Basic Tapwater Manual

Wirsbo Tap Water SystemBasic Manual

Dec. 2001

2 Wirsbo Tap Water System Basic Manual

Page

Introduction...................................................................................................... 4

Chapter 1 System description The Wirsbo Tap Water System.........................................................................5 Wirsbo-PEX pipe..............................................................................................5 Easy to install ................................................................................................... 6 Security against water damage ......................................................................6 Wirsbo conduit................................................................................................. 7 Marking and identifi cation ..............................................................................7 Longitudinal expansion...................................................................................7 Longitudinal contraction (shrinkage) ............................................................. 8 Joining methods ..............................................................................................8

Chapter 2 Calculation principles Water fl ow demand .........................................................................................9 Design fl ow...................................................................................................... 10 Velocity of fl ow................................................................................................ 11 Hot water circulation (HWC) .......................................................................... 11 Pressure drop .................................................................................................. 11 Generally ......................................................................................................... 13

Chapter 3 Diagrams and tables Pressure drop nomograms ............................................................................ 14 Heat emission loss.......................................................................................... 16 Working pressure/temperature...................................................................... 18 Thermal expansion ......................................................................................... 19

Chapter 4 Calculation methods Calculation example 1 ....................................................................................20 Calculation example 2 ....................................................................................22

Chapter 5 Installation methods/directions Traditional method..........................................................................................25 Manifold system .............................................................................................25 Conduit Pipe-in-Pipe system......................................................................26 Securing the conduit ......................................................................................26 Location of the manifolds ..............................................................................27 Location of the pipes ......................................................................................28 Installation in concrete structures .................................................................28 Installation in wooden structures ..................................................................29 Installation in single-family houses............................................................... 29 Installation in a block of fl ats .........................................................................30 Installation in basements and ceilings.......................................................... 30 Installation not allowing for thermal expansion .......................................... 31 Installation allowing for thermal expansion................................................. 32 Fixing and clamping pipes on to a rack ........................................................ 32 Installation in a vertical pipe duct..................................................................33 Expansion compensating devices .................................................................34 Calculation of a fl exible arm and expansion loop........................................ 34

Contents

Wirsbo Tap Water System Basic Manual 3

Page

Chapter 6 General directions Storage and general care ...............................................................................36 Uncoiling the pipe...........................................................................................36 Method of cutting ...........................................................................................36 Assembling a Wirsbo Q&E fi tting ..................................................................37 Assembling a compression fi tting.................................................................38 Assembling a WIPEX Coupling ......................................................................39 Minor repairs................................................................................................... 40 Inserting a PE-X pipe into a conduit .............................................................. 41 Replacing a damaged pipe.............................................................................42 Pipe bending ................................................................................................... 44 Minimum bend radius ....................................................................................44 Filling the system............................................................................................44 Pressure test.................................................................................................... 44 Fire protection ................................................................................................. 45

Chapter 7 Wirsbo-PEX Technical data.............................................................................46

Chapter 8 Quality Assurance, tap water approvals ....................................................... 47

Chapter 9 Conversion tables ...........................................................................................49

Chapter 10 List of fi gures, tables and diagrams Figures ............................................................................................................. 55 Tables ............................................................................................................... 56 Diagrams ......................................................................................................... 56


This manual will give basic information regarding the design of tap water systems incorporating Wirsbo-PEX pipes and is intended mainly for use in the design of systems for apartments and houses.

Wirsbo systems are easy to install and calculation principles, with the exception of material and installation costs, are the same as for other systems.

However it is recommended that design and installation be carried out by experienced personnel. Local authority regulations in any case govern the kind of persons authorised to carry out this work, which in most instances will be certifi ed plumbers. Moreover, although recommendations given here are in general based on Nordic norms (NKB), individual requirements specifi c to the country concerned should be taken in to account where necessary.

In the case of high-rise buildings such as hotels or offices, necessary additional information is available from Uponor Wirsbo AB or one of our many agents and distributors throughout the world.

Uponor Wirsbo AB

Uponor Wirsbo AB, Sweden in December 2001.

Reprinting, copying or any kind of reproduction is allowed provided the source of the

material is mentioned.

Introduction


Chapter 1System description

For years, selecting a tap water system was done in a routine fashion. Choice of material was limited, and attention was paid only to basic requirements. Today, selecting a tap water system involves taking into consideration a wider range of aspects. Although the purpose is the same, a modern tap water system has a number of additional features, features which have a direct impact on the overall performance of a system.

As in other aspects of modern life, development and improvement are continuous. Wirsbo piping systems are by no means new on the market. These have been developed and improved on since 1972.

Wirsbo offers a complete system for domestic hot and cold water. The system consists of a wide range of pipes and accessories. It is clean, easy to install and fl exible. Being fl exible means for example, that longer lengths of pipe can be installed, resulting in fewer joints and less associated installation work. The Wirsbo Tap Water System includes components for installation in new buildings as well as in renovation projects, and is suitable for concealed runs in building structures of wood, concrete and brick, and for exposed runs in basements or ceilings.

Wirsbo-PEX is a pipe for hot and cold water applications. The pipes are made from cross-linked high-density polyethylene (PE-X) in accordance with the Engel process. Cross-linking is a process which changes the chemical structure of the plastic material in such a way that the polymer chains are connected with each other to form a strong three-dimensional net of chemical bonds.

The new chemical structure makes it impossible to melt or dissolve the polymer, without fi rst destroying its structure. Wirsbo-PEX pipes are therefore suitable for use at pressures and temperatures for which previously only metal pipes were appropriate.

In addition, Wirsbo-PEX pipes have a unique elasticity. Thus, when expanded, a pipe will always strive to resume its original dimension (unless it is expanded beyond the breakpoint which is over 300%). Using this feature for example means that pipes can be simply and securely connected to each other (see joining methods below).

