Plumbing & Heating

Technical manual sanitary/heating

The comfort
pipe
Technical Manual Mainpex

Table o
Along the road
to master
at full throttle!
Atze Rohrstolz
Pipologist

2
f Contents
Simple processing for more comfort ......................... 4
Pipe system and drinking water ordinance ................ 6
Quality and safety for professionals .......................... 7
Technology . ......................................................................... 7
Pipe . ..................................................................................... 8
Pipe structure ....................................................................... 9
System advantages ........................................................... 10
Resistance .......................................................................... 10
Processing instructions ............................................ 11
Sliding sleeve...................................................................... 11
Bending............................................................................... 12
Thermal change in length ................................................. 12
Expansion compensation and attachments .................... 13
Contact with other building materials ..............................13
Protection against external corrosion .............................. 14
Connection to water heater
or continuous-flow water heaters...................................... 14
Mixed installation ...............................................................14
Insulation of pipes...............................................................14
Thermal insulation ................................................... 15
Preventive fire protection ........................................ 19
Pipe system and drinking water ordinance .............. 20
Reference values for minimum flow pressures ................ 23
Pipe friction pressure loss with Vs .................................... 24
Project planning and quick calculation
of drinking water systems ................................................. 25
Pressure test according to 1988 part 2 ............................ 26
Pressure test protocol ....................................................... 27
Flush protocol .................................................................... 28
Mainpex heating system installation . ...................... 31
Pipe performance data ..................................................... 32
Connection options . ......................................................... 33
Thermal insulation ............................................................. 33
Heat demand calculation . ................................................ 33
Flushing heating systems . ................................................ 33
Pressure testing heating systems ..................................... 33
Practical aids ...................................................................... 34
Tips and notes ................................................................... 34
DIN standards .......................................................... 35
3
Technical Manual Mainpex

Simple processing
for more comfort
Double profile
With the first double
groove, the support
sleeve is protected
against mechanical
damages.

The multi-layer compound pipe MPX sets the standards

MPX
in the field of processing. It is suited ideally for fast and
safe installation, because it can be bent easily and never-
theless it is inherently stable. – advantages hitherto only
TECHNOLOGY
known from the field of pressed systems.
As one single pipe system is sufficient to implement nu-
merous different applications in the field of HVACR in an
ideal manner, additional tools and fitting systems, as well
as expensive material transportation are not applicable.
Fast, technically perfect, and economic solutions are the
result.

• high processing comfort Fields of application

• easy to be bent
• inherently stable
• no spring-back forces
• less required tools
• for drinking water system installation
according to DIN 1988
• for heating system installation
according to DIN EN 12831
• for panel heating systems according
to DIN EN 1264 and DIN 18560

4
 The pipe with comfort.

Without O ring
nothing will age
Profile Undercut Due to the Attachment of the
The optimized special design of the sleeve
lands of the fittings, any contact The sleeve is
support sleeve between the equipped with an
maintain the aluminum layer and additional groove.
leak-proofness the fitting body is Here, the material
of the joint on a prevented. flows in and prevents
permanent basis - that the sleeve loses
without O rings. its position.

Sleeve can be used

on both sides
The sleeve can be
mounted in any
direction, improper
attachment is impos-
sible.

More flow
By expanding the MPX
pipe, the cross-section
in the joint is substan-
tially larger when com-
pared to traditional
joint systems.

The MPX pipe system is connected by means of slid- • permanently impermeable without
ing sleeves and does not require any O rings for being O rings
impermeable. Thus, no rubber seal can become porous • time-saving routing
and your lines will remain leak-proof on a permanent • sleeve can be used on both sides
basis. • higher flow rates
• special brass, tin-plated,
protects against corrosion

5
Technical Manual Mainpex
Pipe system and
drinking water regulation
As of January 1, 2003, drinking water
lines in buildings have to comply with
even more stringent requirements as be-
fore. Already on November 3, 1998,
the regulations were put into national
legislation with the amendment of the
drinking water directive 98/83/EC. In
doing so, the individual components
and their materials in the drinking water
installation (e.g. pipes, fittings, faucets)
are observed closer. The monitoring
has become significantly more strin-
gent and exceeds the water supplier
and has been extended to cover the
last faucet. Thus, for example the lim-
its for nickel have become stricter from
50 to 20µg/L and for copper from 3 to
2mg/L. Copper lines should only be used
when the pH value is 7.4 or higher, or when
the TOC value (total organic carbon) is
below 1.5mg/L for lower pH values. We
recommend consulting the water supply
company in case this value is not complied
with. Thus, everyone assumes a higher
6
responsibility for the food drinking wa-
ter complying with the requirements.
It includes all home owners, designers,
architects, and installers in the fields of
sanitation, heating, and air conditioning
and controls the responsibilities of the
chemical and microbiological param-
eters so that the same comply with the
regulation.
The use of plastic pipe systems in the field
of HVACR minimizes the risk of high, in-
admissible, metallic values in the drinking
water. Given the possibility of extreme pH
values in the drinking water it is important
to be able to resort to state-of-the-art plas-
tic pipe systems without brass connectors.
The installation system MAINPEX com-
plies with the requirements of the drinking
water regulation to the full extent. By using
tin as fitting coating, the direct contact of
the drinking water with brass or red bronze
is prevented. Many changes in direction
occurring while routing the lines during
the construction phase can be implement-
ed without formed parts with the help of
the multi-layer compound pipe MAINPEX.
The use of fittings is only required in a few
installation situations. Changes in direc-
tion can be implemented manually or with
tools.
MAINPEX compound pipes consist of PE-
RT, a material the installer has been famil-
iar with for decades and suited very well
for drinking water lines. The quality of the
drinking water is in no way impaired by us-
ing MAINPEX pipes. MAINPEX pipe sys-
tems are approved and can be used in the
field of drinking water installation. The re-
quirements of the DIN 1988 are complied
with by the MAINPEX pipe system.
 The pipe with comfort.

MAINPEX - Quality and

safety for professionals
The technology
The MAINPEX sliding sleeve joint is a permanent, O ring-free,
permanently leak-proof, and DVGW-tested joint that does not re-
quire any additional seals or seal materials between pipe and fit-
ting. On the basis of the expansion technology, the pressure loss
and the flow rate in the formed parts are very low. Furthermore,
there is no need for deburring or marking the insertion depth.

The advantages of the MAINPEX pipe system at a glance

• 100% oxygen-proof multi-layer compound pipe

• inherently stable pipe, thus no back-spring effects and nevertheless flexible
• no need for formed parts by simply bending the pipe manually
• linear expansion similar to metal pipe
• shorter installation time due to simple connection technology
• non-pressed joint 100% "leaky" and easily to be recognized, thus, sleeve has no firm seat
• already pressed fittings are re-usable by heating the same and loosening the sleeve
• additional protection against corrosion due to tin-plated fitting surfaces
• prevention of stress corrosion cracking due to additional reannealing of the fittings

General facts on the use

The MAINPEX pipe system is characterized by a high resilience:

• maximum temperature 95 °C
• maximum continuous operating temperature 70 °C at 10 bar

Attention

The MAINPEX pipe system must not be connected directly to

systems with operating temperatures above 95 °C, e.g. solar or
district heating plants. It has to be ensured that the application
parameters of the MAINPEX pipe system cannot be exceeded in
any operating situation.
In case of questions on different fields of application, please con-
sult the department Technology.

