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3 GEORGE FISCHER General Information 4 Working with plastic pipes and fittings 5 INSTAFLEX technical information 7 Flange connections/unions 13 ‡ FIRESTOP Firesleeves 14 Specification guide for consultants 15 Standards & Regulations 20 Product Range 21 Pipe 22 Pipe supports and brackets 24 Accessories 25 ‡ Armaflex Insulation 26 ‡ Firestop 26 Fittings for Socket Fusion Jointing 27 Unions 32 Flange Jointing (Socket Fusion) 36 Fittings for Electrofusion Jointing 37 Manifold Plus Compression Jointing System 43 Flange Jointing - Electrofusion 50 Valves 51 INSTAFLEX (PB) Valves 51 PB to PVC-C Quarter Turn Valve 54 Metal Butterfly Valves Type 037 55 INSTAFLEX Installation Quick Reference Guide 56 Contents Page The technical data given in this publication are for general information purposes only and are subject to change. They imply no warranty of whatever kind. Please consult our General Conditions of Supply.
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  • 3GEORGE FISCHER

    General Information 4Working with plastic pipes and fittings 5

    INSTAFLEX technical information 7

    Flange connections/unions 13 FIRESTOP Firesleeves 14

    Specification guide for consultants 15

    Standards & Regulations 20

    Product Range 21Pipe 22

    Pipe supports and brackets 24Accessories 25

    Armaflex Insulation 26

    Firestop 26

    Fittings for Socket Fusion Jointing 27Unions 32

    Flange Jointing (Socket Fusion) 36

    Fittings for Electrofusion Jointing 37

    Manifold Plus Compression Jointing System 43

    Flange Jointing - Electrofusion 50

    Valves 51INSTAFLEX (PB) Valves 51PB to PVC-C Quarter Turn Valve 54

    Metal Butterfly Valves Type 037 55

    INSTAFLEX Installation Quick Reference Guide 56

    Contents Page

    The technical data given in thispublication are for generalinformation purposes only andare subject to change. Theyimply no warranty of whateverkind. Please consult our GeneralConditions of Supply.

  • 4 GEORGE FISCHER

    PB PolybutylenePE PolyethylenePP Polypropylened Pipe outside diameterEPDM Ethylene propylene rubbers Wall thickness of the pipedCu Copper pipe outside diameterDN Nominal bore DiameterLK Hole circleSW Dimension across flats (A/F)G Pipe thread, not pressure tight in

    the thread (with flat seat) to ISO228

    R Taper male thread, pressure tightin the thread to ISO 7

    Rp Parallel female thread, pressuretight in the thread to ISO 7

    M Metric thread to ISO 261m MeterSP Items per standard packg Gramme

    Explanation of signs

    Dimensions

    All dimensions are given in mm andare intended as nominal or averagesizes. Subject to alteration resultingfrom modifications in design.

    For compressed air applications with air containing mineral oil, EPDMgaskets must be replaced by NBR units.

    This mainly concerns unions and flange connections.

    NBR gaskets are not contained in this Product Range. Please contact theGeorge Fischer sales consultant or sales support office assigned to yoursales area.

    and INSTAFLEX are registered trademarks.

    Always protect plastic pipes and fittings from external influences.Direct sunlight and the effects of impact and pressure shoud be avoided.Always leave the pipes and fittings in its packaging until ready to use. Donot storage outside.

    General Information

    !

    n.b. inch o.d. metric n.b. metric

    3/8 16 101/2 20 153/4 25 20

    1 32 25

    11/4 40 32

    11/2 50 40

    2 63 50

    21/2 75 65

    3 90 80

    4 110 100

    4 125 110

    5 140 125

    6 160 150

    6 200 180

    8 225 200

    Inch - Metric Equivalents

  • 5GEORGE FISCHER

    Working with plastic pipes and fittings

    W R O N G R I G H T

    Transport and storage of plastic pipes

    Plastics are materials sensitive toimpact and crushing at lowtemperatures.The temperature limit depends on therelevant material.

    PP-RPVC-C +5 C

    PB 10 C

    VPE 20 C

    Below these temperatures pipes andfittings would have to be protectedparticularly from impacts, crushingand other external mechanicalstresses.

    Plastic pipes and plastic fittings must be protected in principle from externalinfluences. Direct sunlight, impacts and compressive stresses should beavoided. The pipes and fittings must be left in their packing until used. Theyshould not be stored out of doors.

    Safety instruction

    !

  • 6 GEORGE FISCHER

    INSTAFLEX

    The modern versatile piping system

    A full range of pipe and fittings makes the INSTAFLEX system highly versatile.

    Allowing prefabrication and beinglightweight make the installation of anINSTAFLEX system highly cost effective.

  • 7GEORGE FISCHER

    What is INSTAFLEX?

    The versatile pressure pipingsystem for building services

    For use on:

    Hot & cold water services

    Heating systems

    Chilled water

    Compressed airlines

    The INSTAFLEX system has beendesigned for use as a completebuilding services piping system whichprovides a solution to the problemsfaced by traditional materialsnamely:

    No corrosion

    No encrustation/limescale

    No noise emmission

    Long service life

    High flexibility

    Fast assembly

    Lightweight

    Launched in 1980 into mainlandEurope and into the UK in 1995 thissystem has provided installers anddesigners with a flexible system whichmeets the stringent demands ofmodern building design andconstruction.

    MaterialManufactured from polybutylene(PB), a high performance plasticsmaterial, which was specificallydeveloped for use in piping systemsfor potable water. Its inherentcharachertistics make it ideal for thispurpose and for other buildingservices applications.

    RangeA full range of pipe and fittings areavailable with adaptors to join ontoother piping system components.

    Pipe & fittings 16 -110mm Pipe-in-sleeve Accessories & jointing equipment Valves

    Jointing & installationThe INSTAFLEX system utalises threecomplimentary jointing techniques:

    socket fusion

    electrofusion

    compression fittings

    Each of which have advantagesdepending on the installation inquestion. Most installation tend toincorporate more than one type ofjointing method.Due to the flexibility of the system andthe material's lightweight significantsavings can be made on installationtime and costs.