The Wirsbo Tap Water System

Wirsbo-PEX pipe

Figure 1 Molecule chain for a cross-linked

polyethylene pipe


Wirsbo-PEX pipes have excellent long-term properties and are proof against corrosion. The internal diameter will not be reduced due to corrosion or to sediment build-up that can often occur in metal pipes. The pipe material also boasts the advantage of not being affected by high fl ow velocities or by low pH-valued water (aggressive water). Nor is it affected by building materials such as concrete, lime mortar, gypsum, etc. Wirsbo-PEX pipes have a very high resistance to chemicals and are thus resistant to chemical additives in water. Wirsbo-PEX does not give off taste and smell, or add any harmful substances to the drinking water.

The material used for Wirsbo-PEX pipes is elastic and has a shock- absorbing effect in situations such as when a mixing tap is suddenly shut off. Water hammer in fact is reduced to one third compared with traditional metal pipes.

Note Prevent tape, paint and sealing compounds containing plasticizers and

other products containing solvents from coming into contact with the pipe as the compositions in these products affect the long-term properties of the pipe negatively.

Since UV radiation affects the pipe, a Wirsbo-PEX pipe should not be stored or installed in such a way as to be exposed to sunlight (UV radiation).

Wirsbo-PEX pipes have many features that simplify the installation work. They are light and flexible and there is no need for high-temperature operations such as soldering or welding. Connecting a Wirsbo-PEX pipe is made simple using Wirsbo Quick & Easy couplings and the pipe can be easily cut and bent by hand. Furthermore the pipes are delivered in coils for easy transportation and handling.

Wirsbo tap water pipes can be safely placed in concealed locations within building structures because they offer security against water damage. This is because the pipes are channelled through a conduit, a protective outer pipe, which can be installed in a single seamless length around the water-bearing pipe from the manifold all the way to the draw-off point (a pipe in pipe system). Thus any water leakage, due for example to a pipe being damaged by a misplaced nail, will be carried and discharged beyond the building structure and will be detected at an early stage.

In addition as a further guarantee against damage, the various cabinets in the Wirsbo range, such as the manifold cabinets, are fi tted with leakage indicators.

Easy to install

Security against water damage

Figure 2 Wirsbo-PEX pipe


The conduit itself is corrugated, which makes it highly fl exible and gives it a high load-bearing capacity. As well as ensuring against water damage, it also provides mechanical protection and allows for the substitution of an accidentally-damaged water pipe.

Wirsbo pipes are always marked with the product name, outer diameter, wall thickness, date of manufacture, and continuous metre marks. They are also marked with the current standard, together with a type approval label and depending on the type of pipe, with the relevant production monitoring authority.

Wirsbo-PEX tap water pipes are approved according to the relevant international standards with respect to material properties, installation technique and health requirements.

Wirsbo conduit

Marking and identifi cation

Longitudinal expansion

Figure 3 Conduit pipe

Figure 4 The marking on Wirsbo-PEX

pipe

Compared to metal pipes, Wirsbo-PEX pipes have a high longitudinal expansion (although associated expansion forces are low).

If a pipe in pipe system is installed in concealed pipe runs, longitudinal expansion is taken up in the space between the water-bearing pipe and the conduit.

In exposed pipe runs, the expansion forces are transmitted to expansion compensating devices or to the structure of the building via anchor points.

Dimension (outside

diameter and wall

thickness)

Approval for potable

water in Germany

Identifi cation:

material, machine, year,

month, day

The name of

the productProduction

monitoring authority

Manufacturing

process (Engel)

DIN standard

specifying pressure

and temperature

rating


When a pipe has been in use for a while, the pressure and temperature of the water can drop and so the pipe may shrink longitudinally by up to 1.5%. If the pipe is prevented from shrinking, a tensile force will be built up. However, since the grip of the coupling on the pipe is stronger than any tensile force and the pipes are often laid somewhat slack, longitudinal shrinkage is normally not a problem.

A wide range of couplings and fi ttings are available for the easy and secure connection of plastic pipes; mainly compression fi ttings, press fi ttings among others of various manufacture.

Wirsbo has developed its own joining method, Wirsbo Quick & Easy (Q&E), based on the unique properties of the Wirsbo-PEX pipe.

A Wirsbo Quick & Easy joint is made by gradually expanding the pipe with a ring of PEX material fi tted on its outside, and then by allowing the pipe and support ring to shrink back onto the fi tting nipple.

This demonstrates the elastic properties of the PE-X material which always strives to resume its original shape as mentioned above and helps give Wirsbo Quick & Easy the reputation of being probably the most effi cient and safe PE-X coupling available today.

The WIPEX coupling is the other main coupling in Wirsbos assortment, designed especially for connecting larger dimension Wirsbo-PEX pipes, used in tap water systems or in district heating installations.

WIPEX couplings are available for pipe dimensions, ranging from outer diameters of 32 mm up to 110 mm. The joints here are sealed with o-rings.

Note For the safest couplings, Wirsbo-PEX pipes should be connected with

approved fi ttings recommended by Wirsbo or any of our retailers.

Longitudinal contraction (shrinkage)

Joining methods


The water fl ow requirements do vary in each country, therefore the following fi gures should be verifi ed with the relevant authorities in your area.

Water fl ow demand l/sApplication Nordic (NKB) prEN 806*Water closet with fl ush tank 0.1 0.13Wash basin 0.1 0.07Shower 0.2 0.15Bath 0.3 0.30Sink 0.2 0.10Washing machine 0.2 0.20Bidet 0.1 0.20

Example 1: BathroomIn a bathroom with bath tub, wash basin, water closet and bidet the maximum fl ow, according to Nordic norms, is:

Cold water (l/s) Hot water (l/s)Bath 0.3 0.3Wash basin 0.1 0.1Water closet 0.1 Bidet 0.1 0.1

Total fl ow rate 0.6 0.5

Bathrooms are normally used by one person at a time, the largest volume of water being taken by the bath. Therefore the maximum water fl ow would be 0.3 l/s and used as design fl ow rate.

