid (A) (isocyanate) is in a completely diffusion-tight section, in which aluminium foil forms part of the construction of the bag.

The clear liquid (B) (polyole) is in a trans-parent section which makes it possible visually to control that the mixing of the liquids has been carried out correctly.

Also see the safety instructions on the carton.

BA

The multi-ply plastic bag

Material safety data sheet

Note! Each country poses its specific requirements to education/training and use of personal protective equipment for working with polyurethane foam. The customer or his representative is responsible for the compliance with these requirements.

It is a requirement in all EU countries that material safety data sheets are issued when using hazard classified products.

Consequently, a material safety data sheet is an integrated part of the product “foam pack”.

It must always be at the user's disposal and may follow material deliveries or be forwarded separately by mail, fax and via data network.

The material safety data sheet contains 16 items of information SAFETY DATA SHEET

Product name FOAM PACK Version no.: 1 Page 5/5Created: 10-01-2008 Date of revision: 10-01-2008 Date of printing: 10-01-2008

Uses and Restrictions:Individuals wit more susceptibility to dermatitis should not be selected to work isocyanates.Not to be handled by persons under the age of 18 years.

Special Education:The user of the product must be thoroughly instructed in working with the product, the dangerous properties of the product and the necessary safety measurements.

OTHER INFORMATION:

R phrases:R11 Highly flammable.R20 Harmful by inhalation.R52 Harmful to aquatic organisms.R53 May cause long-term adverse effects in the aquatic environment.R36/37/38 Irritating to eyes, respiratory system and skin.R42/43 May cause sensitisation by inhalation and skin contact.

Final remarks:This safety data sheet is compiled on the basis of information from the supplier and in accordance with EU legislation. The users working conditions is outside our knowledge and control, we draw to your attention that it's always the users responsibility to take the necessary precautions and follow the given legislation.

References:CHIP3: Chemicals (Hazard Information and Packaging for Supply), Regulations 2002 (SI 2002/1689) and accompanying documentation. EH40/2005 Occupational Exposure Limits. COSHH : The Control of Substances Hazardous to Health Regulations 2992 and subsequent amendments. EC Regulation no. 1907/2006. REACH.HSE INDG388 10/03 C650 (Working with 2-pack isocyanate paints).

Drawn up by: pbb trotters apsQA ah 01-2008Updated by: pbb

16.

SAFETY DATA SHEETProduct name FOAM PACK Version no.: 1 Page 4/5Created: 10-01-2008 Date of revision: 10-01-2008 Date of printing: 10-01-2008

Accumulation:Not Known.

General information:Prevent material from entering drains, streams, lakes etc.

DISPOSAL CONSIDERATIONS:

Disposal considerations:Delivered to disposable centre according to the local regulations.

Waste code: 07 02 13 waste plastic08 05 01 waste isocyanates

General information:EAK 07 02 13 should be use when it is in a mixture or the waste from tiding up in section 6.

TRANSPORT INFORMATION:

ADR/RID UN no. 1866Class: 3Packaging group: IIHazard Identification: 33Proper Shipping Name: RESIN SOLUTION

IMDG-CODE UN no. 1866Class: 3Packaging group: IIEmS: F-E, S-EProper Shipping Name: RESIN SOLUTION

IATA UN no. 1866Class: 3Packaging group: IIProper Shipping Name: RESIN SOLUTION

General information:This Transport information is only relevant for Polyol (component B). Isocyanate (component A) is not comprised by transport regulations of dangerous goods.

REGULATORY INFORMATION:

Special labelling:Contains isocyanates.

Contains: Isocyanate (component A): Diphenylmethane-4,4´-diisocyanate, isomers and homologuePolyol (component B): Polyol with contains of cyclopentane

Labelling: Isocyanat (component A): Diphenylmethane-4,4´-diisocyanate, isomers and homologue

R20 Harmful by inhalation.R36/37/38 Irritating to eyes, respiratory system and skin.R42/43 May cause sensitisation by inhalation and skin contact.S23 Do not breathe vapour/spray.

