GF Piping Systems – worldwide at home

Our sales companies and representatives

ensure local customer support in over 100 countries.

www.piping.georgfischer.com
The technical data are not binding. They neither constitute expressly
warranted characteristics nor guaranteed properties nor a guaranteed durability.
They are subject to modification. Our General Terms of Sale apply. Adding Quality to People’s Lives

Quality Management System Environmental Management System

certified according ISO 9001:2008 certified according ISO 14001:2004

Malaysia / Export Vietnam

George Fischer (M) Sdn Bhd Hanoi Representative Office
No.14, Jalan Anggerik Mokara 31/50, 136E Tran Vu, Ba Dinh Dist., Hanoi.
Section 31 Kota Kemuning, Tel : +84 4 3715 3290
40460 Shah Alam. Fax : +84 4 3715 3285
Tel : +603 5122 5585
Fax : +603 5122 5575 Ho Chi Minh City Representative Office
my.ps@georgfisher.com Room 203, The Office Building
42 Le Trung Nghia Str, Ward 12,
Singapore / SEA* Tan Binh Dist., HCM
George Fischer Pte Ltd Tel : +84 8 3948 5784
11 Tampines Street 92, #04-01/07, Fax : +84 8 3948 5786
Singapore 528872
Tel : +65 67470611 Philippines
Fax : +65 67470577 George Fischer Representative Office
#3 E. Rodriguez Jr. Avenue,
Bagong Ilog (C5) Pasig City,
SEA Distribution Centre 1604 Philippines.
52 Tanjong Penjuru, Tel : + 632 571 2365 to 67
#04-01, CWT Logistics Hub 3, Fax : + 632 571 2368
Singapore 609034
Tel : +65 65052299
Fax : +65 65052298

Indonesia
Georg Fischer Indonesia
Komplek Perkantoran Alam Sutera Town Centre (ASTC)
Blok 10E No. 19, Jl. Alam Sutera Boulevard
Alam Sutera, Tangerang 15325 - Indonesia
Phone : +62-21 2900 8564/ 8557/ 8567
Fax : +62-21 2900 8566

GF_MY 2000/4 (6.13) * Thailand, Cambodia, Myanmar, Laos,

Printed in Malaysia Brunei and East Timor / Timor-Leste
List of Abbreviations
d, d1, d2, D Diameter
e Wall thickness
g Weight in gram
kg Weight in kilogram
z Pipe length between fittings
AL Number of bolt holes
DIN Deutsche Industrie-Normen
DN Nominal diameter
EPDM Ethylene Propylene Rubber
G Pipe thread, not pressure tight in the thread to ISO 288-1
H, H1, H2 Height
ISO International Standardization Organization
L, L1, L2 Length
PN Nominal Pressure at 20°C, water
PP-R Polypropylene Random
R Taper male thread, pressure tight in the thread to ISO 7-1
RP Parallel female thread, pressure tight in the thread to ISO 7-1
S Pipe series
SDR Standard Dimension Ratio
SP Pieces per Standard Packaging
GP Gross Packing

General Information
Dimension
All dimensions are given in mm and are intended as nominal or average sizes. Subject to alteration resulting
from modifications in design.
Orders
Always quote the Georg Fischer code when placing orders.
Technical Information
For more detailed technical information, please consult our sales representative.
Ordering example
Pipe d32 PP-R PN 10 300 206 004
Elbow 45° d110 PP-R 300 206 060

Technical Standards
EN ISO 15874 : Plastics piping systems for hot and cold water installations - Polypropylene (PP)
EN ISO 15874 – Part 1: General (MS 2286-1)
EN ISO 15874 – Part 2: Pipes (MS 2286-2)
EN ISO 15874 – Part 3: Fittings (MS 2286-3)
EN ISO 15874 – Part 5: Fitness for purpose of the system (MS 2286-5)
EN ISO 15874 – Part 7: Guidance for the assessment of conformity

Other Reference Standards:

ISO 9080 Plastics piping and ducting systems – Determination of the long-term hydrostatic strength of
thermoplastics materials in pipe form by extrapolation
ISO 9624 Thermoplastics pipes for fluids under pressure – Mating dimensions of flange adapters and
loose backing flanges
ISO 10508 Plastics piping systems for hot and cold water installations – Guidance for classification and
design
ISO 8795 Plastics piping systems for the transport of water intended for human consumption – Migration
assessment
ISO/TR 10501 Thermoplastics pipes for the transport of liquids under pressure – Calculation of head losses
DIN 8077 Polypropylene (PP) Pipes – Dimensions
DIN 8078 Polypropylene (PP) Pipes – General quality requirements and testing
DIN 16962 Pipe Fittings & Joint Assemblies for Polypropylene (PP) Pressure Pipes
ENV 12108 Plastics piping systems – Recommended practice and techniques for the installation inside
building structures of pressure piping systems for hot and cold water intended for human
consumption
DVS 2207 Welding regulations for thermoplastic materials
MS 2286 Plastics piping systems for hot and cold water installations Polypropylene (PP)
 TABLE OF CONTENTS

Introduction 2
+GF+ Piping Systems
A Green Solutions 3
+GF+ AQUASYSTEM 16
+GF+ AQUASYSTEM
Added Value
Application Range
Characteristics of the Material PP-R

AQUASYSTEM Product Range 24

Pipes
Socket Fusion Fittings
Butt Fusion Fittings
Electro Fusion Fittings
Transition Fittings
Valves
Unions
Machines & Tools

General Precautions 57
Precautions
Working with Plastic Pipes & Fittings

Technical Features 60
Selection of Pipe Diameter
Assessment of Pressure
Regression Curve
Permissible Operating Pressure
PP-R Resin (Raw Material) Qualification
Chemical Resistance
Thermal Expansion & Contraction
Position of the Flexible Arms
Insulation & Thermal Conductivity
Installation Recommendations
Quality & Control
Packaging

Instruction for correct Installation 77

Electro Fusion Installation
Socket Fusion Installation
Butt Fusion Installation
Hole Repairing
Saddles Installation

Approvals & Certificates 85

Unparalleled
hygiene standards
thanks to
modern plumbing
installations from
GF Piping Systems
 introduction
Comfort We bring you clean water

Piping Systems
Supplying the world with clean water is one of the Quality management
major challenges of the 21st century. GF Piping All system components are stringently tested in
Systems rises to this challenge by providing high accredited test laboratories. Management and
quality piping systems. We develop and produce production procedures are certified to ISO 9001
pipes, fittings, valves, flow measurement devices and ISO 14001 to guarantee form, fit, function and
and fusion machines. These application-oriented compliance in whatever application they may be
system solutions allow transporting water, gas and used throughout the world.
industrial liquids safely and reliably. Whether in
industry, utilities or building technology - GF Piping Sales and service – worldwide
Systems has the right solution for you. Our local sales companies and representatives in
over 100 countries provide “one stop“ shopping,
Innovation and technology including planning support, training and product
GF Piping Systems, through focussed research, is availability.
continually developing new products and
technologies, setting new global standards in Facts and figures
quality and performance for our customers. GF Piping Systems with its 3 200 employees
achieves an annual turnover of about CHF 1,299
All from one source million in 2012. GF Piping Systems is part of the
GF Piping Systems covers the growing demand for Georg Fischer Corporation.
complete solutions from a single source in a wide
range of applications.

2|
 introduction

30

25
Production of raw material
Kilogram CO2-equivalents

Production of pipes
20
Transports
Disposal
15

10

0
Copper

High-grade
steel

Steel
galvanized

Steel
uncoated

ABS

PE 100

PVC-C

PVC-U

PVDF
PB

PP

Pioneering Towards A Green Solutions

In focus: Plastics and metal The added value of our solutions: plastics are
Climate change, the finiteness of fossil fuels “greener“ than metals
and a rapidly rising demand for energy are among Plastic piping systems of Georg Fischer offered
the challenges we face in the future. applications and dimensions almost ever have
For companies it will become even more important better results than competitive materials. In
to offer products and solutions which match these the case of PP-R the carbon dioxide emissions
challenges. For example, piping systems made of are roughly five times lower than those of a
plastic cause less carbon dioxide emissions than comparable steel pipe. This is the result of an study
metal piping systems. We offer complete plastic that focused on the ecological footprint of various
systems for nearly every application, whether in piping materials.
building technology, water treatment, cooling or
other segments. Our plastic piping systems are Our devotion
leak proof, corrosion-resistant, lightweight and The environment and nature form the foundation of
long-lived. our lives. For that reason, Georg Fischer considers
the consumption of energy and resources as well
as the production of air emissions to be major
challenges for an industry devoted to people.

|3
 +GF+ AQUASYSTEM

AQUASYSTEM
AQUASYSTEM is a comprehensive plastic piping Georg Fischer is a leader producer of pipe fittings
system which complies with the requirements made of various materials since 1858. In the field
for hot and cold plumbing system. The wide of thermoplastic materials, Georg Fischer is
product range provides the right solution for considered to be a pioneer, as well as one of the
each application: pipes for hot water (PN 20 & best known producers, utilising the most advanced
PN 16) and cold water (PN 16 & PN 10) as well as technology in the world.
socket fusion fittings and a wide selection of metal
transition fittings. The test laboratory is one of the most established
in the world in the field of plastic materials, and it
As a full system “AQUASYSTEM” is totally is completely dedicated to research, development
corrosion free, reduce noise transmission and testing of new products. The equipment and
through pipes and save energy due to low thermal instruments used are the most modern and up-to-
conductivity. The outstanding properties of date in the market today, this makes it possible to
PP-R and superior +GF+ product quality make carry out the most sophisticated tests.
AQUASYSTEM a practically maintenance free and
extremely durable system. High quality plastic This all comes together with the highest standard
valves are also available. of technology, production and logistics, which
contributes to guaranteeing the best
Water services in buildings are complex, requiring product for the end users:
both experience and careful material selection. • quality
The goal is to design and produce a piping system • experience
for hot and cold water supply that is easy to use • reliability
and instal. All components are fully integrated and
sturdy, whilst maintaining a competitive price.