7
Technical Manual Mainpex

Pipe
The MAINPEX system pipe is a pressure-
resistant multi-layer compound pipe con-
sisting of PE-RT material. On the basis of
the 100% oxygen proofness, this pipe is
suited ideally for being used in the heat-
ing area.
When using MAINPEX system pipes as
drinking water line, the raw material suited
very well from the point of view of hygien-
ics is significantly superior to other raw
materials.

creep behavior PE-RT vs. PEX

100

PE-RT 110oC

PE-RT 80oC

PE-RT 20oC

10 PEX 110oC

PEX 80oC

PEX 20oC

1
1 10 100 1.000 10.000 100.000 1.000.000
time h
Creep behavior of PE-RT Dowlex pipes in comparison with PE-X pipes
Source: PE-RT 2388 made of Bodycote - measurement report, PEX from DIN 16892

PE-RT layer
Adhesion promoter
Aluminum layer
Adhesive layer
PE-RT layer

The MAINPEX multi-layer compound a low aluminum thickness and a stronger

pipe is the first PE-RT compound pipe
system for sliding sleeves.
Due to the special design of the pipe,
back-spring during bending is impossible.
The force required for bending the pipe
is substantially lower than for pipes with
internal PE layer. The internal PE layer on
MAINPEX is not as thick as for all other
sliding sleeve systems. Bearing frames to
support the pipe are not required.

8
 The pipe with comfort.

Pipe structure
Wall thickness

Pipe dimension
PE-RT

Adhesion promoter

Diffusion barrier
PE-RT

Material properties
• multi-layer compound pipe PE-RT / AL / PE-RT • no spring-back effect
• 5 layer technology • acid-resistant and resistant against chemicals
• pressure-resistant • very good flow resistance

System data overview

Dimension mm 16 x 2.2 20 x 2.8 25 x 3.5 32 x 4.4 40 x 4 50 x 4.5
External diameter
Length ring m 200 100 50 / / /
Length bar m 3.5 3.5 3.5 3.5 5.0 5.0
Water volume (L/m) 0.106 0.163 0.254 0.423 0.803 1.32
Pipe roughness k (mm) 0.0004 0.0004 0.0004 0.0004 0.0004 0.0004
Thermal conductivity
( W/m x K ) 0.4 0.4 0.4 0.4 0.4 0.4
Coefficient of expansion
mm/m x K 0.025 0.025 0.025 0.025 0.025 0.025
Bending radius manual mm 5 x D / 80 5 x D / 100 5 x D / 160 / / /
Bending radius machine mm 4 x D / 64 4 x D / 80 4 x D / 100 4 x D / 128 / /

Attachment intervals m
Wall 1.50 1.70 1.90 2.0 2.2 2.4
Ceiling 1.00 1.10 1.30 1.50 1.70 1.50

Pressure stages 70 °C / 10 bar or 95 °C / 6 bar (permanent operating pressure at T max)

Internal pipe material PE-RT PE-RT PE-RT PE-RT PE-RT PE-RT

Fitting material
Brass CW 617 N (Cu Zn 40 Pb 2)
Finish: tin (Sn)

9
Technical Manual Mainpex
System advantages
The MAINPEX compound pipe system
ensures low flow resistance and pressure
losses due to the fitting. One of the ad-
vantages of MAINPEX can be seen clearly
when routing pipes with many fittings. The
zeta value is substantially lower compared
Coating
Many installers do not want to use brass
anymore. One reason is the introduction of
the new drinking water regulations in Janu-
ary 2003.
The installer is responsible for the compat-
ibility of his pipe system with the drinking
water to be transported.
The coating of our fittings with 99.9 % pure
tin is an additional safety for designing and
executing drinking water lines.
The closed tin layer allows for hardly any
contact with the brass material.
Resistance
MAINPEX is resistant for all drinking waters
and drinking water admixtures according
to DIN 1988. Rain water lines (pH value 6.2-
8.7) may be routed without limitations using
MAINPEX system pipes.
When using heating water additives, please
10
to comparable pipe systems.
All fittings and sliding sleeves of the MAIN-
PEX system can be used for all fields of
application, heating and sanitation instal-
lation, without limitations. Sanitary pipes
Another advantage of the tin layer is the re-
duction of the risk of corrosion.
For pipe systems with multi-layer com-
pound pipes made of brass or red bronze
there is a huge possibility of electrochemi-
cal corrosion. Aluminum and copper are
very far apart in the electrochemical series.
Within the electrochemical series tin is sig-
nificantly closer to aluminum than copper.
Additionally, both materials are part of the
base metals, which is why aluminum cannot
be dissolved in a cathodic manner.
consult the factory. For compressed air sys-
tems installed with MAINPEX system pipes,
the use of oil-containing compressed air
is inadmissible. When transporting other
gases or fluids as those we approved, it is
indispensable that you consult MAINPEX.
from MAINPEX can be used for heating
installations without limitations as well.
Other metals can be combined to become
our fittings without "transition piece".
Compliance with a certain installation ar-
rangement "in flow direction" as known for
copper and tin-plated pipes does not have
to be taken into account with MAINPEX.
In order to reduce the corrosion risk as re-
gards to the sliding sleeves as well, the slid-
ing sleeves have been coated as well.
PE raw material is resistant against numer-
ous substances. Please consult the factory
for precise information and the written ap-
proval.
 The pipe with comfort.

Processing instructions
Sliding sleeve
Step 1 Step 2
Cut pipe at right angle with the MAINPEX Push sliding sleeve over pipe end. Push
pipe cutter the pipe end onto the expansion head as
far as it will go and expand the same. Push
together the expansion pliers up to the
next mechanic stop.
Step 3
Upon expansion, push the expanded pipe
end over the fitting. The pipe has to be
pushed along the complete fitting profile.
Push the sliding sleeve manually up to the
expanded pipe end.

Step 4
Insert the pipe with the fitting into the slid-
ing tool. Use the sliding pliers with the
appropriate inserts!
The inserts are marked with the letters F
for fitting and S respectively H for sliding
sleeve.
Observe a safe seat of the tool!
The sliding procedure is completed when
the sleeve has been pushed onto the pipe
as far as it will go. The sleeve has to be
pushed onto completely!

The external pipe skin being compressed slight-

ly is possible, but does not lead to any impair-
ments regarding the joint.

11
 Technical Manual Mainpex

Bending
Basically, the compound pipe from MAIN-
PEX can be bent when the smallest bend-
ing radii are complied with. The pipes can
be bent manually or with the help of tools.
If the pipes are bent manually, use both
hands.
The pipes must not be bent directly at the bending devices. It is indispensable for you
joint. to observe our smallest bending radii.
For better processing, you can use a knee.
This results in the bends showing small kinks.
Pipes with kinks must not be installed!
Auxiliary tools can be bending springs or

Bending radii Minimum radii (mm) for pipe bending

The smallest possible bending radii, as
shown in the table below, have to be ob-
served and must not be fallen below.
Pipe
size Bending radius (manual) Bending
radius (tool)
AD 16 5 x D / 80 4 x D / 64
AD 20 5 x D / 100 4 x D / 80
AD 25 5 x D / 160 4 x D / 100
AD 32 - 4 x D / 128

Thermal change in length

When routing MAINPEX pipes the chang- formula has to be used when calculating
es in length due to heating have to be the change in length.
taken into consideration. The following

Linear expansion (mm) = coefficient of linear expansion (mm/m x K) x pipe length (m) x temperature difference (K)

The coefficient of linear expansion for MAINPEX compound pipe = 0.025 mm/m x K

Example:
20 m of pipe have to be routed in a hall. In order to accept the Within the heating line the water may cool down to 5 °C. You have
expansion by means of expansion brackets at the hall ends, the to assume that the max heating water temperature of 95 °C flows
max linear expansion for the clamp attachment and the attach- through the line.
ment interval have to be determined. The following values have to be entered into the formula:
20 m x 90 K x 0.025 mm/m x K = 45 mm linear expansion
100
90 ∆t = 70K
80
∆t = 60K
∆t = expansion mm

70
∆t = 50K
60
50 ∆t = 40K
40 ∆t = 30K
30
∆t = 20K
20
∆t = 10K
10
0
0 10 20 30 40 50
Line length m

12
 The pipe with comfort.

Expansion compensation and attachments

Expansion compensation
Changes in pipe lengths for MAINPEX
pipes result from heating and cooling.
These changes in length of the pipes have
to be considered by taking measures al-
ready during installation.
The following options to compen-
sate the linear expansion are available:
routing the lines with bending brackets.
This is the easiest way to compensate
linear expansions. However, bending
brackets cannot be installed in all places.
Regarding this installation type it is impor-
tant that the expansion bend is equipped
with a sliding clamp on the one side and a
fixing point clamp on the other side. The
space requirements for this type of routing
have to be dimensioned sufficiently. The
expansion length has to be calculated us-
ing the formula on page 12.
Using expansion bends is possible. A slid-
ing clamp has to be installed on each side
of the expansion bend. The space require-
ments for this type of routing have to be
dimensioned sufficiently. The expansion
length has to be calculated using the for-
mula on page 12.
Bellow expansion joints can be used for
the MAINPEX pipe system.
The position of the sliding and fixing point
clamps has to be selected properly and
the installation has to be implemented in
accordance with the recognized rules of
technology.

