Process air systems

Process air systemsProducts and components for

industrial needs

Process air systems

In its process air technology range, BerlinerLuft. offers

products and components for industrial needs.

The products are designed for specific applications and

specific systems and are manufactured on the basis

of the latest standards. Services range from custom

products to special corrosion protection and coating of

components.

Duct components, coated 419

Welded and folded tubing 422

Protection against corrosion by coating

the components according to requirement

FROM PRODUCT TO SYSTEM

BerlinerLuft. manufactures and supplies specific compo-

nents and systems for ventilation and air conditioning. Both

for non-residential buildings and industrial plant construction.

A public building requires a different air treatment to that

needed for an industrial production process. We develop solu-

tions and products for industrial production processes in vari-

ous industries.

Ventilation towers

and steel chimneys

Products and components

for industry

Ventilation components and parts

in folded and welded design

High performance fans and special fans

For example, our devices and systems provide for clean re-

moval of hot, toxic or aggressive media used for drying or dust

removal.

For regenerative exhaust systems, we provide components

adapted to your specific needs and develop acoustic solutions

to reduce noise.

416 | Process air technology

417

Folded ducting components in tightness classes A, B and C as per DIN EN 1505.

Welded ducting components up to airtightness class D as per DIN EN 1505.

Multi-leaf dampers for

industrial requirements

Industrial silencers, sound enclosures, splitters and welded custom products

417Process air technology |

418 | Process air systems

Service

OURSERVICES

Design, manufacture and delivery of fans and sound insulation

solutions tailored to the customer’s needs

Manufacture and delivery of ducting systems

and associated components

Coordination and assembly of the system components

Technical support for the design of ducting systems

Project and detail design according to design plans

Extended service work such as conversion

and conversion/replacement of existing systems.

Preparation of technical documentation

THE ADVANTAGES FOR YOU

Industry-specific ventilation technology products

and components for industrial applications

Easing the burden of project management and advantages

in purchasing

Customer-optimised and plant-specific solutions

Avoidance of additional interfaces

Support of the value creation process

1 | Execution drawing

2 | Example of a regenerative ventilation system

1

2

Coated ducting components


GALVANISED STEEL DUCT COMPONENTS,

WELDED EPD COATED

Sheet metal ducts and fittings with a rectangular cross section

similar to DIN EN 1505, 1507 and DIN 18379 in welded design.

Sendzimir galvanised thin sheet metal, quality DX51D + Z275MA-C

(DIN EN 10346 and DIN EN 10143) or black sheet S 235 JRG2 as

per DIN EN 10025

With cathodic dip coating (EPD coating)

For UV-resistance: also available with additional powder coating

Sheet thickness according to pressure rating requirements

Airtightness class C and D as per DIN EN 1507

Cross connection using moulded frames.

With perforation according to factory standard

(hole spacing 125 mm)

Turning vanes as per DIN EN 1505

Fixed duct length depending on the cross connection

30 mm moulded frame 30/15 mm,

section length 1,350 mm





Other frame geometries on request

STAINLESS STEEL DUCTING COMPONENTS,

WELDED HALAR® ECTFE COATED

Sheet metal ducts and fittings with rectangular cross section

similar to DIN EN 1505, 1507 and VDI 3803 in welded design.

Stainless steel 1.4301, 1.4571 or 1.4404

With inner coating of Halar® ECTFE

Sheet thickness according to pressure rating requirements

Airtightness class C and D as per DIN EN 1507

Cross connection using moulded frames.

With perforation according to factory standard

(hole spacing 125 mm)


Fixed duct length depending on the cross connection







Larger formed frames available on request (individual assessment)

Coated ducting components

Welded stainless steel ducting components,

Halar coated on the inside

421Process air systems |

FOLDED DUCTING COMPONENTS

– GALVANISED STEEL EPD COATED

Sheet metal ducts and fittings with rectangular cross section

similar to DIN EN 1505, 1507 and DIN 18379 in folded design.

Made of sendzimir galvanised sheet steel grade DX51D +

Z275MA-C (DIN EN 10346 and DIN EN 10143).

With cathodic dip coating (EPD coating)

For UV-resistance: also available with additional powder coating

Sheet thickness according to low pressure (-500/+1,000 Pa)

or medium pressure (-750/+2,000 Pa) pressure rating

Airtightness classes A, B and C as per DIN EN 1507

Longitudinal seams folded; end connections with slip connection


Walls reinforced with trapezoidal corrugation

Additional reinforcements according to pressure rating as

per factory standard

Standard duct section length 1,500 mm

Section width 20 mm – up to edge length 1,000 mm

Section width 30 mm – from edge length 1,000 mm to 2,000 mm

Section width 40 mm – up to edge length 2,000 mm

Surface that is resistant to solvents and corrosions,

acid and alkali-resistant

System suitable for environmental conditions of corrosivity

category C5-M according to ISO 12944-6

Welded tubing


PRODUCT DESCRIPTION

Tubing which is welded or longitudinally folded is used in

ventilation systems to convey air for ventilation, extraction,

dedusting or exhaust air purification.