4|
+GF+ AQUASYSTEM

AQUASYSTEM Added Value

• Longevity Benefits of Fusion Jointing:

Designed To Operate More Than 50 years • Homogeneous connection
» No cement / glue used
• Low Density At 0.91g/cm3 » Fitting and pipe become one unit =
(1/9 of Metal Pipes) Homogeneous
» Joint with same characteristics of
• High Elasticity pipe material
» Resistance against impact and bending » No solvent that could affect the
stresses water quality
» Abrasion resistance
» Noise level reduced (water hammer) • Easy and fast
» Socket Fusion jointing is done in seconds
• Chemical Resistance: » Only simple and inexpensive 230V
» Hygienically safe tooling used
» No corrosion
• Reliable and long lasting
• Neutral Taste & Odour » No more leaking joints
Homogeneous joint
» Suitable for food processing » Life time of 50 Years or more
» Jointing system tested according to
• Low Thermal Conductivity: EN ISO 15874 – 5 & 7
» Thermal losses reduced
» Low formation of condensation • No theft value

• Smooth Surfaces:
» Pressure losses reduced
» No incrustation
» Bacteriologically neutral

• Low Electrical Conductivity

» No electrolytic corrosion

• Fast & Easy installation

• Leak Proof with homogenous Joints

|5
 +GF+ AQUASYSTEM

Application Range
Hotel
Hotel guests expect first-class service which includes a perfectly functioning
heating, air-conditioning and water supply at all times Disturbances and noise
Hotel
– caused by repair work on defective piping systems – or even rust-coloured
water from corroding pipes are unpleasant and make a negative impression
on hotel guests. That is why it is always worth while to invest in good quality
piping systems from GF Piping Systems. Our piping systems are corrosion –
and repair-free and offer a prompt return on investment.

Hospital
Maintenance free Piping systems for water treatment, water supply and
air-conditioning are of vital importance. Hygiene is another concern and
everything must be in perfect working order. Quality products are therefore
essential. Compact, space-saving fittings, flexible piping and easy installation
Hospital
technology are the answer. GF Piping Systems supplies all this and more. You,
your engineers and installers are provided with solutions for all your needs.

Industrial Building
Factories, production plants or research facilities – the requirements are
extremely diverse. But they have one thing in common: they all need a reliable
supply of water, gas and compressed air. Production processes must operate
without fail. Whether a new building, renovation or extension – GF Piping
Systems has optimal systems for all areas so that you are assured the best
possible solution. We focus on such important features as safety, environment
Industrial Building protection, durability and cost effectiveness.

Residential Building
Home owners expect leak free and reliable piping systems for plumbing
heating and air conditioning installations. Piping systems that are embedded
in walls and floors must be of highest quality to ensure trouble-free use
over years. Our long proven systems provide clean water in houses and
apartments, no more rust coloured water due to corroding pipes. All our
products are hygienic and safe. No toxic chemicals are used for manufacturing
or jointing of pipes and fittings. Our systems are affordable but very durable
Residential Building and conform with international standards.

Hot and Water 1 Chilled Water 2 Compressed Air 3 Heating 4

6|
 +GF+ AQUASYSTEM

Characteristics of the material PP-R

Pipes and fittings are made of Polypropylene Random, also known as type 3. The quality of our material can
guarantee a long life (50 years), high resistance to pressure and temperature. This material is suitable for hot and
cold water and heating systems.
The special properties of the material, compared to the other materials, give the following advantages
• high dimensional stability (when hot) • maximum resilience

Properties ISO DIN Unit Values

Flow index ISO 1133 DIN 53735
MFI 190/5 Procedure 18@ Code T g/10 min 0,4
MFI 230/2,16 Procedure 12 Code M g/10 min 0,25
MFI 230/5 Procedure 20 Code V g/10 min 1,25
Density a 23°C ISO/R 1183 DIN 53479 g/cm³ 0,90-0,91
Resilience (Charpy)
23°C ISO 179/2D DIN 53479 kJ/ m² n.r.
-30°C ISO 179/2D normal scale kJ/ m² 40
Chipping resilience
(notch-engraved sample test)
23°C ISO 179/2C DIN 53453 kJ/ m² 25
-30°C ISO 179/2C normal scale kJ/ m² 2,5
Resilience (Izod)
23°C ISO 180/1C - kJ/ m² n.r.
-30°C ISO 180/1C - kJ/ m² 28
Scratching resilience
(engraved sample test) (Izod)
23°C ISO 180/1A - kJ/ m² 23
-30°C ISO 180/1A - kJ/ m² 2,5
23°C ASTM D 256 - kJ/ m² 27
-30°C ASTM D 256 - kJ/ m² 4
Traction test
Yield test ISO 527 DIN 53455 N/mm² 27
Yield Elasticity Forwarding speed Forwarding speed % 11
Breakage Elongation - % > 800
Traction Module E ISO 527 DIN 53457 N/mm² 900
Elasticity yield to tangental tension ISO/R 537Metod A. DIN 53445 N/mm² 450
Bending stress 3.5% ISO 178 standard test 5.1 DIN 53452 N/mm² 24
Brinell hardness test ISO 2039 (H358/30) DIN 53456 (H358/30) N/mm² 49
VICAT A/°C Melting point ISO 306 DIN 53460 °C 135-145
Dimensional heat stability °C ISO 75/B DIN 53461 °C 75
Surface Resistance DIN 53482  >1013
Mass resistivity DIN 53482  cm >1016
Dielectric loss angle (tg.) (106Hz) DIN 53483 - 2 x 10-4
Relative dielectric constant (10-6Hz) DIN 53483 - 2,3
Dielectric rigidity ASTM D149 kV/mm 75
Termal conductivity at 20° C VDE 0304 (1-4) 52612 W/mK 0,22
Termal expansion factor mm/m°C 0,15
Specific heat 20°C Kj/KgK 2,0

The characteristics are

the results of the tests
on extruded samples
Resistance to internal hydrostatic pressure after 96 hours storage at
normal room conditions
Condition Required Typical Value Test Method 23/50 (2) DIN 50014 and
represent indicative
20°C 16 MPa 1 hr >10 hrs ISO 1167 values.
95°C 3.5 MPa 1,000 hrs >5,000 hrs ISO 1167
110°C 1.9 MPa 8,760 hrs >10,000 hrs ISO 1167

|7
 +GF+ AQUASYSTEM – Pipe PN 10 1001
• Polypropylene-Random (PP-R) • EN ISO 15874, DIN 8077, DIN 8078, MS 2286
• PN 10, SDR II, ISO Series 5 • Colour: Grey
Pipes
PIPE

dxs Code Code SP Kg/m Length

(mm) Blue Strips Lilac Strips* (m) (m)
20 x 1.9 300 206 012 100 0.107 4
25 x 2.3 300 206 013 300 206 213 60 0.164 4
S

32 x 2.9 300 206 014 300 206 214 48 0.261 4

40 x 3.7 300 206 015 300 206 215 32 0.412 4
d

50 x 4.6 300 206 016 300 206 216 20 0.638 4

63 x 5.8 300 206 017 300 206 217 16 1.010 4
75 x 6.8 300 206 018 300 206 218 4 1.410 4
90 x 8.2 300 206 019 300 206 219 4 2.030 4
110 x 10.0 300 206 020 300 206 220 4 3.010 4
125 x 11.4 300 206 021 300 206 221 4 3.910 4
160 x 14.6 300 206 945 4 6.380 4
* For Grey Water Application

+GF+ AQUASYSTEM – Pipe PN 16 1002

• Polypropylene-Random (PP-R) • EN ISO 15874, DIN 8077, DIN 8078, MS 2286
• PN 16, SDR 7.4, ISO Series 3.2 • Colour: Grey

dxs Code Code SP Kg/m Length

(mm) Blue Strips Red Strips (m) (m)
20 x 2.8 300 206 932 300 206 950 100 0.148 4
25 x 3.5 300 206 933 300 206 951 60 0.230 4
S

32 x 4.4 300 206 934 300 206 952 48 0.370 4

40 x 5.5 300 206 935 300 206 953 32 0.575 4
d

50 x 6.9 300 206 936 300 206 954 20 0.896 4

63 x 8.6 300 206 937 300 206 955 16 1.410 4
75 x 10.3 300 206 938 300 206 956 4 2.010 4
90 x 12.3 300 206 939 300 206 957 4 2.870 4
110 x 15.1 300 206 940 300 206 958 4 4.300 4
125 x 17.1 300 206 941 300 206 959 4 5.530 4
160 x 21.9 300 206 942 300 206 960 4 9.040 4

+GF+ AQUASYSTEM – Pipe PN 20 1003

• Polypropylene-Random (PP-R) • EN ISO 15874, DIN 8077, DIN 8078, MS 2286
• PN 20, SDR 6, ISO Series 2.5 • Colour: Grey

dxs Code Code SP Kg/m Length

(mm) Red Strips Blue Strip (m) (m)
20 x 3.4 300 206 002 300 206 970 100 0.172 4
25 x 4.2 300 206 003 300 206 971 60 0.266 4
S

32 x 5.4 300 206 004 300 206 972 48 0.434 4

40 x 6.7 300 206 005 300 206 973 32 0.671 4
d

50 x 8.3 300 206 006 300 206 974 20 1.040 4

63 x 10.5 300 206 007 300 206 975 16 1.650 4
75 x 12.5 300 206 008 300 206 976 4 2.340 4
90 x 15.0 300 206 009 300 206 977 4 3.360 4
110 x 18.3 300 206 010 300 206 978 4 5.010 4

8|
 SOCKET FUSION FITTINGS
Socket 2001
• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey

Socket Fusion Fittings d Code GP g D L z

(mm) (mm) (mm) (mm)
20 300 206 022 300 12 29 34 2
25 300 206 023 200 16 34 38 2
32 300 206 024 160 27 43 43 3
40 300 206 025 200 50 55 47 3
50 300 206 026 120 92 70 53 3
63 300 206 027 60 177 88 62 4
75 300 206 028 25 242 103 67 5
90 300 206 029 16 347 122 73 5
110 300 206 030 10 586 148 83 5
125 300 206 031 8 699 160 91 5