Pipe attachment
Pipe clamps and attachment materials for
MAINPEX pipes must be used only if the
same are suitable for the pipe material and
diameter. Requirements regarding noise
protection and pipe expansion have to be
observed.
Pipes have to be attached at sufficient dis-
tances to ceilings and walls.
Attachment intervals (m)
Pipe size vertical pipes horizontal pipes
16 1.50 1.00
20 1.70 1.10
25 1.90 1.30
32 2.00 1.50
40 2.00 1.50
50 2.00 1.50

The dimensions shown in the table are
maximum distances. For pipes heated by
more than 40 °C the distances have to be
reduced by approx. 20 %!
When attaching MAINPEX pipes on the
floor, attachment intervals of 75 cm have to
be observed. In bending areas intervals of Our pipes have to be attached according
30 cm to the bend have to be observed. to the recognized rules of technology.
When attaching MAINPEX pipes the over-
all weight of the installation has to be ob-
served. The same depends on the insula-
tion, the medium, and the pipe expansion.

Contact with other building materials

Wall and ceiling ducts for MAINPEX pipes
have to be implemented in a way that the
regulations regarding fire and noise pro-
tection in buildings are complied with.
Direct contact to wall and concrete parts
is inadmissible. The fittings have to be
protected against aggressive media and
substances. Contact with bitumen or oil-
containing substances is prohibited. The
pipes have to be protected against UV
radiation. Depending on the application
case, the seals for wall and ceiling ducts
have to be implemented according to the
regulations for noise and fire protection.

13
Technical Manual Mainpex

Protection against external corrosion

MAINPEX fittings and connectors have to be ronmental substances by means of appropri-
protected against external corrosion, if re- ate coatings. Please observe that insulation
quired. The connectors have to be protected and coating materials must not have corro-
against salt-containing air or aggressive envi- sive effects on connectors or formed parts.

Connection to water heater

or continuous-flow water heaters
Basically, it is possible to connect MAIN-
PEX system pipes directly to water heaters
or continuous-flow water heaters without
special measures. However, it has to be
ensured that the devices correspond to
the technical specifications (DIN 4753, DIN
VDE 0700, and DIN 1988) and do not gener-
ate temperatures above 95 °C. If this is not
possible, a cool-down distance of at least
0.8 m consisting of metallic pipe should
be installed after the hot water output be-
tween water heater or continuous-flow wa-
ter heater and the MAINPEX system pipe. In
order to prevent damages to the pipe sys-
tem, further measures have to be taken in
case of a possible pressure increase during
operation of the hot water generator.

Mixed installation
If it is necessary to connect the MAINPEX ter systems made of copper, stainless steel The portfolio covers special fittings for di-
pipe system directly onto copper, stain- or tin-plated pipes without taking specific rect connection to press or soldering sys-
less steel, or tin-plated steel pipes, this is measures, e.g. "insulating piece". tems.
possible. Our fittings are made of coated
brass. This ensures that our MAINPEX pipe
system can be connected with drinking wa-

Insulation of pipes
Insulation according to DIN 1988
When designing the insulation of pipes according to DIN 1988, the following require-
ments have to be observed:

• compliance with statutory obligations and further obligations, such as for example
state building regulations. It has to be observed that DIN 4140 part 1 and part 2 are not
applicable to drinking water lines
• protection against moisture penetration of the insulation layers
• Compliance with designed and specified operating temperatures

14

Thermal insulation
Technical notes and fields of application
of pre-insulated MAINPEX heating and sanitation pipes
Insulation thickness: 5 mm
Available as MPX compound pipe in the dimensions: 16 x 2.2 / 20 x 2.8 / 25 x 3.5
Fields of application:
HVAC
• radiator connection lines (controlled)
between heated rooms in the same
accommodation unit
• when the heating pipes are routed on
a ceiling (foundation slab) against soil
and partially heated or unheated rooms an
additional insulation (100 %) has to be
placed below the pipes (e.g. EPS 20)
Insulation thickness: 9 mm
Available as MPX compound pipe in the dimensions: 16 x 2.2 / 20 x 2.8 / 25 x 3.5
Fields of application:
HVAC
• all radiator connection lines and
distribution lines between heated
rooms in the same and against other
accommodation units
• when the heating pipes are routed on
a ceiling (foundation slab) against soil
and unheated rooms an additional
insulation of 100 % has to be placed
below the pipes (e.g. EPS 20)
• other: heating pipes in unheated
and against adjacent unheated rooms
have to be insulated 100 %
Drinking water cold
• for lines above ground in unheated
rooms
• on concrete ceilings
• in wall slots for single connection lines
• in installation ducts without hot lines
• other notes: next to hot lines all TWK
lines have to be insulated with 13 mm,
without insulation regulations, TWK and
TWW have to be insulated with 9 mm
Drinking water cold
• for lines above ground in unheated
and heated rooms
• on concrete ceilings
• in wall slots for single connection lines
and as riser
• in installation ducts without hot lines
• other notes: next to hot lines all TWK
lines have to be insulated with 13 mm,
without insulation regulations, TWK and
TWW have to be insulated with 9 mm
The pipe with comfort.
Drinking water hot
• in wall slots for single connection lines
in the same accommodation unit
• for circulation connection between
heated rooms in the same accommoda-
tion unit
• other notes: TWK with circulation
has to be insulated with 100 %
Drinking water hot
• in wall slots for single connection lines
in the same accommodation unit
(heated similarly)
• for circulation connection between
heated rooms in the same accommoda-
tion unit
• other notes: where no insulation
is specified, TWK with circulation has
to be insulated with 100 %
15
Technical Manual Mainpex

Insulation of pipes according to Enev

Details on the requirements, fields of application, and insulation thicknesses can be found in table 1. Table 1 corresponds to table 1
of § 14, annex 5 of the EnEV 2007.

EnEV 2007

Annex 5 (for § 14 section 5)

Requirements for the limitation of heat dissipation of heat distribution and hot water lines as well as faucets
Table 1
Thermal insulation of heat distribution and hot water lines as well as faucets

Minimum thickness of the insulation layer, referred to a ther-

Line Type of line / faucets
mal conductivity of 0.035 W/(m K)

1 Internal diameter up to 22 mm 20 mm

2 Internal diameter above 22 mm up to 35 mm 30 mm

3 Internal diameter above 35 mm up to 100 mm equal to internal diameter

4 Internal diameter above 100 mm 100 mm

Lines and faucets according to lines 1 to 4 in wall and ceiling

5 breakthroughs, in the area of crossing lines, at line joints, at ½ of the requirements of the lines 1 to 4
central network manifolds

Lines of central heating systems according to lines 1 to 4

6 routed in parts between heated rooms of different users after ½ of the requirements of the lines 1 to 4
this regulation came into force.