S45 In case of accident or if you feel unwell, seek medical advice immediately (show the label where possible).

Xn

HarmfulS36/37 Wear suitable protective clothing and gloves.

Polyol (component B):R11 Highly flammable.

S9 Keep container in a well-ventilated place.S16 Keep away from sources of ignition - No smoking.

F

Highly flammable

S33 Take precautionary measures against static discharges.

14.

13.

15.


PHYSICAL AND CHEMICAL PROPERTIES:Isocyanate (component A) Polyol (component B)

Form: Liquid Liquid

Colour: Brown Clear, yellowing

Odour: Weak Weak

Density: 1,23 g/cm³ 1,04 g/cm³

Explosion limits: - 1,1-8,7 % (Cyclo pentane)

Boiling point: - > 48°C (Cyclo pentane)

Flash point: > 200°C 8°C

Melting point < 0°C <-10° C

Ignition temperature: > 400°C 380° C (Cyclo pentane)

Vapour pressure 1 hPa (20°C) 345 hPa (20°C) (Cyclo pentane)

Viscosity: 200 mPa (20°C) 690 mPa (23°C)

Water solubility: No No

STABILITY AND REACTIVITY:

Stability:Isocyanate (component A): Polymerisation occurs by 200°C. The polymerisation will develop CO2.Polyol (component B): The product is s table if it is handled and stored according to section 7.

Conditions to avoid:Temperature above 40°C.

Substances to avoid:Oxidizing agents and acids. Bases. Alcohols. Amines. Isocyanate (component A): Isocyanates reacts strongly with water under a heating development.

Hazardous Decomposition Products:When heated to high temperatures, or in case of fire, the product can liberate toxic gases/vapours of: Carbon oxides, nitrogen oxides, isocyanate, compound of cyanides.

Hardening time for Isocyanates.5 minutes at 20°C

TOXICOLOGICAL INFORMATION:

Inhalation:Isocyanate (component A): May irritate respiratory tract and may cause coughing, asthmatic breathing and difficulty in breathing. Polyol (component B): Vapours may cause bluntness and dizziness.

Contact with skin:Irritating to skin.

Contact with eyes:Irritating to eyes.

Ingestion:Ingestion may cause nausea and queasy.

Chronic effects:Isocyanate (component A): May cause sensitisation by inhalation and skin contact. Polyol (component B) Inhalation of vapours may cause drowsiness, dizziness and can cause damage to the central nervous system by prolounged exposure.

ECOLOGICAL INFORMATION:

Eco toxicity:None known.

Mobility:Isocyanate (componenet A), Polyol (componenet B) and the mixture are not soluble in water. Therefore there is no mobility in water.

Degradability:Isocyanate (component A): Bio-degradation: Difficult.Polyol (component B): Bio-degradation: Difficult.

9.

10.

11.

12.


Special protective equipment:Wear self-contained breathing apparatus and full protective gear when extinguishing fire.

General information:If it is without risk containers should be removed from the area where there is a risk of f ire.

6. ACCIDENTAL RELEASE MEASURES:Personal precautions:Remove all ignition sources and ensure sufficient ventilation. Avoid inhalation of vapours/aerosols and contact with skin and eyes. Unauthorized persons are forbidden to enter. Regarding personal protection - see section 8.

Prevent material from entering drains, streams, lakes etc.Environmental precautions:

Absorb spill with non flammable, absorbing material, e.g. sand, soil, vermiculit, and place in suitable disposable container (section 13). The container should not be closed caused by the developing of CO2 from the waste. The container should be under observation. Keep it in the open container outside. The total time of reaction: 7-14 days. Dispose according to section 13.

