4-Raupex Pipes 0509

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RAUPEX® PIPES: PEXaPROVEN PERFORMANCE

© REHAU 27-Apr-09 - Page 2

RAUPEX PIPES

- What is PEX?- What is PEXa?- RAUPEX Non-Barrier and

RAUPEX O2 Barrier pipes- RAUPEX UV Shield pipes- RAUPEX capabilities and limits- Markings and certifications- PEXa extrusion process- PEXa: The Green Choice

OUTLINE


“RAUPEX” PIPES

- RAUPEX Non-Barrier, RAUPEX O2 Barrier, RAUPEX UV Shield- Similar pipes, same pressure ratings, special capabilities- RAUPEX O2 Barrier has special coating to block oxygen (O2) diffusion- RAUPEX UV Shield has special coating to block sunlight

REHAU’s TRADENAME FOR PEXa CROSS-LINKED (X) POLYETHYLENE


POLYETHYLENE CROSS-LINKED (X), OR P-E-X

- “Poly Ethylene” means “many ethylene molecules”- Ethylene gas is the building block for

polyethylene (PE)- Polyethylene is used for thousands of engineering

applications, construction products and household goods

- Cold water pipes, gas pipes, milk jugs, auto parts, toys, etc.

- PE is not suitable for high-temperature applications- Susceptible to “creep”- Pressure resistance declines over time

- Polyethylene is the building block for PEX

PolyEthylene Molecule

Ethylene Hydro-carbon


CROSS-LINKED POLYETHYLENE

- PEX is Poly Ethylene that has been chemically or physically modified – cross-linked (X) -to cause the molecules to link together, permanently

- Once PE is cross-linked into PEX, it becomes a thermo-set plastic, meaning that it cannot be melted and reshaped

- Compared to standard PE pipes, PEX has desirable high temperature strength, reduced sensitivity to notching, improved chemical resistance, and high flexibility

- There are 3 commercial processes or methods:- PEXa: High-pressure peroxide (“Engel”) – PEXb: Silane (“moisture cure”) – PEXc: Radiation (“electron beam” or “nuclear”)

- PEXa was pioneered by REHAU

ENHANCED POLYETHYLENE


REHAU PEXa

History: - Dr. Thomas Engel, German Inventor

- Originally known as “Engel Method”- REHAU licensed the patent for the special

PEXa process in 1967- Started development work in 1968- Began series production in 1972 for PEXa

radiant heating pipes- Now known as “High-pressure peroxide”

cross-linking, or simply, PEXa

“CROSS-LINKED (X) POLYETHYLENE”

Signatures from original contract


REHAU PEXa

REHAU process: PEXa - Cross-linking takes place in special

extruders designed for high pressure- Typical result is 85% cross-

linking, which is the highestavailable

- REHAU is a worldwide leader in PEXa technology

“CROSS-LINKED (X) POLYETHYLENE”

PEXa “molecule”


RAUPEX PIPES

- RAUPEX Non-Barrier (Natural Opaque) - Solid wall of PEXa- Oxygen can pass through the pipe

wall (diffuse) and be absorbed into the heating system water

- This may cause corrosion of iron or steel components

- All RAUPEX pipes have the same temperature and pressure capabilities

NON-BARRIER: THE ORIGINAL PIPE

PEXa “molecule”


RAUPEX PIPES

- RAUPEX O2 Barrier (Red) - EVAL oxygen diffusion barrier

is the outer layer, held on by special adhesive (red)

- Prevents oxygen diffusion through the pipe wall

- Meets requirements of DIN 4726, German standard for oxygen diffusion protection


Adhesive (Red)RAUPEX

EVAL O2 Barrier

O2 BARRIER: THE “HEATING” PIPE


RAUPEX PIPES

- RAUPEX O2 Barrier (Red) - EVAL oxygen diffusion barrier

is the outer layer, held on by special adhesive (red)

- Prevents oxygen diffusion through the pipe wall

- Protects iron and steel (ferrous) components from corrosion caused by oxygen in the water


O2 BARRIER: THE “HEATING” PIPE


RAUPEX PIPES

- RAUPEX UV Shield- (Red, White, Blue)- Colored HDPE shield is the

outer layer- Superior UV protection- Plumbing and non-ferrous

heating applications - 1/2”, 3/4” and 1”, coils, straight

lengths - No oxygen barrier


UV SHIELD: SUPERIOR UV PROTECTION


RAUPEX PIPE LABELS1/2” RAUPEX NON-BARRIER1/2” RAUPEX O2 BARRIER


RAUPEX PIPE LABELS1/2” RAUPEX UV SHIELD BLUE1/2” RAUPEX UV SHIELD RED


RAUPEX PIPE CAPABILITIES

Flexibility- Bending radius of 5 times the pipe OD; the tightest of all PEX pipes- Pipes are less likely to kink when bending quickly or too tightly- Flexible to below -100°F; will not become brittle or break at cold temperatures

Freeze resistance- With room to expand evenly along its length, RAUPEX pipe will expand when frozen and

not break; pipe will return when thawed- This helps a pipe installed in a wall, but Not when inside a floor- Pipes inside a concrete floor are likely to break if allowed to freeze

Kink Resistance- PEXa resists kinking, even well below freezing temperatures- If kinked, PEXa can be field-repaired without cutting

- See instructions- Be sure to let pipe cool before moving it or applying any stress

CAPABILITIES AND LIMITSFLEXIBILITY, FREEZE RESISTANCE, KINK RESISTANCE


If RAUPEX pipe becomes kinked… …it may be heated to 265°F (130°C) with hot air to remove the kink.

