RAUTHERMEX

Technical information 817600 EN

Subject to technical modifications / Valid as from December 2005
Table of contents

Page Page

1. Introduction 3 5. Installation 16
1.1 Features and benefits 3 5.1.1 Handling 16
1.2 Scope 3 5.1.2 Transporting 16
1.3 Application 3 5.1.3 Lifting with a digger 16
5.1.4 Lifting with a fork lift 16
2. Main components 4 5.1.5 Storing 16
2.1 RAUTHERMEX pipe 4 5.2.1 Preparing the trench 16
2.2 REHAU compression sleeve system 4 5.2.2 Trench design 17
2.3 REHAU insulation kits 4 5.2.3 Proximity to other services 17
5.2.4 Sloped trenches 17
3. Material properties 5 5.3.1 Laying pipes 18
3,1 RAUTHERMEX pipe 5 5.4.1 Joining pipes 19
3.1.1 Carrier pipes 5 5.4.2 Installing T-insulation kit 20
3.1.2 RAUTHERMEX SDR 11 carrier pipes 5 5.4.3 Installing coupler insulation kit 20
3.1.3 RAUTHERMEX SDR 7.4 carrier pipes 5 5.4.4 Using foam cartridge 21
3.1.4 Pressure and temperature limits 5 5.4.5 Using PU foam from canister 22
3.1.5 PE-Xa properties values 5 5.4.6 Heat shrinking of sleeves 23
3.1.6 Approvals for carrier pipe 5 5.5 Wall penetrations 24
3.2 Pipe insulation 6 5.5.1 Connecting through basement 24
3.2.1 Properties 6 5.5.2 Wall seals 24
3.3 RAUTHERMEX outer jacket 6 5.5.3 Compression wall seals 25
3.3.1 Outer jacket properties 6 5.5.4 Compression wall seals FA 80, watertight
3.4 Compression sleeve system 6 up to 1.5 bar 25
3.4.1 Material 6 5.5.5 Compression wall seals FA 40 25
3.5 RAUTHERMEX insulation kits 6 5.5.6 Prefabricated bends 26
3.5.1 RAUTHERMEX insulation kit for T-pieces 7 5.5.7 Ends caps 27
3.5.2 RAUTHERMEX insulation kit for couplers 7 5.6 Linear expansion in trench 28
3.5.3 Socket material properties 7 5.6.1 Linear thermal expansion when connecting to buildings 28
3.5.4 Heat-shrink sleeves 7 5.7 Miscellaneous 28
3.5.5 Material properties 7 5.7.1 Pipe in sleeve system 28
3.6 PU foam cartridge 7 5.7.2 Installing during land development phase 28
3.6.1 Technical data of component A, colour: yellow 7 5.7.3 Tapping into existing lines 28
3.6.2 Component B, colour: brown 7
3.6.3 Typical process data on foaming 7 6. Commissioning 29
3.7 RAUTHERMEX pipes sizes 8
7. Standards and guidelines 29
4. Design 9
4.1 General design considerations 9
4.1.2 Suitable pipe laying methods 9
4.1.3 Pipe routing considerations planning 9
4.1.4 Pipe sizing 9
4.1.5 Design tips 9
4.2 Piping strategies 10
4.2.1 Branch piping 10
4.2.2 Building to building piping 10
4.2.3 Branching off a plastic jacketed main line 10
4.3 Pipe laying techniques 11
4.3.1 Open cut technique 11
4.3.2 Horizontal directional drilling (HDD) 11
4.3.3 Pull-through method 11
4.4 Computing pressure-loss for SDR 11 pipes 12
4.4.1 Head loss with SDR 7.4 pipes 12
4.5 Energy loss with SDR 11 pipes 14
4.6 Energy loss with SDR 7.4 pipes 15

2
1. Introduction

To meet energy efficiency targets modern

industrial and residential construction pro-
jects often require central heating or cooling
plants combined with long-distant insulated
pipe networks.
Considerable CO2 savings can be achieved
with centralised plant rooms using
condensing bio-mass, bio-gas technology
or a combined heat and power unit. The
same is true for using waste heat from
industrial plants.
The RAUTHERMEX pipe system is a pre-
insulated pipe system which meets the high
demands for all these technologies and is
designed for the future.

1.1 Features and benefits:

■ Flexible pipe system enables cost-effec-
tive pipe routing.
■ Non-corrosive material of the
RAUTHERMEX pipe ensures long service
life of pipe network.
■ No linear expansion as pipe layers are
fully bonded together.
■ No expansion bellows or compensators
Fig. 1 Bio-mass plant heat supply
required.
■ Fully bonded pipe layers limit water
penetration to absolute minimum.
■ System components for all applications.

1.2 Scope
This technical information applies to the
design, installation and operation of the
flexible RAUTHERMEX pre-insulated pipe
system, the REHAU compression sleeve
joints and the RAUTOOL tools.

1.3 Applications
RAUTHERMEX is a pre-insulated pipe
system used predominantly below ground.
■ District heating
■ Cold and hot water mains services
■ Swimming pool technology
■ Cooling technology
■ Industry and agriculture
■ Flow and return connections to external
surface heating
■ Geothermal applications

Fig. 2 Waste-heat from a bio-gas plant used for school heating

Subject to technical modifications!

Fig. 3 Hot-water supply to a swimming pool

3
2. Main components

2.1 RAUTHERMEX pipe

RAUTHERMEX pre-insulated pipes consist
of coextruded fully bonded layers resulting
in a system, where water penetration along
the pipe is reduced to a minimum and no
movement between the individual layers is
possible.
The UNO and DUO variant features one or
two carrier pipes, respectively, made of high-
pressure crosslinked polyethylene (RAU-PE-
X) in accordance with DIN 16892/93, SDR
11 with an oxygen-barrier layer in accordan-
ce with DIN 4726 OR SDR 7.4 for drinking-
water applications with DVGW (German
Technical and Scientific Association for Gas
and Water) approval. The insulation is made
of polyurethane foam and the outer jacket is
made of PE-LD.
Advantages:
■ Fully bonded system ensures, no linear
expansion in the pipe trench.
■ No static pipe load calculation required.
■ Quick installation.
■ Small bending radius.
■ Low energy loss due to excellent thermal
conductivity properties of insulation.
Fig. 4 RAUTHERMEX UNO and DUO pipe

2.2 REHAU compression sleeve joint

The compression sleeve technology is a
method developed and patented by REHAU
for quick, secure and permanently leakproof
connections between PE-Xa pipes. It com-
prises a fitting and sleeve. Since the pipe it-
self acts as the seal, additional O-rings are
unnecessary. Four sealing ribs guarantee
absolute security of the connection, which
also resists the tough conditions on con-
struction sites. Specially designed ribs pre-
vent the pipe from separating itself during
operation.

Advantages:
■ Secure and permanent connection.
■ Carrier pipes are exepanded to make
connection, therefore No bore reduction.
The resulting pressure loss is negligible
and no cavitation forms.
■ Quick installation
■ Can be pressurized immediately.
■ Works under any site conditions
(rain, low temperatures, etc) .

Fig. 5 RAUTHERMEX compression sleeve joint

2.3 REHAU insulating kits

Joints below ground such as couplers and
T-pieces have to be insulated and water-
proofed to the same level as the main
RAUTHERMEX pipe network. The insulation
kits specifically developed for this applica-
tion consists of a plastic socket with
stepped ends to adapt to the varying sizes
of the outer jackets. Two heat-shrink
sleeves are used for sealing the coupler
socket and three for marking the T-socket
waterproof.
For insulation purposes high-quality PU
foam is available in cartridges, or in cani-
sters if larger quantities are needed.

Advantages:
■ Quick and easy installation.
■ Secure sealing.
■ Very good heat retention properties.
■ Only four components for all pipe sizes.

Subject to technical modifications!

Fig. 6 RAUTHERMEX Insulated T-piece

4
3. Material properties

3.1 RAUTHERMEX pipe

RAUTHERMEX pipe is made up of the
following main components:
■ Carrier pipe
■ Insulation layer
■ Outer jacket pipe
These components are explained in more
detail below.