Methods for cleaning up:

7. HANDLING AND STORAGE:

Handling:Avoid inhalation of and contact with product. Eating, drinking, smoking or storage of food, drinks and tobacco must not take place where there is a risk of contamination of the product. Wash hands before any breaks and after working hours. Ensure adequate ventilation. Local mechanical exhaustion could be necessary. Take measures to prevent static electricity. Ensure access in the working area to "rinse the eye" facility. Ensure access to ample water, shower facility and changing-room.Personal protective equipment: Refer to section 8.Storage:Store securely, away from children, away from food, animal foodstuffs, medicaments or the like. Stored in temperatures between 10 and 40°C. Keep the product away from ignition sources, oxidizing agents and strong acidic and basic substances.Follow the HSG51 "The storage of flammable liquids in containers."

8. EXPOSURE CONTROLS/PERSONAL PROTECTION:Engineering Control Measures:All work must be planned with a view to limit the breathing of fumes and the exposure to the skin. Ensure adequate ventilation. There must be access to ample supplies of water and eye wash bottles.Respiratory Protection:In poor ventilated areas use fresh air equipment.

Hand Protection:Use protective gloves of nitril rubber, butyl or any suitable material. Break through time > 480 min. Follow the glove manufacturer's recommendations on use and replacement.Eye protection:Use protective goggles or face shield.

Skin Protection:Use special working clothes.

General information:The employer has a duty to ensure that pregnant women are not exposed to any influences, which may be a risqué to the unborn child.Occupational Exposure Limits:The general exposure limits of all isocyanates are 0,02 mg/m³. EH40/2005 Workplace exposure limits.


enFOAM PACK1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY/UNDERTAKING:

Product Name: FOAM PACK

Emergency telephone number :Dial 999 in case of a emergency, or NHS Direct for advice 0845 4647 (GB). Both services are available 24 hours.

Supplier:LOGSTOR A/S

Danmarksvej 11DK-9670 LoegstoerTelephone no.: 0045 99 66 10 00Responsible for the Safty Data SheetE-mail: [email protected]

Uses:Insulation for district heating joints

2. HAZARDS IDENTIFICATION:

Main Toxicological and Ecological hazards:Isocyanate (component A): Harmful by inhalation. Irritating to eyes, respiratory system and skin. May cause sensitisation by inhalation and skin contact.Polyol (component B): Highly flammable.

3. COMPOSITION/INFORMATION ON INGREDIENTS:

Isocyanate (component A) CAS no: 9016-87-9Polyol (Component B) contains CAS no: 287-92-3

Contains:CAS number: %: Note:Chemical Name: Classification:EC-no.:

diphenylmethane-4,4'-di-isocyanate, isomers and homologue

Xn, Xi R20, R36/37/38, R42/43

9016-87-9 100%

cyclo pentane F R11, R52, R53287-92-3 206-016-6 < 10%

4. FIRST AID MEASURES:General information:In case of doubt or if the symptoms are continuous, seek medical advice.

Inhalation:Move the injured person into fresh air, if symptoms are continuously seek medical aid. If the patient is conscious examine if patient is breathing. If the unconscious person is breathing, lay person in recovery position and keep warm with blankets or the like. If breathing has stopped, apply artificial respiration. Seek medical attention.Contact with eyes:Open your eye wide. Make sure to remove any contact lenses. Immediately flush eyes with water for at least 10 minutes. Seek medical attention.Contact with skin:Remove contaminated clothes immediately, and wash skin thoroughly with soap and water. Always end cleansing with applying moisturising cream to degreased skin. Obtain medical attention if irritation continues.Ingestion:Rinse mouth with water. Drink afterwards plenty of water. Seek medical attention.

Burns:Polyol (component B): Flush with plenty of water until pain ceases. Whilst flushing with water, remove all loose clothing from area of burns. If medical treatment is necessary, continue flushing until medical trained staff takes over treatment.

5. FIRE-FIGHTING MEASURES:Suitable extinguishing media:Fire is extinguished with water fog, foam, powder or carbon dioxide.

Do not use full jet of water. The fire will spread.Extinguishing media that must not be used:

If heated or in case of fire toxic fumes are formed.Special hazards:

Safety regula-tions


3.10.0.1

Insulating jointsStoring and handling foam packs

Overview

Liquid tempera-ture/Storage

Liquid tempera-ture in insulation box

Liquid tempera-ture in carton

Besides the correct dosing of foam liquids which is ensured through the filling in the factory and through the numbering of foam pack sizes on joints and cartons, there are 4 factors which are important for a correct foaming process:· Liquid temperature· Job-site temperature· Dry joints· Mixing

It is very important to keep the temperature of the foam liquids within certain limits to obtain a homogeneous foam quality.