Elbow 90° 2002

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey

d Code GP g D L z
(mm) (mm) (mm) (mm)
20 300 206 032 250 18 29 42 5
25 300 206 033 150 30 34 48 6
32 300 206 034 200 46 43 60 10
40 300 206 035 120 90 55 71 14
50 300 206 036 60 188 70 88 19
63 300 206 037 30 343 88 106 24
75 300 206 038 10 490 103 124 31
90 300 206 039 6 775 122 145 39
110 300 206 040 8 1260 148 171 47
125 300 206 041 1 2311 160 195 55
160 300 206 601 Please refer to Butt Fusion Section

Elbow 45° 2003

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey

d Code GP g D L z
(mm) (mm) (mm) (mm)
20 300 206 052 300 15 29 21 5
25 300 206 053 200 20 34 24 6
32 300 206 054 300 31 43 27 7
40 300 206 055 150 69 55 31 9
50 300 206 056 80 124 70 37 12
63 300 206 057 40 237 88 45 16
75 300 206 058 10 365 103 121 20
90 300 206 059 6 592 122 142 22
110 300 206 060 8 952 148 164 33
125 300 206 061 1 1080 160 185 52
160 300 206 611 Please refer to Butt Fusion Section

|9
SOCKET FUSION FITTINGS

Equal Tee 90° 2004

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey

d Code GP g D L z z1
(mm) (mm) (mm) (mm) (mm)
20 300 206 062 200 23 29 55 12 10
25 300 206 063 300 36 34 64 14 14
32 300 206 064 160 69 43 77 19 19
40 300 206 065 80 126 55 87 22 23
50 300 206 066 50 229 70 105 28 28
63 300 206 067 25 444 88 126 34 35
75 300 206 068 20 584 103 141 40 42
90 300 206 069 10 932 122 163 48 46
110 300 206 070 6 1077 145 197 60 59
125 300 206 100 1 1685 160 216 65 64
160 300 206 621 Please refer to Butt Fusion Section

Reducing Tee 90° 2005

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey

d-d1-d2 Code GP g D L z z1
(mm) (mm) (mm) (mm) (mm)
25-20-25 300 206 071 250 38 34 64 14 16
32-20-32 300 206 074 160 64 43 77 19 22
32-25-32 300 206 075 60 65 43 77 19 20
40-20-40 300 206 078 100 113 55 88 22 28
40-25-40 300 206 079 100 114 55 88 22 26
40-32-40 300 206 080 80 115 55 88 22 24
50-20-50 300 206 081 60 208 70 106 28 36
50-25-50 300 206 082 60 210 70 106 28 34
50-32-50 300 206 083 60 215 70 106 28 32
50-40-50 300 206 084 50 218 70 106 28 30
63-20-63 300 206 150 25 184 83 90 15 32
63-25-63 300 206 085 25 397 88 128 35 45
63-32-63 300 206 086 10 399 88 128 35 43
63-40-63 300 206 087 25 403 88 128 35 41
63-50-63 300 206 088 25 414 88 128 35 38
75-25-75 300 206 097 20 532 103 141 40 51
75-32-75 300 206 089 20 533 103 141 40 49
75-40-75 300 206 090 20 537 103 141 40 47
75-50-75 300 206 091 20 548 103 141 40 44
75-63-75 300 206 092 20 564 103 141 40 40
90-32-90 300 206 093 10 866 122 163 48 57
90-40-90 300 206 094 10 871 122 163 48 55
90-50-90 300 206 095 10 878 122 163 48 52
90-63-90 300 206 096 10 889 122 163 48 48
110-50-110 300 206 098 6 1490 148 197 60 61
110-63-110 300 206 099 6 1490 148 197 60 57

10 |
 SOCKET FUSION FITTINGS
Reducing Bush 2006
• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey

d-d1 Code GP g D L z D1
(mm) (mm) (mm) (mm) (mm)
25-20 300 206 102 400 10 29 38 4
32-20 300 206 103 240 16 29 39 5
32-25 300 206 104 200 18 34 43 4
40-20 300 206 105 150 23 29 44 5
40-25 300 206 106 150 24 34 44 5
40-32 300 206 107 250 34 43 50 7
50-20 300 206 108 100 41 29 50 5
50-25 300 206 109 100 40 34 50 6
50-32 300 206 110 40 44 43 50 4
50-40 300 206 111 40 61 55 57 5
63-20 300 206 112 60 73 29 63 9
63-25 300 206 113 80 74 34 63 10
63-32 300 206 114 50 73 43 59 8
63-40 300 206 115 50 74 55 55 4
63-50 300 206 116 40 111 70 64 6
75-25 300 206 118 25 251 103 54 5 34
75-32 300 206 119 25 255 103 56 5 44
75-40 300 206 120 25 247 103 58 5 55
75-50 300 206 121 25 245 103 61 5 70
75-63 300 206 122 25 252 103 65 5 88
90-50 300 206 125 10 357 122 64 5 70
90-63 300 206 126 16 357 112 68 5 88
90-75 300 206 127 16 361 112 70 5 103
110-63 300 206 129 10 604 148 74 6 88
110-75 300 206 130 10 589 148 75 5 103
110-90 300 206 131 10 585 148 78 5 122
125-110 300 206 132 10 920 160 90 8 148

| 11
SOCKET FUSION FITTINGS

End Cap 2007

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey

d-1 Code GP g D L z
(mm) (mm) (mm) (mm)
20 300 203 132 300 7 28 22 9
25 300 203 133 200 9 35 25 7
32 300 203 134 200 15 114 30 9
40 300 203 135 150 31 53 31 11
50 300 203 136 80 69 67 41 7
63 300 203 137 100 115 83 44 17

Swan Neck 2008

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey

d Code GP g L L1
(mm) (mm) (mm)
20 300 203 142 80 44 300 40
25 300 203 143 50 75 320 60
32 300 203 144 30 126 350 64

Manifold 2009
• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Beige

d Code SP GP g D L z
(mm) (mm) (mm) (mm)
40 X 20 760 840 182 1 10 203 55 255 57
40 X ½” 760 840 186 1 10 461 55 255 57

12 |
 SOCKET FUSION FITTINGS
Saddle with Spigot 2010
• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Beige

d-d1 Code SP GP B D E
(mm) (mm) (mm) (mm)
40-20 760 840 190 10 10 22 20 6,5
40-25 760 840 191 10 10 22 27 6,5
50-20 760 840 192 10 10 22 20 8
d
50-25 760 840 193 10 10 22 27 8
63-20 760 840 194 10 10 22 20 10
B d1 63-25 760 840 195 10 10 22 27 10
63-32 760 840 196 10 10 32 30 10
E D 75-20 760 840 197 10 10 22 20 10
75-25 760 840 198 10 10 22 27 10
75-32 760 840 199 10 10 32 30 10
75-40 760 840 200 10 10 32 30 15
90-20 760 840 220 10 10 22 20 15
90-25 760 840 221 10 10 22 27 15
90-32 760 840 222 10 10 32 30 15
90-40 760 840 231 10 10 32 30 15
110-20 760 840 223 10 10 22 20 15
110-25 760 840 224 10 10 22 27 15
110-32 760 840 225 10 10 32 30 15
110-40 760 840 226 10 10 32 30 15
125-20 760 840 227 10 10 22 27 15
125-25 760 840 228 10 10 22 30 15
125-32 760 840 229 10 10 32 30 15
125-40 760 840 230 10 10 32 30 15

Threaded Female Saddles with Spigot 2011

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Beige

d-Rp Code SP GP B C D
(mm)/(inch) (mm) (mm) (mm)
40-½ 760 840 764 10 10 22 13 27
50-½ 760 840 766 10 10 22 13 27
d 50-¾ 760 840 767 10 10 32 21 30
63-½ 760 840 768 10 10 22 13 27
63-¾ 760 840 769 10 10 32 21 30
B d1
C 75-½ 760 840 770 10 10 22 13 27
75-¾ 760 840 771 10 10 32 21 30
D
75-1 760 840 772 10 10 32 22 34
90-½ 760 840 773 10 10 22 13 27
90-¾ 760 840 774 10 10 32 21 30
90-1 760 840 775 10 10 32 22 34
110-½ 760 840 776 10 10 22 13 27
110-¾ 760 840 777 10 10 32 21 30
110-1 760 840 778 10 10 32 22 34
125-½ 760 840 779 10 10 22 14 27
125-¾ 760 840 780 10 10 32 22 30
125-1 760 840 781 10 10 32 22 34

| 13
BUTT FUSION FITTINGS

Elbow 90° ** 3002

• +GF+ AQUASYSTEM • Colour: Grey
• Polypropylene-Random (PP-R)

PN 16
d Code GP Kg L L1 e
(mm) (mm) (mm) (mm)
160 300 206 601 1 4.470 231 99 21.9
L
L1
PN 10 • Chamfered from PN 16
d Code GP Kg L L1 e
(mm) (mm) (mm) (mm)
160 300 206 605 1 4.270 231 99 14.6
L
L1

e
D

Elbow 45° ** 3003

• +GF+ AQUASYSTEM • Colour: Grey
• Polypropylene-Random (PP-R)

PN 16
d Code GP Kg L L1 e
(mm) (mm) (mm) (mm)
160 300 206 611 1 3.740 151 99 21.9

PN 10 • Chamfered from PN 16
d Code GP Kg L L1 e
(mm) (mm) (mm) (mm)
160 300 206 615 1 3.540 151 99 14.6

Equal Tee 90° ** 3004

• +GF+ AQUASYSTEM • Colour: Grey
• Polypropylene-Random (PP-R)

PN 16
d Code GP Kg L L1 e
(mm) (mm) (mm) (mm)
160 300 206 621 1 6.180 475 99 21.9

PN 10 • Chamfered from PN 16
d Code GP Kg L L1 e
(mm) (mm) (mm) (mm)
160 300 206 625 1 475 99 14.6