Example 2: ApartmentAn apartment has a bathroom, a toilet and a kitchen:

a) The bathroom is similar to the bathroom in example 1b) The toilet has one water closet and one wash basin (only one used

at a time)c) The kitchen has a sink and a washing machine

The total fl ow rate in l/s to be considered for cold water is:

a) Bathroom in example 1 0.6b) WC and wash basin 0.2c) Sink and washing machine 0.4

Total fl ow rate 1.2

Chapter 2Calculation principles

Water fl ow demand

Table 1 Water fl ow demand

(* method 4)


According to Nordic norms, when the demand fl ow of an apartment is larger than 0.7 l/s, it is suffi cient to calculate with 0.7 l/s for both cold and hot water supply. If hot water is to be heated in the apartment, then the supply to the apartment should be 1.6 l/s.

In practice, most faucets used in tap water installations have a predominantly short usage time (less than 15 minutes per 24 hours) and not all faucets are in use at the same time. For this reason the design fl ow is based on the total fl ow (total volume required), and accordingly reduced by a design factor.

The table below shows design fl ow (Nordic norms) according to various total fl ows.

Total Design Total Design Total Design Total Design fl ow fl ow fl ow fl ow fl ow fl ow fl ow fl ow 0.3 0.30 3.2 0.59 12.0 0.98 27.0 1.46 0.4 0.35 3.4 0.61 12.5 1.00 28.0 1.49 0.5 0.37 3.6 0.62 13.0 1.01 29.0 1.52 0.6 0.39 3.8 0.63 13.5 1.03 30.0 1.55 0.7 0.40 4.0 0.64 14.0 1.05 32.0 1.60 0.8 0.41 4.2 0.65 14.5 1.07 34.0 1.60 0.9 0.42 4.4 0.66 15.0 1.08 36.0 1.71 1.0 0.43 4.6 0.67 15.5 1.10 38.0 1.77 1.1 0.44 4.8 0.68 16.0 1.12 40.0 1.82 1.2 0.45 5.0 0.69 16.5 1.13 45.0 1.95 1.3 0.46 5.5 0.71 17.0 1.15 50.0 2.08 1.4 0.47 6.0 0.74 17.5 1.17 60.0 2.33 1.5 0.48 6.5 0.76 18.0 1.18 70.0 2.57 1.6 0.49 7.0 0.78 18.5 1.20 80.0 2.81 1.7 0.49 7.5 0.80 19.0 1.22 90.0 3.04 1.8 0.50 8.0 0.82 19.5 1.23 100.0 3.26 1.9 0.51 8.5 0.84 20.0 1.25 110.0 3.49 2.0 0.52 9.0 0.86 21.0 1.28 120.0 3.70 2.2 0.53 9.5 0.88 22.0 1.31 130.0 3.92 2.4 0.54 10.0 0.90 23.0 1.34 140.0 4.13 2.6 0.56 10.5 0.92 24.0 1.37 150.0 4.34 2.8 0.57 11.0 0.94 25.0 1.40 160.0 4.55 3.0 0.58 11.5 0.96 26.0 1.43 170.0 4.76

Note For hotels, offi ce buildings and other large installations the above in-

formation should not be used. Consultation with your local authority is recommended in these instances.

Design fl ow

Table 2 Design fl ow


Velocity of fl ow Velocity of fl ow in a tap water system has a direct infl uence on:- Internal erosion- Noise level- Water hammer- Pressure drop

With the use of copper pipes, limiting the velocity of fl ow to a maximum of 1.5 m/s is recommended. Wirsbo-PEX pipes are not subject to this restriction. Tap water system installations with Wirsbo-PEX pipes can be designed to a maximum calculated water velocity of 2.5 m/s.

When designing a hot water system, consideration should be given to the installation of a circulation system, which reduces to a minimum the time between turning on the tap and the arrival of the hot water. This not only saves time but also reduces water consumption, since water need not cool between tap usage and unwanted cold water need not therefore be drawn off.

The following example shows the method for calculating the time with the hot water circulating relatively close to the manifold.

Example:The waiting time requirement is 10 seconds. The distance between the faucet (wash basin; 0.1 l/s) and the manifold is 10 m. The pipe from the manifold to the faucet is a Wirsbo-PEX pipe of 16x2.2 mm.

The internal volume of a Wirsbo-PEX pipe of 16x2.2 mm is 0.099 l/m. Since the distance is 10 m, there will be 0.99 l in the pipe between the connection points. The water fl ow is 0.1 l/s.

0.99 l0.1 l/s

= 9.9 s

Thus the time of under 10 seconds is acceptable.

Once the total fl ow (total volume required) in each main supply pipe has been calculated and the design fl ows have been determined, pressure requirements must then be considered before selecting a pipe dimension. The pressure drop in valves, mixers, fl ow metres, shut-off valves, fi ttings, etc., has to be taken into account when calculating these requirements. The pressure drop diagrams for Wirsbo-PEX pipes in the next chapter can now be used. These are based on specifi c temperatures. Calculations based on other temperatures are subject to a correction factor as shown in the table below.

Temp. Correction Factor C 70C 10C 90 0.95 0.76 80 0.98 0.78 70 1.00 0.80 60 1.02 0.82 50 1.05 0.84 40 1.10 0.87 30 1.14 0.91 20 1.20 0.96 10 1.25 1.00

Hot water circulation (HWC)

Pressure drop

Table 3 Correction factors


Explanation:For each marked value of fl ow in table 4, is a marked value for pressure drop in each column. This marking indicates the pressure drop level for the maximum recommended velocity of 2.5 m/s.

Example:The total fl ow for a cold water supply pipe (20C) is 5 l/s. The pipe length is 20 m and the pressure drop must not exceed 40 kPa.

From the table above we can see that pipe sizes 40, 50 and 63 mm can be used. Pipe sizes of 63 mm give a pressure drop of 1.49 kPa/m. The length of the pipe is 20 m so the pressure drop would be:

20 x 1.49 = 29.8 kPa

However, the correction factor in table 3 must be used since the pipe will be used for cold water:

29.8 x 1.20 = 35.8 kPa

The value above is therefore acceptable.