7 Lines according to line 6 in the floor structure 6 mm

Table 2: Explanations/examples heating, for § 14, annex 5, table 1, EnEV 2007

Apartment house / Single-family house /

Heating systems
non-residential building several users non-residential building 1 user

Lines in unheated rooms and cellars 100 % 100 %

Lines in external walls, external parts, between an unheated and a heated

100 % 100 %
room, in shafts and ducts

Manifold lines to supply several, different users 100 % no requirements

Underfloor lines, also heating/cooling connection lines against soil /

100 % 100 %
unheated rooms1)

Lines and faucets in wall and ceiling breakthroughs, in the area of crossing
50 % 50 %
lines, at line joints, at central line manifolds

Lines in parts, between heated rooms of different users 50 % no requirements

Lines routed in the floor structure, between heated rooms of different see EnEV, table 1
no requirements
users Annex 5, line 73)
heating lines in heated rooms or in parts between heated rooms of a user
/ no requirements 2)
and lockable

1)
Eccentric/asymmetrical pipe hoses are admissible to limit the heat dissipation. The nominal width has to point towards the cold side. Details can be found in the required
general technical approval of the corresponding manufacturer.
2)
Although there are no requirements applicable at this point, insulation has to be provided due to the following reasons: corrosion protection, avoidance of impulsive and
flow noises, impact-sound insulation, reduction of the thermal load.

16
 The pipe with comfort.

The following insulation thicknesses apply to pipes of all dimensions routed in the floor structure
(independent of the position) between heated rooms of different users:

Minimum thickness referred to a thermal conductivity of

0.040 W/(mK) for eccentric /

0.035 W/(mK) for concentric insulation 0.040 W/(mK) for concentric insulation
asymmetrical insulation
see general technical
>
_ 6 mm >
_ 9 mm
approval of the corresponding manufacturer

Cold water lines are not subject to the EnEV, but have to be insulated accord-
ing to DIN 1988, part 2 as follows.

DIN 1988 part 2 for cold water lines

Installation situations Insulation layer thickness at y = 0.040 W/mK*)

Pipes above ground, in unheated room (e.g. cellar) 4

Pipes above ground, in heated room 9

pipes in ducts, without hot pipes 4

pipes in ducts, next to hot pipes 13

Pipes in wall slots, riser 4

Pipes in wall recess,

13
next to hot pipes

Pipes on concrete ceiling 4

*)
The insulation layers have to be converted correspondingly for other values of thermal conductivity, for a diameter of d=20 mm.

17
Technical Manual Mainpex

Protection against heating and condensation

for drinking water systems in the cold water range
The DIN 1988 provides an overview for
better overview over the selection of insu-
lation materials for cold water-containing
drinking water lines.
The overview is designed for the operating
conditions typical in the field of domestic
construction.
Pipe in pipe provides sufficient condensa-
tion protection!
Installation situation Insulation layer thickness at
y = 0.040 W/(mK)*) mm
Pipe above ground, in unheated room (e.g. cellar) 4
Pipe above ground, in heated room 9
Pipe in ducts, without hot pipes 4
Pipe in ducts, next to hot pipes 13
Pipe in wall slots, riser 4
Pipe in wall recess, next to hot pipes 13
Pipe on concrete ceiling 4

*) For different values of thermal conductivity theinsulation layer thicknesses,

referring to a diameter of d = 20mm have to be converted correspondingly.

Protection of hot water and circulation lines

Regarding thermal insulation for hot water Further details can be found in the DIN
and circulation lines the minimum require- 1988 part 2.
ments of the heating systems regulation
to the Energy Conservation Act are appli-
cable.

Thermal insulation
The minimum thickness of the insulation
layers refer to a thermal conductivity of
0.035 W/m x K (WLG 035) according to
EnEV. When using insulations with different
thermal conductivities, the insulation layer
thicknesses have to be converted. The pro-
tective pipe of MAINPEX is not an insula-
tion within the meaning of ENEV 2/02.
Possible insulation materials include:
• mineral fiber
• foamed plastics
• soft and hard foams
• further recognized insulation materials are possible
You will find more information on thermal insulation in the specialized areas.

Noise protection
Wall and ceiling ducts for MAINPEX pipes
have to be implemented in a way that the
regulations regarding fire and noise protec-
tion in buildings are complied with. Direct
contact to wall and concrete parts is inad-
missible. The fittings have to be protected
against aggressive media and substances.
The pipes must not be subjected to UV
rays for longer periods of time. Depending
on the application case, the seals for wall
and ceiling ducts have to be implemented
according to the regulations for noise and
fire protection.
Pipes should be protected and insulated
due to many reasons.
A very comprehensive description of this
can be found in the DIN 1988-2. An impor-
tant reason is the protection of the pipes
against impact sound transmission. Even
small contact points of the pipe with parts
are sufficient. Regarding the aforemen-
tioned, the DIN 1988 writes as follows:
"The standards of the DIN 4109 are ap-
plicable to the requirements regarding
the noise protection. There, the values
for the admissible noise levels in rooms
to be protected are determined. De-
tails on design, execution, and opera-
tion of the systems, as well as on the
certification of noise protection can also
be found in the standards of the series
DIN 4109 (see also datasheet of the
ZVSHK3).
When insulating the pipes please observe
in particular that the pipe insulation com-
pletely encloses the pipe and is not dam-
aged.

18
 The pipe with comfort.

Preventive fire protection

for HVACR in buildings and houses
The preventive fire protection as one of the
most important tasks when routing and in-
stalling lines is specified very precisely and
comprehensively in Germany.
The same specifies the requirements for
the preventive fire protection in pipe sys-
tems, in the state building regulations intro-
duced by the building law, and in the pipe
system guidelines of the federal states.
For the user, the fact that according to building regulations to the MBO 2002.
the Building Code (MBO 2002) §§ 40 and MAINPEX pipe system corresponds to
41 there are no requirements for sealing building material class B2 (normally flam-
pipe systems, installation shafts, ducts, mable) according to DIN 4102.
and ventilation systems within apart-
ments and units with a maximum of
400 m² in less than 2 floors is important.
Along with the provisions of the MBO 2002,
please also observe the corresponding state

Fire protection
Fire protection insulation is required
when HVACR installation lines go
through fire-resistant ceilings and walls.
In these cases measures have to be tak-
en preventing fire and smoke from en- differentiation is made between flam-
croaching. These measures are classified mable and flame-proof building materi-
according to building type and material. als as follows:
As regards to the building material, the

Flame-proof:
• A1, e.g. concrete or rock wool
• A2, e.g. foil-laminated pipe shells
made of rock wool
Flammable:
• B1, flame-retardant building materials, Mainpex pipes are classified into building
e.g. gypsum plasterboards material class B2, continue to burn without
• B2, normally inflammable building back-up fire, and are not self-extinguishing.
materials, e.g. wood and Pex pipes
• B3, easily flammable building materials
must not be used in buildings in
Germany.

Insulated Mainpex pipes (16 mm-25 mm) may be routed in common or individual ceiling and wall breakthroughs,
provided that:

• minimum wall or ceiling thickness =
80 mm
• insulation in the area of the conduit
has to be building material class A1 or
A2
• length of the fire protection insulation
has to correspond at least to the wall
and ceiling thickness
• for continued insulation with
building material classes A1 or A2 the
clear distance between the fire
protection insulation is 50 mm
• for continued insulation with
building material classes B1 or B2 the
clear distance between the fire
protection insulation is 160 mm
• the residual aperture has to be closed
with concrete or cement mortar
• if tested systems with general techni-
cal test certificate are to be used, no
minimum pipe distance is required

Furthermore, the following is applicable to Mainpex pipes larger than dimension 32mm:

• basically, systems with general techni- • the insulation material layers and
cal test certificate have to be used thicknesses depend on the manufac-
(minimum distance pipe not applicable) turer's specifications

Basically, free routing of Mainpex pipes in
emergency exits and escape routes is pro-
hibited. The same have to be routed in fire
protected installation ducts, suspended
ceilings, false floors, or flush mounted. In Recommendation:
these cases, insulation of the fire protec-
Mainpex recommends products of the
tion classes B1 or B2 is sufficient.
company Rockwool Conlit.