Advantages:
■ Flexibiliy; small bending radius of only
0.7 m (DN 20) to 1.4 m (DN 125) are
possible.
■ Large coil lengths of 86 m (DN 125) to
760 m (DN 20) mean few joints and less Outer jacket pipe
installation work.
Pipe insulation

Carrier pipe
3.1.1 Carrier pipes
The carrier pipe is made out of crosslinked
polyethylene (PE-Xa) in accordance with
DIN 16892 and DIN 16893. PE-Xa pipes Fig. 9 RAUTHERMEX pipe make-up
are available for two pressure levels with
different wall thicknesses (SDR 11 and Advantages: Chemical resistance
SDR 7.4). ■ Excellent chemical resistance RAUTHERMEX PE-Xa carrier pipe exhibits a
The carrier pipes are crosslinked via the ■ Low friction coefficient (e = 0.007 mm at very good resistance to the majority of che-
addition of peroxide at high pressure and 60 °C) micals and concentrations. Safety factor
temperature. The cross-linking process ■ No incrustations and temperature resistance depend on the
bonds the macromolecules in a robust ■ Low pressure loss over the entire service medium used in the application (e.g. hot
3-dimensional network. lifetime water, chilled water etc).
■ SDR 11 pipes with special orange EVOH The resistances listed in DIN 8075,
oxygen-barrier layer Supplement 1, also apply to PE-Xa.
3.1.2 RAUTHERMEX carrier pipes ■ Corrosion resistance
SDR 11 ■ Advantageous aging properties
■ Creep resistance 3.1.5 PE-Xa properties
■ Good recovery/memory effect
■ Heat resistance Density 0.94 g/cm3
■ Does not carry sound well Average linear thermal 1.5 10-4 K-1
■ Pressure resistance longitudinal expansion
■ Toxicologically and physiologically harm- coefficient in the temperature
less range of 0° to 70 °C
■ Excellent notched impact resistance Thermal conductivity 0.38 W/mK
Young’s modulus 600 N/mm2
Surface resistance > 1012 ς
3.1.4 Pressure and temperature Material class B2 (normal
limits flammability)
For continuous temperatures and assuming German
a safety factor of 1.25 in accordance with Standard
DIN 16892/93, the following temperature Pipe surface roughness 0.007 mm
and pressure limits (application: water,
safety factor: 1.25) apply to RAUTHERMEX
Fig. 7 SDR 11 carrier pipes pipes: 3.1.6 Approvals for carrier pipe
The RAUTHERMEX SDR 11 pipes are pre-
RAUTHERMEX, SDR 11 SDR 11 approvals:
dominantly used for heating and cooling
40 °C 11.9 bar 50 years ■ France:
applications. Hence they have an additional
50 °C 10.6 bar 50 years Atec 15+15/99-553
oxygen-barrier layer made of EVOH in
60 °C 9.5 bar 50 years
accordance with DIN 4726. The colour of
70 °C 8.5 bar 50 years SDR 7.4 approvals:
these pipes is orange.
80 °C 7.6 bar 25 years ■ Germany:
90 °C 6.9 bar 15 years DVGW (DW-8301A02102
95 °C 6.6 bar 10 years DW-8302A02931)
3.1.3 RAUTHERMEX SDR 7.4
■ Austria:
carrier pipes
RAUTHERMEX, SDR 7.4 ÖVGW (W 1.094)
The RAUTHERMEX SDR 7.4 pipes are used
40 °C 18.9 bar 50 years
in many countries for drinking-water applica-
50 °C 16.8 bar 50 years
tions (see item 3.1.7, Approvals). The colour
60 °C 15.0 bar 50 years
of these pipes is natural.
70 °C 13.4 bar 50 years
80 °C 12.1 bar 25 years
90 °C 11.0 bar 15 years
95 °C 10.6 bar 5 years

For varying operating pressures and tempe-

ratures, the expected service life can be
determined according to the "Miner's Rule"
DIN 13760.
The carrier pipes are designed for maximum
operating temperatures of 95 °C, but can
tolerate temperatures up to 110 °C for short
periods in the case of malfunctions.

Fig. 8 SDR 7.4 carrier pipes

Subject to technical modifications!

5
3.2 Pipe insulation
The RAUTHERMEX SDR 11 and 7.4 pipes
are manufactured with PU foam using CO2
as blowing agent.
The PU foam is therefore free from CFCs
and HCFCs.
3.3 RAUTHERMEX outer jacket
The RAUTHERMEX SDR 11 pipes have a
mild corrugated jacket, that improves static
load capability, increased longitudinal flexibi-
lity, and smaller bending radii, particularly for
jacket pipe diameters of 162 - 182 mm.
The RAUTHERMEX SDR 7.4 pipes have a
black outer jacket.
To increase longitudinal flexibility, the outer
jackets of RAUTHERMEX SDR 11 and SDR
7.4 pipes are manufactured from
the flexible PE-LD material.
3.4.1 Material
The compression sleeve fittings are made of
either specially dezincification-resistant
brass in accordance with DIN EN 1254/3 (E)
Class A or gun metal or ST37. The sleeves
are made of annealed standard brass
CuZn39Pb3 / F43 in accordance with DIN
17671 or gun metal.
RAUTOOL M1
Manual tool with dual clamping jaws for two
dimensions. Available for carrier pipe sizes
16 - 40. The M1 compression jaws must
only be used with the RAUTOOL M1.

Fig. 10 Exposed pipe layers

Advantages:
■ Very fine pores (up to 95 % closed cells). Fig. 13 RAUTOOL M1
■ Cells contain no flammable gases
■ High water vapour transfer coefficient Fig. 11 Outer jacket RAUTOOL A2
and consequently no moisture penetra- Battery operated electrohydraulic tool with
tion during operation Advantages: dual clamping jaws for two dimensions.
■ Very good bond with the PU foam The hydraulic pump and tool cylinder are
■ Extruded seamlessly around the PU incorporated into one single portable and
3.2.1 Properties foam compact unit. Available for carrier pipe sizes
Thermal conductivity ≤ 0.032 W/mK ■ Ideal for use with the heat-shrink sleeves 16-40.
according of the insulation kits
to EN 253

GWP (greenhouse 3.3.1 Outer jacket properties

warming potential): 0 PE, low density polyethylene (PE-LD)
ODP (ozone Thermal conductivity: 0.43 W/mK
depletion potential): ≤0
Crystallinity melting range: 105 -110 °C
Density: > 57 kg/m³
Density: 0.93 g/cm³
Compressive strength: 30 N/cm³
Young’s modulus 400 N/mm2
Water absorption: 5 % in accor-
dance with Material class B2 (normal
EN 253 flammability) Fig. 14 RAUTOOL A2
Add GERMAN
Long term heat DIN standard RAUTOOL G1
resistance: 120 °C Tool for carrier pipe sizes 50 - 110; optional-
ly available for pipe size 40 x 5.5. It is powe-
Shear strength: 200 kPa 3.4 Compression sleeve system red either through a hydraulic foot pump or
according to EN 253 an electrohydraulic unit.
pipe. The pipe system operator must be able to
rely on the jointing technology if the system
is installed below ground.
A permanent leak proof connection can be
guaranteed only if REHAU compression
sleeve joints are utilised with REHAU
RAUTOOLS.

Fig. 15 RAUTOOL G1

3.5 RAUTHERMEX insulation kits

The insulation pods are made from extreme-
ly robust and impact-resistant LLDPE.
REHAU provides all specialist accessories
and tools required to achieve a high quality
Fig. 12 Compression sleeve joint insulation, including textile reinforced sand-
paper, temperature indicator strips and
Forstner drill bits.
Subject to technical modifications!