    Technical advice & supportGeorge Fischer's expertise andtechnical knowledge in the pipingsystem field is recognised worldwide.In order to assist designers andinstallers in the optimum use of theINSTAFLEX system the followingsupport is available :

    On-site support & advice Design take-offs Certificated jointing training courses Technical support CAD Custom products

  • 8 GEORGE FISCHER

    Polybutylene is a thermoplastic fromthe polyolefine family. It is a semi-crystalline material. Its density is in therange of other thermoplastics such asPE or PP. It has good mechanicalproperties and chemical resistancemaking polybutylene an importantmaterial for piping systems.

    PB is created by polymerizingbutylene (C4H8) and is, therefore, anecologicaly safe hydrocarbonproduct.

    The material which we use, may beused with foodstuffs due to its safestabilizing agent. The fittings andpipes are odourless and tasteless aswell as physiologically safe. It isperfect for use in drinking waterinstallations.

    Like PE and PP, PB belongs to thegroup of co-valent materials, whosesurfaces do not swell and are notsoluable. Solvent cementing is,therefore, not possible without specialsurface treatment. PB is, however,easily fused. Compression, socketfusion and electrofusion jointing canbe used.

    Flexibility, even at low temperatures,high thermal stability makepolybutylene a modern material. Notonly for hot and coldwater distribu-tion but also in industrial applications and com-pressed air.

    George Fischer are able to supplymetric socket and electro fusion pipe,fittings and valves as well as mechan-ical joints in the following size range.

    socket fusion 16mm - 110mm o.d. electro fusion 16mm - 110mm o.d.

    Property PB Unit

    Density 0.93 g/cm3

    Melt flow index MFI @90/5 0.4 g/@0 min

    Yield strength 17 N/mm2

    Elongation at fracture >125 %

    Bending-creep modulus (@ min.) 800 N/mm2

    Impact strength 23 C no failure mJ/mm2

    Impact strength 20 C 40 mJ/mm2

    Crystalline fusion temperature 0.013 C

    Coefficient of linear expansion 0.13 mm/mC

    Thermal conductivity at 20 C 0.22 W/m . K

    Surface resistance 0.007 W

    Normal working temperature range -15 to 95 C

    Properties of Polybutylene

    Testingspeed@25 mm/min

    The physical values shown in the table beloware to be treated as guide values.

    What is Polybutylene (PB)?

  • 9GEORGE FISCHER

    Time in hours

    Creep behaviourCreep behaviour is an importantfactor in plastic construction. It mustbe given special consideration withjointing and fastening techniques.It can be seen from the adjacentgraph that with a creep test, where aweight is hung from a piece of PB itscreep is slower than PEX

    Tensile strength 8 MPa (8 N/mm2)Temp. 20 C

    PEX

    PB

    10-3 103100

    10

    20

    Cre

    ep

    %

    Creep is the extension of amaterial in relation to timeunder constant load andconstant temperature.

    The E-modulus is the ratioof stress to strain in theelastic range of thematerial.

    Determining the expansionloop according toCEN/TC. 155/WG 5C for:PB 10PEX 12PE 27PVC-C 34PP-R 30Steel 94Cu 54Stl.Steel 61

    Expansion loop comparison

    Although the coefficient ofexpansion for PB is not the lowestdue to the material's flexibility (i.e.it's modulus of elasticity is by farthe lowest), the ability to cater forany expansion or contraction ismost favourable

    Using a typical example, withvalues

    Temp difference t = 50CPipe diameter d = 40mmPipe length = 10m

    The expansion of L of thedifferent materials is as follows:

    PB L = 65mmPEX L = 100mmPVC-C L = 40mmPP - R L = 90mmSteel L = 6mmCopper L = 9mmStl. Steel L = 9mm

    using the formula

    LLLLLBSBSBSBSBS = C x = C x = C x = C x = C x L x dL x dL x dL x dL x dwhere LBS = expansion loop leg

    L = primary pipeexpansion

    d = outside dia.. of pipeC = factor

    expansion

    L

    10m

    LBS

    Therefore, under the sameconditions the expansion legrequired for the different materialswould be as follows:

    Material Expansion leg LBS

    PB 510PEX 760PVC-C 1360PP-R 1800Steel 1450Cu 1030Stl. Steel 1150

    As can be seen from the above theexpansion leg required for PB isconsiderably less than all the othermaterials.

  • 10 GEORGE FISCHER

    Minimum breaking strength The minimum breaking strength isgiven as the hoop stress .

    Comparison of minimum breakingstrengths of PB, PEX, PP-R, PVC-C,applying to a material life expectan-cy of one year at different tempera-tures.

    Long-term BehaviourThe long-term behaviour is therelationship between the hoop stress,the temperature and the lifeexpectancy of a material.Allowable permanent internalpressure in bar:

    P perm =

    Hoop stress is based on a servicelife of 50 years and a constantoperating temperature of 70 C,without considering the safety factorfor:PB 7.5PEX 5.3PP-R 3.1PVC-C 7.5

    Ho

    op

    stress

    in M

    Pa

    100

    100908070

    50

    40

    30

    60

    20

    2

    3

    4

    5

    1098

    6

    7

    20 9030 8070605040

    Temperature in C

    MPa

    50

    40

    30

    20

    Ho

    op

    str

    ess

    in M

    Pa

    1098

    7

    6

    4

    5

    3

    2

    10.9

    0.5

    0.6

    0.70.8

    0.1 101 102 103 104 105 106

    Time in hours

    } {R

    PEX

    Long-term behaviour of pipes at 70C

    = Sigma/Break

    The hoop stress in the pipewall is the result of internalpressure. If this pressure iscontinuous the pipe willfracture with time

    Safety against breakagedue to stress from internalpressure is given with therelationship between pipewall stress to hoop stress.

    1 MPa = 1 N/mm2

    PVC-CPB

    PP

    PEX

    PVC-CPB

    PP

    50 years

    Pperm Internal pressures Pipe wall thicknessd Pipe outer-SF Safety factor

    RMinimum breakingstrength (R =

    Rupture)

    20 s 6R

    (d-s) SF

  • 11GEORGE FISCHER

    In reference to the 70Ccurve with a service life of50 years and safety factorincluded.

    Comparison of potablewater pipes used indomestic installations.

    Comparision of flow characteristicsThe pipe wall thickness is determinedby the hoop stress, the pipe outerdiameter and the allowableoperating pressure at 20C.