14 | ** Buttfusion data from Machine Manual

 BUTT FUSION FITTINGS
Reducer ** 3007
• +GF+ AQUASYSTEM • Below 160mm fittings ends are only suited
• Polypropylene-Random (PP-R) for socket fusion welding
• Colour: Grey • Fabricated fittings

PN 16
d Code GP Kg L e
(mm) (mm) (mm)
(actual product differ from picture)
160-125 300 206 642 1 2.30 255 21.9

PN 10 • Chamfered from PN 16
d Code GP Kg L e
(mm) (mm) (mm)
160-125 300 206 662 1 2.15 255 14.6

Flange Adaptor ** 3012

• +GF+ AQUASYSTEM • Colour: Grey
• Polypropylene-Random (PP-R)

PN 16
d Code GP Kg L L1 L2 D D1 e
(mm) (mm) (mm) (mm) (mm) (mm) (mm)
160 300 206 651 1 1.740 158 25 99 175 212 21.9

PN 10 • Chamfered from PN 16
d Code GP Kg L L1 L2 D D1 e
D1
D
d
e

(mm) (mm) (mm) (mm) (mm) (mm) (mm)

160 300 206 657 1 1.540 158 25 99 175 212 14.6

L2 L1
L

** Buttfusion data from Machine Manual | 15

ELECTRO FUSION FITTINGS

Electric Socket ** 4001

• +GF+ AQUASYSTEM • Colour: Beige
• Polypropylene-Random (PP-R)

d Code SP GP g D L L1
(mm) (mm) (mm) (mm) (mm)
20 760 840 452 10 10 40 33 70 50
25 760 840 453 10 10 49 38 70 57
32 760 840 454 10 10 63 46 79 62
40 760 840 455 5 5 92 55 90 71
50 760 840 456 2 2 149 67 100 82
L1

63 760 840 457 1 1 263 86 106 101

D
d

75 760 840 458 1 1 320 103 121 115

90 760 840 459 1 1 475 121 131 134
L
110 760 840 460 1 1 805 142 142 156
125 760 840 461 1 1 1080 163 151 175
160 760 840 470 1 1 1950 183 161 195

16 | ** Buttfusion data from Machine Manual

 TRANSITION FITTINGS
Threaded Male Coupling 5001
• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey
• Brass Male - Threaded • Nickel Coating

d-R Code Code* GP g D L z

(mm) (inch) (DZR Brass) (mm) (mm) (mm) (mm)
20-½ 300 206 241 300 206 841 80 75 28 56 25
20-¾ 300 206 242 300 206 842 60 98 34 59 24
25-½ 300 206 243 300 206 843 60 75 33 58 25
25-¾ 300 206 244 300 206 844 60 96 34 59 24
32-¾ 300 206 245 300 206 845 60 99 42 61 23
32-1 300 206 246 300 206 846 30 204 43 75 22
40-1¼ 300 206 248 300 206 848 10 402 54 90 31
50-1½ 300 206 249 300 206 849 10 526 68 93 31
63-2 300 206 250 300 206 850 6 719 86 105 30

Threaded Female Coupling 5002

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey
• Brass Female - Threaded • Nickel Coating

d-Rp Code Code* GP g D L z

(mm) (inch) (DZR Brass) (mm) (mm) (mm) (mm)
20-½ 300 206 271 300 206 861 80 50 28 41 25
20-¾ 300 206 272 300 206 862 80 67 34 42 26
25-½ 300 206 273 300 206 863 80 52 33 43 25
25-¾ 300 206 274 300 206 864 60 65 34 42 24
32-¾ 300 206 275 300 206 865 60 69 42 44 22
32-1 300 206 276 300 206 866 30 130 43 56 23
40-1¼ 300 206 278 300 206 868 10 274 54 69 31
50-1½ 300 206 279 300 206 869 10 384 68 72 31
63-2 300 206 280 300 206 870 6 492 86 80 31

* Brass insert in dezincification resistant material (DZR) | 17

TRANSITION FITTINGS

Threaded Male Elbow 90° 5003

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey
• Brass Male - Threaded • Nickel Coating

d-Rp Code Code* GP g D L z

(mm) (inch) (DZR Brass) (mm) (mm) (mm) (mm)
20-½ 300 206 291 300 206 881 50 81 30 65 12
20-¾ 300 206 292 300 206 882 50 102 30 66 12
25-½ 300 206 293 300 206 883 40 94 34 72 14
25-¾ 300 206 294 300 206 884 40 113 34 74 14
32-¾ 300 206 295 300 206 885 25 128 42 82 16
32-1 300 206 296 300 206 886 20 165 44 95 19

Threaded Female Elbow 90° 5004

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey
• Brass Female - Threaded • Nickel Coating

d-Rp Code Code* GP g D L z

(mm) (inch) (DZR Brass) (mm) (mm) (mm) (mm)
20-½ 300 206 301 300 206 891 50 59 30 50 12
20-¾ 300 206 302 300 206 892 50 72 30 50 12
25-½ 300 206 303 300 206 893 50 70 34 57 14
25-¾ 300 206 304 300 206 894 40 93 34 57 14
32-¾ 300 206 305 300 206 895 30 96 42 65 16
32-1 300 206 306 300 206 896 20 163 44 77 19

Threaded Male Elbow 90° with Bracket 5005

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey
• Brass Male - Threaded • Nickel Coating

d-R Code Code* GP g D L z

(mm) (inch) (DZR Brass) (mm) (mm) (mm) (mm)
20-½ 300 206 321 300 206 901 50 83 30 65 12

18 | * Brass insert in dezincification resistant material (DZR)

 TRANSITION FITTINGS
Threaded Female Elbow 90° with Bracket 5006
• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey
• Brass Female - Threaded • Nickel Coating

d-Rp Code Code* GP g D L z

(mm) (inch) (DZR Brass) (mm) (mm) (mm) (mm)
20-½ 300 206 331 300 206 905 50 61 30 50 12

Threaded Male Tee 5007

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey
• Brass Male - Threaded • Nickel Coating

d-R Code Code* GP g D L L1 z

(mm) (inch) (DZR Brass) (mm) (mm) (mm) (mm) (mm)
20-½ 300 206 341 300 206 911 50 85 29 55 65 12
25-½ 300 206 343 300 206 913 50 97 34 64 72 14
25-¾ 300 206 344 300 206 914 40 119 34 64 74 14
32-¾ 300 206 345 300 206 915 30 145 44 77 81 19
32-1 300 206 346 300 206 916 20 247 43 77 96 19

Threaded Female Tee 5008

• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962, MS 2286
• Polypropylene-Random (PP-R) • Colour: Grey
• Brass Female - Threaded • Nickel Coating

d-R Code Code* GP g D L L1 z

(mm) (inch) (DZR Brass) (mm) (mm) (mm) (mm) (mm)
20-½ 300 206 351 300 206 921 50 62 29 55 50 12
25-½ 300 206 353 300 206 923 50 74 34 64 57 14
25-¾ 300 206 354 300 206 924 40 86 34 64 57 14
32-¾ 300 206 356 300 206 926 30 114 44 77 64 19
32-1 300 206 357 300 206 927 20 174 43 77 78 19

* Brass insert in dezincification resistant material (DZR) | 19

TRANSITION FITTINGS

Union Socket PP-H (PN 10) 5009

• Polypropylene Homo Polymeride (PP-H) • High Impact Strength, abrasion and
chemicals
Transition
Transition F
Fittings
d Code GP g D L1 L2 z1 z2 G
(mm) (mm) (mm) (mm) (mm) (mm) (inch)
25 727 510 157 1 62 58 21 28 5 12 1¼
32 727 510 158 1 79 65 23 30 5 12 1½
40 727 510 159 1 137 79 25 34 5 14 2
50 727 510 160 1 180 91 28 39 5 16 2¼
63 727 510 161 1 312 111 32 47 5 20 2¾

Flange Adaptor 2012

• +GF+ AQUASYSTEM • Colour: Grey
• Polypropylene-Random (PP-R) • Socket - Fusion
• EN ISO 15874, DIN 16962, MS 2286

d Code GP g D L D1 z h
(mm) (mm) (mm) (mm) (mm) (mm)
40 300 206 415 200 30 50 28 62 6 10
50 300 206 416 120 45 61 31 74 6 12
h 63 300 206 417 60 74 76 35 91 6 14
75 300 206 418 25 110 90 37 108 6 13
90 300 206 419 16 163 108 40 128 6 16
110 300 206 420 10 242 131 45 151 6 19
125 300 206 421 8 337 148 53 169 10 20
160 300 206 651 Please refer to Butt Fusion Section

Backing Flange 5010

• +GF+ AQUASYSTEM • Galvanized Steel
• Coated with PP

d Code SP D D1 D2 D3 H AL
(mm) (mm) (mm) (mm) (mm)
40 727 700 209C 1 140 100 54 18 18 4
50 727 700 210C 1 150 110 67 18 20 4
63 727 700 211C 1 165 125 85 18 20 4
75 727 700 212C 1 185 145 100 18 20 8
90 727 700 213C 1 200 160 120 18 22 8
110 727 700 214C 1 220 180 147 18 22 8
125 727 700 215 1 250 210 150 18 22 8
160* 727 700 317 1 285 240 178 22 24 8

20 |
 TRANSITION FITTINGS
Flat Gasket EPDM 5011
• +GF+ AQUASYSTEM • Suited for all metric +GF+ Flange Adaptors
Transition
Transittion Fittings • EPDM Material • Hardness approx. 65° shore
• Intergrated Fixation

d Code SP g D D1 H
(mm) (mm) (mm) (mm)
40 748 400 309 5 8 59 40 3
50 748 400 310 5 12 71 50 3
63 748 400 311 5 17 88 63 3
75 748 400 312 1 24 104 75 3
90 748 400 313 1 32 123 90 3
110 748 400 314 1 62 148 110 4
125 748 400 315 1 58 168 125 4
160 748 400 317 1 63 211 160 4

| 21
 Stop Valve PP-R 6001
• +GF+ AQUASYSTEM • Colour: Grey
• Polypropylene-Random (PP-R) • EPDM Gasket
VALVES