As pressure tubing for conveying media in a wide range of

applications, these tubes are suitable under very specific con-

ditions.

FOLDED DESIGN

WELDED DESIGN

Material quality, design, wall thickness, and surface treatment

depend exclusively on the respective application or use.

The respective specifications and requirements are to be

stipulated by the client or the planner, in direct consultation

with BerlinerLuft. (manufacturer).

Longitudinally folded tube

with flange

Welded and folded tubing

Welded tube,

stainless steel

Longitudinally folded tube with

recessed flange

Longitudinally folded tube

with section flange

and clamping ring (e.g. Metu)

Welded tube with flange

(sheet thickness max. 2.0 mm)

Welded tube with recessed

flange (sheet thickness

max. 2.0 mm)

Welded tube with

fixed flange



1 | Tube

2 | Tube with cover

3 | Concentric reduction

4 | Eccentric reduction

5 | 90° junction

6 | 45° junction

OVERVIEW OF TUBING

AND ROUND FITTINGS AS PER DIN EN 1506

ÜBERSICHT ROHRLEITUNGEN

UND FORMTEILE RUND NACH DIN EN 1506

d1

L1

d1

L1

d1

d2

lp lp

L1d

1

d2

L1

d3

d1

d3

L1L1

d1

L1

d3

d1

L1

d3

45°

1

3

5

2

4

6


7 | 90° junction reduction

8 | 45° junction reduction

9 | 90° segment bend

10 | 45° and 30° segment bend

11 | Cross piece

12 | Y-piece

OVERVIEW OF TUBING AND ROUND FITTINGS

AS PER DIN EN 1506

3

d1

L1

d2

45°

d

d1 d2

d3

L1

d1

d2

L1

d3

lp

r

lp

d2

45°

lplp

r

d1

30

°

lp

lp

r

d145

°

d1

d2

d3

w°

d1

d2

d4

d3

7

9

11

8

10

12



OVERVIEW OF TUBING

AND ROUND FITTINGS AS PER DIN EN 1506

13 | Offset piece

14 | Expansion joints

15 | Regulating dampers

16 | Base

17 | Wall sleeve

d2

lp

L1

v

d1

lp

d1

L1

d1

DA

DA

d1

d1

L113

15

17

14

16


Welded tube V2A (1.4301)

with welded flat flanges

as per DIN 24154 R2

CERTIFICATE OF CONFORMITY WITH VDI 6022

Air ducting made of sheet metal with circular cross-section

from BerlinerLuft. Technik GmbH are VDI 6022 certified and

have the following registration number: HKP/D/011/7a/8/

BL/0910/0913/MZ

STANDARDS AND GUIDELINES

In the field of air conditioning and ventilation technology, pre-

viously important national DIN standards have been replaced

by European standards (DIN EN), and international standards

(ISO) are also becoming increasingly important.

Many specifications from previously valid DIN standards have

not been adopted by the EN standards and must be defined

within the framework of the system-specific requirements.

The present documentation is based on the current standards

and the withdrawn standards mentioned here, which have been

Valid standards and guidelines

DIN EN 1506

Sheet metal air ducts circular cross-section

DIN EN 12237

Round ducts in process air systems

DIN EN 12599

Test procedures and measurement methods for handing over

installed ventilation systems

DIN EN ISO 12944

Corrosion protection by coating

DIN 25496

Ventilating components in nuclear facilities

KTA 3601

Ventilation systems in nuclear power plants

ATEX Directive

Directive 94/9/EC Article 8(1)b)ii)

VDI 6022

Hygiene requirements for ventilation systems

adopted as recognised rules for technology. These apply as

a guideline for ordering and manufacturing the components.

As a matter of principle, the latest valid standards are always

authoritative, and therefore the respective contents must al-

ways be checked before placing an order to ensure they are

up to date.

The following is an overview of withdrawn and valid standards

which were used for the documentation.

Withdrawn standards

DIN 24147

Round fittings – Survey, dimensions, general principles

DIN 24150

Tube connections

DIN 24151/1 and /2

Welded tubes, class 1 and 2

DIN 24152

Longitudinally folded tubes

DIN 24153

Tubes for flanged connection

DIN 24154/1 and /2

Flanges, class 1 and 2

DIN 59232

Tubes – Tolerances


MATERIALS

Ducting for process air technology can be made from

different metallic materials, depending on the application.

1 Limiting value for short-time operation, no permanent load, application to be agreed with the material manufacturer or an information centre for steel

2 For all seals, only silicon-free materials are used

3 Special seals for specific applications are available on request

SURFACE PROTECTION

Measures for surface protection must always be derived from

the intended use. The necessary coating thickness must be

specified by the user in accordance with the relevant corrosion

protection guidelines.