6
3.5.1 RAUTHERMEX insulation kit for
T-piece
The RAUTHERMEX insulation kit for
T-pieces is used to insulate branches. Only
two insulation socket sizes are required to
accommodate all pipe sizes thanks to the
specially designed, stepped ends of each
socket.
The insulation kit consists of
■ 1 T-piece LARGE or small
■ 3 pieces of heat-shrink sleeving
■ 1 textile reinforced tape for small T-piece
and 2 textile reinforced tapes for LARGE
T-piece
■ Installation instructions

Fig. 16 Insulated branch using insulation kit

for T-pieces Cut away of insulated branch connection using REHAU insulation kit

3.5.2 RAUTHERMEX insulation kit 3.6 PU foam cartridge 3.6.1 Technical data
for straight couplers RAUTHERMEX joints are insulated using Component A, colour: yellow:
The RAUTHERMEX insulation kit for coup- two-component PU foam. The PU foam is
lers is used for insulation of couplings and available in cartridges and canisters. The Freezing temperature: < 0 °C
end stop. The insulation kit consists of: cartridge is supplied as set and includes
■ 1 coupler LARGE or small ■ 1 cartridge Flashpoint: > 180 °C
■ 2 pieces of heat-shrink sleeving ■ 1 vent plug
■ Installation instructions ■ 1 hexagon bolt (for mixing of foam) Density: 1.064 g/cm3 (20 °C)
■ Installation instructions

3.6.2 Component B, colour: brown:

Flashpoint: > 250 °C

Vapour pressure: < 0.01 Pa

(20 °C)

Density: 1.24 g/cm³

(20 °C)
Fig. 18 insulated coupler using insulation kit
for couplers
3.6.3 Typical process data on
foaming (measured values)
3.5.3 Socket material properties
PE, low density polyethylene (PE-LD) Measurement
temperature: 20 °C
Thermal conductivity: 0.43 W/mK
Mix ratio: 100 : 160
Crystallinity melting range: 105 -110 °C Fig. 19 Photo of PU foam cartridge
Reaction starts after: 40 seconds
Density: 0.93 g/cm³ When using PU foam in canisters, the
following articles are required: Thread time: 130 seconds
Young’s modulus 600 N/mm2 ■ Canister with component A and canister
with component B in appropriate quanti- Rise time: 180 seconds
Material class B2 (normal ties (see foaming table on REHAU home-
flammability) page, www.REHAU.de/ Raw density: 59 kg/m³
GERMAN RAUTHERMEX) (unrestricted foaming)
standard ■ Foam cup
■ Vent plug Raw density (core): 68 kg/m³
3.5.4 Heat-shrink sleeving
The inner surface of the heat-shrink sleeving Compressive strength: 0.44 N/mm³
is coated with a hot-melt adhesive.
Upsetting deformation
3.5.5 Material properties need to discuss: 6%
Tensile strength 14 MP Closed-cell factor: 95 %
Max. elongation 300 %
Note:
Density 1.1 kg/dm³ Carefully read safety data sheets and
installation instructions supplied with
Water absorption < 0,1 % the products before using the foam
products.
Softening 80 - 90 °C
temperature of adhesive

Material class B2 (normal

flammability) Fig. 20 Components A and B with foam
GERMAN sample
standard
7
3.7 RAUTHERMEX pipe sizes

UNO pipes, pipe series 1, SDR 11

Designation d s D Volume Weight Max. coil length [m]

[mm] [mm] [mm] inner pipe [l/m] [kg/m] 2.8 m x 0.8 m 2.8 m x 1.2 m

25/91 25 2.3 93 0.327 1.20 377 560

32/91 23 2.9 93 0.539 1.34 377 560
40/91 40 3.7 93 0.835 1.84 377 560
50/111 50 4.6 113 1.307 1.97 271 380
63/126 63 5.8 128 2.091 2.60 192 280
75/162 75 6.8 163 2.961 4.11 92 144
90/162 90 8.2 163 4.256 1.56 92 144
110/162 110 10.0 163 6.362 6.37 92 144
125/182 125 11.4 184 8.120 7.22 - 86
160/225 160 14.6 225 13.430 11.43 6 m straight lengths

DUO pipes, pipe series 1, SDR 11

Designation 2xd s D Volume Weight Max. coil length [m]

[mm] [mm] [mm] inner pipe [l/m] [kg/m] 2.8 m x 0.8 m 2.8 m x 1.2 m

25+25/111 25 2.3 113 2 x 0.327 1.73 271 380

32+32/111 32 2.9 113 2 x 0.539 1.87 271 380
40+40/126 40 3.7 128 2 x 0.835 2.45 192 280
50+50/162 50 4.6 163 2 x 1.307 3.96 92 144
63+63/182 63 5.8 184 2 x 2.07 5.28 - 86

UNO pipes, pipe series 2, SDR 7.4

Designation d s D Volume Weight Max. coil length [m]

[mm] [mm] [mm] inner pipe [l/m] [kg/m] 2.8 m x 1.2 m

20/76 20 2.8 75 0.163 0.8 500

25/76 25 3.5 75 0.254 1.00 500
32/76 32 4.4 75 0.423 1.10 500
40/91 40 5.5 90 0.660 1.55 360
50/111 50 6.9 110 1.029 2.25 240
63/126 63 8.6 125 1.633 3.00 170

DUO pipes, pipe series 2, SDR 7.4

Designation d1 s1 d2 s2 D Volume Weight Max. coil length [m]

[mm] [mm] [mm] [mm] [mm] inner pipe [kg/m] 2,8 m x 1,2 m

25+20/91 25 3.5 20 2.8 90 0.254+0.163 1.40 360

32+20/111 32 4.4 20 2.8 110 0.423+0.163 2.00 240
40+25/126 40 5.5 25 3.5 125 0.660+0.254 2.60 170
50+32/142 50 6.9 32 4.4 140 1.029+1.633 3.50 150

8
 4. Design
4.1 General design considerations
Efficient RAUTHERMEX pipes make it poss-
ible to achieve the operational cost savings
of district heating networks and supply lines
between two buildings.
4.1.2 Suitable pipe laying methods
The flexibility of RAUTHERMEX pipes makes
them suitable for a wide range of laying
methods as long as the correct method for
the local conditions is selected. The fully
bonded RAUTHERMEX system is also ideal
for bridging long distances with trenchless
laying methods such as trench ploughing
and horizontal directional drilling .
4.1.3 Pipe routing considerations
The proximity to other services must be
taken into account when routing the pipes.
The burial depth for achieving the minimum
coverage (section 5.2.2) is particularly
important when pipes are buried underneath
roadways to keep the stress loads on the
pipe within the permitted limits. In such
cases the correct compacting of the final
cover according to the relevant standards
should also be ensured.
Venting of the RAUTHERMEX pipes is gene-
rally done via the branch connections to the
buildings. If this is not possible, vents can
100
90
80
plant in %in %
70
Heizwerk
60
heat
capacity exab
50
Wärmeleistung
40
Heating
30
20
10
0
0 1000
Fig. 22 Annual heat demand
be fitted at the highest points of the under-
ground network.
For larger pipe networks, it is recommended
to divide the network into smaller subsection
with below ground isolating valves.
Subsections can so be isolated when the
network is extended at a later time.
A static pipe network calculation with
expansion legs, bellows or compensators is
not necessary with RAUTHERMEX pipes
thanks to their self compensation.
4.1.4 Pipe sizing
The hydraulic performance of
RAUTHERMEX pipes is considerably greater
compared to steel pipes due to the lower
pipe roughness. For this reason, pressure-
loss tables for steel pipes cannot be used
for the pressure-loss calculation of
RAUTHERMEX pipes.
It is recommended when sizing
RAUTHERMEX pipes to compare the heat
losses and pump capacities. Since full
pump capacity is usually only required on a
few days of the year, reducing the pipe
dimensions can lead to a considerable
reduction in heat loss and materials used.
For optimal sizing of the network, the varia-
tions in heat demand over one year must be
analyzed.
The charts on pages 12 and 13 can be
used for estimating the pressure-loss.
2000 3000 4000 5000 6000 7000 8000
Operating hours
Betriebsstunden
4.1.5 Design tips
From the heat demands plotted over one
year (see Fig. 22), it is quite clear that full
heating capacity is only required on a few
days a every year.
Investment and (due to higher heat losses)
running costs of district heating networks
rise with increasing pipe diameter the
Therefore the smallest possible pipe diame-
ters should be designed for RAUTHERMEX
pipe networks. The Additional costs requi-
red to compensate the higher pressure loss
at full capacity are more than outweighed by
the savings in investment and running costs.
To further maximise the efficiency of the
system a second pump which starts auto-
matically when the primary pump reaches
full capacity can be utilised. The primary
pump is therefore sized for average demand
rather than peak demand, ensuring for the
majority of operation it is run at optimum
duty. The secondary pump is utilised as a
back-up pump in the case of mechanical or
electrical failure.
Another possibility is to split the supply lines
into three (two flow pipes and one return
pipe) or four pipes (two flow pipes and two
return pipes) If the second supply lines are
only switched on when the capacity of the
first is exceeded, the complete network can
indeed be operated with minimal heat
losses for most of the year.
9
4.2 Piping strategies
4.2.1 Branch piping
Buildings are connected via branches from
a main line. Mixed types are also possible,
of course.