Table 4 Pressure drop for various Wirsbo-

PEX pipe dimensions at 70C

Pressure drop kPa/m 70C

Flow Pipe Dimension, mm l/s 12x2 20x2.8 32x4.4 50x6.9 75x10.3 110x15.1 16x2.2 25x3.5 40x5.5 63x8.7 90x12.3 0.10 5.68 1.01 0.15 11.78 2.09 0.20 19.79 3.52 1.13 0.25 5.25 1.69 0.30 7.30 2.35 0.84 0.35 9.64 3.10 1.11 0.40 12.27 3.94 1.41 0.45 4.87 1.74 0.50 5.90 2.11 0.62 0.60 8.20 2.93 0.87 0.70 10.83 3.87 1.14 0.80 4.93 1.45 0.90 6.10 1.80 0.61 1.00 7.38 2.18 0.74 1.20 10.27 3.03 1.02 1.40 4.00 1.35 0.49 1.60 5.10 1.72 0.63 1.80 6.31 2.13 0.78 2.00 7.64 2.58 0.94 0.28 2.50 3.87 1.41 0.43 3.00 5.39 1.96 0.59 0.26 3.50 7.13 2.60 0.78 0.34 4.00 3.31 1.00 0.44 4.50 4.10 1.23 0.54 0.22 5.00 4.97 1.49 0.65 0.27 6.00 2.08 0.91 0.37 7.00 2.76 1.20 0.49 0.19 8.00 3.51 1.54 0.63 0.24 9.00 1.90 0.78 0.30 10.00 2.31 0.94 0.36 12.00 1.32 0.51 14.00 1.74 0.67 16.00 0.85 18.00 1.06

20.00 1.28


1. The design fl ow for a room is the maximum volume needed to supply the faucet which requires the maximum flow. In bathrooms this is normally the bath tub.

2. The pressure drop for fi ttings supplied in the Wirsbo Tap Water System is equivalent to a pipe length of less than 0.5 m. (0.1 m for Wirsbo Q&E and 0.5 for WIPEX).

3. When a pipe dimension is selected the common acceptable value is 1-10 kPa/m (10-100 H

2O).

4. There are occasions where approximations can be useful for selecting a pipe dimension. The following table gives an indication of the required Wirsbo-PEX pipe dimension considering three various selection criteria. The values in the table are based on the examples, rules and tables shown in this manual.

A. Number of B. Number of Pipe Apartments bathrooms C. Total dimension (acc.to ex 2 (acc.to ex 1 fl ow l/s mm in section 2.1) in section 2.1) 20x2.8 1 2 1.4 25x3.5 3 6 3.7 32x4.4 12 24 14.2 40x5.5 29 57 34.2 50x6.9 43 86 51.5 63x8.7 107 213 127.9

Example1:Dimension a supply pipe for 30 apartments of the same sort as in example 2 in Chapter 2, Water fl ow demand.

Conclusion: Wirsbo-PEX 40x5.5 mm is suffi cient for 29 apartments but not for 30. Select Wirsbo-PEX 50x6.9 mm.

Example 2:Dimension a supply pipe for two bathrooms of the same sort as in example 1 in Chapter 2, Water fl ow demand.

Conclusion: Wirsbo-PEX 20x2.8 mm is suffi cient for these two bath-rooms.

Example 3:Dimension a supply pipe for a total fl ow of 3 l/s.

Conclusion: Wirsbo-PEX 25x3.5 mm is suffi cient for this fl ow.

Note You have to consider the pipe length, hoisting height and available

pressure.

Generally

Table 5 Indication of required Wirsbo-

PEX pipe dimension


Chapter 3Diagrams and tables

Pressure drop nomogram Wirsbo-PEX 1.0 MPa 90C

100

10

1

0.1

0.01

0.01 0.1 1 10 100 kPa/m

m/s

Correction factors for Temperature C 90 80 70 60 50 40 30 20 10other temperatures Factor 0.76 0.78 0.80 0.82 0.84 0.87 0.91 0.96 1.00

0.1 0.15 0.2

0.25

0.3

0.4

0.50.6

1.0

1.251.5

1.752.0

2.53.0

4.0

5.06.0

7.0

10.0

12.063x8

.7 mm

50x6

.9

40x5

.5

32x4

.4

25x3

.5

20x2

.8

16x2

.2

12x2

.0

l/sWater temperature 10C

Diagram 1 Pressure drop nomogram Wirsbo-PEX 1.0 MPa 90C


Pressure drop nomogram Wirsbo-PEX 0.6 MPa 90C

100

10

1

0.1

0.01

0.01 0.1 1 10 100 kPa/m

m/s

Correction factors for Temperature C 90 80 70 60 50 40 30 20 10other temperatures Factor 0.95 0.98 1.00 1.02 1.05 1.10 1.14 1.20 1.25

0.20.25

0.3

0.4

0.50.6

1.0

1.251.5

1.752.0

2.53.0

4.05.0

6.07.0

10.012.0

63x5

.8

50x4

.6

40x3

.7

32x3

.0

25x2

.3

20x2

.0

16x2

.0

75x6

.9

l/sWater temperature 70C

90x8

.2110

x10 m

m

Diagram 2 Pressure drop nomogram Wirsbo-PEX 0.6 MPa 90C


Heat emission loss Heat emission loss can be calculated according to the formula in fi gure 5. The diagrams show heat emission loss for Wirsbo-PEX pipes rated 1 MPa, 90C and 0.6 MPa, 90C. Temperature difference (water - ambient).

T = + T2Q

d4 2

Q = (T1-T2) l

1 1 1 d2 1 d3 1 d41d1 2d4 21 d1 22 d2 23 d3

+ + ln + ln + ln

Q = WT = Cd = m = W/m K = W/m2 Kl = m

1 = Piping wall

2 = Insulating layer

3 = Insulating layer

3

d1d2d3

d4T1

1

T23 21 2

2

1

Figure 5 Heat loss from a pipe based

upon a length of 1 metre.