Designs

Black and galvanised sheet steel

Surface pretreatment/wash and passivation

Undercoat or primer

Paint

Powder coating

Stainless steels

Pickling and passivation

Bead-blasted

Material type Grade Standardmax. operating temperature 1

t max (°C)

Welded designBlack sheet Galvanised steel(Sendzimir galvanised fine sheet steel)Boiler plate Stainless sheet steel (surface III C)

AluminiumFAL (hot-dip aluminised sheet steel)

S 235 JRG 2 DX51D+Z275 MA-C

16 MO 31.4301 (V2A)1.4571 (V4A)ALMg3

DIN 10130DIN 10327

EN 10028 DIN 17440DIN 17440EN 485-2 EN 1396

-40 °C-60 °C

-20 °C-200 °C-270 °C-250 °C

+450 °C+250 °C

+500 °C+550 °C+550 °C+300 °C+700 °C

Folded design (longitudinally folded tube)Galvanised steel (Sendzimir galvanised fine sheet steel)FAL (hot-dip aluminised sheet steel)Stainless sheet steel (surface III C)

DX51D+Z275 MA-C

1.4301 (V2A)

DIN 10327

EN 1396DIN 17440

-60 °C

-200 °C

+250 °C

+700 °C+550 °C

Sealant materials 2, 3 for fold sealingSingle-component sealantBasis: butyl rubber/synthetic resin

Silicone-free Permanently elasticUV-resistantResistant to fatty acids

VDI 6022 Certified

-30 °C +80 °C



RECOMMENDATIONS FOR USE/WALL THICKNESS

For all applications, the client or planner must determine

which material type and material quality (e.g. wear-resistant

steels) is to be used. The planner or client must also decide

which wall thickness is to be used and, if necessary, whether

a wear-resistant inner coating is to be provided.

1 Limiting value for short-time operation, no permanent load, use to be agreed with the material manufacturer or an information centre for steel

Note: Other diameters, wall thickness, bend radii or special requirements are possible in consultation with the manufacturer, BerlinerLuft. Technik GmbH.

The following data are recommendations from which no war-

ranty claims can be derived.

Uses

Diameter range/wall thickness(Minimum requirement)

Bend radius

[mm] [mm]

Welded tubing forTube series 1 Air without addition of aggressive vapours up to DN 250 1.2 R = 1.0 D

or solids that increase wear DN 280 to DN 1000 1.5

(in accordance with DIN 24151-1) DN 1120 to DN 1250 2.0

> DN 1250 3.0

Tube series 2Air without addition of aggressive vapours up to DN 250 1.5 R = 1.0 D


(in accordance with DIN 24151-2) DN 560 to DN 1000 3.0

> DN 1000 3.0

Air with light suspended matter (e.g. fibres) up to DN 250 1.5 R = 1.5 D or 2.0 D

DN 280 to DN 500 2.0

DN 560 to DN 1000 3.0

> DN 1000 3.0

Dust extraction systems or chip extraction1Straight tubes

up to DN 500 2.0

> DN 500 3.0

Fittings dependant on Up to 8.0 R = 1.5 D or 2.0 D

solids content

Longitudinally folded tubes for

air without addition of aggressive vapours up to DN 150 0.6 R = 1.0 D


(in accordance with DIN 24152) DN 600 to DN 900 1.0

DN 1000 to DN 1250 1.2


PERMISSIBLE PRESSURE LOADS

The permissible pressures given in the table apply to non-

reinforced tube lengths of max. 2,000 mm. For longer tube

lengths of up to 6,000 mm, the specified pressures are reduced

by up to 50%.

Data refer to a tube length of max. 2,000 mm, without flange connection.

When using flanges as tube reinforcement at intervals of max.

2,000 mm tube length, the pressure data can be universally

applied.

Nominal diameter [mm]

Tube series 1 [Pa]

Tube series 2[Pa]

Longitudinally folded tube[Pa]

100

* -2500 to +6300 -2000 to +5000

*

*

250

300

*

* -6300 to +10000 -500 to +2500

*

500 -2000 to 6300

560

*

*

* -100 to +2500

1000

1120

1250

* -1600 to +6300 -5000 to +6300

*

*

2000



AIRTIGHTNESS REQUIREMENTS

Airtightness requirements for process air ducting depend

on the various applications. The essential requirements are:

The energy-saving operation of the air handling unit

An oil-tight design for extraction systems

An aerosol-tight design

The application in ventilation systems in nuclear power plants as

per DIN 25496.

The data given in the following table refer to a measuring con-

dition of t = 20 °C and an atmospheric pressure of 101,325 Pa.

Measurement conditions deviating from this are to be deter-

mined with a correction factor as per DIN EN 12237.

1 E.g. use of ventilation components in nuclear facilities as per DIN 25496. Components for this application are additionally tested with a Nekal leak test.

Airtightness classas per DIN EN 12237

Limiting value of the static pressure

Limiting value of the air leakage rate

Use recommendation

positive [Pa] negative [Pa] m³ x s-1m–2

A 500 500 0.027 x pt0.65 x 10–3 Not recommended

B 1000 750 0.009 x pt0.65 x 10–3 Not recommended

C 2000 750 0.003 x pt0.65 x 10–3 Standard requirement

D1 2000 750 0.001 x pt0.65 x 10–3 Maximum requirement


Average internal pressure in the ducting system in Pa

100

200 2000150010008006004000,01

0,02

0,04

0,06

0,080,1

0,2

0,4

0,6

0,8

1

2

4

6810

Airtightness class A

Airtightness class B

Airtightness class C

Airtightness class D

Leak

rat

e in

10

-3 m

3/s

m2

PROOF OF AIRTIGHTNESS

The diagram below can be used to estimate the expected leak

loss for a round ducting system or a section of it.