19
Technical Manual Mainpex
Pipe system and
drinking water regulation
Legionella issues no problem for MAINPEX
Legionella and the risks for human beings
caused by this bacterium were unknown
until approx. 1977. Only after at first mys-
terious diseases developed amongst the
participants of a meeting of legionnaires
in the USA, this type of bacteria and the
diseases caused by the same were discov-
ered, such as legionella pneumonia and
the Pontiac Fever.
Human beings mostly pick up legionella
by inhaling contaminated water aerosols
in their lungs. The same can cause the
Pontiac Fever or legionella pneumonia (le-
gionnaire's disease) in human beings.
Legionella can be found in natural and arti-
ficial humid zones: running waters, thermal
waters, drinking water lines, shower heads,
hot water accumulators, air conditioning
systems, and similar. Sporadically, legion-
ella are also found in humid soils, sludge,
and compost soil.
In order to prevent legionella contamina-
tion, avoiding errors during the design and
execution phases of drinking water lines is
particularly important.
The following reasons can result in a
contamination:
• improper planning
• inappropriate system selection to heat
the drinking water
• poor observation of regulations
• error during installation (design,
hydraulic comparison,...)
• poor maintenance
• contaminations within the pipe
20
The Legionella pneumophila are rod-
shaped bacteria. At temperatures from
5 °C – 66 °C and a pH value of 5 and 8.5
they can survive. They proliferate very
strongly at approx. 37 °C and a slightly
acid or neutral pH value. Legionella have
the ability to proliferate within free liv-
ing amoeba, microorganisms with their
enzymes and nutrients form the food re-
source for legionella.
The following procedures to eliminate
legionella in drinking water systems are
possible:
• short-term excess chlorination
• thermal water treatment (please
observe W552)
• hydrogen peroxide disinfection
• ozone treatment
• disinfection with chlorine dioxide
• UV radiation
• copper/silver ionization
• anodic oxidation
Often it is sufficient just to observe the
regulations during drinking water instal-
lation and to select an appropriate pipe
system in a reasonable manner.
The following regulations and work sheets
on this topic have to be observed:
DIN 1988 TRWI
DVGW work sheets W 551, W 552, and
W 553.
DIN 4753
DIN 4708
VDI 6023
The raw materials are demonstrably in-
significant for the settlement of legion-
ella. Together with other microorganisms
legionella form a biological film in pipes,
in which they can also proliferate. Cavities
(grooves) in the pipe system are particu-
larly suited for the settlement. Biological
films can form in pipes made of copper,
steel, or plastic. Even increased water flow
does not flush out the legionella.
Nevertheless, you should not use any
material when selecting the raw materi-
als for you drinking water installation. We
recommend using only pipes that have an
approval. In the field of hygienics this is
a passed KTW test, as well as the test of
the pipe according to work sheet W 270
(micro-organic growth).
MAINPEX pipes have a KTW approval and
are particularly suited for drinking water
lines.
On the basis of mixing waters, the devel-
opment of new wells, and feeds in peak
times by other suppliers fluctuations
as regards to the specific properties of
the drinking water occur in waterworks.
These fluctuations have to be taken into
account during the planning stage, be-
cause traditional metallic materials may
be deluted and exceed the limits. When
selecting the raw materials, please con-
sider that the pipe network will be ex-
posed to fluctuating water qualities for
many years.
 The pipe with comfort.

Regulation/organization (mg/L) Type of limit concentration Justification

EC drinking water directive 3.0 reference value after 12 h stagnation aesthetically

WHO drinking water guidelines 1.0 Reference value aesthetically
2.0 guide value regarding health
TrinkwV ( annex 7, No.1 ) 3.0 reference value after 12 h stagnation aesthetically
German Health Authority Observe the regulations of the German Health Authority!

Please also observe the information and We can also provide personal support
examinations of the "committee for plas- during the design and execution phase
tic pipe systems" of the "Robert-Koch In- of drinking water lines or in case of prob-
stitute". lems.

Trace heating
Using trace heating tapes is possible.
The heating tapes to be used have to ensure
that too high a pressure increase within
the pipe system due to uncontrolled heat-
ing can be ruled out. Too high a pressure
increase is also possible when the water ex-
panding in the pipes cannot be prevented
due to shut-off units or at water heaters.
In this case, the aforementioned has to be
prevented by appropriate safety measures
(diaphragm expansion containers or safety
valves).
The heating tape has to be attached accord-
ing to the manufacturer's specifications.
MAINPEX pipes can be classified in the cat-
egory "plastic pipes".
When routing the heating tapes, please ob-
serve the installation guidelines and routing
instructions of the manufacturer.

Circulation line system

The installation of a circulation line in hot
water systems does not only enhance the
user comfort when drawing water, but is
required in many cases.
In apartment houses it is normally impor-
tant to provide hot water around the clock.
The need to ensure the aforementioned
is determined in the work sheets W 551,
W 552, W 553, and in the DIN 1988-3. It is
important to note that a maximum of 3L
water may run out before hot water is pres-
ent at the faucet.
Using the MAINPEX pipe system any type
of circulation line can be created. Even
"internal hot water circulation systems"
can be implemented with MAINPEX in an
extraordinary manner. On the basis of the
very low flow reduction within the connec-
tors, the system is suited particularly well
for this type of hot water circulation. How-
ever, the MAINPEX system pipe must only
be used as external pipe and not as inter-
nal circulation pipe.

Drinking water lines from the point of view of hygienics

• pipes that are as short as possible and
small but hydraulically sufficient pipe
diameters, in order to achieve a short
dwell time of the drinking water in the
system.
• stagnation of the drinking water in
system parts without flow has to be
avoided.
• heating cold drinking water manifold
systems has to be avoided.
• unused pipe parts have to be drained.
The technical rules regarding the imple-
mentation and operation of drinking wa-
ter systems are determined in the DIN
1988 (TRWI) – technical rules of the DVGW
(German Technical and Scientific Associa-
tion for Gas and Water) . The DVGW work
sheets W 551 and W 552 on the avoid-
ance of legionella growth are applicable
as well.
When erecting and planning the instal-
lation, changing drinking water proper-
ties have to be considered. The installer
should consult the water supplier on the
quality, by means of § 21 of the drinking
water regulations the supplier is obliged
to do so.

21
Technical Manual Mainpex

Dimensioning
Drinking water systems are planned and installed according to to the recognized rules of technology from the points of view of
DIN 1988, VDI 6023, and the DVGW work sheets W 551 and W hygienics and hydraulics.
553. Please observe that the drinking water systems correspond

Determination of the pipe diameters according to DIN 1988

Scheme of the calculation steps

Differentiated calculation run (D)

1 Determine the calculation flows of the
faucets. D 7 Determine the pressure losses from the
individual resistances via the loss coefficient
2 Determine the total flows and assign
the same to the sections. D 8 Calculate the total pressure loss from
pipe friction and individual resistanc-
3 Determine the peak flow from the total es and compare to available
flow. pressure differential

4 Determine the available pressure differen- D 9 If applicable, check with modified

tial for pipe friction and individual resistances. pipe diameters.

5 Deduct the estimated share of

available pressure differential for indi-
vidual resistances and determine the Simplified calculation run (V)
available pipe friction pressure loss.
V7 Calculate the sum of the pressure losses
6 Select the pipe diameter and deter- from pipe friction of all sections and
mine the pipe friction pressure loss and compare to the pressure differential
the related calculatory flow rate available for the same.

V 8 If applicable, check with modified

pipe diameters.