Surface

temperature T


140

120

100

80

60

40

20

0

200

180

160

140

120

100

80

60

40

20

0

0 10 20 30 40 50 60 70 80 C

0 10 20 30 40 50 60 70 80 C

W/m

Heat emission loss Wirsbo-PEX 1.0 MPa 90C

63x8.7 50x6.9

40x5.5

32x4.4

25x3.5

20x2.8

16x2.2

12x2.0

110x10 90x8.2

50x4.8

40x3.7

32x3.0

25x2.3

20x2.0

16x2.0

75x6.9 63x5.8W/m

Heat emission loss Wirsbo-PEX 0.6 MPa 90C

Diagram 3 Heat emission loss Wirsbo-PEX 1.0 MPa 90C

Diagram 4 Heat emission loss Wirsbo-PEX 0.6 MPa 90C

mm

mm


Working pressure/temperature

The following diagram shows the applicable working pressure for Wirsbo-PEX pipes series S = 3.2 (10 bar at 95C) and series S = 5 (6 bar at 95C) at different continuous temperatures.

Diagram 5 Working pressure as a

function of temperature for normal hot

water use

ISO/DIS 15875 is the standard documentation which classifi es service conditions for plastic pipes and fi ttings for hot and cold water systems.

The service conditions with safety factors for 10 bar (class 2, hot water supply, 70C) are specifi ed below.

Dimen- Opera- Time Max. Time Malfunc. Time Typical sion tive at temp. at temp. at fi eld series temp. Top Tmax, Tmax, Tmal, Tmal of appli- Top, C Years C Years C Hours cation

3.2 70 49 80 1 95 100 Hot water

supply

Note Systems are not always in operation throughout their 50-year service life,

and therefore, when calculating the projected service life to ensure that it equates with the actual service life, allowance must be made for the time the system is not in use. A temperature of 20C, approximating to room temperature, must be used for calucation purposes for this period.

Pipes in series 3.2 should be installed in a hot water supply system with a maximum design pressure of 10 bar. Pipes in dimension series 5 should be installed in a hot water supply system with a maximum design pressure of 6 bar.

Pressure (bar) Sf 1,3 = Safecty factor 1.3

30

20

10

0

0 20 40 60 80 100 120

Temperature C

S = 5

S = 3.2

Table 6 Service conditions with safety

factors


Thermal expansion

25

20

15

10

5

0

Expansion, mm/m

Temperature, C

0 10 20 30 40 50 60 70 80 90 100Diagram 6 Thermal expansion

The diagram below shows the thermal expansion of a Wirsbo-PEX pipe as a function of the temperature.

This diagram is used in the example on page 35.


Chapter 4Calculation methods

In this chapter we will show two calculation examples to do with risers. For the sake of simplicity any pressure loss through manifolds and fi ttings has been omitted since it would have an insignifi cant effect upon calculations.

Example 1 shows a pressure loss calculation for the dimensioning of a riser in a small-size building.

Calculation example 1

The basic criteria required for pressure loss calculations:

A fi ve fl oor buildingA bathroom on each fl oorEach fl oor has a height of 3 mThe available water pressure at ground level is 400 kPa (hypothetical fi gure)The pressure loss through the heater is 100 kPa (hypothetical fi gure)The pressure loss in every faucet is 50 kPa (hypothetical fi gure)

Step 1 Calculate the known pressure loss

Pressure loss in the heater 100 kPaPressure loss due to the forceof gravity 147.2 kPa (9.81 x 3 m x 5 fl oors) Pressure loss in each faucet 50 kPa 297.2 kPa

l/s

0.6

1.2

1.8

2.4

3.0

5

4

3

2

1Heater

Figure 6 Outline drawing of an installation

MP0

l/s 0.3 0.1 0.1 0.1kPa/m

7.30 1.01 1.01 3.52


Step 2 Calculate the average pressure loss/m of the riser

This calculation gives an indication of the pressure loss when a pipe dimension is to be selected. Approximate pipe length = 15 m (3 m x 5 fl oors) + 5 m (bathrooms) = 20 m

The average pressure loss will be the difference between the available pressure from the pump (400 kPa) and the known pressure loss (297.2 kPa), which is 102.8 kPa. Thus

102.8 kPa 20 m

= 5.14 kPa/m

Step 3 Calculate the maximum pressure loss in the bathroom

The maximum fl ow in the bathroom comes from supply to the bath which is 0.3 l/s and gives a pressure loss of 7.3 kPa/m for a Wirsbo-PEX pipe of 16x2.2 mm. The distance from the manifold to the draw-off point is 4 m. The pressure loss will therefore be:

7.3 kPa/m x 4 m = 29.2 kPa

The maximum pressure loss is a function of the fl ow requirement, pipe dimension and pipe length. It is not always the outlet with the highest water fl ow requirement that gives the maximum pressure loss. That is why a comparison of pressure loss for all the outlets in the bathroom should be made.

Distance to Pipe Pressure Pressure Outlet manifold dim Flow loss/m loss (m) (mm) (l/s) (kPa/m) (kPa) Bath 4 16x2.2 0.3 7.30 29.2 Wash basin 6 16x2.2 0.1 1.01 6.06 Toilet 7 16x2.2 0.1 1.01 7.07 Bidet 4 16x2.2 0.1 1.01 4.04

Step 4 Calculate the pressure loss in the riser

According to Nordic norms, (NKB), the required fl ow for every bathroom is 0.3 l/s. However, the riser must be dimensioned for the total fl ow rate of each bathroom. In this case 0.6 l/s.

The total fl ow will thus be 3.0 l/s. From table 2 (Chapter 2; Design fl ow) we know the design fl ow is 0.58 l/s. Using this value in table 4 (Chapter 2; Pressure drop) will give an indication of a suitable pipe dimension.

In step 2, the average pressure loss/m was calculated at 5.14 kPa/m. This should not be exceeded. If we select a pipe dimension of 25x3.5 mm this will give a pressure loss of 2.77 kPa/m.

By using table 2 and then table 4 the value of the pressure loss in the riser can be determined. Here for example are comparison values obtained from the tables for a dimension of 25 x 3.5 mm.