To do this, starting with the average internal pressure2,

the leakage rate is read off of the diagram and multiplied by

the round ducting surface area.

The proof of airtightness is to be carried out in accordance

with DIN EN 12599 – Test procedures and measurement meth-

2 Static pressure difference between the internal duct pressure

and the ambient pressure (for both positive and negative pressure)

ods for handing over installed ventilation systems. To achieve

airtightness, it is essential to assemble the tubing according

to the highest standard. Leakages must always be verified in

a fully assembled section of tubing. In order to be able to in-

fluence the assembly process, random verification of the air

leakage rates must be carried out as per DIN EN 12599.

AIRTIGHTNESS



Not fixed, recessed flange

(only up to sheet thickness 2.0 mm)

COMPONENT CONNECTIONS –

welded AREA OF APPLICATION

Flange/flange gasket/quick release clamping ring

(only up to sheet thickness 2.0 mm)

Smooth tube end, butt welded Tube end with flange, welded

Smooth tube end with flat flange, welded Smooth tube end with angle flange, welded

DN 100 - DN 1250

DN 100 - DN 1000

DN 100 - DN 2000 (3000)

DN 100 - DN 630

DN 100 - DN 1600

DN 100 - DN 2000 (3000)



welded AREA OF APPLICATION

Section flange with clamping ring

Flange welded externally at flange end


Flange welded internally at flange end

Section flange with clamp

Flange welded externally at tube end

Section flange with clamp

Flange butt welded to tube end

DN 200 - DN 3000

DN 200 - DN 3000

DN 200 - DN 3000

DN 100 - DN 2000 (3000)



Tube-tube via plug-in connector


AREA OF APPLICATION, FOLDED

Tube-tube via plug-in connector

Tube-fitting directly connected

Recessed flange

DN 80 - DN 1250

DN 80 - DN 1250

DN 80 - DN 1250

DN 80 - DN 1250


Welded tube V2A (1-4301)

with flange and not fixed

flat flanges as per DIN 24154 R2

Spigot with recessed flange


AREA OF APPLICATION, FOLDED

Flange/flange gasket/quick release clamping ring


DN 80 - DN 1250

DN 80 - DN 2000

DN 80 - DN 630



1 Diameter related to maximum sheet thickness

2 Maximum section length of tube without circumferential weld, larger section lengths with circumferential weld

3 SSR = quick release clamping ring

4 Flange according to DIN up to DN 2000, larger flanges according to factory standard


DIMENSIONS – WALL THICKNESS

Welded tubes and fittings

Connection typeDiameter

[mm]

max. sheet thickness 1

[mm]max. nominal tube

length 2

[mm]Steel sheets Stainless steel Aluminium

Component ends, smooth(butt welded at assembly)

160-280 1.5 1.5 1.5 1500

300-710 3.0 3.0 3.0 3000

400-1600 5.0 4.0 5.0 3000

Ends with flange(assembly via quick release clamping ring 3 or not fixed, recessed flange)Quick release clamping ring – max. = 630 mm

100-1000 1.2 1.2 1.2 1500

160-1000 1.5 1.5 1.5 1500

300-1250 2.0 2.0 2.0 3000

Fixed flange 4

(assembly via threaded connection)

100-1000 1.2 1.2 1.2 1500

160-1250 1.5 1.5 1.5 1500

300-1250 2.0 2.0 2.0 3000

400-3000 5.0 4.0 5.0 3000



1 Diameter-related to maximum sheet thickness

2 Maximum section length of tube without circumferential fold, larger section lengths with circumferential fold

COMPONENT CONNECTIONS – DIMENSIONS –

WALL THICKNESS

Folded tubes and fittings (tubes longitudinally folded)

Connection typeDiameter

[mm]

max. sheet thickness 1

[mm] max.

nominal tube length 2

[mm]Steel sheets Stainless steel Aluminium

Component ends, smooth(assembly via SV)

80-150 0.6 0.6 0.6 1000

160-224 0.8 0.8 0.8 1500

250-1000 1.2 1.2 1.2 1500

Ends with flange(assembly via quick release clamping ringmax. = 630 mm

80-150 0.6 0.6 0.6 1000

160-224 0.8 0.8 0.8 1500

250-630 1.2 1.2 1.2 1500

Ends with section flange(e.g. Metu flange)

80-150 0.6 0.6 0.6 1000

160-224 0.8 0.8 0.8 1500

250-1600 1.2 1.2 1.2 1500

Ends with flangerecessed(assembly via threaded connection)

80-150 0.6 0.6 0.6 1000

160-224 0.8 0.8 0.8 1500

250-1600 1.2 1.2 1.2 1500


1 The specified masses refer to a sheet thickness of 1.0 mm and do not include flange connections.

For all other sheet thicknesses, the mass is determined by multiplying by the respective sheet thickness as factor