Advantages:
■ Flexible in design
■ Easy installation even before buildings
are erected .
■ Staged developments possible as new
branches can be easily added.

Fig. 23 Branch piping

4.2.2 Building-to-building
("Daisy Chain") piping
In many cases, the availability of long deli-
very lengths of RAUTHERMEX pipes allows
for a complete elimination of below-grade
connections or branches by laying the
RAUTHERMEX pipes from one building to
the next and back.

Advantages:
■ No connections below grade.

Fig. 24 Building-to-building ("Daisy Chain") piping

4.2.3 Branching off a plastic
jacketed main line
A take off from a plastic jacketed main pipe
to a RAUTHERMEX pipe to extend an
existing network or to connect of a single
building is possible.

Advantages:
■ If the operating temperatures of the main
line are too high, a secondary network
with RAUTHERMEX pipes can be crea-
ted via a network decoupling.
■ If the heating capacity of the main line is
too high for the RAUTHERMEX pipes,
branches can be added without the
need for any special precautions.

Subject to technical modifications!

Fig. 25 Branching off a plastic jacketed main line

10
4.3 Pipe laying techniques
4.3.1 Open cut technique
This is the most common laying method.
RAUTHERMEX pipe trenches can be very
narrow. Only at junctions and branches is
sufficient space required to complete the
joints.
Fig. 26 Open cut technique
4.3.2 Horizontal Directional Drilling
(HDD)
This method is also suitable for
RAUTHERMEX.
Fig. 27 Horizontal Directional Drilling (HDD)
4.3.3 Pull-through technique
With the pull-through method,
RAUTHERMEX pipes can be installed in
disused channels, already laid pipes or in
plastic jacket pipes which require renova-
ting.
Fig. 28 Pull-through method
Subject to technical modifications!
Advantages:
■ Flexible laying without special equip-
ment.
■ Narrow pipe trenches.
Advantages:
■ High-quality surface structures can thus
be bypassed cost-effectively.
Advantages:
■ Defective pipelines can be renovated
easily.
■ Cost-effective laying through empty
pipes which already exist or have been
installed using Horizontal Directional
Drilling (HDD).
■ Obstacles can be bypassed with minimal
costs.
■ Additional connections can be made at
any time.
■ It is even possible to cross under water
reservoirs. In these cases, the
RAUTHERMEX pipes should be installed
in a protective sleeve.
■ The fully bonded construction allows
high pull forces to be used and therefore
large distances to be covered.
11
4.4 Computing pressure-loss for
SDR 11 pipes
To estimate the head loss in a section of
pipe, the pipe length is required and the
pipe routing defined.
Water temperature
Head loss diagram
Heating capacity Q in kW with temperature drop σ = 20K
Heating capacity Q in kW with temperature drop σ = 30K
Fig. 29 SDR 11 head loss diagram
Computing pressure loss using flow
rate Q [litres/sec]:
Example:
SDR 11 pipes
Flow rate:
Section length:
= total pipe length:
Start point
Draw a vertical straight at 0.55 l/s (red line)
Pipe size and associated head loss
Where it crosses the respective line for each
pipe size (circles), draw a horizontal line to
the left axis. (green lines)
The intersections of each horizontal line with
the vertical axis indicate the expected head
loss. [Pa/m].
Resulting velocity [metres/sec]
Starting where the vertical line crossed the
lines for each pipe size, draw a straight line
diagonally up and left. (blue line)
Subject to technical modifications!
12
The flow rate quantity Q [litres/sec] or the
heat carrying capacity [kW/h] together with
the design temperature drop [K] can be
used for system design. The bore of SDR
11 and SDR 7.4 pipes is different and con-
sequently different head loss tables apply.
circle 1
circle 2
circle 3
Flow
Possible options: Pipe sizes and associated head loss
Circle 1 Pipe size: 32 x 2.9 Identify the correct axis for the selected
Green line head loss: 550 Pa/m temperature drop and draw a vertical
Total pressure loss: 550 Pa/m x 200 m straight line at the 80 kW mark (yellow line).
=110000 Pa = 1.1 bar = 11 mWs All subsequent steps follow the same
0.65 l/s Blue line velocity: 1.3 m/s sequence and logic as for the previous
100 m computing method using the flow rate as a
200 m Circle 2 Pipe size: 40 x 3,7 starting point.
Green line head loss: 200 Pa/m
Total pressure loss: 200 Pa/m x 200 m Calculation including heat loss to the
= 40000 Pa = 0.4 bar = 4 mWs ground
Blue line velocity: 0.8 m/s A total value including expected heat losses
to the ground can be computed by adding
Circle 3 Pipe size: 50 x 5.7 the heat losses of Tables 1 and 2 to the
Green line head loss: 65 Pa/m heat carrying capacity.
Total pressure loss: 65 Pa/m x 200 m
= 1300 Pa = 0.13 bar = 1.3 mWs
Blue line velocity: 0.5 m/s 4.4.1 Pressure loss with SDR 7.4
pipes
Computing pressure loss using heat- The RAUTHERMEX SDR 7.4 pipes are pre-
carrying capacity [kW] dominantly used for transporting drinking
If the required heat carrying capacity in water. Local guidelines for calculating the
[kW/h] and the design temperature drop [K] peak flow rates for drinking water have to be
are available, the first step is also to draw a followed. The pressure loss in Pa is dictated
vertical line. by the required peak flow rate [litres/sec].
The peak flow rate [litres/sec] is then identi-
Example: cal to the flow rate [litres/sec] in Fig. 31.
Temperature drop: 30 K
Heat carrying capacity: 80 kW
Length: 100 m
Head loss diagram Water temperature

Flow

Heating capacity Q in kW with temperature drop σ = 20K

Heating capacity Q in kW with temperature drop σ = 30K

Fig. 30 SDR 11 head loss diagram

Water temperature
Head loss diagram

Flow

Fig. 31 SDR 7.4 head loss diagram

Subject to technical modifications!

13
4.5 Energy losses with SDR 11 pipes Assumptions Energy losses during operation:
H = K (TB - TE) [W/m]
Assuming an ambient soil temperature of K = thermal heat transfer coefficient [W/mK]
10 °C, soil conductivity of 1.2 W/mK, depth UNO pipes: 2 pipes in trench TB = mean water supply temperature [°C]
of 0.6 m from the surface and (in case of below grade TE = ambient soil temperature [°C]
two UNO pipes side by side) pipe spacing of DUO pipes: 1 pipe in trench
0.1 m, the following energy losses per meter below grade
of pipe can be expected for the indicated Pipe spacing: CAUTIONARY NOTE:
mean water supply temperatures. for UNO pipes a = 0.1 m Soil type, moisture content and soil tempe-
The indicated energy losses apply per for Depth from surface: H = 0.6 m rature have a significant effect on the energy
1 meter of RAUTHERMEX pipe. Ambient soil: TE = 10 °C losses. The given values are provided as a
Soil Conductivity: lE = 1.2 W/mK guideline and offer a general understanding
Cond. of PUR foam lPU = 0.032 W/mK of the estimated energy losses one may
Cond. of PE-Xa pipe lPE-Xa = 0.38 W/mK expect. If precise calculations are desired,
Cond. of we recommend you consult a professional
outer PE jacket lPE= 0.043 W/mK engineer.