    Pipe Material PB PEX PP-R PVC-C

    Pipe dimension d 40 x 3.7 5.5 6.7 4.5 mm

    Pipe inner diameter 32.6 29.0 26.6 31.0 mm

    Pipe inner surface area 834 660 555 754 mm2

    Nominal pressure PN 16 PN 20 PN 20 PN 25

    Flow velocity at = 2.0 l/s 2.4 3.0 3.6 2.7 m/s

    Pressure drop at = 2.0 l/s 18.4 32.5 49.5 23.6 mbar/m

    v = Velocity

    Example for pipes 40mm o.d., with DVGW/SVGW approval

    Because at any given size the wallthickness of PB pipe is less than theother materials the flow velocity andpressure drop will be best.

  • 12 GEORGE FISCHER

    Temperature/Pressure ratingThe George Fischer INSTAFLEX system ismanufactured from polybutylene which isa thermoplastic material. As the namethermoplastic suggests, it is affected bytemperature. When the temperature ofthe liquid in the pipeline rises thematerial will soften and its ability towithstand pressure reducescorrespondingly. To calculate thepressure rating at any given temperaturethe well known "vessel" formula is usedin conjunction with the long termregression curves of the material.

    SF for non-dangerousliquids = 1.5SF for dangerousliquids =2.0

    Design life 50 years.

    Safety Factor 1.5

    Note:Size 16 & 20mm is25 bar25 to 110mm is16 bar.

    Temperature/Pressure chart

    P = x 20 x s

    SF x (d-s)

    SF = x 20 x s

    P x (d-s)or

    where P = pressure in bar = hoop stress of material atany given temp. in M Pas = pipe wall thickness in mmd = pipe o.d. in mmSF = safety factor

    Example

    What is the maximum pressure for a110mm pipe carrying water at 70Cwith a working life of 50 years?

    s = for 110mm INSTAFLEX pipe is 10mm

    SF = 1.5

    d = 7.5 MPa taken from long term regression curve opposite.

    P = x 20 x s

    SF x (d-s)

    P =7.5 x 20 x10

    1.5 x (110-10)

    P = 10 bar

    26

    24

    22

    20

    18

    16

    14

    12

    10

    8

    6

    4

    2

    0

    ma

    xim

    um a

    llow

    ab

    le p

    ress

    ure r

    atin

    g i

    n b

    ar

    Temperature in C

    0 10 20 30 40 50 60 70 80 90 100

    16 & 20mm o.d. pipe

    25 & 110mm o.d. pipe

  • 13GEORGE FISCHER

    Pipe external diameter mm 16 20 25 32 40 50 63 75 90 110

    Torque Nm 3 3 4 5 10 12 15 18 20 22

    Connection:plastic/plastic

    Flange connections/unions

    O-ring sealing unions or flangeconnections should be used in principlefor detachable connection of plasticpipes or adaptors between plastic pipesand metal pipes or metal fittings (valves,pumps). Unions up to d 63 Flange connections up to d 110

    High screw tightening forces are notrequired for making flange connectionswith O-rings. It is recommended to usetorque wrenches to prevent excessivetightening of screws.Nominal values for the screw fixing offlange connections with O-Ring:

    Connection:plastic/metal

    Flange seals are normally used inflange connections for the transitionfrom plastic to metal, since the jointingfaces of the metal flange are usuallyserrated.

    The screws should also be tightenedwith a torque wrench for flange

    Pipe external diameter mm 16 20 25 32 40 50 63 75 90 110

    Nominal internal diameter DN mm 10 15 20 25 32 40 50 65 80 100

    Torque Nm 6 7 9 10 20 25 30 35 40 45

    Commercially available screws, nuts,washers.Washers should be used in general

    connections with flange seals, in orderto prevent damage to flanges orflange adaptors. The table belowshows nominal values of torquesrequired for the various pipediameters.

  • 14 GEORGE FISCHER

    Firestop Firesleeves

    Product Specification

    Firestops are a one piece, onelength stainless steel sleeve completewith closure tabs and slots, having anintumescent lining running the full lengthof the unit with 3 bands of AccousticFoam adhered to the bore.The units are wrapped around theplastic pipes by hand and slid into thewalls/partitions.In the event of a close proximity fire thePacifyre fire sleeve lining of intumescentactivates at 140C and expands to over16 times its own volume to create a fireproof seal between the pipe and thewall which prevents the spread of the firebetween building compartments.The foam, whilst creating a smoke andaccoustic seal against the pipe, allowsfor pipe expansion and buildingmovement and is also an anti-vibratorymaterial.Firestops can be fitted to eitherhorizontal or verical pipework andalthough they can be freely moved intoposition, they will remain in place evenon vertical pipework.

    Firestops do not give off toxic fumes orsmoke in the event of a fire

    Firestops are asbestos free and do notcontain any hazardous materials andthere are no special precautionsrequired for handling or installing theunits.

  • 15GEORGE FISCHER

    Specification Guide for Consultants

    General

    The polybutylene system shall be byGeorge Fischer, Telephone 024 76535535, Fax 024 7653 0450.

    Requirements specific to the design ofPB pipework systems are contained inthis section. Polybutylene (PB) pipeworksystems shall be used for theconveyance of heating, LTHW andpotable cold water for use in alldomestic cold water services, chilledwater, hot water services andcompressed air should comply with therequirements specified in BS 7291(Parts 1 and 2) Class 'S' or DIN16968/DIN 16969.

    The whole of the PB pipeworkinstallations should be tested inaccordance with the requirements asset out in BS Code of Practice 312:and installed in accordance with BS6700 and the relevant manufacturer'sinstructions.

    Care should be exercised whilstoffloading, storing, transporting aboutthe site and whilst installing thepipework and fittings to ensure that noaccidental damage occurs to thepipework or fittings. Also, the pipeworkand fittings should not be stored wherethey be exposed to the effects of ultra-violet radiation including daylight.

    Pipes

    All PB piping should be to BS 7291:Part 182 or DIN 16968/DIN 16969.

    Pipe Fittings and Valves

    Unless specified otherwise, allassociated pipe fittings (viz. Manifolds,unions and flanges) should be of PBmanufacture generally in accordancewith BS 7291: Parts 1 and 2 and brassfittings manufactured generally inaccordance with BS 864, Part 2 andbe fully compatible with the pipesystem they are to be installed with.

    Polybutylene (PB) Pipework System

    Valves for PB pipework should be fullycompatible with the pipework system towhich they are to be connected,comprising variously:

    (i) PB gate valves for pipe sizes up toand including 63mm outside diameter,allowing bi-directional flow with directsealing of slide in valve bodyoperating at 90 to direction of pumpflow with non raising valve spindle.