As the reaction time of the foam liquids depends on the storage temperature (1), the mixing (2) and filling times (3) vary.

They appear from the foam pack carton.

It is best to keep foam liquids in storage rooms at a temperature of 16-22°C.

On condition that the cover of the insulation box is always replaced immediately after tak-ing a carton from it, the insulation box can keep the foam liquids hot or cold throughout an ordinary working day, i.e. eight hours.

When the carton is removed from the insula-tion box a correct temperature of application can be kept for approx. two hours.

Symbol key to the shown figures:tree = job-site temperaturehouse = storage temperatureThe shown figures are found on every insula-tion box and carton.

˚C ˚C81132x1323.96

5

°C°C

0700000000815 4809

5

t°C

10 25

30 20

70

20

20

3495

5

1

2

3

15 30

25 15

60 50 45 40

sec.

sec.

°C


3.10.0.2

Insulating jointsStoring and handling foam packs

Job-site tempera-ture

Dry joints Moisture in a joint gives a poor foam quality.Therefore, always see to it that- the joint area is dry, before the joint is installed- avoid foaming during rainy weather. If necessary use a tent.- foam the joint the same day it has been installed.

If the job-site temperature is down to +10° C, then insulation is carried out as described on the carton, the label of the fitting or in this handbook.If the temperature is below +10° C, then the fitting/joint parts - particularly the lower halves - must be preheated with a soft gas flame to 30-40° C.If hot water is circulating in the pipeline, it suffices that the fitting parts have reached a temperature of approx. +20° C.

10°C10°C

Mixingt°C

10 25

30 20

70

20

20

3495

51

2

3

15 30

25 15

60 50 45 40

sec.

sec.

°CCareful mixing ensures a homogeneous foam quality and therefore a correctly filled joint.

Dependent on the liquid temperature (the lower the liquid temperature, the longer the mixing time) the two liquids are carefully shaken and mixed togehter for 15-30 sec-onds until the mixture has a homogeneous light brown colour.

The insulation process is described as a strip on the carton and on the label of the fitting.


3.11.0.1

Insulating jointsUsing foam packs for shrink joints

Application

Tools

In FlexPipe systems foam packs are used to insulate joints on Twin FlexPipes.

The required tools appear from the relevant installation instructions.

Venting holes/plugs

a b

12It is important that the filling holes always face upwards (12 o'clock position).

The foam liquid should always be filled into the lower filling hole of the joint to ensure an optimum venting.

The holes in the venting plug ensure that the air in the joint can escape quickly and easily during the foaming process.

a. SXJoint predrilled hole

b. T-joint straight ø 25 mm holes must be drilled prior to foaming

Correct foam pack number

1. Find the relevant foam pack number in the folder in the insulation box, on the label of the casing joint or page 3.12.0.1 of this handbook. The cartons must be marked with the cor-responding foam pack number.

NB! Please differentiate between series 1 and series 2.

5

LOGSTOR A/S · Tel. +45 99 66 10 00 Product Catalogue · 2009.05

15.2.6.1

Series 1 pipesø 225-800 mmStraight joints

Series 2 pipesø 225-800 mmStraight joints

Foam packFoam pack numbers for band joint, medium

Series 1 pipesø 225-315 mmBand joint branch

The list below details which foam pack numbers to use for the different Series 1 pipes.

The list below details which foam pack numbers to use for the different Series 2 pipes.

Dimension Joint type outer casing, ø mm 225 250 315 400 450 500 520 560 630 780 800

Band joint 7 8 9 11 2x9 12 2x9 12 10+11 12+13 10+13 Band joint, long 8 9 10 12 12 13 10+11 10+11 10+12 2x13 12+13 Band joint, E 9 10 11 10+11 13 10+12 13 10+12 10+13 2x12+13 2x13 Band joint, E long 10 10 2x9 13 10+12

This list details which foam pack numbers to use for the different Series 1 pipes.