Energy loss of SDR 11 UNO pipe

Energy losses [W/m]

mean water supply temperature TB [ºC]
RAUTHERMEX UNO k [W/mK] 40 º 50 º 60 º 70 º 80 º 90 º
25/91 0.147 4.4 5.9 7.4 8.8 10.3 11.8
32/91 0.177 6.2 8.3 10.4 12.5 14.6 16.6
40/91 0.244 6.7 9.0 11.2 13.4 15.7 17.9
50/111 0.228 6.8 9.1 11.4 13.7 16.0 18.2
63/126 0.257 7.7 10.3 12.9 15.4 18.0 20.6
H=0.6m

75/162 0.236 7.1 9.4 11.8 14.2 16.5 18.9

a=0.1m
90/162 0.299 9.0 12.0 15.0 17.9 20.9 23.9
110/162 0.428 12.8 17.1 21.4 25.7 30.0 34.2
125/162 0.432 13.0 17.3 21.6 26.0 30.3 34.6
160/225 0.522 15.7 20.9 21.6 31.4 36.6 46.9
Tab. 1 Energy loss of SDR 11 UNO pipes
TE E
Fig. 32 RAUTHERMEX SDR11 UNO

Energy loss of SDR 11 DUO pipe

Energy losses [W/m]

mean water supply temperature TB [ºC]
RAUTHERMEX DUO k [W/mK] 40 º 50 º 60 º 70 º 80 º 90 º
25+25/111 0.212 6.4 8.5 10.6 12.7 14.8 17.0
32+32/111 0.282 8.5 11.3 14.1 16.9 19.7 22.6
H=0.6m

40+40/126 0.319 9.6 12.8 16.0 19.1 22.3 25.5

50+50/162 0.297 8.9 11.9 14.9 17.8 20.8 23.8
63+63/182 0.332 10.0 13.3 16.6 19.9 23.2 26.5
Tab. 2 Energy loss of SDR 11 DUO pipes
TE
E

Fig. 33 RAUTHERMEX SDR11 DUO

Subject to technical modifications!

14
4.6 Energy losses with SDR 7.4 pipes Assumptions Energy losses during operation:
H = K (TB - TE) [W/m]
Bei einer Erdeichtemperatur von 10 °C, K = thermal heat transfer coefficient [W/mK]
einer Leitfähigkeit des Bodens von 1,2 UNO pipes : 2 pipes in trench TB = mean water supply temperature [°C]
W/mK, einer Überdeckungshöhe von 0,6 m below grade TE = ambient soil temperature [°C]
und (bei Verwendung von zwei UNO- DUO pipes: 1 pipe in trench
Rohren) below grade
einem Rohrabstand von 0,1m stellen sich je Pipe spacing:
Rohrmeter folgende Wärmeverluste bei der for UNO pipes a = 0.1 m
jeweiligen mittleren Betriebstemperatur ein. Depth from surface: H = 0.6 m
Ambient soil
temperature: TE = 10 °C
Soil conductivity: lE = 1.2 W/mK
Cond. of PUR foam lPU = 0.032 W/mK
Cond. of PE-Xa pipe lPE-Xa = 0.38 W/mK
Cond. of
outer PE jacket lPE= 0.043 W/mK

Energy loss of SDR 7.4 UNO pipe

Energy losses Q [W/m]

k [W/mK] mean water supply temperature TB [ºC]
RAUTHERMEX UNO 40 º 50 º 60 º 70 º
20/76 0.153 4.6 6.1 7.78 9.2
25/76 0.187 5.6 7.5 9.4 11.2
32/76 0.213 6.4 8.5 10.7 12.8
40/91 0.230 6.9 9.2 11.5 13.8
50/111 0.234 7.0 9.4 11.7 14.0
63/126 0.266 8.0 10.6 13.3 16.0
Tab. 3 Energy loss of SDR 7.4 UNO pipes

Fig. 34 RAUTHERMEX SDR 7.4 UNO

Energy loss of SDR 7.4 UNO pipe

Energy losses Q [W/m]

k [W/mK] mean water supply temperature TB [ºC]
RAUTHERMEX DUO 40 º 50 º 60 º 70 º
25+20/91 0.284 8.5 11.4 14.2 17.0
32+20/111 0.236 7.1 9.4 11.8 14.2
40+25/126 0.261 7.8 10.4 13.1 15.7
50+32/126 0.347 10.4 13.9 17.4 20.8
Tab. 4 Energy loss of SDR 7.4 DUO pipes

Fig. 35 RAUTHERMEX SDR 7.4 DUO

Subject to technical modifications!

15
5. Installation
Fig. 36
5.1.1 Handling
Incorrect transport or storage can result in
damage to RAUTHERMEX pipes, accesso-
ries and fittings which could effect the ope-
rational safety and/or thermal insulation pro-
perties of the pipe network.
Pipes, fittings and accessories must be
checked for any transport and/or storage
damage before being placed in the trench.
Damaged pipes fittings and accessories
must not be installed.
Fig. 39
5.1.4 Lifting with a fork lift
When using a fork lift, ensure the forks are
covered with a soft material (cardboard,
plastic tubes).
Note: When using plastic tubes make sure
they are secured properly to prevent them
from slipping off.
Fig. 42
5.2.1 Digging trenches
The dimensions of the pipe trench influence
the level and distribution of the soil and traf-
fic loads and thus the load-bearing capacity
of the pipeline. The width at the bottom of
the trench depends on the outer diameter of
the pipe, quantity of pipes and also whether
or not additional working space is required
to lay the pipes. Sections underneath road-
ways must comply with loading classifica-
tions SWL 30 or SWL 60 in accordance
with DIN 1072.
Subject to technical modifications!
16
Fig. 37 RAUTHERMEX coil on trailer
5.1.2 Transport
Pipe coils are to be transported horizontally
on a load area must lie completely flat and
be secured to prevent shifting. The load
area must be cleaned before loading up the
pipe coils.
Fig. 40
5.1.5 Storing
We recommend storing pipe coils horizon-
tally on wooden planks. In general this will
avoid any pipe damage and allow easy lifting
when moved at a later stage. Under no cir-
cumstances are pipe coils to be stored on
top of sharp-edged objects. Pipe coils
should not be stacked on top of each other.
Fig. 43
For RAUTHERMEX additional working
space is only necessary in the jointing areas
and should be in accordance with the requi-
rements set by the local standards and wor-
king regulations.
The minimum pipe cover for RAUTHERMEX
pipes is 60 cm. The maximum cover is 2.6
m. For bigger pipe covers a static load cal-
culation is required.
Fig. 38 Lifting of RAUTHERMEX
5.1.3 Lifting with a digger
When lifting a pipe coil, ensure that the
lower part of the coil, which initially is still
touching the ground and carrying part of the
total weight, is not dragged across the
ground or load area.
Take extra care when putting down the pipe
coils:
Do not use ropes for lifting, only transport
straps at least 50 mm wide.
Fig. 41
Coils must not be stored in an upright posi-
tion. Attention: Danger of injury!
The resulting small contact area between
ground and coil would also allow objects to
easily penetrate the outer jacket.
Fig. 44
The bottom of the trench has constructed in
such a way, that it meets the specified width
and depth and the pipeline can be in
contact with it over its entire length.
5.2.2 Trench design
. .
. . . . . .
. . . . . . . . .. . . .
. . . . . . . . . . .
. . . . . . . .. . .
. . . . . .
. . . . . . .
. .
. .
. . . .

60
. . . . .
. . . . . . .
. .
. . .
. .
.