    (ii) PVC-C ball valves for pipe sizes upto and including 63mm outsidediameter, meeting the resistance topressure requirement of DIN 3441,allowing bi-directional flow withfloating ball and complete with doublesocket disconnecting ends andremovable seals.

    (iii) PVDF flanged butterfly valves forpipe sizes over 63mm outside diameter,allowing bi-directional flow or overalldimensions complying with DIN 3441:Part 5 or ISO 7508 and having valvebody holes to allow connection toflanges drilled in accordance with BS8063: Part 4, ISO 2536 or BS 10; tableD or E.

    (iv) Brass valves should be suitable forconnection with PB pipe directly orwith adaptors to flanged or threadedconnectors.

    (v) Only pipe cleaner and sealantspecifically approved by the pipe andfittings manufacturer should be used.

    The above valves should be used forbalancing and regulation purposes.Unless otherwise indicated on thedrawings, draw-off isolating valvesshould be of approved constructionwith female threaded enda suitable forPB threaded adaptors.

  • 16 GEORGE FISCHER

    Selection of PB Pipe Systems

    The selection is based on the followingdiameters:

    The installed system shall be theGeorge Fischer PB pipework systemand shall have the following diameterpipework.

    Outer Diameter Inner Diameter

    16 11.620 14.425 20.432 26.040 32.650 40.863 51.475 61.490 73.6

    100 90.0

    All PB pipework sizes stated on thedrawings refer to outside diameters.

    Workmanship, Finish & Appearance

    The finished tube shall be smooth, freeof internal and external mechanicalimperfections and internally shall havea smooth appearance.

    Packaging & Transportation

    The pipes should be delivered in coilsor straight lenghts and the tubes shallbe bundled by size in suitable bags orcardboard boxes, clearly marked withthe purchase order number, materialdesignation, size, total length or piececount and name of supplier.

    Pipe Joints

    The pipes and fittings should beentirely compatible with each otherand the jointing should be carried outin strict accordance with themanufacturer's printed instructions.

    Unless indicated otherwise, the pipejoints in PB pipework should be madeby socket fusion, electrofusion orcompression. The assembly of theseshould be carried out in strictaccordance with the manufacturer'sinstructions. Only fully trainedinstallers should be used for

    assembling PB pipe systems. Trainedand certified by George Fischer.

    (i) Socket FusionUtilising the correct tools for assembly,heating and jointing times inaccordance with the manufacturer'sinstructions. This shall only be carriedout at a work bench, with the heatingelement securely fixed to the workbench.

    (ii) ElectrofusionUtilising correct tools for assembly,heating and jointing times inaccordance with the manufacturer'sinstructions.

    (iii) Brass CompressionFittings to include internal pipe sleeveas integral part of fitting with grip ringto hold pipe in place. Assembly inaccordance with the manufacturer'sinstructions. This method shall only beused to connect to items of plant or tometallic pipework sections.

    Where directed, to enabledisconnections to be undertaken, socketunions should be fitted on pipes up toand including 63mm outside diameter.Above 63mm outside diameter, flangedjoints should be used.

    Note: Locations for demountableunions and flanges shall be as shownon the drawings.

    Screwed adaptor fittings should beused at screwed joints to appliancesup to 2" nominal bore. PB flangeadaptors having dimensions inaccordance with BS 4504, should beprovided for connection to pumps,tanks or equipment above 2" nominalbore.

    Pipework System

    The piping contractor should providesamples of the following for approval:- PB Piping- PB pipework regulation and isolation valves- PB Pipework bends, tees and tap connectors- PB cleaner and jointing equipment or (if applicable) compression fittings for use with PB.

  • 17GEORGE FISCHER

    Orders for the pipework system shouldnot be confirmed, nor should the theconstruction of the installation of thesystem proceed until these sampleshave been approved in writing.

    The approved samples should beretained on site for comparison withthe work as actually installed.

    The connections to taps on sinks,worktops etc should be installed withthe manufacturer's suitable outletconnectors. Arrangements should bemade to ensure that the fittings andthe PB pipe to which it is joined areguarded and secured in such a wayas to be protected from undue impactor excessive torque.

    PB pipework can be connected to anyheat source (for example domestic hotwater storage calorifier or direct gasfire water heater).

    Cleaning

    In general the pipe should be flushedwith mains cold water after finishingthe installation.

    Disinfection

    Disinfection shall be carried out inaccordance with Section 218 and themanufacturer's guidelines.

    Fire Sleeves

    Fire sleeves should be used wheresingle PB pipes of 20mm outsidediameter and above or multiple banksof pipes penetrate fire barriers. Theyshould generally comply with therequirements of the local fire authority.

    (i) They should be constructed with anintumescent lining.

    (ii) Casings should accommodate theexpansion of intumescent linings duringfire conditions.

    (iii) Intumescent linings should expandinwards at a temperature of about140C and completely seal theopenings against the passage offlames, fumes and smoke. Such liningsshould also be in accordance with thepipe manufacturer's requirements.

    Note: The pressure of the expandingintumescent lining may crush PB pipes.

    (iv) Individual sleeves mounted onvertical pipework should:- be of construction suitable for surfacemounting- be installed on the pipe immediatelybelow the barrier (the collar should besecurely fixed to the sleeves, the sleeveand the flanged collar butted upagainst the fire barrier and the flangebolted into position) or similar.

    Installing the pipework system

    The contractor should:

    (i) Check that the exterior of the pipingis marked at intervals not exceedingone metre with the manufacturer'sname, type of material, pipe size andstandard with which it complies.

    (ii) Check that all the piping andfittings supplied are uniform in colourdensity.

    (iii) Exercise particular care in theirstorage, handling and installation toavoid deterioration due to ultravioletlight and impact damage.

    The piping manufacturer's printedinstructions should be rigidly adheredto in all respects of storage, stacking,handling and installation. The pipeworkshould be supported as indicated uponthe drawings and as detailed withinthe contract documents.

    It is essential that cleaners are correctlyapplied to the pipe ends and socketsprior to fusion and electrofusion jointingwith cleaning pads changed regularlyin accordance with manufacturer'sinstructions. After fusion jointing, a ringof Polybutylene will be visible on theoutside of the pipe as evidence that ajoint has been completed. Afterelectrofusion an indicator pip will raiseabove the surface of the fitting asevidence that a joint has beencompleted.