(e.g. sheet thickness 1.5 mm = factor 1.5)

BSE = sheet segment

SURFACES AND DIMENSIONS FOR ROUND

AIR DUCTS

Nominaldiameter DN

[mm]

Cross-sectionalarea[m²]

SurfaceTube

[m²/m]

Weight 1

Tube [kg]

SurfaceBSE 90°

[m²]

Weight 1

BSE 90°[kg]

SurfaceBSE 60°

[m²]

Weight 1

BSE 60°[kg]

80100125

5.03 x 10 –3

7.85 x 10 –3

12.30 x 10 –3

0.2510.3140.393

2.002.483.12

0.030.050.08

0.240.400.64

0.020.030.05

0.160.240.40

150160180

17.70 x 10 –3

20.10 x 10 –3

25.43 x 10 –3

0.4710.5020.565

3.764.004.56

0.110.130.16

0.881.041.28

0.070.080.11

0.560.640.88

200225250

31.40 x 10 –3

39.74 x 10 –3

49.10 x 10 –3

0.6280.7060.785

5.045.606.32

0.200.250.31

1.602.002.48

0.130.170.21

1.041.361.68

280300315

61.54 x 10 –3

70.70 x 10 –3

77.90 x 10 –3

0.8790.9430.990

7.047.527.92

0.390.440.49

3.123.523.92

0.260.300.33

2.082.402.64

355400450

98.90 x 10 –3

0.1260.159

1.1101.2601.410

8.9610.0811.28

0.620.791.00

4.966.328.00

0.410.530.67

3.284.245.36

500560600

0.1960.2460.283

1.5701.7601.884

12.5614.0815.07

1.231.551.76

9.8412.4014.08

0.821.311.58

6.5610.4812.64

630710800

0.3120.3960.503

1.9802.2302.510

15.8417.8420.08

1.962.493.16

15.6819.9225.28

1.631.662.11

13.0413.2816.88

90010001120

0.6360.7850.985

2.8303.1403.520

22.6425.1228.16

4.004.937.03

32.0039.4456.24

2.663.294.97

21.2826.3239.76

125013001400

1.2301.3261.538

3.9304.0824.396

31.4432.6435.20

8.659.57

10.99

69.2076.5687.92

6.086.797.77

48.6454.3262.16

15001600

1.7662.009

4.7105.024

37.6840.24

12.5214.14

100.16113.12

8.829.93

70.5679.44



1 The specified masses refer to a sheet thickness of 1.0 mm and do not include flange connections.

For all other sheet thicknesses, the mass is determined by multiplying by the respective sheet thickness as factor

(e.g. sheet thickness 1.5 mm = factor 1.5)

BSE = sheet segment

SurfaceBSE 45°

[m²]

Weight 1

BSE 45°[kg]

SurfaceBSE 30°

[m²]

Weight 1

BSE 30°[kg]

SurfaceATE 90°

[m²]

Weight 1

ATE 90°[kg]

SurfaceAYE 45°

[m²]

Weight 1

AYE 45°[kg]

SurfaceUSE[m²]

Weight 1

USE[kg]

0.020.020.04

0.160.160.32

0.010.020.03

0.080.160.24

0.100.130.17

0.801.041.36

0.140.170.20

1.121.361.60

0.030.040.05

0.240.320.40

0.060.060.08

0.480.480.64

0.040.040.05

0.320.320.40

0.250.260.31

2.002.082.48

0.260.370.44

2.082.963.52

0.100.110.08

0.800.880.64

0.100.120.15

0.800.961.20

0.070.080.10

0.560.640.80

0.390.460.59

3.123.684.72

0.520.610.78

4.164.886.24

0.090.100.13

0.720.801.04

0.190.220.24

1.521.761.92

0.130.150.16

1.041.201.28

0.730.810.87

5.846.486.96

0.970.671.18

7.765.369.44

0.170.340.36

1.362.722.88

0.310.390.50

2.483.124.00

0.210.260.33

1.682.082.64

1.081.381.66

8.6411.0413.28

1.421.812.19

11.3614.4817.52

0.230.300.38

1.842.403.04

0.620.770.88

4.966.167.04

0.410.520.59

3.284.164.72

1.962.362.64

15.7018.8521.10

2.613.313.74

20.8826.4829.92

0.420.500.55

3.364.004.40

0.981.241.58

7.849.2012.64

0.650.831.05

5.206.648.40

2.863.654.45

22.8729.1635.57

4.045.086.25

32.3240.6450.00

0.590.750.94

4.726.007.52

2.002.473.94

16.0019.7631.52

1.331.642.91

10.6413.1225.28

5.436.508.19

43.4152.0065.55

7.679.2311.78

61.3673.8494.24

1.091.221.52

8.729.7612.16

4.805.406.16

38.4043.2049.28

3.514.014.54

28.0832.0836.32

9.9110.6112.09

79.2984.9196.71

14.3116.6617.92

114.48133.28143.36

1.842.883.65

14.7223.0429.20

6.977.82

55.7662.56

5.115.72

40.8825.76

13.6615.32

109.27122.59

20.6322.79

165.04182.32

3.924.52

31.3636.16


Dimension TABLE, FLAT FLANGES

(BASED ON DIN 24154 – EDITION JULY 1990)

Note: For connecting welded tubing, preferably flat flanges series 1 or series 2 are used in accordance with DIN 24154.