Pressure loss Design Total fl ow kPa/m fl ow l/s l/s 1.35 0.39 0.6 1.74 0.45 1.2 2.11 0.50 1.8 2.44 0.54 2.4 2.77 0.58 3.0

Table 7 Calculated pressure loss for all

outlets in the bathroom

Table 8 Values based on total fl ow


1.35 kPa/m x 3 m = 4.05 kPa 1.74 kPa/m x 3 m = 5.22 kPa2.11 kPa/m x 3 m = 6.33 kPa2.44 kPa/m x 3 m = 7.32 kPa2.77 kPa/m x 3 m = 8.31 kPa 31.23 kPa

Step 5 Add together the calculated pressure loss

Known pressure loss (step 1) 297.20 kPaMaximum pressure loss (step 3) 29.20 kPaPressure loss in riser (step 4) 31.23 kPa 357.63 kPa (


Step 1 Calculate the minimum available pressure from the water tank

The minimum available pressure is the pressure in the manifold nearest the water tank. In this example the vertical distance to the nearest manifold is 9 m. Thus the available pressure is:

9.81 x 9 m = 88.3 kPa

Step 2 Calculate the pressure loss from the water tank down to the nearest bathroom

If we calculate initially for a 32x4.4 mm pipe, using the same tables (tables 2 and 4) as in example 1 will give a pressure loss of 0.82 kPa/m for 0.58 l/s. The vertical pipe length to be calculated for is 9 m.The pressure loss is then:

0.82 kPa/m x 9 m = 7.38 kPa

For Wirsbo-PEX 32x4.4 mm

Pressure loss Design Total fl ow kPa/m fl ow l/s l/s 0.82 0.58 3.0 0.72 0.54 2.4

Step 3 Calculate the maximum pressure loss in the nearest bath-room

As the water tank is located on top of the building, the nearest bathroom will be on the top fl oor. This bathroom is the same as the one in the previous example. The calculated pressure loss will thus be 29.2 kPa.

Step 4 Calculate if the available pressure is suffi cient to supply the bathroom on the top fl oor

Available pressure 88.30 kPaPressure loss in riser - 7.38 kPaPressure loss in bathroom - 29.20 kPa Pressure loss in faucet - 50.00 kPa 1.72 kPa

There is suffi cient pressure available to supply water to the bathroom. Again, if the pressure loss had been greater than the available pressure, a larger pipe diameter would have had to be used.

Step 5 Check the available pressure for the floors below the top fl oor

Due to the force of gravity, the available pressure will increase for every fl oor below the top fl oor, as the riser descends. This fi nal check is intended to:

a) Ascertain if the available pressure is sufficient to supply the required fl ow to the 4th fl oor.

The pressure loss from the riser is:

0.8 kPa/m x 3 m = 2.4 kPa



The pressure increase due to the force of gravity is:

9.81 x 3 m = 29.43 kPa

Since the pressure increase is higher than the pressure loss, the available pressure will be suffi cient for the demand fl ow on the 4th fl oor.

b) Ascertain if the available pressure on the bottom floor is excessive. If so this would indicate that a reduction in pipe size is necessary to limit the pressure.

For Wirsbo-PEX 25x3.5 mm

Pressure loss Design Total fl ow kPa/m fl ow l/s l/s 2.11 0.50 1.8 1.74 0.45 1.2 1.35 0.39 0.6

The pressure loss from the riser is:

0.72 kPa/m x 3 m = 2.16 kPa 2.11 kPa/m x 3 m = 6.33 kPa1.74 kPa/m x 3 m = 5.25 kPa1.35 kPa/m x 3 m = 4.05 kPa 17.79 kPa

The pressure increase is:

9.81 x 12 m = 117.72 kPa

Comment:The available pressure is in fact excessive so that the dimension of the riser should be reduced from the 4th fl oor downwards in order to reduce the pressure in the system.



Chapter 5Installation methods/directions

The Wirsbo Tap Water System can be installed in the same fashion as a traditional system made of metal pipes i.e. a Tee system. The advantage with this installation method is that it does use less piping than the manifold system described below. However, the traditional method has some inherent disadvantages that should be taken into consideration.

The design work for example is more complicated. Most engineers wish to reduce the pipe dimension, from a larger one at the beginning of the system to a smaller one at the end, which is why calculations are needed to determine the various pipe sizes.

Also, there are temperature and pressure variations due to the fact that one supply pipe normally has more than one draw-off point. In addition, there are more connection points than with the manifold system and these are often inaccessibly situated within the walls. Furthermore, because of the various pipe dimensions and the large number of corresponding fi ttings, stock keeping is more complicated on-site.

The manifold system does not present any of the above-mentioned diffi culties. It can be designed with one single pipe dimension from the manifold to the draw-off point, which simplifi es design and installation work. With connection points only at the manifold and the faucet, the risk of leakage from joints is considerably reduced and there are no awkward connections within the walls. Since also there are no other draw-off points on the same supply pipe, pressure and temperature variations are minimal when faucets are turned on and off in varying sequences. Furthermore fewer pipe dimensions and fi ttings allow for easier stock keeping and save on installation time and labour costs.

Traditional method

Figure 8 Traditional method with 16 joints

Manifold system


Figure 9 Manifold system with 10 joints

Although a properly installed Wirsbo piping system is secure from leakage, there may be occasions when extra precautions against damage from leakage within the construction of a building are required. Different local standards and regulations or simply the demands of the purchaser may require this. Using a manifold system in conjunction with Wirsbo Pipe-in-Pipe, the factory prefabricated Wirsbo-PEX pipe within a conduit, will meet these requirements. With Wirsbo-PEX Pipe-in-Pipe, any leakage caused by accidental damage is retained within the conduit and easily detected after being carried safely beyond the building structure. In addition, in a concealed pipe run, without the complicating Tee-joints of a traditional pipe system, an accidentally damaged length of pipe can be substituted from within the conduit without causing structural harm in the process.

Wirsbo-PEX Pipe-in-Pipe comes in ready-to-install prefabricated lengths. However if so desired, the conduit may be installed separately with the water pipe being inserted at a later stage.