    Great care should be taken to ensurethat only the manufacturer's installationprocedures are followed and inparticular that the full cooling period is

  • 18 GEORGE FISCHER

    maintained before any joint isconsidered to be complete.

    No pipework, or section thereof, shallhave water pressure applied until themanufacturer's stipulated setting periodhas elapsed (a minimum of at leastone hour after the last fusion joint).

    Where an existing heat source has tobe maintained, with pipes eitherrunning parallel or crossing each other,thermal insulation should be applied.

    On no account should ladders,scaffold or other building items bepropped up against the PB installation.

    Changes in direction can be achievedusing the pipe's flexibility inaccordance with the manufacturer'sinstructions. No thermally inducedbending of PB pipes through theapplication of local heating should bepermitted.

    All PB pipes should be supported bypipe clips or support brackets, thespacing of which should not exceedthe maximum intervals as advised andconfirmed by the pipe manufacturer.

    Where a pipe clip or support bracketis being used to support a number ofpipes of different materials and sizes,the spacing interval between such clipsand brackets should not exceed thesmallest of the 'maximum intervals'stated or advised for each of the pipesbeing supported.

    PB pipework in exposed positions (orwhere distortion is likely to occur)should be supported using the pipingmanufacturer's standard pipe clip orsupport pipe carriers.

    Where PB piping is supported usingother than the standard PB pipe clips,the supports should comprise steel splitpipe rings with rubber insert, nipplingrod nuts and washers with backplateas required, either fixed to rail supportor building fabric.

    The test pressure should be maintainedthroughout the period of time of notless than one hour and not less thanone and a half times working pressure.

    There should be no loss of pressureabove that detailed in themanufacturer's handbook, to allow forthe expansion and the seting in periodof PB pipes, during the period the testis being carried out. The results of thepressure test should be recorded on alog sheet.

    Expansion

    Expansion loops or changes in thepipe direction should be allowed for atregular intervals in accordance withmanufacturer's guidelines.

    Where expansion loops and changesin direction are impractical, fixed pointassembly may be used on pipes up to75mm diameter to prevent the PB pipesfrom expanding or contracting, inaccordance with manufacturer'sguidelines.

    Warning: Not all PB piping systemsare suitable for fixed point assembly toresist the effects of expansion. Pleaseconsult the manufacturer beforeconsidering the use of this method.

    If fixed point brackets are being usedto avoid longitudinal expansion of PBpipes, the installation instructions ofbothe the pipe and bracketmanufacturers should be adhered to.Fixed point brackets should be locatedat fittings and must grip the pipe onboth sides of the fittings or accordingto manufacturer's instructions.

    Fixed point supports should be locatedat fusion or electrofusion fittings andmeet the manufacturer's requirements toabsorb forces and transfer them to thestructure. Fixed points should not belocated more than a maximum of 6mapart.

    Pipe support carriers shall be of semicircular shape to closely match theoutside diameter of the pipe.Manufactured from galvanised or sizeplated steel. The coating inside andoutside are to be of the samestandard. The finish is to be smoothalong the surfaces and edges toprevent damage to the pipes. When

  • 19GEORGE FISCHER

    cut the edges of the carrier are to befiled smooth. The carrier is to beattached to the pipe by approvedcable ties suitable to support theforces, at intervals recommended bythe manufacturer (never more than500mm). The carrier is not to be runover fittings, but to terminate 10 -15mmshort both sides with adequate supportthrough cable ties and brackets.

    Only installers carrying a GeorgeFischer training certificate shall beused for assembling George FischerPolybutylene pipe systems.

    Water Treatment

    On completion of installation, thewhole of the heating and primary hotwater system is to be filled and after asatisfactory pressure and heat test isachieved, emptied and flushed cleanof all foreign matter.

    When a clean water condition isproven, the system is to be dosed withan approved and recognised chemicalscale and corrosion inhibiting agent.

    The dosing operation is to be carriedout by an approved specialist and oncompletion certificates are to besubmitted indicating the chemical used(and its characteristics) the percentagedosage introduced and all otherrelevant details required to maintainsatisfactory protection.

    Immediately upon completion of thedosing process, notices are to beposted in plant rooms indicating thatthe system has been treated, thechemical used, the percentageconcentration etc and particularlyrelevant information required by theHealth & Safety at Work regulations.

    Prior to the dosing processcommencing, the Contractor is tosubmit details of the company it isproposing to engage to perform theoperation, complete with all relavantinformation regarding the type ofchemicals to be used and the method.

    Dosing by the mechanical contractoror any other organisation not aspecialist will not be permitted.

  • 20 GEORGE FISCHER

    Standards and Regulations

    The standards and regulations specific toeach country are the Bible of theWater Installation Specialist.

    The actual standards for waterinstallations are intended for bothmechanical services designers and alsofor manufacturers. This is to ensure theycomply with the requirements for partsand for materials.

    Until uniform European TechnicalRegulations for Water Installation areestablished, the specific country'sRecognized Technical Guidelinesare valid.

    Technical Regulations for WaterInstallation are in:

    UK Water Byelaws &British StandardsBS & WRAS

    Germany DVGWDIN 1988 (TRWI)

    Switzerland SVGWGuidelines W3

    Austria Standard in preparationbased on DIN 1988

    With these regulations in mind, the legalrequirements for hygienic and technicalsuitability of parts and materials have tobe met. For the purposes of productidentification, the manufacturer isrequired to label his products and theinstaller is required to use only clearlymarked products.

    For the construction of water systems, thefollowing standards and regulations mustbe considered:

    United Kingdom BS & WRAS BS 5955 Specification for the Pt 8 installation of thermo-

    plastic pipes andassociated fittingsfor use in domestic hotand cold waterservices and heatingsystems.

    BS 7291 Thermoplastic pipesClass S and associatedfittings for hot and coldwater for domesticpurposes and heating,chilled water andcompressed airinstallations inbuildingsPart 1: GeneralrequirementsPart 2: Specifications forpolybutylene (PB) pipesand associated fittings.

    UK Water Fittings Scheme Listing

    Germany DVGW DIN 1988 (TRWI) DIN 4109 Noise protection in

    buildings DIN 4102 Behaviour of construction

    materials in fire HeizAnlV Heating installation

    regulation

    Switzerland SVGW W3 Guidelines for the

    installation of watersystems

    SIA 181 Noise protection inresidential buildings

  • 21GEORGE FISCHER

    INSTAFLEXProduct Range

  • !" !