Non-Barrier pipe turns clear when fully Stop when the kink is gone!heated; coated pipes simply re-round Do not overheat the pipe!

RAUPEX PIPE CAPABILITIESCAPABILITIES AND LIMITSTHERMAL MEMORY: ONLY PEXa ALLOWS THIS!


RAUPEX PIPE CAPABILITIES – THERMAL MEMORY

Do not use a torch and do not overheat the pipe!

CAPABILITIES AND LIMITSNEVER USE A TORCH



RAUGEO PEXa pipes are made according to national standards which establish the capabilities and application limits:

- Pipes are CTS (copper tube size), SDR9, with tight tolerances on dimensions

- Pipes have long-term pressure ratings* of:- 160 psi @ 73.4°F, 130 psi @ 120°F, 100 psi @ 180°F, 80 psi @ 200°F- These certifications are based on a 50-year extrapolation according to D 2837- Temperature/pressure ratings are marked on the pipes - Pipes will withstand short-term exposure over 230°F

- Pipes have minimum quick-burst capability (short-term) per ASTM F 876:- 475 psi @ at 73.4°F, 210 psi @ 180°F, 180 psi @ 200°F

CAPABILITIES AND LIMITSTEMPERATURE / PRESSURE CAPABILITY

*Temperature/Pressure ratings are based on an extrapolated time-to-failure prediction as defined in ASTM D 2837,with 2:1 Safety Factor on pressure



- RAUPEX Coefficient of longitudinal thermal expansion:9.3 x 10-4 in/ft x °F (0.14 mm/m x °C)

- Rule of thumb:1 inch of expansion/contraction per 10°F temperature change per 100 ft. length

Example:- 100 foot length of pipe heated from 70°F to 100°F - Thermal expansion = almost 3 inches for an unrestrained pipe

CAPABILITIES AND LIMITSTHERMAL EXPANSION



Chemical resistance (see REHAU TB120R2)- RAUPEX pipes are resistant to glycols, latex paints, silicone, urethane foam, most acids

and bases- RAUPEX Non-Barrier pipes are sensitive to certain adhesives at elevated temperatures- Do not apply adhesive tape to RAUPEX Non-Barrier pipes- If in doubt, check with REHAU

Chlorine and Chloramines potable water disinfectants (see REHAU TB135R2)- RAUPEX meets the strict requirements of ASTM F 876 and ASTM F 2023 for chlorine

resistance; pipe is tested also in accordance with NSF P171 - RAUPEX is chlorine resistant- Tested with free chlorine (Cl2) at 4.0 ppm, pH 6.8, 80 psi, 140°F - Chloramines (another water disinfectant) are not as aggressive as free chlorine

CAPABILITIES AND LIMITSENVIRONMENTAL RESISTANCE



UV Resistance (see REHAU TB218)- RAUPEX pipes are tested in the desert

near Phoenix, AZ for natural exposure to prove the capabilities, following ASTM F 2657 test procedure

- Then the pipes are subjected to the chlorine resistance test and must show retention of chlorine resistance

Results:- RAUPEX Non-Barrier -15 days- RAUPEX O2 Barrier - 30 days- RAUPEX UV Shield White – up to 3 months- RAUPEX UV Shield Red & Blue – up to 1 year

CAPABILITIES AND LIMITSENVIRONMENTAL RESISTANCE


RAUPEX PIPE CAPABILITIESCAPABILITIES AND LIMITSSEE PRODUCT SUBMITTALS FOR FURTHER DETAILS


PEX PIPE EXTRUSION

Basic Extrusion Process:1. Polymer compound is blended 2. Melted to temperature3. Compressed in extrusion chamber4. Forced through extrusion die that controls shape and dimensions

PEXa: cross-linking takes place in a special extruder, right at the die

HOW IS PEXa MADE?


PEX PIPE EXTRUSION

1

34

Hopper (materials fed in)

Heating chamber (melts materials)

Compression chamber

Die (forms the shape)

REHAU PVC extruder: 1948

1

2

3

4

2


REHAU PEXa EXTRUSION: RAUPEX NON-BARRIER (PEXa)

REHAU - R....

High Density Polyethylene

(HDPE) Heat Stabilizers

ExtruderWater Bath

Ink Jet

Inspection DevicesCoiler

Anti-Oxidants

UV Stabilizers

Liquid Peroxide


REHAU PEXa EXTRUSION: RAUPEX O2 BARRIER (PEXa)

REHAU - R....