Conduits should be properly secured, particularly so if run in wooden structures. This not only simplifi es the insertion of the water pipe into the conduit as required, but also helps reduce any noise from water hammer and pipe expansion. Note that Wirsbo-PEX Pipe-in-Pipe should be laid with the fewest possible bends and the largest possible bend radii. This too will help minimise noise, but in addition, it will make easier the removal of the water pipe at a later stage if this should prove necessary.

Securing to timber studs and joists is done with nailed clips placed at suitable intervals and with straps or securing plates, specially designed and supplied by Wirsbo. Pipes should be secured to concrete structures with tying wire.

However please note the following: Conduits running in stud walls, a timber fl oor structure or in a pipe

duct should not be secured above an interval of 1000 mm (as measured from the centre of the clips).

Pipes run at right angles through studs or wooden frames should be secured to these by securing plates.

When studs or joists are spaced 600 mm apart they should be secured at every other stud or joist.

Where the pipe run bends, the conduit should be fastened at either side of the bend.

Conduit Pipe-in-Pipe system

Securing the conduit


Figure 10 A conduit run through joists

with pipe clips and securing plates

Manifolds should be positioned for easy access to maintenance and in close proximity to all faucets. Location should also permit convenient connection to the supply mains, provide adequate protection from freezing, especially in areas with very low winter temperatures, and should be situated away from load-bearing parts of the building.

It may sometimes be appropriate to have more than one manifold location. In some cases, in keeping with local standards and regulations, a manifold may be best located where any leakage can be quickly detected, such as near a fl oor drain. Alternatively, manifolds can be placed in special watertight cabinets where any leakage, from for example a pipe damaged during installation, can be run off and quickly discovered at an appropriate detection point away from a buildings structure. Location could for example be on the wall in the laundry room, under a wash basin, or in a kitchen cabinet.

Location of the manifolds

Figure 11 Manifold in a watertight

cabinet (left)

Figure 12 An example of a manifold

attached to the wall (right)


Figure 13 Example of a manifold situated

in a ceiling

Location of the pipes

Installation in concrete structures

Figure 14 A temporary stand supports

the pipe and manifold (left)

Figure 15 A temporary stand supports a

pipe. Note the end cap is retained as long

as the pipe remains unconnected (right)

The pipe runs should be located where there is no risk of freezing and where there is least danger of an accidental drilling. The length of pipe between the manifold and the faucet should be kept to a minimum so as to reduce the number of bends, which in turn will keep pressure loss as low as possible.

Wirsbo-PEX pipes are not affected by concrete. Thus they can be cast directly into structural concrete or run in recesses made after casting.

Always allow some extra piping at the beginning and at the end of the runs to simplify connection to manifolds and fi ttings. The pipes should be tied to the reinforcement mesh at a maximum spacing of 750 mm, with wire or plastic straps. These must not deform or damage the pipe or the conduit.

A pipe bend support supplied by Wirsbo is recommended for perpendicular upturns from the fl oor whilst a temporary stand is often used to hold in place a loose pipe end, and in some cases even a manifold, if it is mounted before the wall is built.

Note When installing Wirsbo-PEX Pipe-in-pipe make sure that no concrete or

mortar forces its way into either water pipe or conduit. Before casting or otherwise concealing the conduit, make sure it has

not been deformed or blocked. An obstruction may affect the insertion of the water pipe.


If pipes are run in wooden fl oor structures and stud walls, they should be laid in runs which are simple to locate in order to help prevent any puncturing with nails or screws.

A pipe bend support is recommended for vertical upturns from the fl oor or where a small bend radius is needed.

Openings cut in joists along inner and outer walls should be under 250 mm from joist supporting points.

If the pipes are run in load-bearing structures, they must be laid so that the load-bearing capacity of the fl oor will not be impaired.

In general if an opening for a pipe run is to be made in a wooden structure, always check with the building constructor fi rst as to how this will affect the structural strength of the building.

Installation in wooden structures

An installation here could, for example, start with pipes run from the water heater to the manifold. The manifold could be located near the water heater, as long as any extra pipe length incurred between the manifold and the faucets does not increase pressure loss to the extent that it will affect the function of the system. In such cases it may be convenient to install several manifolds.

The pipe runs can be concealed in the foundation slab, stud walls, fl oor structures or loft fl oor structure.

An outside water outlet could ideally be located under the sink in the laundry room or kitchen, or under the wash basin in the bathroom.

Figure 16 Suggested run of pipes along

an outer wall (left)

Figure17 Suggested run of pipe along an

inner wall (right)

Figure 18 Suggested run of pipes in

secondary boarding in the ceiling

Installation in single-family houses

Figure 19 An example of manifolds

vertically connected to each other in a

single-family house (left)

Figure 20 An example of manifolds

horizontally connected to each other in a

one-storey house (right)


In keeping with good design, manifold cabinets should be used in installations in multi-family houses where concealed pipe runs are used. These cabinets are designed to be built into the wall for close connection to a pipe duct. Using Wirsbo-PEX pipes in straight lengths, running from fl oor to fl oor, will facilitate installation work.

Installation in a block of fl ats

Installation in basements and ceilings

Figure 21 Riser installation using

watertight cabinets

The installation of Wirsbo-PEX pipes in a basement or under a ceiling in the traditional manner, with pipes suspended from hangers, can be carried out with or without allowance for expansion.

Linear expansion in plastic pipes is greater than in metal pipes (although associated expansion forces are low). Plastic pipes may expand to such an extent that, without any support along their length, they may sag between the hangers. Although this does not affect the operation of the system, in exposed runs it gives a poor general impression.

To give the impression of neat installation work, Wirsbo recommend that channels should be used to support the pipes. The examples shown below are in accordance with European draft standards (prENV 12108).