    "

    ! " ! " !

    #

    ! ! "

    $#%&$# '()#&

  • " *

    ! "! ! ! !! !

    !

    ! " ! "

    "" *

    ! " ! " !"" ! !"

    !" "

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    ! ! !" !!

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  • + , -,

    !" ,. / +-- 0 1 1"

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    " " "" " " " " " "

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  • 2

    !" 3,

    4

    ! ""

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    4

    3 3 3 3 3 3

    ! " ! !! " ! "! !

    !

    L

    -

    4

    " !

    2, (752'4#83)

    "3 4

    " "" " "

    $#%&$# '()#&

  • 26 GEORGE FISCHER

    760 305 000760 305 001760 305 002760 305 003760 305 004

    760 305 005760 305 006

    Code

    9mm Insulation Tube for chilled & cold water applications

    od

    1620253240

    5063

    Armaflex Insulation

    760 305 010760 305 011760 305 012760 305 013760 305 014

    760 305 015760 305 016760 305 017760 305 018760 305 019

    Code

    13mm Insulation Tube for heating & hot water applications

    od

    1620253240

    50637590

    110

    /m

    0.690.870.951.101.26

    1.802.54

    /m

    0.921.051.351.491.74

    2.182.794.345.256.75

    SP L (m)

    2020202020

    2020

    22222

    22

    SP L (m)

    2020202020

    2020202020

    22222

    22222

    760 856 250760 856 251760 856 252760 856 253760 856 254

    760 856 255760 856 256760 856 257760 856 258760 856 259

    Code

    Fire Protection Sleeves

    od

    1620253240

    50637590

    110

    Firestop

    13.7114.3920.6222.3924.68

    27.2030.6133.7537.5342.73

    SP g

    1212121212

    1212888

    5965

    124141167194237272315368

    60 85 62

    60 30 50

    New

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    4 =

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    "33

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    $#%&$# '()#&

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    #>+, .

    4 =

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    " ! " " " " "

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    *

    " ! "" " !!

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  • 31GEORGE FISCHER

    PIL 000 032PIL 000 033PIL 000 034

    Code

    Undrilled Reducing Bush

    d

    75

    90

    110

    Socket Fusion Block Reducers

    10.8013.4517.26

    SP Kg

    0.200

    0.250

    0.400

    761 069 500761 069 501761 069 502761 069 503761 069 504761 069 505

    Code

    Pre-drilled Reducing Bush 75mm-

    16

    20

    25

    32

    40

    50

    18.0018.0018.0018.0018.0018.00

    SP Kg

    0.200

    0.200

    0.200

    0.200

    0.200

    0.200

    761 069 506761 069 507761 069 508761 069 509761 069 510761 069 511

    Code

    Pre-drilled Reducing Bush 90mm-

    16

    20

    25

    32

    40

    50

    20.0020.0020.0020.0020.0020.00

    SP Kg

    0.250

    0.250

    0.250

    0.250

    0.250

    0.250

    New

    761 069 512761 069 513761 069 514761 069 515761 069 516761 069 517

    Code

    Pre-drilled Reducing Bush 110mm-

    16

    20

    25

    32

    40

    50

    22.0022.0022.0022.0022.0022.00

    SP Kg

    0.400

    0.400

    0.400

    0.400

    0.400

    0.400

  • ?

    ?. 3

    ! "#$ %&' ( &) *&(

    4 =" = $

    " !" !! " ! " + " ! "" + " ! "

    " ! +

    " ! ! + " ! +

    2, + 3, *,

    ! "#$ %&' ( &) *&(

    3& 4 * = $

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    + " +

    + " ! + " " +

    2, +. 39, *,

    ! "#$ %&' ( &) *&(

    3& 4 =" = $

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    + " ! " +

    + " " + " "" +

    $#%&$# '()#&

  • ! 2, +. 39, *, ! "#$ %&' ( &) *&(

    3& 4 = * $

    + " ! ++ " ! ! + " !! "

    $#%&$# '()#&

  • 34 GEORGE FISCHER

    101010

    10101010

    5 5 5

    1 1 1

    2 3 4 5

    6 8 16

    d Code SP g

    16 20 25

    32 40 50 63

    75 90 110

    5080 O-Ring, EPDM quality for potable wateri D b

    3.53.53.5

    3.55.35.35.3

    5.35.37.0

    D i

    b

    748 410 000748 410 001748 410 007

    748 410 002748 410 003748 410 012748 410 013

    748 410 014748 410 015748 410 016

    18.6 23.4 28.2

    36.1 43.8 53.3 69.2

    81.9 101 120

    25.7 30.5 35.2

    43.2 54.5 64.0 79.9

    92.5111.6134

    0.750.750.88

    1.041.171.291.47

    1.712.883.43

    484001 Flat Gaskets for all pipe materials

    for all Flange Adaptors No. 5030 etc.Material: EPDMHardness: 65 Shore approx.

    D Inch g i D b

    16 3/8 16 027 2020 1/2 20 032 2025 3/4 25 039 2032 1 32 048 2040 11/4 40 059 3

    050 11/2 50 071 3063 2 63 088 3075 21/2 75 104 3090 3 90 123 3110 4 110 148 4

    Code

    748 400 014748 400 015748 400 016748 400 017748 400 018

    748 400 019748 400 020748 400 021748 400 022748 400 023

    0.270.350.380.440.48

    0.691.161.181.472.00

    761 066 739761 066 740761 066 993761 066 994

    1010

    5

    155190220305

    g

    *16*20*25*32

    zhH DG

    62627076

    42424751

    5555

    111/411/22

    41505669

    SPCodedH

    zh

    G d Dd

    Union, socketspigot, PB pipe to PB fittingincluding EPDM O-Ring, (suitable for potable water)

    5034

    10.4611.4312.2015.00

    5032

    Gd

    H

    h z

    zhH DG1gSPCoded-G

    Adaptor union, spigot, PB fitting with metal female BSP threadincluding EPDM O-Ring (suitable for potable water)