• EN ISO 15874, DIN 16962, MS 2206 • Nickel Coating

d Code* Code* GP g L H D
(mm) (DZR Brass) (mm) (mm) (mm)
20 300 206 832 300 206 835 30 120 72 82 29
25 300 206 833 300 206 836 20 207 84 90 37
32 300 206 834 300 206 837 20 370 104 95 47

Ball Valve Type 546 PP-H (PN10) with Fusion Socket Metric 6002
• Polypropylene Homopolymeride (PP-H) • Ergonomic handle (optional lockable) with
• Biggest range of products (via the integrated tool for dismounting the union
configurator several executions can be bush
generated) • For easy installation and removal
• Integrated fixation system with mounted
threaded inserts

d Code Code SP g D L z
(mm) (without inserts) (with inserts) (mm) (mm) (mm)
20 167 546 002 167 546 402 1 115 50 95 66
25 167 546 003 167 546 403 1 180 58 109 77
32 167 546 004 167 546 404 1 255 68 119 83
40 167 546 005 167 546 405 1 440 84 135 99
50 167 546 006 167 546 406 1 610 97 147 105
63 167 546 007 167 546 407 1 1145 124 168 117

Butterfly Valves Type 567 PP-H (PN10) Hand Lever with

Ratchet Settings 6003
• Polypropylene Homopolymeride (PP-H) • Standard 5° ratchet setting / fine adjustment
• Double internal shaft sealing on both sides as option
• Double eccentric operating principle • Lockable

d Code SP g D H H1 H2 H3
(mm) (mm) (mm) (mm) (mm) (mm)
63 167 567 002 1 969 19 264 77 134 54
75 167 567 003 1 1061 19 277 83 140 54
90 167 567 004 1 1191 19 289 89 146 54
110 167 567 005 1 1751 19 325 104 167 55
160 167 567 006 1 2989 24 373 130 189 55

22 | * Brass insert in dezincification resistant material (DZR)

 Ball Valve with Handle 6004
• +GF+ AQUASYSTEM • EN ISO 15874, DIN 16962
• Polypropylene-Random (PP-R) • Colour: Beige

VALVES
d Code GP g L a z L1
(mm) (mm) (mm) (mm) (mm)
20 760 804 792 25 115 67.5 102 38.5 60
25 760 804 793 20 135 70.5 102 38.5 60
32 760 804 794 15 190 79.5 102 43.5 63
a 40 760 804 795 8 350 94 119.5 54 78
50 760 804 796 6 510 109 119.5 63 83
63 760 804 797 3 935 146 146 78 103
L1
d

d
g

z
L

| 23
 Adaptor Union Male Thread 5015
• +GF+ AQUASYSTEM • EPDM O-Ring
• Polypropylene-Random (PP-R) • Colour: Grey
UNIONS

dxR Code Code* GP g L

(mm) DZR (mm)
20 - ½ 300 206 702 300 206 690 80 140 52
25 - ¾ 300 206 703 300 206 691 60 160 56
32 - 1 300 206 704 300 206 692 30 220 61
40 - 1¼ 300 206 705 300 206 693 10 280 76
50 - 1½ 300 206 706 300 206 694 10 360 79
63 - 2 300 206 707 300 206 695 6 480 89

Adaptor Union Female Thread 5016

• +GF+ AQUASYSTEM • EPDM O-Ring
• Polypropylene-Random (PP-R) • Colour: Grey

dxRp Code Code* GP g L

(mm) DZR (mm)
20 - ½ 300 206 712 300 206 722 80 120 39
25 - ¾ 300 206 713 300 206 723 60 140 41
32 - 1 300 206 714 300 206 724 30 200 43
40 - 1¼ 300 206 715 300 206 725 10 240 54
50 - 1½ 300 206 716 300 206 726 10 320 57
63 - 2 300 206 717 300 206 727 6 440 63

Union Socket-Socket 5017

• +GF+ AQUASYSTEM • EPDM O-Ring
• Polypropylene-Random (PP-R) • Colour: Grey

dxRp Code Code* GP g L

(mm) DZR (mm)
20 300 206 731 300 206 741 80 120 41
25 300 206 732 300 206 742 60 140 45
32 300 206 733 300 206 743 30 200 49
40 300 206 734 300 206 744 10 240 60
50 300 206 735 300 206 745 10 320 66
63 300 206 736 300 206 746 6 440 74

24 | * Brass insert in dezincification resistant material (DZR)

Complete Socket Welder (Set) 7001
• Complete set in a Metal case • Fusion marking template
• Socket welder with electronic temperature • Floor stand

UNIONS
control • Pipe shears
• Heating bushes • Instruction Manual
• Timer

d Code SP kg
(mm)
20-32 300 206 539 1 7.10 230V / 800W
20-63 300 206 540 1 13.10 230V / 800W
75-110 300 206 541 1 14.20 230V / 1500W

Standard Socket Welder 7002

• Socket welder with electronic temperature • Instruction Manual
control • Excluding Heating Bushes
• Floor stand

d Code SP kg
(mm)
20-63 300 206 518 1 1.80 230V / 800W
20-110 300 206 519 1 3.55 230V / 1500W

SG 125 Socket Fusion Machine 7003

• Portable socket fusion machine for use in • Heater with electronic temperature control
workshop and on job sites • Excluding Heating Bushes
• Dimension d20-d125

d Code SP kg
(mm)
20-125 790 310 034 1 65.00 230V /1500W

TM 160 ECO Butt Fusion Machines

TM 160 ECO Machine Complete 7004
• Flexible and user-friendly heating element element with electronic temperature control
Butt Fusion machine for fusion jointing box, storage case for the planer and heater
PE, PP, PB and PVDF pipes and fittings on • Including transport packaging (carton pallet),
building sites and in trenches without accessories and without reduction
• Scope of delivery includes: lightweight inserts
ECO hydraulic unit, flexible base machine, • 115 V on request!
powerful planer, high performance heating

Type d-d Performance Code kg

(mm)
TM 160 ECO 40-160 230V/1900W 790 150 010 86.00

| 25
MACHINES & TOOLS

TM 160 TOP Butt Fusion Machines

TM 160 TOP Machine complete 7005
• High quality, flexible and user-friendly powerful planer, high performance heating
heating element Butt Fusion machine for element, storage case for the planer and
Machines & Tools fusion jointing PE, PP, PB and PVDF pipes heater
and fittings on building sites and in trenches • Including transport packaging (wooden crate),
• Scope of delivery includes: innovative TOP without accessories and without reduction
hydraulic unit, flexible base machine, inserts

Type d-d Performance Code kg

(mm)
TM 160 TOP 40-160 230V/1900W 790 150 011 125.00

TM 160RU Vertical Installation Unit 7006

• Unit with 2 clamping devices and a pair of • Heating element, planer, hydraulic unit and
cylinders, especially convenient for butt- reduction inserts could be used from the
fusion joints in narrow trenches or inside of corresponding TM machine.
buildings and industrial plants.

Type Code kg
RU 160 790 150 045 8.800

TM 160 Hydraulic Adapter Hose Package 7007

• Flexible hydraulic hoses, with drip-proof, • Required when connecting a GF or KL base
quick-coupling action machine to the TM TOP hydraulic unit
• Required when assembling a TM base • Hoses with quick action couplers (M3/8” – F
machine to GF or KL hydraulic units ¼” , F 3/8” – M ¼”)

Code kg
790 150 003 3.862

TM 160 RU Outer Clamp 7008

• An additional clamping device can be mounted on the cylinders to improve the alignment of the
components to be welded.

Type Code kg
RU 160 790 150 046 2.000

26 |
 MACHINES & TOOLS
TM 160 - 250 - 315 ECO Planer 7009
• Powerful parallel planer for single or double- • Optimised cutting geometry for even and
sided facing of pipe ends chatter-free planing
• Reliable torque transmission via robust • Safely switch to prevent undesired start-up
Machines & Tools worm-gear device • Self-locking mechanism in working position
• Ergonomic, weight-balanced handling • 115 V on request!

Type d-d Performance Code kg

TM 160 ECO 40-160 230V/630W 790 150 014 7.000

TM 160 - 250 - 315 Heating Element 7010

• High performance, electronically controlled • Temperature indicator integrated into the
heating element handle
• Uniform temperature distribution over the • Easy placement in the correct working
entire heating surface position with automatic heater release
• High-quality, non-stick PTFE-coating with mechanism
long service life • Self-locking mechanism in working position
• 115 V on request!

Type d-d Performance Code kg

TM 160 40-160 230V/1200W 790 114 004 5.402

TM 160 - 250 - 315 Case 7011

• For safe storage of planer and heating element

Type d-d Code kg

TM 160 40-160 790 150 295 7.000

TM 160 - 250 - 315 ECO Hydraulic Unit 7012

• Clearly visible, vibration-free pressure guage • High pressure consistancy during cooling
with precision scaling phase
• Compact construction with protection frame • Fix attached hydraulic hose
• Fine adjustment of pressure • 115 V on request!

Type d-d Performance Code kg

TM 160 40-160 230V/1200W 790 150 013 5.402

| 27
MACHINES & TOOLS

TM 160 - 250 - 315 ECO Temperature Controller 7013

• Electronic temperature control • Digital display of current and set-point
• Accurate adjustment (set point) of heating temperature
element temperature • 115 V on request!