10 D 5 D 10 30
60
.
60
. ..
.
.
. . . . . . . . . . . . .

10 D 10 30
.. .
. . . . .

D 10 30
. . .
.. . .
.
..

T
. .

T
.

T
10

10 D 10 D 10
10 D 10 10 D 10 D 10
B
B B

Fig. 44 DUO pipes Fig. 45 Two-pipe system with UNO pipes Fig. 46 Four-pipe system with UNO pipes, 2
x 2 arrangement

. .
. .
.
. . ..
...
.
.
. .
.
Other Crossover Parallel
. . .
.
.
. . . .
. . Service >5 m
. .
60

. . .
. . . . ..
. .
1 kV -, signal, 0.3 m 0.3 m
10 D 10 30

. .
. . . .
Sensor cable
T

10 kV or a 0.6 m 0.7 m
30 kV cable
Several 30 kV 1.0 m 1.5 m
cables or cables
10 D 10 D 10 D 10 D 10 over 60 kV
B (4xD + 5x10) Gas and 0.2 m 0.4 m
water services
Fig. 47 Four-pipe system with UNO pipes, 1
x 4 arrangement Fig. 48 Minimum separation

The required trench widths are shown in Fig. Fig. 49

44 through 47. Only sand of grade 0/4 is to
be used around the pipes and must be 5.2.3 Proximity to other services The trench bottom may not be aerated.
manually compacted. Minimum separations to other services must Aerated, cohesive soil is to be removed
be observed. down to the bottom of aeration before laying
Drinking-water services adjacent to district the pipes and replaced with non-cohesive
heating pipes are to be separated by the soil or a special pipe support. Aerated, non-
minimum distance to prevent them from cohesive soil is to be packed again.
warming up above the temperatures speci-
fied by the applicable standards. If the spe-
cified minimum distance cannot be achie-
ved, the drinking-water lines may have to be
insulated.

concrete bracket

non-woven



 

gravel
 

 

Fig. 50 Fig. 51 Non-woven in pipe trench Fig. 52 Cross brackets

In rocky and stony conditions, the trench is If pipes are laid in swampland and marsh- 5.2.4 Sloped trenches
to be excavated to a depth of at least 0.1 m land with varying water table or underneath On slopes, cross brackets are required to
below the bottom of the pipe. and the roadways solid obstructions which can prevent the bedding from being washed
excess excavation shall be filled with com- effect the pipe support must be removed to away. In some cases Drainage may be
pacted washed sand of grade 0 - 3/4. a sufficient depth under the pipes. In cases needed.
where the bottom of the trench is unstable
or the soil is highly saturated the pipes have
to be secured through adequate construc-
tion measures, e.g. using non-wovens.
The same applies where the load bearing
capability of the soil changes along the
trench.

Subject to technical modifications!

17
Fig. 53 Fig. 54 Fig. 55

5.3.1 Laying pipes
Cutting straps
Safety Warning:When cutting the straps on
coils undoing the coil bindings, pipe ends
can spring outward! Always cut straps open
bindings layer by layer (Fig. 54).Do not stand
in the danger zone (Fig. 54)!
Warning:
When undoing the bundled coil bindings,
pipe ends can spring outward! Always open
bindings layer by layer (Fig. 54).
Do not position yourself in the hazar-
dous area (Fig. 54)!
Ensure that the uncoiled pipe section does
not twist, as otherwise kinks may form.
Another reason for cutting the straps layer
by layer.

RAUTHERMEX- Minimum bending

outer diameter radius at 10 °C
[d] outer jacket temper.
[R]
76 mm 0.7 m
91 mm 0.8 m
111 mm 0.9 m
126 mm 1.0 m
142 mm 1.1 m
162 mm 1.2 m
182 mm 1.4 m
Tab. 5
Fig. 56 Fig. 57

Uncoiling Bend areas Bending radii

For pipes with outer diameter up to 126
mm, the coils are usually uncoiled in their
upright position. For larger pipe sizes, we
recommend a mechanical uncoiler be used.
The coils can then, for example, be positio-
ned horizontally on the uncoiler and uncoiled
by hand or a slowly-moving vehicle.
The high flexibility of the RAUTHERMEX
pipes allows easy and quick laying.
Obstacles can be bypassed and changes of
direction in trenches are possible without
the need for fittings. However, based on the
pipe temperature, the minimum bending
radii as specified in the following table must
be observed.
If the above bending radii have to be achie-
ved at lower jacket pipe temperatures, the
bend area of the pipe can be preheated with
a low burner flame. For installation in frost
conditions the bend area of the pipe must
always be preheated.

Fig. 58 Fig. 59 Fig. 60

The reduction of pipe flexibility at low tem-
peratures around the freezing point means
that the RAUTHERMEX pipes cannot be
easily uncoiled. To minimize the effect of low
temperatures on the flexibility the pipe coils
can be warmed up for a few hours in a hea-
ted building or a heated tent.
Backfilling with sand
Fill pipe trench up to 10 cm over the top of
the pipes using sand of grade 0/4 and com-
pact by hand.
Identification tape
For better identification during future exca-
vation work, an identification tape should be
laid 40 cm above the pipes. The identificati-
on tape should comply with the local stan-
dards and regulations. For easier location of
the installed pipeline, identification tape with
metallic strips can be used.

Subject to technical modifications!

18
5.4.1 Joining Pipes

Fig. 61 Fig. 62 Fig. 63

Installation tool and accessories Cut pipe Stripping lengths

■ Hand saw Attention: RAUTHERMEX pipe can spring according to diameter of carrier pipe:
■ Knife or chisel back! OD 20 - 40 mm: 100 mm
■ Safety goggles OD 50 - 110 mm: 125 mm
■ Gloves OD 125 - 160 mm: 150 mm
■ Soft-flame torch Strip at least 2 - 4 cm extra so that the carri-
■ Sandpaper / Abrasive cloth and er pipe can be trimmed square (see Fig. 66).
Forstner drill bit

Fig. 64 Fig. 65 Fig. 66

Cut pipe jacket all the way round with a saw Remove foam. Cut carrier pipe square.
or pipe cutter and peel it off. Attention: Take care not to damage the oxy-
Attention: Do not damage carrier pipe! gen-barrier!

Fig. 67 Fig. 68 Fig. 69

Using the sandpaper /abrasive cloth remove Slide compression sleeve onto the pipe Expand pipe twice offset approx. 30°.
the remaining PU foam from carrier pipe. ensuring the square end faces to the insula-
tion and the chamfered end towards the Note: For diameters above 63 mm use
joint. REHAU lubricant on the carrier pipe.

Attention:
Before using the tool, read The ope-
rating instructions supplied with the
tool very carefully!
Fig. 70

Insert fitting. Position the tool jaws such that

the pipe and fitting is fully within the jaws
and start compression.

Subject to technical modifications!

19
5.4.2 Installing insulation kit for T-piece

Fig. 71 Fig. 72 Fig. 73

Drill 3 mm vent holes at both ends (not at Drill 25 mm hole on branch to pour in foam. Trim ends according to outer jacket diame-
branch end). ters (see markings on the levels).

[A3]

Fig. 74 Fig. 75 Fig. 76

Slide on all three heat-shrink sleeves with If required cut out recess for tool. Making compression joint.
the chamfered side towards the fitting.
Outer [A] [A]
Attention: Take care to keep inside of slee- diameter WZ A1 WZ G1
ves clean. Carrier and M1
20 - 40 mm 170 mm ------
40 - 110 mm -------- 270 mm
125 - 160 mm -------- --------
Tab. 6

Fig. 77 Fig. 78

Slide complete T-piece onto the branch
pipe as shown and complete 3rd
compression sleeve joint.
5.4.3 Installing insulation kit for
coupler
Pull back T-piece over the completed T-joint Rohr zwei Mal um ca. 30° versetzt aufweiten
and secure 5x with reinforced tape as
shown.
Flare pipe twice offset by approx. 30°

Fig. 79 Fig. 80 Fig. 81

Preparation of pod
■ Drill vent hole
■ Drill hole to pour foam
■ Trim ends according to outer jacket dia-
meters (see markings on the levels)
Slide socket and heat-shrink sleeves onto Position socket as shown.
the RAUTHERMEX pipe and complete com-
pression sleeve joint.