Resistances / loss coefficients (fittings and pipe)

No. Individual resistance Graphic symbol, Loss coefficient
simplified representation

1 Change in direction by bend 90° 0.3

2 Change in direction by bend angle 90° 0.7

3 T piece, branch at stream separation 1.3

4 T piece, passage at stream combination 0.9

5 T piece, passage at stream separation 0.3

6 T piece, counter current at stream combination 3.0

7 T piece, counter current at stream separation 1.5

8 Change in direction by angle 45° 0.4

22
 The pipe with comfort.

Reference values for minimum flow pressures and calculation flows of common drinking water tapping points

Minimum Calculation flow when tapping

flow pressure
P min Fl Type of drinking water tapping point mixed water *) only cold or heated
drinking water
bar VR VR VR
cold L/s hot L/s L/s

Discharge valves
0.5 without aerator**) DN 15 - - 0.30
0.5 DN 20 - - 0.50
0.5 DN 25 - - 1.00
1.0 with aerator DN 10 - - 0.15
1.0 DN 15 - - 0.15

1.0 Shower heads for cleaning showers DN 15 0.10 0.10 0.20

1.2 Pressure flusher according to DIN 3265 part 1 DN 15 - - 0.70

1.2 Pressure flusher according to DIN 3265 part 1 DN 20 - - 0.70
0.4 Pressure flusher according to DIN 3265 part 1 DN 25 - - 1.00
1.0 Pressure flush for urinal DN 15 - - 0.30

1.0 Domestic dishwasher DN 15 - - 0.15

1.0 Domestic washing machine DN 15 - - 0.25

Faucet for
1.0 Shower tubs DN 15 0.15 0.15 -
1.0 Bathtubs DN 15 0.15 0.15 -
1.0 Kitchen sinks DN 15 0.07 0.07 -
1.0 Vanities DN 15 0.07 0.07 -
1.0 Bidet DN 15 0.07 0.07 -

1.0 Faucet DN 20 0.30 0.30 -

0.5 Toilet tank according to DIN 19 542 DN 15 - - 0.13

1.0 Electronic water kettle DN 15 - - 0.10***)

*) The calculation flows for mixed water
tapping are based on 15 °C for cold
drinking water and 60 °C for heated
drinking water.
**) For discharge valves without aerator ***) At fully opened throttle screw.
and with hose coupling, the pressure Comment: tapping points and
loss in the hose line (length 10 m)- devices of the same type not includ-
and in the connected apparatus (e.g. ed in the table having larger fitting
lawn sprinkler) is considered across flows or minimum flow pressures than
the board by means of the minimum specified have to be considered in
flow pressure. In this case, the mini- accordance with the information of
mum flow pressure is increased by the manufacturers when determining
1.0 bar to 1.5 bar. the pipe diameters.

23
Technical Manual Mainpex
Pipe friction pressure loss with Vs
Peak DN 8 DN 12 DN 15 DN 20
flow di = 8.4 mm di = 11.6 mm di = 14.4 di = 18.0
Vs V/L=0.06L/m V/L=0.11L/m V/L=0.16L/m V/L=0.25L/m
L/s R mbar/m v m/s R mbar/m v m/s R mbar/m v m/s R mbar/m v m/s
0.01 1.2 0.2 0.3 0.1 0.1 0.1 0.0 0.04
0.02 3.7 0.4 0.8 0.2 0.3 0.1 0.1 0.08
0.03 7.4 0.5 1.6 0.3 0.6 0.2 0.2 0.12
0.04 12.1 0.7 2.6 0.4 0.9 0.2 0.3 0.16
0.05 17.8 0.9 3.9 0.5 1.4 0.3 0.5 0.20
0.06 24.5 1.1 5.3 0.6 1.9 0.4 0.7 0.24
0.07 32.1 1.3 6.9 0.7 2.5 0.4 0.9 0.28
0.08 40.6 1.4 8.7 0.8 3.1 0.5 1.1 0.31
0.09 49.9 1.6 10.7 0.9 3.8 0.6 1.3 0.35
0.10 60.1 1.8 12.8 0.9 4.6 0.6 1.6 0.4
0.15 123.8 2.7 26.1 1.4 9.3 0.9 3.2 0.6
0.20 207.9 3.6 43.5 1.9 15.4 1.2 5.3 0.8
0.25 311.6 4.5 64.8 2.4 22.8 1.5 7.8 1.0
0.30 434.8 5.4 89.9 2.8 31.6 1.8 10.8 1.2
0.35 577.0 6.3 118.8 3.3 41.6 2.1 14.2 1.4
0.40 738.2 7.2 151.3 3.8 52.9 2.5 18.0 1.6
0.45 187.4 4.3 65.4 2.8 22.2 1.8
0.50 227.2 4.7 79.1 3.1 26.8 2.0
0.55 270.5 5.2 94.0 3.4 31.8 2.2
0.60 317.3 5.7 110.1 3.7 37.2 2.4
0.65 367.7 6.2 127.3 4.0 43.0 2.6
0.70 145.8 4.3 49.2 2.8
0.75 165.3 4.6 55.7 2.9
0.80 186.1 4.9 62.6 3.1
0.85 208.0 5.2 69.9 3.3
0.90 231.0 5.5 77.5 3.5
0.95 255.2 5.8 85.5 3.7
1.00 280.5 6.1 93.9 3.9
1.05 102.7 4.1
1.10 111.8 4.3
1.15 121.3 4.5
1.20 131.1 4.7
1.25 141.3 4.9
1.30 151.8 5.1
24
Peak DN 25 DN 40 DN 50
flow di = 23.2 mm di = 36.2 mm di = 45.6 mm
Vs V/L=0.42L/m V/L=1.03L/m V/L=1.63L/m
L/s R mbar/m v m/s R mbar/m v m/s R mbar/m v m/s
0.1 0.5 0.2 0.1 0.1 0.0 0.1
0.2 1.6 0.5 0.2 0.2 0.1 0.1
0.3 3.2 0.7 0.4 0.3 0.1 0.2
0.4 5.3 0.9 0.6 0.4 0.2 0.2
0.5 7.9 1.2 0.9 0.5 0.3 0.3
0.6 10.9 1.4 1.3 0.6 0.4 0.4
0.7 14.4 1.7 1.7 0.7 0.6 0.4
0.8 18.3 1.9 2.2 0.8 0.7 0.5
0.9 22.6 2.1 2.7 0.9 0.9 0.6
1.0 27.3 2.4 3.2 1.0 1.1 0.6
1.1 32.5 2.6 3.8 1.1 1.3 0.7
1.2 38.0 2.8 4.4 1.2 1.5 0.7
1.3 44.0 3.1 5.1 1.3 1.7 0.8
1.4 50.3 3.3 5.8 1.4 1.9 0.9
1.5 52.0 3.5 6.6 1.5 2.2 0.9
1.6 64.2 3.8 7.4 1.6 2.4 1.0
1.7 71.7 4.0 8.3 1.7 2.7 1.0
1.8 79.6 4.3 9.2 1.7 3.0 1.1
1.9 87.9 4.5 10.1 1.8 3.3 1.2
2.0 96.5 4.7 11.1 1.9 3.6 1.2
2.1 105.6 5.0 12.1 2.0 4.0 1.3
2.2 115.0 5.2 13.2 2.1 4.3 1.3
2.3 14.3 2.2 4.7 1.4
2.4 15.4 2.3 5.0 1.5
2.5 16.6 2.4 5.4 1.5
2.6 17.8 2.5 5.8 1.6
2.7 19.1 2.6 6.2 1.7
2.8 20.4 2.7 6.7 1.7
2.9 21.7 2.8 7.1 1.8
3.0 23.1 2.9 7.5 1.8
3.1 24.5 3.0 8.0 1.9
3.2 26.0 3.1 8.5 2.0
3.3 27.5 3.2 9.0 2.0
3.4 29.0 3.3 9.5 2.1
3.5 30.6 3.4 10.0 2.1
3.6 32.2 3.5 10.5 2.2
3.7 33.9 3.6 11.0 2.3
3.8 35.6 3.7 11.6 2.3
3.9 37.3 3.8 12.1 2.4
4.0 39.1 3.9 12.7 2.4
4.1 40.9 4.0 13.3 2.5
4.2 42.7 4.1 13.9 2.6
4.3 44.6 4.2 14.5 2.6
4.4 46.5 4.3 15.1 2.7
4.5 48.5 4.4 15.7 2.8
4.6 50.5 4.5 16.4 2.8
4.7 52.6 4.6 17.0 2.9
4.8 54.6 4.7 17.7 2.9
4.9 56.7 4.8 18.4 3.0
5.0 58.9 4.9 19.1 3.1
 The pipe with comfort.