Type d-d Performance Code kg

TM 160 40-160 230V/1200W 790 152 006 5.402

Heating Bushes 7020

• Coated with Polytetrafluoroethylene (PTFE) • Corrosion Free
• Incrustation Free • Low thermal Conductivity
• EN ISO 15874, DIN 16962

d Code SP kg
(mm)
20 300 206 561 1m + 1f 0.120
25 300 206 562 1m + 1f 0.150
32 300 206 563 1m + 1f 0.210
40 300 206 564 1m + 1f 0.310
50 300 206 565 1m + 1f 0.450
63 300 206 566 1m + 1f 0.600
75 300 206 567 1m + 1f 0.965
90 300 206 568 1m + 1f 1.440
110 300 206 569 1m + 1f 2.210
125 300 206 570 1m + 1f 2.900

Hole Mender 7021

• Coated with Polytetrafluoroethylene (PTFE)

d Code SP GP
(mm)
7.5 760 840 481 1m+1f 1m+1f
11.4 760 840 482 1m+1f 1m+1f

Repairing Hole 7022

• +GF+ AQUASYSTEM • Colour: Beige
• Polypropylene-Random (PP-R)

d Code GP g D L L1 L1
(mm) (mm) (mm) (mm) (mm) (mm)
7.5/11.4 760 840 425 1 4 11.4 42 22 14

28 |
 MACHINES & TOOLS
Heating Tools for Saddle with Spigot 7023
• Coated with Polytetrafluoroethylene (PTFE) • Corrosion Free
• Incrustation Free • Low Thermal Conductivity
• EN ISO 15874, DIN 16962

d Code SP GP
(mm)/(inch)
40-20-25-½ 760 840 585 1m+1f 1m+1f
50-20-25-½ 760 840 586 1m+1f 1m+1f
63-20-25-½ 760 840 587 1m+1f 1m+1f
75-20-25-½ 760 840 588 1m+1f 1m+1f
90-20-25-½ 760 840 589 1m+1f 1m+1f
110-20-25-½ 760 840 590 1m+1f 1m+1f
125-20-25-½ 760 840 591 1m+1f 1m+1f
50-32-40-¾ -1 760 840 592 1m+1f 1m+1f
63-32-40-¾ 760 840 593 1m+1f 1m+1f
75-32-40-¾ -1 760 840 594 1m+1f 1m+1f
90-32-40-¾ -1 760 840 595 1m+1f 1m+1f
110-32-40-¾ -1 760 840 596 1m+1f 1m+1f
125-32-40-¾ -1 760 840 597 1m+1f 1m+1f

Milling Cutter for Saddles with Spigot 7024

• Coated with Polytetrafluoroethylene (PTFE)

d Code SP GP
(mm)/(inch)
20-25-½ 760 840 600 1 1
32-¾ 760 840 601 1 1

Timer 7025

d Code SP kg
(mm)
761 066 798C 1 0.042

| 29
MACHINES & TOOLS

Welding Template 7026

d Code SP kg
(mm)
20-10 300 206 530 1 0.040

Pipe Shears 7027

d Code SP kg
(mm)
20-32 300 206 161 1 0.472
20-63 300 203 162 1 1.072

Pipe Cutter 7028

d Code SP kg
(mm)
20-75 760 840 505 1 0.800
50-110 300 206 506 1 1.400

Table Stand 7029

d Code SP kg
(mm)
300 147 941 1 0.860

30 |
 MACHINES & TOOLS
Chamfering and Peeling Tool for PP-R Pipes 7030

d Code GP
(mm)
20 760 840 822 1
25 760 840 823 1
32 760 840 824 1
40 760 840 825 1
50 760 840 826 1
63 760 840 827 1
75 760 840 828 1
90 760 840 829 1
110 760 840 830 1

Handle for Chamfering 7031

20/32 760 840 818 1

Side Handle 7032

40/110 760 840 819 1

Pipe clamp 7033

d Code SP GP g a h
(mm) (mm) (mm) (mm)
20 167 061 036 10 200 8 36 25
25 167 061 037 10 200 10 41 27
32 167 061 038 10 200 13 51 31
40 167 061 039 10 150 23 62 35
50 167 061 040 10 140 32 72 40
63 167 061 041 10 80 45 88 52
75 167 061 012 10 60 62 102 58
90 167 061 013 10 - 91 123 70
110 167 061 014 10 - 123 146 80
125 167 061 015 10 - 174 176 90

| 31
MACHINES & TOOLS

Plan Test Plug 7034

d Code SP kg
(mm)
½ 300 206 533 1 0.001
¾ 300 206 534 1 0.001

KS Tangit Cleaner 7035

d Code SP kg
(mm)
799 298 023 1 0.890

MSA 330
MSA 330 Electrofusion unit with jointing data recording 7036
The MSA 330 electrofusion unit combines high performance in jointing with easy and safe handling.
The internal memory has a capacity of 500 jointing records, for data transfer the unit is equipped
with a USB interface. The record is delivered as PDF or CSV format, both are mangeable with
common and free PC software applications.
An intuitive operation menu guides you through the complete jointing process. For fusion data
input a barcode reader pen or a scanner is connected. The entire welding process is controlled and
regulated with energy output compensation depending on ambient temperature and the indication
of cooling time. Robust aluminum housing with convenient cable winding and handle for weight
balanced transport. The unit is suitable for jointing in series.
Scope of delivery: dedicated transport case, pouch for optical pen or scanner, 2 pairs of angle
adapter clips 4,0mm and 4,7mm, operation instructions and configuration chart.

Technical Data • Mains cable: 4m

• Ambient temperature: -10°C to + 45° • Fusion: 4m
• Mains valtage: 180V – 265V AC • Interface: USB (typeA) for PC communication
• Mains frequency: 40Hz-70Hz and software updates
• Fusion voltage: 8-48 V AC • Dimensions (WxHxD): 280 x 480 x 320 mm
• Fusion current: max.90 A • Weight incl. cables: ca. 21,7kg
• Suggested power generator: 3,5kVA (5,0kVA • Display: LCD (20 alphanumerical char. X4
for fittings with Ø > 200mm) lines), contrast adjustment, blue background,
white characters
• Protection Class: 1/IP 54
• Languages: 10

Description Code kg
Barcode reader pen, transport case 790 160 004 30
Barcode scanner, transport case 790 160 005 30

32 |
Precautions

UV Rays
To avoid damage from UV Rays, PP-R shall not be
exposed to direct sunlight.

general precautions
30° Low Temperatures
Plastics can become brittle at low temperature.
0° 60°
Installation shall be performed at temperature
above 0°C. Knocks and impacts shall be avoided at
temperature below -5°C.
We suggest to cut the pipe end of 5 cm.

Threaded Fittings
The threaded fittings are recommended to be
joined with Polytetrafluoroethylene (PTFE) tape.
The thread shall not be over tightened as the
plastic parts may be damage.

Pipes Bending
The minimum bending radius must be equal or
more than 8 times of the pipe diameter. For this
purpose, heat the part which will be bent by using
a industrial heat blower or suitable equipment.
Do not use flame.
WE HIGHLY RECOMMEND TO CONTACT OUR
TECHNICAL SUPPORT FOR ADVICE ON PIPE
BENDING.

| 33
 Working with plastic pipes & fitting

Transport and storage of plastic pipes

Plastic are materials sensitive to impact and crushing at low temperatures. The
temperature limit depends on the relevant material.
Material Temperature
PP-R -5C
PVC-C +5C
PB 0C
PE -40C
PE-RT -40C

Below these temperatures pipes and fittings would have to be protected

particularly from impacts, crushing and other external mechanical stresses.

Plastic pipes and plastic fittings must be protected in principle from external
influences. Direct sunlight, impacts and compressive stresses should be
avoided. The pipes and fittings must be left in their packing until used. They
should not be stored outdoors.

34 |
 Selection of Pipe Diameter

In order to select the best water flow depending on the available water pressure and corresponding
usage, please refer to the table here below:

Table for the selection of pipes diameters and water flow

Water Connection Point Flow Pressure Pipe Diameter
(l/sec). (bar) (mm)
Wash Basin
Tap DN 15 0.07 0.50 20

general precautions
Mixer Tap DN 15 0.07 1.00 20
Bidet
Tap DN 15 0.07 0.50 20
Mixer Tap DN 15 0.07 1.00 20
Bath tub
Mixer Tap DN 15 0.15 1.00 20
Mixer Tap DN 20 0.40 1.00 25
Mixer Tap DN 25 1.00 1.00 32
Shower
Sprinkler DN 15 0.15 1.00 20
Sprinkler DN 15 0.06 1.00 20
Sprinkler DN 20 0.18 1.00 20
Sprinkler DN 25 0.31 1.00 20
Flush and flushing tank
Flush DN 20 1.00 1.20 32
Flush Tank DN 15 0.13 0.50 20
Electric and gas boilers
6 kW 0.07 1.00 20
12kW 0.10 1.00 20
18kW 0.15 1.00 20
21kW 0.17 1.00 20
24kW 0.20 1.00 20
33kW 0.30 1.00 20
Sinks
Mixer DN 15 0.07 1.00 20
Mixer DN 20 0.02 1.00 20
Dishwashers Washing 0.15 1.00 20
Machines 0.25 1.00 20
Urinals
Flush DN 15 0.30 1.20 20
Flushing Tank DN 15 0.13 0.50 20

| 35
 Assessment of Pressure

The pressure losses for distribution in the Georg Fischer piping system can be assessed by means of
the following chart or by means of the following formula:

Where:
pressure loss in a straight pipe (bar)
pipe friction factor (in most cases 0.02 is sufficient)
length of straight pipe (m)
density of transported media (kg/m³)
flow velocity (m/s)
inside diameter of pipe (mm)

Loss Pressure Diagram for PN 20 Pipe

Example:
Pipe: 40 X6.7 mm From the diagram,
Flow = 0.2 l/s Pressure loss
Water velocity = 0.4 m/s = 70 Pa/m
= 0.7 mbar
(10,000 Pa = 0.1 bar = 100 mbar)

36 |
 Assessment of Pressure

Loss Pressure Diagram for PN 10 Pipe

technical features

| 37
 Assessment of Pressure

Pressure Losses in Georg Fischer Fittings

Description Symbol Coefficient of resistance

Equal coupling 0.25

Elbow 90° 2.00

Elbow 45° 0.60

Equal tee 90° 1.80

Reduced tee 90° 3.60

Equal tee 90° 1.30

Reduce tee 90° 2.60

Equal tee 90° 4.20

Reduced tee 90° 9.00

Equal tee 90° 2.20

Reduce tee 90° 5.00

Threaded tee 90°, male 0.80

Concentric reductions up to 2 size 0.55

Concentric reductions up to 3 size 0.85

Threaded fitting, male 0.40

Threaded fitting, male, reduced 0.85

Threaded elbow, male 2.20

Threaded elbow, male, reduced 3.50

38 |
 Regression Curve

The regression curves affect pipe life depending on the fluid pressure, temperature and outer stress (see chart).