Subject to technical modifications!

20
5.4.4 Using foam cartridge

 

 
 

 






Fig. 82 Fig. 83 Fig. 84

Equipment Wear safety goggles, gloves and long slee- The ideal foaming temperature is between
■ Cordless drill, 700 - 900 r.p.m. ves shirts and pants when using foam. Only 15 °C and 22 °C.
■ Safety goggles use foam in well ventilated workspaces!
■ Disposable gloves

Fig. 85 Fig. 86 Fig. 87

Foam cartridge with mixing rod. Screw in mixing rod. Push mixing rod fully into cartridge ensuring
the safety ring stays firmly attached to the
mixing rod.

Fig. 88 Fig. 89 Fig. 90

Attach the screwdriver immediately after ins- After mixing Remove the black safety ring Use the mixing rod to perforate the cartridge
erting the mixing rod and mix evenly at and hold the cartridge over the 25mm hole seal, rotate it a full 360º and pull it back
> 700 r.p.m. for approx. 20 sec. in the pod. again by 5 cm.

Fig. 91 Fig. 92 Fig. 93

Once all the foam is poured in the vent plug The hole in the vent plug must remain visible Now the vent plug can be pushed in com-
is pushed in up to the first stop. until the PU foam is coming through. pletely.

Subject to technical modifications!

21
5.4.5 Using PU foam from a canisters

Fig. 94 Fig. 95 Fig. 96

PU foam components A and B. Using the REHAU table for mixing ratios, Add in component B to the cup until the
pour the required amount of component A correct total is reached. The required total
into the mixing cup. The cups have a mea- amount can be taken from the last column
suring scale printed on them. of the REHAU table for mixing ratios.

Fig. 97 Fig. 98 Fig. 99

Mix components A and B evenly together in Fill foam into the socket. Insert the vent plug up to the first stop and
the mixing cup for 20 sec. proceed as with cartridge foam.

Subject to technical modifications!

22
5.4.6 Heat shrinking of sleeves
Fig. 100
Remove surplus foam after 60 minutes.
Fig. 103
Preheat the area gently with a soft-fame.
Fig. 106
Position the chamfered heat-shrink sleeves
pressing the sleeve against the socket on
the outside. The heat-shrink sleeve must lay
flat against the side opposing the branch
(see arrow).
Subject to technical modifications!
Fig. 101 Fig. 102
Clean the areas on the socket and outer Trim back the vent plug to make it flush with
jackets where the sleeves will be fitted to the socket.
from PU foam, dirt and oils/greases. Areas
must also be kept dry.
Rough up the surface with sandpaper /
abrasive cloth.
Fig. 104 Fig. 105
The socket surface temperature must be Position heat-shrink sleeves and shrink
at least 60 °C and can be checked using them with a soft-fame.
the temperature indicator strips. At the cor-
rect temperature the green area turns dark.
Fig. 107 Fig. 108
Apply only so much heat at the chamfered Move heat-shrink sleeve 5 cm beyond the
ends that the adhesive is activated. If neces- trimmed vent plug and shrink on.
sary press sleeve on by hand.
23
5.5 Wall penetrations

5.5.1 Connecting through basement

The RAUTHERMEX pipe routes should be
as straight as possible. If the RAUTHERMEX
pipeline runs parallel to the building, the




bend for entry into the building must have a


radius of at least 2.5 x the value specified in
Table 5. This prevents the pipe from unne-


cessary stress where it penetrates the wall.

5.5.2 Wall seals

Wall seals can be installed in field core drills
or in standard wall penetrations. Table 7 lists
the recommended dimensions of the wall
penetration for grouting the wall seals into








place in the wall.

For standard wall penetrations a free gap of
8 cm between the outer pipe jacket and the
wall must be ensured. For two pipes pene-
trating the wall, the minimum dimensions
are also listed in Table 7.

Wall seals can be easier pushed onto the Fig. 110 Wall seals, side view, in standard Fig. 111 Wall seals, front view, in standard
outer pipe jacket when REHAU lubricant is wall penetration wall penetration
used. The stepped end of the wall seal must
face to the inside of the building, and the
square end to the outside.
Install the pipe with the wall seal into the
field core drill or standard wall penetration.
The wall seal should be at least 80 mm from
the outside wall surface. The opening can
be sealed using conventional expansive





mortar.


Fig. 112 Wall seals, side view, in field core Fig. 113 Wall seals, front view, in field core
drill drill

Fig. 109 Wall seals

Outer diameter Core Standard wall penetration Standard wall penetration
of pipe jacket drill for 1 pipe for 2 pipes
[mm] D [mm] H x L [mm] H x L [mm]
76 180 250 x 250 250 x 450
91 200 250 x 250 250 x 500
111 220 300 x 300 300 x 500
126 240 330 x 330 330 x 550
142 260 350 x 350 350 x 600
162 280 350 x 350 350 x 650
182 300 370 x 370 370 x 700
Tab. 7

Subject to technical modifications!

24
5.5.3 Compression wall seals
For sealing RAUTHERMEX pipe in slab,
ceiling or similar type penetrations com-
pression wall seals should be used. They
can be used in core drills and plastic walls
sleeves. The minimum separation between
core drills or walls sleeves must be
300 mm.

Note: For plastic wall sleeves, we recom-

mend to properly secure the sleeves and
prevent any movements by using brackets
or clamps.
Where hairline cracks are created during
core drilling or other construction work, we
recommend sealing the entire core drill sur-
face.
The maximum grade for RAUTHERMEX
pipes in core drills is 7°.

5.5.4 Watertight compression wall

seal FA 80 for pressures up to
1.5 bar
The FA 80 compression seal is to be used Fig. 115 Compression wall seal for water Fig. 116 Compression wall seal for water
where penetrations must be watertight. To pressure up to 1.5 bar not under pressure
increase the stabilisation of the pipes in the
core drill, the FA 40 compression seal can
be used.

5.5.5 Compression wall seal FA 40

for water not under pressure
A second compression wall seal FA 40 can
be used to provide additional support of the

RAUTHERMEX pipe.

Installation


The RAUTHERMEX pipes must first be
uncoiled. The pipe is then inserted into the
penetration and properly secured in the pipe
trench. Place the compression seal into the

core drill, align it and tighten the bolts with a
torque wrench set as per table 8.

Fig. 117 Compression wall seal, 1 x, side Fig. 118 Compression wall seal, 1 x, front
view view

RTX-outer Core drill size/ Bolts Spanner Torque

Diameter Inner diameter size [mm] [Nm]
[mm] wall sleeve
76 125 +- 2 mm M6 10 5
91 150 +- 2 mm M6 10 5
111 200 +- 2 mm M8 13 10
Fig. 114 Compression wall seal
126 200 +- 2 mm M8 13 10
142 200 +- 2 mm M8 13 10
162 250 +- 2 mm M8 13 10
182 250 +- 2 mm M8 13 10
Tab. 8 Dimensions of compression wall seal

Subject to technical modifications!

25
5.5.6 Prefabricated bends Installation
■ Install wall seal, and position prefabrica-
The prefabricated RAUTHERMEX bends are ted bend in the foundations.
used where the required bending radius is ■ The vertical end can be secured with a
smaller than the minimum permitted for square timber / reinforcement bar.
RAUTHERMEX pipes. This is usually the Note: Do not remove the protective
case in ground-level building construction. end caps until the final connec-
tions are made. If there is a danger
the unprotected pipe ends can get
dirty or damaged by UV radiation
they must be protected with a UV-
resistant plastic foil / tape.

Fig. 119 Prefabricated bends for UNO and

DUO pipe

Ground level








1,00 m













1,50 m






Fig. 120

Subject to technical modifications!

26
5.5.7 End caps
If the end cap is inside a wall the pipe jacket
and PU foam must be stripped back in the
trench before the RAUTHERMEX pipe is
positioned. For all other cases the pipes can
be placed into position first and stripped
afterwards.