    290290390

    707074

    47 47 51

    11 11 11

    11/211/22

    52 52 64

    761 066 998761 066 999761 066 288

    *25-3/4*25-1*32-1

    G1

    D

    9.7010.9014.10

  • 35GEORGE FISCHER

    24 70 16

    l

    d Code

    20 25 32 40 50

    63 75 90 110

    SP g D

    95105115140150

    165185200220

    a

    28 34 42 51 62

    78 92110133

    k

    65 75 85100110

    125145160180

    b l

    1515151515

    18181818

    Dk

    a

    b

    r

    r11111

    1111

    724 701 606724 701 607724 701 608724 701 609724 701 610

    724 701 611724 701 612724 701 613724 700 014

    2203204108201040

    1220140015301840

    7 7 7 8 8

    10101010

    suitable for PB flange adaptors (cat. no. 5030 & 5031 pages 10 & 11)Galvanised mild steel drilled to BS 4504: 1969 NP10/16

    Galvanised steel backing flange

    44444

    4488

    bolts

    M12 x 55M12 x 60M12 x 60M16 x 70M16 x 75

    M16 x 80M16 x 85M16 x 90M16 x 95

    boltholes

    4.494.665.205.306.55

    9.2512.7014.0518.20

    761 066 980761 066 971761 066 972761 066 973761 066 974

    761 066 975761 066 976

    1010101010

    102

    0,1200,0900,1100,1300,180

    0,2100,280

    kg

    16-120-11/425-11/232-240-21/2

    50-2 3/463-31/2

    SPCoded-G

    Unionsuitable for flange adaptor and union

    5081

    2.422.823.424.548.00

    9.2012.50

  • ', : / '+0

    ', ,, 9,

    ,&) ( & (

    4 * " =

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    $ , & ) )(/

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    4 =

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    $#%&$# '()#&

  • 41GEORGE FISCHER

    761 066 250761 066 251761 066 252761 066 253761 066 254

    Code

    5062

    d-d1

    25-1625-2025-1625-1625-16

    Electrofusion Manifold in Polybutylene d25 (DN20)

    7.859.45

    13.2518.4024.30

    SP Kg

    d-d1 L L1 h

    singlesingledoubletriple4 fold

    11111

    0,0310,0410,0620,0920,121

    25-1625-2025-1625-1625-16

    h1 H z z1 z2

    31 - 63 32 60 45 36 1339 - 78 39 64 60 35 2131 45 108 32 60 90 36 1331 45 153 32 60 135 36 1331 45 198 32 60 180 36 13

    Connection left Connection right

    singlesingledoubletriple4 fold

  • 42 GEORGE FISCHER

    Special Block Reducers (Prices available on request)Order form

    d2

    d1

    d1

    d2

    d1

    d

    2

    Rp

    d

    16 20 25 32 40 50

    75

    90

    110

    d2

    d1

    16 20 25 32 40 50

    75

    90

    110

    d2

    d1

    16 20 25 32 40 50

    75

    90

    110

    d2

    d1

    1/2

    3/4

    1

    75

    90

    110

    Rpd

    StraightFemale electrofusion socket

    90 ElbowFemale electrofusion socket

    45 ElbowFemale electrofusion socket

    Adaptor UnionMale/female BSP thread

  • 43GEORGE FISCHER

    762 501 016762 501 020

    Code

    Flexalino Thin Wall PB Pipe in Coilsfor compression fittings only in Manifold Plus Range (not suitable for fusion)

    od

    16 x 1.520 x 1.9

    Manifold Plus Compression Jointing System

    /m

    1.201.60

    SP L (m)

    60m60m

    762 500 016762 500 020

    Code

    Flexalino Thin Wall PB Pipe in Protective Pipe in Coilsfor compression fittings only in Manifold Plus Range (not suitable for fusion)

    od

    16 x 1.520 x 1.9

    /m

    1.852.30

    SP L (m)

    60m60m

    760 856 380

    767 856 393

    Code

    ManifoldsCaps and plugs required to close future connection

    od

    3/4 x 15/16/202-port3/4 x 15/16/203-port

    8.50

    12.50

    SP Kg

    760 305 120

    Code

    Bracketing for ManifoldsSet of two

    od

    3/4

    4.25

    SP Kg

    760 305 124760 305 125

    Code

    Plugs and Caps for Manifolds

    od

    3/4 Plug3/4 Cap

    1.101.10

    SP Kg

    For final flexible connection from manifold ports to services.

    For final flexible connection from manifold ports to services.

    For connection from manifold ports to services in either 15mm, 16mm or 20mm.

  • 44 GEORGE FISCHER

    760 305 151760 305 153760 305 152

    Code

    Manifold AdaptorBody only - adaptor fitting required for PB/Cu connection

    od

    15/16/20 x 3/422 x 3/425 x 3/4

    1.701.952.10

    SP L (m)

    760 305 102

    Code

    Equal TeeBody only - adaptor fitting required per inlet/outlet

    od

    15/16/20

    1.60

    SP Kg

    e.g. use 15mm or 16mm adaptor fittings to reduce on a branch

    760 305 104

    Code

    Elbow 90Body only - adaptor fitting required per inlet/outlet

    od

    15/16/20

    1.50

    SP Kg

    e.g. use 15mm or 16mm adaptor fittings to reduce

    760 305 127

    Code

    Radiator Duckfoot BendBody only - adaptor fitting required per inlet/outlet

    od

    15/16/20

    2.55

    SP Kg

    e.g. for use with 15mm Cu or 16/20mm PB

    To connect copper or INSTAFLEX to manifolds.

    760 305 148

    Code

    Back Plate ElbowBody only - adaptor fitting required for PB/Cu connection

    od

    RBM x 1/2 BSP

    2.45

    SP Kg

    e.g. right angle connection of either 15mm Cu or 16/20mm PB to 1/2" BSP

    New

    New

    New

  • 45GEORGE FISCHER

    760 305 138760 305 146

    Code

    INSTAFLEX Female AdaptorBody only - adaptor fittings required for INSTAFLEX side

    od

    15/16/20 x 1/2 25 x 3/4

    1.352.10

    SP Kg

    e.g. use 16mm adaptor fittings to reduce on a branch

    760 305 140760 305 146

    Code

    INSTAFLEX Male AdaptorBody only - adaptor fittings required for INSTAFLEX side

    od

    15/16/20 x 1/225 x 3/4

    1.352.10

    SP Kg

    e.g. use 16mm adaptor fittings to reduce on a branch

    760 305 132760 305 133

    Code

    Tap ConnectorsBody only - adaptor fittings required for INSTAFLEX side

    od

    15/16/20 x 1/215/16/20 x 3/4

    2.953.50

    SP Kg

    e.g. use to connect 16mm or 20mm PB pipe to BSP male thread tap connection

    761 856 385769 856 398

    Code

    Ball Valve (1/4 turn)Body only - adaptor fittings required for INSTAFLEX side

    od

    15/16/2025

    3.004.20

    SP Kg

    762 856 387760 305 150760 305 147

    Code

    INSTAFLEX to Copper connectorsBody only - adaptor fittings required for PB/Cu connection

    od (PB x Cu)