Angle flanges are manufactured in accordance with DIN 24155, if required.

DIN 24155 contains various series. For production, therefore, the diameter of the bolt holes and the number of holes,

related to the respective diameter, must always be concretely specified.

Nominaldia-

meterDN

Flat flanges, series 1 Flat flanges, series 2

Bolt hole

Width x thickness

AmountHoles

HoleDN

WeightSteel

Bolthole

Width x thickness

AmountHoles

HoleDN

WeightSteel

[mm] [mm] [mm] [pieces] [mm] [kg] [mm] [mm] [pieces] [mm] [kg]

80100125150

112132157182

25x3 4 9.50.180.210.260.44

118139165190

30x6 4 100.480.550.680.89

160180200225250280

192212233257283317

25x4

6

9.5

0.460.510.560.620.690.93

200219241265292332

35x6

8

11.5

0.981.081.191.321.452.51

300315355400450500

339352392438488538

30x4

8

9.5

0.971.031.151.281.431.58

352366405448497551

40x8

8

11.5

2.782.983.103.443.844.13

12

560600630710800900

1000

6006416707508409401041

35x4

12

9.5

2.072.202.312.582.903.243.59

6296686987758619581067

50x8

16

14

5.906.256.597.388.199.17

10.20

16

24

112012501300140015001600

116912991349144915491649

40x5 24 9.5

5.746.386.657.127.638.11

120013371375147515751675

60x10

32 18

16.9018.8019.6021.0022.4023.80

40



FLANGE GASKETS

Flange gaskets must always be selected taking into account

the intended use. The resistance of the respective gasket to

a specific medium also depends on other factors such as tem-

perature, pressure, duration of contact, and mechanical stress.

For this reason, it is necessary to have the seal material tested

by the manufacturer under actual or simulated conditions be-

fore it is used. It is recommended that a chemical sample of the

Note: For the production of tubing which must be “oil and/or aerosol-tight”, detailed requirement specifications must be agreed by

the client and the manufacturer of the seals and tubing.

1 Data refer to manufacturer’s designs without consideration of the specific application.

conditions of application be submitted to the manufacturer so

that appropriate tests can be carried out.

The following designs are recommendations for use without

any claim to functional safety in the respective application.

Overview of common gasket materials

for flange gaskets in ventilation tubing

Seal Properties 1 Fields of application 1

Sealing compound Butyl mastic

Single-component plastic-elastic sealing compound Excellent adhesion to galvanized bare and painted sheets High elasticity Temperature resistant -30 °C to +80 °C Permanently elastic, resistant to ageing, Silicone-free, good chemical properties Building material class B3 as per DIN 4102

Sealing of flange connections on tubes Sealing of folds, seams and small connections

Sealing tapes Made of polyethylene

Temperature resistant -70 °C to +70 °C Resistant to ageing Building material class B3 as per DIN 4102 Silicone-free (except self-adhesive strips)

Sealing of section flange/clamping ring Resistant to oils and fuels (in case of insufficient contact pressure, however, absorbent and thus permeable)

Made of cellular rubber Temperature resistant -30 °C to +70 °C Resistant to ageing Building material class B3 as per DIN 4102 Silicone-free (except self-adhesive strips)

Sealing of section flange/clamping ring for air ducts without chemical load

Made of ceramic fibre Temperature resistant up to +1,100 °C Resistant to ageing, does not rot, Non-flammable, silicone-free (except self-adhesive strips)

Sealing of section flange/clamping ringResistant to oils and fuels (in case of insufficient contact pressure, however, absorbent and thus permeable)

Made of rock wool Temperature resistant from -50 °C up to +200 °C Resistant to ageing, does not rot, Non-flammable, silicone-free (except self-adhesive strips)

Sealing of section flange/clamping ring Resistant to oils and fuels (in case of insufficient contact pressure, however, absorbent and thus permeable)


Note: For the production of tubing which must be “oil and/or aerosol-tight”, detailed requirement specifications must be agreed by the client

and the manufacturer of the seals and manufacturer of the tubing.

1 Data refer to manufacturer’s designs without consideration of the specific application.

FLANGE GASKETS

Overview of common gasket materials

for flange gaskets in round ventilation ducting

Seal Properties 1 Fields of application 1

Sealing strips made of PTFE

Temperature resistant from -240 °C to +270 °C Resistant to ageing, does not rot, Non-flammable, silicone-free (except self-adhesive strips)

Sealing of flange connections on round ducts resistant to all media with the exception of dissolved alkali metals and element. Fluorine leakage requirement, according to TA-Luft, of < 10–4 mbar l/sm is fulfilled if the assembly instructions are observed.