(HDPE)Heat

Stabilizers

Liquid Peroxide

ExtruderWater Bath

Co-ExtruderEVAL Adhesive

Ink Jet

Inspection Devices

Coiler

Anti-Oxidants

UV Stabilizers


REHAU PEXa EXTRUSION: RAUPEX UV SHIELD (PEXa)


(HDPE)

Extruder

Liquid Peroxide

Water BathCoiler

Heat Stabilizers

Ink Jet

Inspection Devices

Anti-Oxidants

UV Stabilizers

Co-ExtruderPE Shield


PEX EXTRUSION METHODS

REHAU High-pressure peroxide method (PEXa)

- Compounding: HDPE and stabilizers mixed, then liquid peroxide is carefully added- Compound fed into special extruder, melted at high pressure and precise temperature- Cross-linking occurs as the pipe is extruded, consistently throughout the pipe wall

- Degree of cross-linking is closely controlled- Carbon-Carbon bonds are unbreakable- QA inspection devices are in-line- No secondary process

- Typical degree of cross-linking is 80 - 89% (85% target for REHAU)

REHAU PEXa SUMMARY



Silane method (PEXb)

- HDPE modified with Silane (Silicone) by a custom compounder- Modified compound is mixed with catalyst in the plant and fed into extruder- Partially cross-linked pipe is extruded fast and wound onto large coils- Coils are subjected to steam (sauna) or hot water to cause cross-linking over time- Pipes may be unwound and rewound onto smaller coils for packaging- Typical degree of cross-linking: 65 - 70%

PEXb METHOD



E-Beam method (PEXc)

- Non cross-linked HDPE pipe is extruded from a normal extruder- Non-cross-linked pipe is wound onto large coils after cooling- Pipe is uncoiled and passed under an electron beam and dosed with radiation; several

passes are required to get even cross-linking- Pipes are unwound and rewound onto smaller coils for packaging- Typical degree of cross-linking: 65 - 70%.

PEXc METHOD


SUMMARY OF PEX EXTRUSION METHODS

PEXa - Peroxide: Controlled cross-linking occurs in the extruder - 80-89% cross-linking is typical (REHAU ~ 85%)- Stronger and more flexible

PEXb - Silane: uses secondary moisture-cure process- 65-70% cross-linking is typical

PEXc - E-beam: uses secondary radiation process- 65-70% cross-linking is typical

INDUSTRY SNAPSHOT


PEXa method

- REHAU- Uponor- Golan (HeatLink)- LK Pex (“Mr. Pex”)- Pex-Cor

PEXb Silane method

- Bow - CB Supplies- Genova Plastics- IPEX- JM Eagle- Viega- Watts Industries/Radiant- Zurn/Qest (formerly US

Brass)

PEXc E-Beam method

- Golan (HeatLink, ComfortPro)

- Hewing (Burnham)- Mercury- NIBCO- Roth - Viega

PEX EXTRUSION METHODSINDUSTRY SNAPSHOT: PEX “MANUFACTURERS”


ALTERNATIVE METHODS - COMPOSITES

PEX-AL-PEX (PEXb)- Multi-layer pipe with aluminum- Unicore, Weil-McLain, Uponor

PERT-AL-PERT (PERT = polyethylene Raised Temperature)- IPEX “XPA” (replaced “Kitec”)

- Multi-layer pipe with aluminum- Not a PEX; only PERT

‘Rubber Hose’- Watts Radiant ONIX

INDUSTRY SNAPSHOT


REHAU PEXa AS PART OF SUSTAINABLE DESIGN

- Lower cost to the environment for production- No mining operations for the ore, PE is abundant, created by refining operations- Low energy cost to produce compared with copper- No chlorine is used in production of PEXa

- Reduced heat loss and condensation through pipes- Saves energy, faster delivery of hot water

- Smooth wall, excellent flow characteristics- Reduces pumping costs

- Proven long life and durability- Provides value: Performance vs. environmental cost

PEXa IS GREEN

- Light weight of PEX reduces transportation costs- Light weight also reduces the necessary equipment to install pipes

- Quiet operation - Dampens water hammer, reduces pressure spikes that may harm equipment

- Protects health and safety- Does not add minerals to drinking water or to the public water system


RAUPEX PIPES

- Higher strength- Greater flexibility- Proven longevity 35+ years- Chlorine resistance - UV resistance- Widest range of sizes and colors- The “Green” choice- Backed by:

- REHAU PEXa Limited Warranty- 35+ years of experience- Stringent quality control- ISO 9001 factories in Europe and USA- National and international certifications- REHAU ‘Know-How’

SUMMARY: PROVEN PERFORMANCE

ConstructionAutomotive

Industry

www.rehau.com

RAUPEX PIPES: PEXaPROVEN PERFORMANCE

4-Raupex Pipes 0509

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