    16/20 x 15 16/20 x 22

    25 x 22

    1.152.703.00

    SP Kg

    e.g. use to connect PB pipe to Cu tube

    New

    New

  • 46 GEORGE FISCHER

    761 856 384761 305 126

    Code

    Adaptor Fittingsfor FLEXALINO thin wall PB pipe

    od

    16 x 1.520 x 1.9

    1.201.20

    SP Kg

    760 856 382760 856 383760 856 390

    Code

    for INSTAFLEX PB pipe

    od

    16 x 2.220 x 2.825 x 2.3

    1.201.203.50

    SP Kg

    760 305 154

    Code

    for Copper, Chromed Brass, etc (universal)

    od

    15 x Cu

    1.60

    SP Kg

    760 305 128

    Code

    Washing Machine ValveBody only - adaptor fittings required per inlet/outlet

    od

    15/16/20

    2.40

    SP Kg

    760 305 126760 305 149

    Code

    for copper pipe

    size

    15 x Cu22 x Cu

    1.152.40

    SP Kg

    New

    760 305 143

    Code

    Spanner for RBM fittings

    size

    RBM

    5.70

    SP Kg

    e.g. to allow tightening of fittings onto manifold

    New

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  • " 2, ;* + +. 9, ,. ;* , ( (, & .(& &,/ &( #12

    3$ =

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  • ?

    2, +

    0 ( (, & .(&1 ! "#$ %&' ( &) *&(

    3& ) * *" $

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  • ', : /#9+0

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    $, @, . 9+5&,/- "#$ %&' ( &) *&(6&*. &.(& *. (+( .&3( ,/

    7 , &, (& 3&34

    /70 ) 4 =

    74 " 74 " ! 74 " !!

    74 " ! 74 " ! !! 74 " !"

    $, @, ;* $ " A 9 , / 9+0( ,/ ,5&,/- "#$ %&' ( &) *&(6&*. &.(& *. (+( .&3( ,/, , + - ,,6

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    74 " 74 "

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    74 " 74 " " 74 " "

    $#%&$# '()#&

  • $, @, , / 9+0( ,. ,( ,/ ,5&,/- "#$ %&' ( &) *&(6&*. )' .(,7 , &, (& 3&34

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    74 " 74 " ! 8( ,, , 74 " ! 3&3

    "" $, @, /9+05&,/- "#$ %&' ( &) *&(6&*. &(& *. (+( .&3( ,/

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    /70 ) 4 =

    74 " !

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  • $, @, ;* $" A 9 , /9+05&,/- "#$ %&' ( &) *&(6&*. &(& *. (+( .&3( ,/#(& 3&3 , ) (( ,(&'

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    74 " ! ! 74 " ! ! 8( ,, , 3&3 74 " !

    , , , +

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    $#%&$# '()#&

  • 54 GEORGE FISCHER

    761 066 946761 066 947761 066 948

    761 066 949761 066 950761 066 951

    Code

    5079d

    202532

    405063

    PB to PVC-C Quarter Turn Valves

    23.7027.9034.00

    46.8051.5065.00

    SP Kg

    111

    111

    0,1000,1600,240

    0,3900,6101,120

    Type 346 with PB Union AdaptorsDN L H z D

    152025

    324050

    101119130

    150163195

    506070

    8091

    109

    364367

    8297

    119

    465667

    8297

    119

    The Temperature/Pressurediagram (right) shows atwhat pressure andtemperature the PVC-CType 346 valve will safelyoperate when incontinuous use - allowinga 1 .5 safety factor.

    Technical Data19

    10 20 30 40 50 60 70 80 90 100

    3

    5

    7

    9

    11

    13

    15

    17

    1

    20 Year Life Expectancy

    50 Year Life Expectancy

    Pre

    ssu

    re (b

    ar)

    Temperature (C)

    Valves

  • 55GEORGE FISCHER

    Metal Butterfly - Type 037

    Type 037 M, Butterfly Valve with hand lever

    Dimensions

    Prices for this valve are available on application.

  • 56 GEORGE FISCHER

    16 2.0 15 6 15 4

    20 2.0 15 7 15 4

    25 2.3 18 7 15 4

    32 3.0 20 10 20 4

    40 3.7 22 14 20 4

    50 4.6 25 18 30 4

    63 5.8 28 22 30 6

    75 6.8 31 26 60 6

    90 8.2 36 30 75 6

    110 10.0 42 35 90 6

    INSTAFLEX

    InstallationQuick Reference GuideFor full details refer to full INSTAFLEX Training Manual

    Socket Fusion Jointing1. Chamfer pipe ends

    2. Clean pipe & fittings

    3. Check heater bushes temperature

    4. Check and clean heater bushes

    5. Set timer to correct heating time

    6. Mark fusion depth with gauge

    7. Make joint but Do Not Twist after insertion only

    adjust for squareness

    8. Hold pipe & fitting together for required holding time

    9. Carefully put pipe and fitting down for cooling time

    For 16 to 110mm Pipe & FittingsPolybutylene (PB) Socket Fusion Jointing

    Pipe outside Wall thickness Welding Heating Holding Coolingdiameter minimum length time time timeo.d. (mm) mm L (mm) t (sec) t1 (sec) t2 (min)

    ContentsGeneral InformationWorking with plastic pipe & fittingsINSTAFLEX technical informationFlange Connections/UnionsGF Firestop sleevesSpecification Guide for consultantsStandards & regulations

    Product RangePipePipe supports & bracketsAccessoriesGF Armaflex insulationGF FirestopFittings for socket fusion jointingUnionsFlange jointing (socket fusion)

    Fittings for electrofusion jointingManifold Plus Compression Jointing systemFlange jointing (electrofusion)ValvesINSTAFLEX PB valvesPB to PVC-C quarter turn valvesMetal butterfly valves Type 037

    INSTAFLEX installation quick reference guide