Regression curves
The diagram shows the lowest
life features according to
DIN 8078 standards and life
test results concerning the
polymer used, in order
to confirm the high resistance
to pressure and temperature
of AQUASYSTEM®

Hydrostatic stress: technical features

Expressed in megapascals, induced in the wall of pipe when a pressure is applied using water as a medium.
Using Hydrostatic stress and dimensions, the maximum working pressure can be calculated with the following equation:

Example
The formula joining these parameters is :
T = 60°C Continuous operating life: 50 years
P = maximum inner pressure From the regression curve the result is: R = 4,9 Mpa
d = outer diameter
s = thickness Calculation (from the formula)
R = outer stress P= 19,7 bar
Or P = 13 bar
(using safety coefficient of 1.5)

| 39
 Permissible Operating Pressure

Type of pipe
PN 10 PN 16 PN 20
Water Temperature Working years SDR 11 SDR 7.4 SDR 6
S5 S 3.2 S 2.5
Pressure bar
1 17.6 27.8 35.0
5 16.6 26.4 33.2
10°C 10 16.1 25.5 32.1
25 15.6 24.7 31.1
50 15.2 24.0 30.3
1 15.0 23.8 30.0
5 14.1 22.3 28.1
20°C 10 13.7 21.7 27.3
25 13.3 21.1 26.5
50 12.9 20.4 25.7
1 12.8 20.2 25.5
5 12.0 19.0 23.9
30°C 10 11.6 18.3 23.1
25 11.2 17.7 22.3
50 10.9 17.3 21.8
1 10.8 17.1 21.5
5 10.1 16.0 20.2
40°C 10 9.8 15.6 19.6
25 9.4 15.0 18.8
50 9.2 14.5 18.3
1 9.2 14.5 18.3
5 8.5 13.5 17.0
50°C 10 8.2 13.1 16.5
25 8.0 12.6 15.9
50 7.7 12.2 15.4
1 7.7 12.2 15.4
5 7.2 11.4 14.3
60°C 10 6.9 11.0 13.8
25 6.7 10.5 13.3
50 6.4 10.1 12.7
1 6.5 10.3 13.0
5 6.0 9.5 11.9
70°C 10 5.9 9.3 11.7
25 5.1 8.0 10.1
50 4.3 6.7 8.5
1 5.5 8.6 10.9
5 4.8 7.6 9.6
80°C
10 4.0 6.3 8.0
25 3.2 5.1 6.4
1 3.9 6.1 7.7
95°C
5 2.5 4.0 5.0
DIN 8077 edition 07/1999 - coefficient factor 1.5

40 |
 Thermal Expansion & Contraction

Thermoplastics are subject to greater thermal expansion and contraction than metals.
Pipes installed above ground, against walls or in ducts, especially those exposed to temperature
variations, require changes in length to be absorbed in order to prevent strain on the pipes.
Length changes can be absorbed by:
a) Flexible sections
b) Compensators

Flexible sections are the most common solution, being the simplest and the most economical.
Calculation of the positioning of flexible section are therefore described in detail.

Calculation of change in length

During the design and installation of plastic pipes, it is very important to calculate the expansion caused
by the possible difference between operating temperature and installation temperature.

The change in length is calculated with the following formula:

Where:
L = change in length (mm)
L = initial pipe length (m)
T = temperature difference (°C)
α = expansion coefficient (mm/m°C)

The expansion Coefficient

α indicates the elongation of a 1m pipe under a temperature increase of 1°C

Medium thermal expansion coefficient for PP-R pipelines :

Example

technical features
Changes in length for PP-R pipe:
L=5m
T=50°C
α = 0.15mm/m°C

| 41
 Position of the Flexible Arms

The low modules of elasticity of thermoplastics allows changes in length to be absorbed by special pipe
sections where pipe supports are positioned so that they can take advantage of the natural flexibility of
the material.

The length of such sections is determined by the diameter of the pipeline and the extent of the thermal
expansion to be compensated.

In order to simplify design and installation, the temperature of the pipe wall, a third factor, will not
be taken into account, especially since most pipes are installed in an environment with ambient
temperature in the range of 5 to 30°C.

Arrangement of fixed point support clamps (PF)

Fixed points direct thermal expansion of the pipe in
the desired direction. Fixed points should always be
installed at the fitting and should support it on both
sides or be installed in between two fittings.

Sliding support clamps (PS)

Sliding fasteners allow an axial movement of the
pipe. The clamp must be in line with the pipe.
Sliding clamps must be lined with rubber inserts
suitable for plastic pipe movement to avoid pipe
damage.
PS : sliding point PF: fixed point
PF : fixed point
LBF : flexible arm length

Example for the assessment of the flexible arm

Data: L = 10 m
d = 50 mm
T installation = 15 °C
T max operation = 80 °C
L = 0,15 . 10 . 65 = 97,5 mm

42 |
 Position of the Flexible Arms

Assessment of the flexible arm for PP-R pipe

Example
What is the flexible arms length if the
LBF = flexible arms length expansion ∆L is 37 mm on a d63 pipe?
C = constant PP-R = 20
LBF = 20 x 37 x 63 = 966mm
∆L = change in length (mm)
de = outer pipe diameter

technical features

| 43
 Insulation & Thermal Conductivity

+GF+ AQUASYSTEM for Polypropylene – Random (PP-R) pipes and fittings are designed to have low thermal
conductivity. Generally it would not be required to install thermal insulations for concealed or exposed pipes and fittings
within an enclosed environment. However insulation may be needed, depending on the countries regulations, warm or
cold application or that of energy-saving requirement. Insulation guidelines, as per DIN 1988, depends on the respective
installation; the use of hot or cold water and the wall thickness.

Thermal conductivity
There is a time-dependent transfer of heat (Q) between two points of a body which have different temperatures.
Considering a wall of cross-sectional area A and thickness e, the heat conducted from one side to the other is directly
proportional to the (maintained) temperature difference between the sides, to the area A and to the time t, It is inversely
proportional to the thickness e:
Coefficient of thermal
Substance
conductivity (Wm-1 K-1)
Q = λ • A • t • ∆T/e
Foam Plastics 0.02 - 0.05
The constant of proportionality k depends on the PVC-U 0.16
wall’s material and is caleed its coefficient of PVC-C 0.17
thermal conductivity. PP 0.22

[λ] = W / (m k) = Wm-1 K-1

PE-HD 0.41
Copper 400

W = watt, m = meter, K = Kelvin (= °C) Water 0.61

Air 0.023

Cold Water
Guidelines value for minimum thickness of insulation for
Type of Installation
cold water system ʎ = 0.040 w/mK
Exposed installed Pipe in a unheated room (e.g cellar) 4 mm
Exposed installed Pipe in a heated room 9 mm
Pipes installed in a channel without additional heated pipelines 4 mm
Pipes installed in a channel besides additional heated pipelines 13 mm
Pipes installed in building slit / Raising main 4 mm
Pipes installed in wall recess next to heated pipelines 13 mm
Pipes laid on cement floor 4 mm

The insulation thickness, applied to a diameter of d = 20mm, for other coefficients of thermal conductivity have to be calculated correspondingly.
(DIN 1988 PART 2)

Thermal Conductivity for Hot Water

Based on 60°C water temperature and environment temperature of 30°C per meter (unit in J/s)

Dimension 20 25 32 40 50 63 75 90 110 125 160

PP-R PN 20 99.84 101.31 100.75 101.69 102.82 108.62 102.31 102.31 102.54
Material
PP-R PN 16 126.29 126.29 129.00 129.00 128.45 130.11 129.19 129.93 129.26 129.73 129.70
• Calculation is not considered the friction factor, head loss and any other factor that could effect on the fluid temperature. Calculation is based on steady
state condition
• Theoritical value may differ from the actual condition

44 |
Installation Recommendations

Direct embedding of PP-R pipes

PP-R pipes can be embedded directly in concrete. The pipes can withstand the additional axial strains,
which occur due to impeded expansion. In such cases, the stress present in the pipe and fittings must be
calculated to prevent too high internal stress. It is important to prevent any exposed pipes when the pipe is
covered with mortar.

Indirect embedding of PP-R pipes

Where pipework is installed under plaster or embedded
into concrete, the flexible sections at bends and branches
must be padded for the calculated distance a, as also the
branches and elbows in the affected section.

Installing compensators
The low modulus of elasticity means that the reaction
force of plastic pipes to thermal changes is low compared
to metal pipes. This makes normal compensators
designed for use with metal pipes unsuitable because
of their high inherent resistance. Only freely moving
compensators may be considered: rubber compensators, PTFE-corrugated compensators or suitable
selected metal multi-disc compensators.

Pipes brackets
Plastic pipes need regularly space support (see blow

technical features
table), the bracket distance depends on many factors such
as temperature, pressure, diameter and material. In every
case, the inner diameter of the support must be greater
than the external diameter of the pipe, so as to permit pipe movement due to pipe expansion.

PP-R PN 20/ PN 16/ PN 10 Bracket Spacing distance between two brackets in cm

d PN 10 PN 16 PN 20
(mm) 20°C 30°C 40°C 50°C 60°C
20 75 75 70 65 60
25 85 85 85 80 75
32 100 100 95 90 85
40 110 110 105 100 95
50 130 125 115 110 105
63 150 145 140 125 120
75 170 165 160 150 145
90 180 175 170 165 160
110 190 185 175 170 165
125 195 205 170 - -
160 210 210 180 - -

| 45
 Electro Fusion Installation

Welding can be made by using +GF+ electrofusion machine. This machine is also use in repair works, where
it is difficult to use the standard machine and where there is space constraint.

Pay attention to the following instructions:

1. Wipe the coupling area of the pipe with a clean cloth.

Scrap the fusion area with a appropriate peeling tools to
remove contaminated layer of the pipe.
Check the pipe ovality (< 1.5%).