Flange – sealing rings made of APTIK (EPTIM)

Temperature resistant -40 °C to +150 °CResistant to ageing Silicone-free

Sealant for tube connections via flange or quick release clamping ring Resistant to ozone, acid, alkalis

Made of nitrile Temperature resistant -40 °C to +130 °C Resistant to ageingSilicone-free

Sealant for tube connections via flange or quick release clamping ringResistant to petrol, oil, grease, alkalis

Made of silicone Temperature resistant -80 °C to +200 °CResistant to ageing

Sealant for tube connections via flange or quick release clamping ringResistant to ozone, oil, grease


Welded tubing

Item Description of the range of serviceQuantity

UnitEP GP

Welded tubing for ventilation systems for conveying air, in accordance with the application recommendations in the BerlinerLuft. documentation.

Longitudinally and circumferentially welded tubes and fittings According to BerlinerLuft. documentation from (insert as appropriate)

Black sheet steel

or

Sendzimir galvanised sheet steel

Hot-dip aluminised sheet steel (FAL)

Stainless steel (1.4301, 1.4404 or 1.4571)

Aluminium (AlMg3)

Boiler plate (16Mo3)

Component ends for connection (insert as appropriate)

Component ends, smooth (welded during assembly)

or

Ends with flange (for quick release clamp connection SSV)

Ends with fixed section flange (selection according to document

– BerlinerLuft.-Documentation)

For quick release clamp connection

Ends with fixed flange, series 2 (assembly via threaded connection)

Surface protection (insert as appropriate)

Black

or

Sendzimir galvanized (cold galvanised welds)

Primed

Painted (thickness of coat .......µm)

Powder coated (80µm)

Blasted (for stainless steel)

Pickled and passivated (for stainless steel)

Operating temperature: ........°C (determined by the user with consideration of BT material and seal)

Pressure load: Positive/negative pressure in accordance with DIN 24151 Part 2

Certificate of conformity as per VDI 6022 Reg. no: HKP/D/011/7a/8/BL/0910/0913/MZ

TENDER SPECIFICATION TEXTS




UnitEP GP

Welded tubeDimensions: Nominal width d: ......................... mm Length: l: ......................... mm Sheet thickness: ......................... mm

Make: BerlinerLuft.

Welded segment bendSize: Nominal width d1: ......................... mm Angle: ......................... ° Radius (1.0/1.5/2.0) ......................... 1.0 d1 Sheet thickness: ......................... mm

Make: BerlinerLuft.

Welded symmetrical/asymmetrical reductionSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Sheet thickness: ......................... mmDesign: symmetrical/asymmetrical: ......................... Make: BerlinerLuft.

Welded 90°, 60°, 45° or 30° junction.Size: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm

Make: BerlinerLuft.

Welded 90°, 60°, 45° or 30° junction with reductionSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Nominal width d3: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm

Make: BerlinerLuft.

Welded 90° cross piece Size: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Nominal width d3: ......................... mm Nominal width d4: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm

Make: BerlinerLuft.




UnitEP GP

Welded offsetSize: Nominal width d1: ......................... mm Length l1: ......................... mm Length l2: ......................... mm Sheet thickness: ......................... mm

Make: BerlinerLuft.

Welded 120°, 90°, 60° Y-pieceSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Nominal width d3: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm

Make: BerlinerLuft.

Welded opening for cleaningOpening for cleaning via a welded-on branch saddle, fixed to the tube using a threaded connection. Nominal size determined depending on diameter of tube.

Tube size d1: ......................... mmDimension opening: a x b: ......................... mm

Make: BerlinerLuft.

Quick release clamping ring for flange connection (max. DN 630 mm)Size: Nominal width d1: ......................... mm

Make: BerlinerLuft.

Clamping ring with seal for section flange connectionSize: Nominal width d1: ......................... mmSeal for: maximum temperature t: ......................... °C

Make: BerlinerLuft.

Flange gasket for flange connection (max. DN 630 mm)Size: Nominal width d1: ......................... mmMaterial: APTK (EPTM) Nitrile Silicone

Make: BerlinerLuft.

Welded regulating damper (max. DN 630 mm)For air volume regulation in air distribution lines. Single or double damper blade depending on the nominal size. Damper axle and axle bearing sealed. Manual damper blade adjustment via hand lever with locking device or via actuator (optionally 230 V or 24 V).

Size: Nominal width d1: ......................... mmAdjustment: Hand lever with locking device or actuator: ......................... V

Make: BerlinerLuft.

Welded tubing


Folded tubing



UnitEP GP

Longitudinally folded tube for ventilation systems for conveying air without the addition of aggressive vapours or solids that promote wear, in accordance with the application recom-mendations in the BerlinerLuft. documentation.