The following lengths of carrier pipe need to

be exposed to complete the compression
sleeve joint:

Heat-shrink end caps Length

RAUTHERMEX UNO
Outer dia. Carrier pipe A
20 to 32 mm 140 mm
40 and 50 mm 160 mm
63 to 110 mm 180 mm
RAUTHERMEX DUO
Outer dia. Carrier pipe B
20 to 32 mm 140 mm
40 and 50 mm 160 mm
63 mm 180 mm
Fig. 121 Exposed lengths
Tab. 10

Installation of heat-shrink end cap

■ Expose carrier pipes in accordance with
Table 10.
■ Rough up the effected area with an abra-
sive cloth and preheat it to over 60 °C
with a soft-flame. Use temperature indi-
cator strips to check the temperature!
■ Slide on end cap and shrink.
■ Then complete compression sleeve joint.

Push-on End caps Length

RAUTHERMEX UNO
Outer dia. Carrier pipe A Fig. 122 Heat-shrink end caps for UNO and
DUO pipes
20 to 32 mm 90 mm
40 and 50 mm 110 mm
63 to 110 mm 130 mm
RAUTHERMEX DUO
Outer dia. Carrier pipe B
20 to 32 mm 90 mm
40 and 50 mm 110 mm
63 mm 130 mm
Tab. 11

Installation of push-on end caps

■ Expose carrier pipes in accordance with
Table 11.
■ Push on end cap.
■ Then complete compression sleeve joint.

Fig. 123 Push-on end caps for UNO and

DUO pipes

Subject to technical modifications!

27
5.6 Linear thermal expansion in
trenches
No expansion bellows or compensators are
required for RAUTHERMEX pipes when
installed in trenches, since the friction bet-
ween the pipe and the soil is greater than




the expansion forces of the plastic pipe.



5.6.1 Linear thermal expansion
when connecting to buildings
To keep the thermal expansion within
acceptable limits when connecting to a
building RAUTHERMEX pipes should not
extend more than the distances specified in
Table 12 beyond the finished In case the fixed








fixed



push-on or heat-shrink end caps are point
positioned inside the wall (wall penetration point
or core drill) the dimensions given in
Table 12 can be reduced by 60 mm.

The carrier pipe requires fixed brackets

suitable for the forces listed in Table 12.
Fixed brackets may be attached to the
fitting body, but not to the compression Fig. 124 Fig. 125
sleeves.

Carrier pipe Max distance Max

outer diameter x s to wall Anchor forces
[mm] from - to X [mm] per pipe [kN]
25 x 2.3 220 - 270 0.93
32 x 2.9 220 - 270 1.50
40 x 3.7 220 - 270 2.40
50 x 4.6 220 - 270 3.70
63 x 5.7 260 - 300 5.80
75 x 6.8 260 - 300 8.20
90 x 8.2 260 - 300 11.90
110 x 10 260 - 300 17.70
22 x 3.0 220 - 270 1.00
28 x 4.0 220 - 270 1.70
32 x 4.4 220 - 270 2.10
40 x 5.5 220 - 270 3.30
50 x 6.9 220 - 270 5.20
63 x 8.7 260 - 300 8.20
Tab. 12

5.7 Miscellaneous
5.7.1 Pipe in sleeve system
For crossing underneath buildings or for
areas with difficult access, a pipe-in-sleeve
installation is possible with RAUTHERMEX.
The bore of the sleeve pipe must be at least
2 cm bigger than the outer diameter of the
RAUTHERMEX pipe jacket. The
RAUTHERMEX pipe can be pulled in using a
winching cable and towing sock ensuring
the maximum winching forces are not
exceeded. A lubricant applied to the
RAUTHERMEX pipe jacket minimizes the
pipe friction. Changes in direction should
only be made with the open cut installation
technique.
5.7.2 Installing during land
development phase
To develop plots where buildings will be
erected at a later time, dead legs can be laid
and closed off with isolating valves (available
upon request). The ball valves can be insula-
ted with the REHAU insulation kit for end
stops.
5.7.3 Tapping into existing lines
The flexibility of the RAUTHERMEX pipes
allows the subsequent installation of T-
joints. The network section must be taken
off line for this and the water temperature
must be 30 °C or lower. The usual contrac-
tion associated with polymer pipes installed
above ground, is not present with fully bon-
ded RAUTHERMEX pipes. For this reason
the carrier do not require any anchoring for
cutting.

Subject to technical modifications!

28
6. Commissioning
6.1 General information
The RAUTHERMEX pipes and joints must
be pressure-tested before they are insulated
or the trench is backfilled. The pressure test
can be carried out immediately after com-
pleting the compression sleeve joints.
6.2 Pressure test with water
A pressure test according to DIN 18380
(VOB) or DIN V 4279-7 is to be carried out
with a test pressure of at least 1.5 x the
maximum design pressure for the pipeline.
Test protocols should be completed contai-
ning the following information:
■ Installation/Project details
■ Test pressure
■ Time the pipeline was under pressure
■ Test date
■ Confirmation the pressure test has been
performed properly.
6.3 As-installed drawings
The actually installed pipe lengths are to be
recorded and entered into an as-installed
drawing.
6.4 Flushing
To remove any dirt, soil or other debris,
which could have contaminated the pipeline
during construction work, all pipe sections
should be flushed with sufficient water.
6.5 Heat exchanger
Note: When using corrosion inhibitors or
flow conditioners, confirmation of their com-
patibility with PE-Xa and the fitting materials
is to be obtained from the manufacturer.
6.6 Long term storage
To protect the pipes from dirt and debris
and the carrier pipe from UV radiation the
pipe ends must be kept closed at all times.
Contact with potentially damaging chemi-
cals should be avoided.
RAUTHERMEX pipes with pipe jackets
made from PE-LD can only be stored in
direct sunlight for a limited time. Experience
has shown that in Central Europe pipes can
be stored unprotected for up to 2 years
(starting at the day of manufacture) without
affecting the strength of the pipes. For pro-
longed periods of external storage or in
areas with intense solar radiation sea, or at
altitudes over 1,500 m, the pipes must be
protected from direct sunlight.
When covering with tarps, good ventilation
of the pipes is required to prevent any build
up of heat. Transparent or translucent
covers are not suitable.
Unlimited storage is possible, if the pipes
are protected from any light.
7. Standards and guidelines
■ DIN 2424 Part 2
Design plans for the utility industry, the
water industry and district heating
■ DIN 16892: 2000
Pipes made of crosslinked polyethylene
(CPE)
- General quality requirements, tests
■ DIN16893: 2000
Pipes made of crosslinked polyethylene
(CPE) - Dimensions
■ DIN 13760 Miner's Rule
■ DIN 4726
Plastic Pipelines for hot-water floor hea-
ting - General requirements
■ DIN 4729
Pipelines made of crosslinked polyethyle-
ne for hot-water floor heating
- General requirements
■ DVGW Worksheet W531
Manufacture, quality assurance and
testing of pipes from CPE for drinking-
water installation
■ DVGW Worksheet W534
Compression joints for pipes made of
CPE
■ DVGW Worksheet W534(E)
Pipe connectors and pipe connections

Subject to technical modifications!

29
Notes:

30
Notes:

31
 Insofar as the intended application deviates from that
described in this Technical Information brochure, the user
must consult REHAU and must receive express written
consent from REHAU before commencing this utilization.
The user fails to do so, the sole responsibility for the
utilization shall lie with the individual user.
In this case, the application, use and processing of
products are beyond our control. Should a case of liability
arise, however, this shall be limited to the value of the
goods delivered by us and used by you in all cases of
damage.
Claims arising from granted guarantees shall become
invalid in the case of intended applications that are not
described in the Technical Information brochures.

This document is protected by copyright. All rights

based on this are reserved. No part of this publication may
be translated, reproduced or transmitted in any form
or by any similar means, electronic or mechanical,
photocopying, recording or otherwise, or stored in a
data retrieval system.

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