Dimension Joint type outer casing, ø mm 225 250 280 355 450 500 520 560 630 710 800

Band joint 8 9 9 11 12 10+11 10+11 10+11 10+12 12+13 12+13 Band joint, long 9 10 10 2x9 13 10+12 10+12 10+12 12+13 2x13 2x12+13 Band joint, E 10 11 11 12 10+13 10+13 10+13 10+13 12+13 2x12+13 2x12+13 Band joint, E long 11 11 2x9 10+11 10+13

590/77 8 9 10 590/90 9 9 10 590/110 9 9 10 590/125 10 10 11 590/140 10 10 11 Repair joint: 720/77 9 10 11 720/90 10 10 11 720/110 10 10 11 720/125 10 11 2x9 720/140 11 11 2x9

Length of Dimension, main pipe main pipe casing outer casing ø mm L mm/ø branch mm 225 250 315

0700000000815 4809 5

5102 SX

ø 160 mm


3.11.0.2


Opening carton The cartons with foam packs must be stored in the insulating box until use. Remember to replace the cover of the box to maintain the correct liquid temperature.

2. Open the carton by pulling the perforated flap in the direction of the arrow.

3. Open up the carton by pulling in the two holes.

Mixing foam liquids

4. Pull at both sides of the bag and remove the clip barrier, so the two liquids mix.

5. Mix the liquids by shaking the bag vigor-ously and stirring the two liquids with the built-in mixing stick at the same time. Mix the foam liquids carefully for the num-ber of seconds, appearing from the table on the carton, until the liquid mixture is homogeneous light brown. Hold the mixing stick, not the nozzle.

Filling in foam liquid 2

1

6. Now place the nozzle in the open filling hole - the lower hole of the joint.

7. Press the mixing stick into the nozzle, which is supported by one hand.

8. Twist the mixing stick back and forth several times, until the plastic membrane breaks. It is important that the penetration is thorough, so that the liquids can run down into the joint.


3.11.0.3


9. Squeeze the foam liquid into the joint and flatten/wring the bag during filling, so that no air pockets appear behind the liquid in the bag.

Filling in foam liquid, continued

Venting and hard-ening

10. Fit the venting plugs into the filling holes after filling is complete. Proceed with the next joint. The foam liquid expands in the joint, forcing air through the venting plug. When the ventilation is complete, a little foam will be forced through the venting holes. The insulation of the joint is complete, when the foam, appearing at the holes is hard.

Removing vent-ing plug

1

2

30 min.11. Wait min. 30 min. for degassing to complete. Remove the venting plugs by turning and lifting them. Remove excess foam or spillage, if any.

Installing expan-sion/wedge plugs and patches

1

1-2 sec.

2

20 sec.

12. Install expansion/wedge plugs and patch as described under the individual joints.

The joint is now complete.


3.12.0.1

Foam packFoam pack numbers

SXJoint

Joint type

Dimension, main pipe, outer casing ø mm

Series 1 Series 2

90 110 125 140 160 110 125 140 160 180

Straight joint 1 3 3 4 5 3 4 5 6 7

Reduction joint*) ← 1 2 3 4 ← 3 4 5 6

*) From stated dimension to the next smaller dimension.

T-joint straight

Branch, ø mm

Dimension, main pipe, outer casing ø mm

Series 1 Series 2

90 110 125 160 110 125 140

90 3 4 5 6

110 5 5 7 5 5 6

125 6 7 6 7

140 6 7

160 8

LOGSTOR A/SDanmarksvej 11 · DK-9670 LøgstørTel. +45 9966 1000 · Fax +45 9966 [email protected] · www.logstor.com

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Documents

Handbook – products, design and installation · PDF fileThis LOGSTOR handbook is primarily directed at the community heating ... (If FlexPipes are to be connected to existing systems