2. Thoroughly clean the fittings and pipes with a lint-free tissue

with a suitable plastic pipe cleaner.

3. Unpack the fitting and position it on the pipe, so that the

sleeve-end matches the pipe-end. Insert the end of the other
pipe. Make sure that both ends of the pipe are lined up and
secure the fitting and the pipe.

4. Fix the electrofusion machines cables so that the cables do

not weigh on the clamps. Connect the clamps to the resistor
terminals on the fitting and make sure that the connection is
correct. Follow the instructions to program and operate the
welding machine.

Minimum cooling time without moving sleeve and pipe

d mm minutes d mm minutes
20 10 63 20
25 10 75 25
32 10 90 30
40 15 110 35
50 15 125 40

about 2 hours hardening time must be allowed from when the fitting is cool
before any pressure tests can be used.

46 |
Socket Fusion Installation

Preparation

1. Fix heating bushes

Attach the heating bushes on the heating tool. Maximum
two set of bushes can be attached at the same time.

2. Check the Temperature

Once the socket fusion machine is turned on, set the
temperature on the electronic display which must
range between 255°C and 265°C. To ensure correct
temperature, regular calibration is recommended.

3. Clean the heating tools

After checking the temperature, wipe the heater bush
with a clean cloth. This process must be repeated after
each welding.

4. Cut the pipe

Cut the pipe at right angle; if necessary remove burrs
from inside. If necessary cut deformed or damaged
pipe ends of 5 cm.

5. Clean pipe & fitting

Clean the fittings sockets on the inside and the outer
wall of pipe (the presence of dust, grease or other
impurities can affect the fusion quality and lead to weak
jointing).
correct installation

| 47
 Socket Fusion Installation

Fusion

1. Mark the pipe

Mark the insertion depth on the pipe for (see table).
The mark must remain visible under heating and jointing.

2. Heat pipe & fitting

Push the pipe and the fitting straight into the heating
bushes. Pull out the pipe and fitting slowly and without
twisting once the heating time has elapsed.

3. Joint pipe & fitting

Push the pipe into the fitting so that the welding beads of
pipe and fitting touch together. During the jointing time,
small adjustment in angle and alignment can be made.
During the cooling time, any stress on the joint must be
avoided.

4. Fusion inspection
The outer fusion bead must be inspected. A double bead
must be uninterrupted all around the pipe circumference.

Summary Value table

Pipe minimum wall insertion depth heating time jointing time cooling time
Diameter thickness
(mm) (mm) (mm) (sec.) (sec.) (min.)
20 3.4 14 6 4 2
25 4.2 16 7 4 3
32 5.4 18 8 6 4
40 6.7 20 12 6 4
50 8.4 23 18 6 5
63 10.5 26 25 8 6
75 12.5 28 30 8 8
90 15.0 31 40 10 8
110 18.4 33 50 10 8
125 20.8 40 60 10 8

48 |
 Butt Fusion Installation

Butt Fusion Jointing of PP Piping Systems

The principle of fusion jointing Butt fusion jointing method

The fusion areas of the pipes and fittings are heated to fusion
temperature and joined by means of mechanical pressure, without
using additional tools. A homogeneous joint results. Butt fusion must
only be carried out with fusion jointing machines which allow the
jointing pressure to be regulated. Details of the requirements for
machines and equipment used for butt fusion jointing thermoplastics
are contained in DVS 2208 Part 1. The drawing to the left illustrates
the principle of fusion jointing.
1 Pipe
2 Heating element General requirements
3 Fitting The basic rule is that only similar materials can be fusion jointed. For
best results, only components which have a melt flow index in the
range from MFR 190/5 0.4 to 1.0 g/10 min should be fusion jointed.
This requirement is met by PP butt fusion fittings from GF.
The components to be jointed must have the same wall thicknesses
at the fusion area. Butt fusion jointing may only be performed by
adequately trained personnel.

Join only components with similar wall Check the temperature

thicknesses Recommended temperature of heating element between 200°C to
220°C. Check temperature before commencing the fusion jointing,
this is best carried out with the use of a digital thermometer with a
sensor for measuring surface temperature.
To ensure the right temperature setting should be checked from
time to time during the jointing work. The temperature of the heating
element is particularly sensitive to ambient temperature and drafts.

incorrect correct

correct installation

| 49
 Butt Fusion Installation

Fusion jointing procedure

Once it has attained the fusion temperature, position the heating
element in the fusion jointing machine. Press the surfaces to be
jointed against the heating element with the force required for
equalisation until the entire circumference of each of the jointing
Join and cool
faces rests completely against it and a bead (see the table) has
formed. Reduce the equalisation pressure almost to 0 (p~ 0.01 N/
mm²). The heating time listed in the table is measured from this
moment.

Once the heating period has elapsed, remove the parts from the
Leave parts in the fusion jointing machine at heating element which should then be removed without touching
fusion pressure until the end of the cooling the jointing surfaces and push the heated surfaces together
period! immediately. The changeover time must not exceed the value
listed in the table. Pay particular attention during jointing that
the parts be moved together swiftly until the surfaces are about
to touch. Then they should be moved together so that they are
in contact along the entire circumference. Next the pressure
should be increased rapidly to the present jointing pressure within
the period of time specified in the table. This pressure must be
Fusion check maintained during the entire cooling period. Adjustment may be
necessary, especially shortly after the jointing pressure has been
attained.
The jointed parts must stay in the fusion jointing machine under
jointing pressure until the end of the cooling period specified in
the table.

A bead should form around the entire Carrying out the pressure test
circumference of the pipe. K in the diagram to All fusion joints must be allowed to naturally cooled completely
the left should always be positive. before pressure testing, i.e. as a rule wait about 1 hour after the
last joint has been completed.

Approximate values for Butt Fusion of PP 1)

Wall thickness (mm) Equalisation at Heating time ²) Changeover Time to reach full Cooling time ²)
p=0.10 N/mm² p=0.01 N/mm² time max. (sec) jointing (sec) under jointing
Height of bead (sec) p=0.10 N/mm²
(mm) (min)
up to 4.5 0.5 up to 135 5 6 6
4.5 - 7 0.5 135 - 175 5-6 6-7 6 - 12
7 - 12 1.0 175 - 245 6-7 7 - 11 12 - 20
12 - 19 1.0 245 - 330 7-9 11 - 17 20 - 30
19 - 26 1.5 330 - 400 9 - 11 17 - 22 30 - 40
26 - 37 2.0 400 - 485 11 - 14 22 - 32 40 - 55

• For exact welding value please refer to our technical support team.
• In accordance with DVS 2207-11

50 |
 Hole Repairing

In case of accidental drilling it is possible to repair the pipe as follows:

1. Ensure that the hole to be repaired matches the dimensional

size of the hole mender. The Repairing Hole Tool comes in
7mm and 11mm, able to repair a hole of 6mm and 10mm.

2. Proceed with the normal fusion by heating the two parts for
5 seconds with an appropriate heating element. In relation
to the thickness of the pipe, position the Repairing Hole Tool
perpendicular to the pipe. The heating element must range
between 255°C and 265°C before jointing.

3. Insert the pre-heated Repairing Hole into the pre-heated

hole of the pipe. Remain in perpendicular position to the pipe
for a while for cooling purpose.

4. Wait until the cooling time is complete before cutting the

excess part.

correct installation

| 51
 Saddles Installation

Assemble the special heating tools for saddles with a standard socket welder. Once the socket welder is
on, check the temperature, which must be in the range of 255-265°C (this operation may be performed by
means of thermostatic sticks). Wipe the heating tools with a clean clothe. Clean the surfaces to be welded
by means of light specific solvent (TANGIT KS).

1. Scrap the pipe surface with a scraper. With PPR pipes,

the aluminium layer must be removed.

2. Drill the pipe with the specific drill bit, taking into
consideration the saddle spigot diameter. The chip has to
be taken out to avoid any pipe contamination. It is possible
to smoothen the hole mouth by changing the drill in counter
clockwise direction.

3. Push the saddle heating tool with the spigot into the pipe
hole and the saddle into the other tool. Heat the pipe surface
and the saddle for 30 seconds.

4. Once the heating process is over, remove the socket welder

and push the saddles spigot into the pipe hole with a light
pressure until the surfaces will meet entirely. Hold the
position for 15-20 seconds and let the system cool down for
30 min, before making the pressure test.

52 |
 Saddles Installation

Welding Parameter
Diameter Diameter Heating Heating Holding Cooling
pipe derivation time pipe time saddle time time
(mm) (mm) (sec) (sec) (sec) (min)
40 20 30 30 20 30
40 25 30 30 20 30
50 20 30 30 20 30
50 25 30 30 20 30
63 20 30 30 20 30
63 25 30 30 20 30
63 32 30 30 20 30
75 20 30 30 20 30
75 25 30 30 20 30
75 32 30 30 20 30
75 40 30 30 20 30
90 20 30 30 20 30
90 25 30 30 20 30
90 32 30 30 20 30
90 40 30 30 20 30
110 20 30 30 20 30
110 25 30 30 20 30
110 32 30 30 20 30
110 40 30 30 20 30
125 20 30 30 20 30
125 25 30 30 20 30
125 32 30 30 20 30
125 40 30 30 20 30
40 1/2” 30 30 20 30
40 3/4” 30 30 20 30
50 1/2” 30 30 20 30
50 3/4” 30 30 20 30
63 1/2” 30 30 20 30
63 3/4” 30 30 20 30
75 1/2” 30 30 20 30
75 3/4” 30 30 20 30
75 1” 30 30 20 30
90 1/2” 30 30 20 30
90 3/4” 30 30 20 30
90 1” 30 30 20 30
110 1/2” 30 30 20 30
110 3/4” 30 30 20 30
110 1” 30 30 20 30
125 1/2” 30 30 20 30
125 3/4” 30 30 20 30
125 1” 30 30 20 30
correct installation

| 53
 Approvals & Certificates

54 |
Approvals & Certificates

| 55
 Approvals & Certificates

56 |