Project planning and quick calculation

of drinking water systems:
Determination of the weights by
means of the Mainpex quick calculation
For pure weight determination, we offer
an online calculation program on our web-
site.

The same is released by means of a pass-

word and can be used by our customers
at no costs. Handling is very easy and un-
complicated.

Project planning and

design using the
calculation service
You are also invited to use our in-house
calculation service. We design and plan
the system individually for your building.
The drinking water is designed in accor-
dance with the currently applicable stan-
dards and regulations.

25
Technical Manual Mainpex
Pressure test according to 1988 part 2
The pressure test for the MAINPEX pipe
system has to be implemented after com-
pletion of the installation and in accor-
dance with DIN 1988 part 2. At first, every
Pre-test
During pre-test, an operating pres-
sure of 5 bar has to be exerted as test
pressure (15 bar). This test pressure has
to be reset to the initial test pressure twice
Main test
The main test is implemented directly after
the pre-test. The test pressure read after
the pre-test must not fall by more than 0.2
bar after two hours. Leakages must not be
Special note when performing the pressure test with compressed air or inert gas
All lines have to be closed with metal plugs,
caps, shut-off plates, or blind flanges. De-
vices, pressure vessels, or drinking water
heaters have to be disconnected from the
lines. All pipe joints have been visually in-
Special note when flushing pipes according to DIN 1988 part 2
After the pressure test, the total system
has to be flushed thoroughly. Flushing has
to be implemented according to the spec-
ifications of DIN 1988 part 2.
26
joint has to be subjected to a visual inspec- pressure increase of 0.1 bar are admitted
tion. In doing so, check that all sleeves for pressure testing. The pressure gage
have been pushed on properly. has to be connected to the lowest point
Only devices being able to indicate a in the system.
within a period of 30 minutes at intervals of has expired and no leakages must occur.
10 minutes each. Afterwards, the pressure
must not fall by more than 0.6 bar (0.1 bar
per 5 minutes) after a time of 30 minutes
detectable at any points of the tested sys- datasheet "implementation of a pressure
tem. test with compressed air or inert gases for
Pressure tests with air and inert gases drinking water installations in accordance
are possible. Please observe the ZVSHK with DIN 19887 TRWI".
spected for professional execution. Leak-
age spray can be used for leakage search-
ing purposes. External corrosion has to be
avoided!
Protocols and certificates on the pressure
tests have to be developed. (see page 21)
 The pipe with comfort.

Template for pressure test

Pressure test protocol according to DIN 1988 part 1

for drinking water lines
Pressure test with test medium "water"

Development:

Construction stage:

Testing person / company:

Pre-test:
Test duration approx. 60 minutes

Test pressure = max admissible operating pressure / 10 bar + 5 bar = 15 bar at least 1bar
(referred to the lowest point of the system)

Start: (date, time) Test pressure: bar

Afterwards, within 30 minutes at intervals of 10 minutes, double reset of the test pressure, wait again for 30 minutes and read the test
pressure (max pressure loss 0.6 bar).

End: (date, time) Test pressure: bar

Main test:
test duration approx. 120 minutes

Start: (date, time) Test pressure: bar

End: (date, time) Test pressure: bar

Confirmation:

Both during the pre- and during the main test no leakages could be detected for the system mentioned above.

(place, date) (stamp, signature, contractor)

(place, date) (stamp, signature, customer)

27
Technical Manual Mainpex

Template for pressure test

Pressure test protocol according to DIN 1988 part 2

for drinking water lines
Pressure test medium: oil-free compressed air nitrogen carbon dioxide

Development:

Construction stage:

Testing person / company:

Leakage test:
Test pressure 110mbar. Test duration up to 100 liters output volme at least 30 minutes.
The test duration has to be increased by 10 minutes for each 100 liters.

Output volume: liters

The test duration starts after having waited for temperature and steady state.

Start: (date, time) Test pressure: mbar

End: (date, time) Test pressure: mbar

Strength test:
with increased pressure
Test pressure: ≤ 63 x 6 mm max 3 bar > 63 x 6 mm max 1 bar test duration up to 100 liters output volume at least 30 minutes. The test dura-
tion has to be increased by 10 minutes for each 100 liters. The test duration starts after having waited for temperature and steady state.

Start: (date, time) Test pressure: bar

End: (date, time) Test pressure: bar

Confirmation: Both during the pre- and during the main test no leakages could be detected for the system mentioned above.

(place, date) (stamp, signature, contractor)

(place, date) (stamp, signature, customer)

28
 The pipe with comfort.

Template for flushing protocol

Drinking water system

Flushing protocol according to DIN 1988 part 2

for drinking water lines
Development:

Construction stage:

Testing person:

Raw material: multi-layer compound pipe PE-RT

Connection technology: sliding sleeve system MAINPEX

Largest nominal width

of the manifold line 25 32 40 50 65 80 100
Minimum number of tapping
points DN 15 to be opened 1 2 3 4 6 9 14

Reference value for minimum number of tapping points to be opened, referred to the largest
nominal width of the manifold line.

The line length per flushed section should not exceed 100 m.

The tapping points have to be closed successively, after the last flushing point has been flushed for at least 5 minutes.

Floor shut-off devices, pre-shut-off devices (maintenance fittings) were fully opened during the flushing procedure.

Sensitive fittings and devices have been removed and replaced by fitting parts respectively bypassed by flexible lines.
Control valves and aerators had been removed.

The drinking water used for flushing purposes is filtrated, static pressure pw = bar.

Dirt screens and dirt collectors were cleansed upon completion of the water flushing procedure.
The flushing procedure started at the main shut-off fitting and was implemented section-wise to the farthest
tapping point.

The drinking water system was flushed properly.

(place, date) (stamp, signature, contractor)

(place, date) (stamp, signature, customer)

29
Technical Manual Mainpex

Template for pressure test with MAINPEX

Pressure test protocol according to

DIN 18380 for heating lines
Development:

Construction stage:

Testing person / company:

System height m

Design parameters supply temperature °C return temperature °C

Start: (date, time) Test pressure: bar (min 5 bar, max 6 bar)

End: (date, time) Pressure loss: bar (max 0.2 bar)

max admissible operating pressure (referring to the lowest point of the system) bar

MAINPEX nominal widths

The system mentioned above was heated to the design temperature on and no leakages were found. No leak-
ages resulted after the system had cooled down either.

The connections were subjected to a visual inspection: yes no

Frost protection agent was added to the water: yes no

Procedure explained as specified above: yes no

Certification:

(place, date) (stamp, signature, contractor)

(place, date) (stamp, signature, customer)

30
 The pipe with comfort.

MAINPEX Heating
system installation
General
Using the Mainpex pipe system near-
ly all application options in the field
of heating system installation are at
your disposal. All fittings can be used
for the installation that are also used
in the drinking water installation.
Furthermore, fittings designed espe-
cially for heating system installation are
at your disposal, e.g. the intersection T
piece.

Connections to existing pipe systems such

as copper, stainless steel, or other plastic
pipe systems can be implemented without
using special tools.

Thus, the Mainpex pipe system is not only
usable for installations in new buildings,
but also for old-building renovation in an
ideal manner. All plastic pipe systems used
in heating system installations have to be
oxygen impermeable in accordance with When using heating water additives,
DIN 4726. The limit specified by the stan- please consult the factory.
dard is 0.1g oxygen/m3 at a water temper-
ature of 40 °C. The Mainpex pipe system is
100 % oxygen impermeable.

When designing, installing, and operating heating systems in

buildings, the following regulations and standards have to be complied with:

DIN EN 12831 Method for calculation of
the design heat load of buildings, DIN
EN 12828 Heating systems in buildings,
Design of water-based heating systems,
DIN EN 1254 Copper and copper allow
fittings, DIN EN 14336 Heating systems
in buildings, Installation and commission-
ing of the water-based heating system,
DIN 18380 Heating systems and central
hot water systems, DIN 4102 fire behavior
of building materials and parts, DIN 4108
Thermal insulation and energy savings in
buildings, DIN 4109 Noise insulation in
building construction, DIN V 4701-10 Ener-
getic evaluation of heating and ventilation
systems, DIN 4726 Pipes made of plastics,
EnEV Energy Savings Ordinance, MLAR
Prototype line systems - Directive on fire-
protection requirements for line systems.