Tubes and fittings folded longitudinally and circumferentially according to BerlinerLuft. documentation made of sendzimir galvanised sheet steelComponent ends for connection (insert as appropriate)

Ends with flange for quick release clamp connection (SSV)

Ends with section flange for quick release clamp connection

Ends with fixed, recessed flange, series 1 (assembly via threaded connection)

Surface protection (insert as appropriate)

Sendzimir galvanized

or

Painted (thickness of coat .......µm)

Powder coated (80 µm)

Operating temperature: ........°C (determined by the user under consideration of BT material and seal)

Pressure load: positive/negative pressure in accordance with DIN 24151 Part 2

Certificate of conformity as per VDI 6022 Reg. no: HKP/D/011/7a/8/BL/0910/0913/MZ

Longitudinally folded tube (max. DN 630 mm for quick release clamp connection via flange, otherwise max. 1,250 mm for quick release clamp connection via section flange)Size: Nominal width d: ......................... mm Length l: ......................... mm Sheet thickness: ......................... mm

Make: BerlinerLuft.

Folded segment bendSize: Nominal width d1: ......................... mm Angle: ......................... ° Radius (1.0/1.5/2.0) ......................... 1.0 d1 Sheet thickness: ......................... mm

Make: BerlinerLuft.

Folded symmetrical/asymmetrical reductionSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Sheet thickness: ......................... mm Design: sym./asym: ......................... mm Make: BerlinerLuft.


Folded tubing


UnitEP GP

Folded 90°, 60°, 45° or 30° junctionSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm

Make: BerlinerLuft.

Folded 90°, 60°, 45° or 30° junction with reductionSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Nominal width d3: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm

Make: BerlinerLuft.

Folded 90° cross piece Size: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Nominal width d3: ......................... mm Nominal width d4: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm

Make: BerlinerLuft.

Folded offsetSize: Nominal width d1: ......................... mm Length l1: ......................... mm Length l2: ......................... mm Sheet thickness: ......................... mm

Make: BerlinerLuft.

Folded 120°, 90°, 60° Y-pieceSize: Nominal width d1: ......................... mm Nominal width d2: ......................... mm Nominal width d3: ......................... mm Angle: ......................... ° Sheet thickness: ......................... mm

Make: BerlinerLuft.

Folded opening for cleaningOpening for cleaning as inspection panel RD, nominal size determined depending on diam-eter of tube.

Tube size d1: ......................... mmDimension opening: a x b ......................... mm

Make: BerlinerLuft.





UnitEP GP

Quick release clamping ring for flange connection (max. DN 630 mm)Size: Nominal width d1: ......................... mm

Make: BerlinerLuft.

Clamping ring with seal for quick release clamp connection via section flangeSize: Nominal width d1: ......................... mm Seal for: max. temp. t: ......................... °C

Make: BerlinerLuft.

Flange gasket for quick release clamp connection via flange (max. DN 630 mm)Size: Nominal width d1: ......................... mm Material: APTK (EPTM) Nitrile Silicone

Make: BerlinerLuft.

Folded regulating damper (max. DN 630 mm)For air volume regulation in air distribution lines. Single or double damper blade depending on the nominal size. Damper axle and axle bearing sealed. Manual damper blade adjustment using hand lever with locking device or actuator (optionally 230 V or 24 V).

Size: Nominal width d1: ......................... mm Adjustment: Hand lever with locking device or actuator: ......................... V

Make: BerlinerLuft.


Parts and components for industrial use can retain their

long-term functionality by treating and coating the surface

appropriately.

They offer protection against

Adhesions

Material build-up

Soiling

Corrosion

Acids and alkalis

To prevent corrosion damage and wear in industrial applica-

tions, the following coating variants are available on request:

EPD COATING

Cathodic dip coating is a special process for coating alu-

minium and steel alloys. The coating provides a high level of

protection and thus a long service life for the components. It is

also ideal as a primer.

Process

The coating cross-links in the immersion bath to form a ho-

mogeneous, closed film. This creates a surface resistant to

solvents and corrosion.

Uses

The coating is suitable for applications in the chemical indus-

try. In addition, the system is also used in the commercial vehi-

cle and agricultural machinery industries. It protects structures

exposed to maritime climates as well as structures immersed in

sea and brackish water. To achieve UV resistance, an additional

powder coating is necessary.

Furthermore, the system is also particularly suitable for the in-

ternal coating of media-carrying ducting with high corrosion

resistance requirements. Recommended for applications in the

chemical, pharmaceutical, semiconductor, and solar industries.

Suitable for environmental conditions of corrosivity category

C5-M according to ISO 12944-6. It can be used on both folded

and welded components.

HALAR® ECTFE COATING

ECTFE (ethylene chlorotrifluoroethylene), also known as

Halar© is used as a coating against many organic media, es-

pecially acids and bases, because of its very good chemical

resistance. Due to the presence of fluorine compounds, Halar®

ECTFE forms a very smooth surface and has good non-stick

properties. The coating is temperature resistant up to 150 °C

and also has very high impact strength.

Process

Halar® ECTFE is applied by electrostatic powder spraying.

In this process, the coating is applied in several layers, which

means that the final layer thickness is variable. Depending on

the application, an optimum layer thickness can be selected.

Uses

This coating is recommended for applications in the semi-

conductor and solar industry.

Corrosion protection and coating

Welded high pressure ducting components

with EPD primer and powder top coating

(RAL 5010) inside and outside

Process air systems

Documents