31
Technical Manual Mainpex

Mainpex single-pipe system Mainpex double-pipe system

Return of the previous radiator as supply for the following radia- Pipes are routed below the radiator in the marginal area of the
tor. room.

Mainpex Tichelmann system

Pipe routing as return loop. The first radiator has the shortest
supply and the longest return. Regarding the last radiator it is
the other way around.

Pipe performance data

Performance data of Mainpex MPX pipes

King pin inclination 10 K 15 K 20 K 25 K m R w Recommended maximum pressure losses:

Pipe dimension max heating output Q [KW] [kg/h] [Pa/m] [m/s]
Small heating systems: 50 - 100 Pa/m
16 x 2.2 1.9 2.6 3.4 4.3 146 201 0.38 Large heating systems: 100 - 200 Pa/m
20 x 2.8 3.2 4.7 6.2 7.8 261 199 0.45 Underfloor heating systems: 200 - 250 Pa/m
25 x 3.5 5.8 8.4 11.2 14.0 481 201 0.53
Recommended maximum
32 x 4.4 11.5 16.7 22.2 27.8 955 200 0.63
flow rates:

Radiator
Connection lines: up to 0.5 m/s
Heating manifold lines: up to 1.0 m/s

Errors and technical modifications reserved.

32

Connection options
Radiator connections with the Mainpex
pipe system can be implemented seam-
lessly with the usual methods. This nor-
mally comprises radiator connections from
the raw floor, the wall, and in front of the
Thermal insulation
The EnEV is applicable regarding the
insulation of heating systems. The same
determines that heat distribution lines
Lines routed in parts between rooms
(heated) of different users also have to be
insulated with 50 % only. When routing
within the floor structure, it is admissible
to insulate with concentric insulation.
No insulation is required for pipes routed
in rooms or parts of one (!) user and when
shut-off devices above the floor are used
to detect the heat dissipation In these cas-
es, routing pipe in pipe (TiT) is sufficient.
Heat demand calculation
Planning and dimensioning heating sys-
tems are implemented by calculating the
heat load of the building according to
Flushing heating systems
In order to remove metallic residua or flux
material residua from the lines, a heating
installation has to be flushed thoroughly
before the same is commissioned. This
Pressure testing heating systems
The pressure test is implemented alike the
one for drinking water systems, but the
test pressure is only 1.3-times the operat-
ing pressure. Heating installation systems
have to be subjected to a leakage test ac-
The pipe with comfort.
wall. In doing so, please observe that con- The regulations for fire and noise protec-
tact to other building materials is inadmis- tion have to be complied with. The afore-
sible. Direct contact to wall and concrete mentioned also holds true for string and
parts is inadmissible. The fittings have to manifold lines.
be protected against external corrosion.
have to be insulated with 100 % respec- percental data of the insulation thick-
tively in the area of crossings or wall and ness always refers to the internal pipe
ceiling breakthroughs with 50 %. The diameter.
The table shows the minimum insulation layer thickness at 100 % for MAINPEX
pipes according to EnEV
Dimension Internal diameter Minimum insulation layer thicknesses
y‫=ג‬0.035 W/(m x K)
da x s (mm) di (mm)
16 x 2.2 11.6 20 mm
20 x 2.8 14.4 20 mm
25 x 3.5 18.0 20 mm
32 x 4.4 23.2 30 mm
40 x 4.0 32.0 30 mm
50 x 4.5 41.0 41 mm
If insulation materials having a different thermal conductivity than y =0.035W/(m x K) are
being used, the insulation layer thicknesses have to be converted using the calculation
procedure from the rules of technology.
DIN EN 12813. Normally, HVACR planning by the specialized technician are used for
programs, templates from engineering calculation purposes and to determine the
offices, or the calculation implemented quantities.
is to protect metallic components of the tem is not sensitive as regards to these
heating system, such as radiators or heat contaminations.
generators. The same may be damaged
by galvanic reactions. The MAINPEX sys-
cording to DIN 18380. Upon installation connectors for proper processing visually.
and before closing the wall slots, wall and The contractor has to develop a certificate
ceiling breakthroughs, the system has to on this pressure test and has to provide
be subjected to a pressure test. Before the the customer with the same.
aforementioned, you have to check the
33
Technical Manual Mainpex

Practical aids
Our employees are ready to support you
regarding the development. Please con-
tact your responsible sales representative.
Furthermore, customers of the company
Mainpex may use cost-free programs for
roughly estimated planning by means of
the customer number and a password se-
lected by themselves via our website.

Tips and notes

Our employees are ready to support you regarding the development. Please contact
your responsible sales representative.

Reference values installation times

Mainpex Nominal widths Installation times for running meter

Multi-layer compound (included, completely routed, including
pipe in mm attachment in group minutes)
16 DN 12 4 - 8 min
20 DN 15 5 - 9 min
25 DN 20 6 - 10 min
32 DN 25 7 - 11 min
40 DN 32 13 - 15 min
50 DN 40 15 - 17min
The specified installation times are complete reference values in group minutes.
Calculation installers with system experience.
All other auxiliary services are excluded.

34
 The pipe with comfort.

DIN
STANDARDS
DIN 1988-2 1988-12 Technical rules for drinking water installations (TRWI); Design and execution;
TRWI Parts, devices, materials, technical rules of the DVGW

DIN 1988-2 1988-12 Technical rules for drinking water installations (TRWI); compilation of
supplement 1 standards and other technical rules on materials, parts, and devices;
TRWI Technical rule of the DVGW

DIN 1988-6 2002-05 Technical rules for drinking water installations (TRWI); part 6: Fire extinguishing and
fire protection systems - Technical rule of the DVGW

DIN 2000 2000-10 Central drinking water supply - guidelines for requirements for drinking water,
design, construction, operation, and maintenance of the supply systems - Technical
rule of the DVGW

DIN 4703-1 1999-12 Room radiators - part 1: Dimensions of sectional radiators

DIN 4703-3 2000-10 Room radiators - part 3: Conversion of the standard heat output

DIN 4721 2001-06 Plastic pipe systems for hot water underfloor heating and
radiator connection - Polyethylene of increased temperature stability

DIN 4725-200 2001-03 Hot water underfloor heating systems - systems and components - part 200:
Determination of the heat output (pipe coverage <higher than>0.065 m)

DIN EN 806-1 2001-12 Technical rules for drinking water installations - part 1: General; German
version EN 806-1:2001 + A1:2001

DIN EN 806-2 2005-06 Technical rules for drinking water installations - part 2: Planning; German
version EN 806-2:2005

DIN EN 806-3 2006-07 Technical rules for drinking water installations - part 3: Calculation of the
Internal pipe diameters - simplified procedure; German version EN 806-3:2006

DIN EN 12828 2003-06 Heating systems in buildings - Planning and hot water heating systems;
German version EN 12828:2003

DIN EN 14336 2005-01 heating systems in buildings - Installation and commissioning of the hot water
heating systems; German version EN 14336:2004

35
 www.mainpex.de

MAINPEX GmbH & Co. KG Mainpex GesmbH

Silbersteinstraße 14 Bachwinkl 27
D-97424 Schweinfurt, Germany A-5761 Maria Alm am Steinernen Meer, Austria
Phone +49 (0) 9721/65977-500 Phone +43 (0) 6584/22800
Fax +49 (0) 9721/65977-600 Fax +43 (0) 6584/22888
info@mainpex.de info@mainpex.at
www.mainpex.de www.mainpex.at
MC-E-5/2009-01

DIN EN ISO 9001:2008

DIN EN ISO 14001:2005