Figure 22 Pipe runs in support channels

Figure 23 Pipes run on a rack


Table 11 Binding distances in accordance

with prENV 12108

Pipes should be anchored and clamped so that expansion forces are transmitted to the structure of the building. The fl exible Wirsbo material will ensure a low load on the anchor points because, when the longitudinal expansion is restrained, the pipe will expand radially. In line with prENV 12108 the maximum permitted distance between anchor points is 6 m. Therefore factory supplied 6 m lengths are ideally suited for this purpose.

These examples also illustrate the recommended manner of clamping and fi xing Wirsbo-PEX pipes.

The support channels should overlap by 100 mm and pipes should be secured with straps to these. Otherwise because of axial material stress related to temperature change, the pipes will climb out of the channels. Straps should be fi tted at the following recommended intervals:

Distance (mm) Wirsbo-PEX pipe, Cold water Hot water Do (mm) 500 200 16, 20 500 300 25 750 400 32 750 600 40 750 750 50, 63, 75 1000 1000 90, 110

Installation not allowing for thermal expansion

Figure 25 Wirsbo-PEX pipes in support

channels with anchor points at every 6 m

and supporting hangers inbetween

Hanger Hanger support bar Binding Anchor support bar

Channel

Anchor point

Anchor point Clamp

Figure 24 Branched pipe run in support

channels

Support bars, which act as anchor points, should be secured to the ceiling in pairs at intervals of 6m, and pipes must then be fi xed to them at pipe couplings by means of U-bolts. Support between the anchor points should be provided by hanger support bars fi xed securely to the ceiling. These are then fi tted with hangers clamped to supporting channels. Both hangers and channels should be securely tightened in order to prevent lateral movement. Hanger lengths should not exceed 150 mm. Hanger support bars should be mounted between the anchor support bars at the following recommended distances:


Distance (mm) Wirsbo-PEX pipe, Cold water Hot water Do (mm) 1500 1000 16, 20 1500 1200 25, 32, 40 1500 1500 50, 63 2000 2000 75, 90, 110

In general, pipes should be installed with supports fi tted so that the pipe is free to move. The expansion will then be taken up by expansion compensating devices, such as an expansion loop or a fl exible arm. (see below)

Hangers should be provided as in the preceding example above, with the clamps fi tted at the above recommended distances and tightened so that the pipe is free to move between the anchor points, which must be set at branches and at expansion compensating devices.

For particulars of securing the pipe to the support channels, see also the preceeding example above.

Laying on racks is appropriate where there are pipes of longer lengths and where only a few tees are to be fi tted. The pipes are then free to move on the rack and will, by themselves, take up the linear expansion. In order to control expansion movements it is important to fasten the pipes to the rack at max. 1000 mm intervals and anchor at each tee branch.

Installation allowing for thermal expansion

Figure 26 Pipe runs in support channels

Fixing and clamping pipes on to a rack

Figure 27 Wirsbo-PEX pipes on a

rack where thermal length variation is

compensated by the snaking of the

pipe

Table 12 Distances between hanger

support bars in accordance with prENV

12108


In a vertical pipe duct, pipes must be anchored at each fl oor. This can be done by means of a rubber-lined pipe clamp located on each side of a tee branch. This prevents the spreading of linear expansion from one floor to another. If the riser passes several fl oors without branches, it should be anchored at intervals of max. 6 m as earlier explained.

As the riser is concealed, the pipe need only be supported at the anchor points. However, in order to avoid unwanted sounds generated by pipe movement caused by rapid changes in fl ows and pressures, it is recom-mended that pipe supports should be installed between each fl oor.

Note If a conduit is used it should be

clamped to the pipe duct wall at intervals of max. 1000 mm.

Figure 28 Wirsbo-PEX Pipe-in-Pipe on

a rack will protect the pipes from dirt

accumulation

Installation in a vertical pipe duct

Figure 29 Pipe supported only by anchor

points


FIXL L

Figure 31 Flexible arm

A vertical exposed pipe run with supporting channels could be instal-led in the same way as a horizontal installation which does not allow for thermal expansion (see above).

Note Some of the accessories used in

the described installations are not included in our list of compoents as they are available locally in most countries.

As explained earlier pipes should be insulated according to the standards of each country. Adhe-sives should not be used for faste-ning insulation to the pipe as some of them can damage the PE-X material.

No special expansion compensators are needed if: the water pipe is supported and anchored at a maximum spacing of 6 m the water pipe is run in a conduit where the necessary space for expansion

is provided in the gap between water pipe and conduit the pipe is run in long lengths on a rack.

However, in installations allowing for thermal expansion, where the pipes are expected to stay straight, expansion compensators should be used.

The fl exible arm should be long enough to prevent damage, and support clamps should be placed suffi ciently far from the wall to allow for longitudinal thermal expansion.

Use the formula below to calculate the minimum length of the fl exible arm.

LB = C Do x L

Where:

LB is the fl exible arm in mmC is the material constant (12 for PE-X)Do is the outside diameter of the pipeL is the thermal length variation in mm

Expansion compensating devices

Figure 30 A vertical exposed pipe run

Calculation of a fl exible arm and expansion loop

Anchor

point

Anchor

point

LB


When designing an expansion loop it is preferable to design it so that l

2 = 0.5l

1. In this case the fl exible arm is calculated according to the

equation below:

LB = C Do x 2L = 2l1 + l2 2

FIX

L

L/2

FIX E/2

L/2

E/2

E/4

FIX

25

20

15

10

5

0

Expansion, mm/m

Temperature, C

0 10 20 30 40 50 60 70 80 90 100Diagram 7 Thermal expansion, example

Figure 32 Expansion loop

Example:A Wirsbo-PEX pipe with an outside diameter (Do) of 50 mm is installed with 30 m between anchor points. The hot water it carries is 70C and the ambient temperature is 20C. Calculate the length (LB) of the fl exible arm.

Calculate the thermal length variation by using the diagram from Chapter 3.

Anchor

point

Anchor

point

l2

l1l1

From the graph, the thermal expan-sion at 20C is 2.5 mm/m, while the expansion at 70C is 12.5 mm/m.

The expansion of the pipe will be 12.5-2.5 = 10 mm/m when carrying water at 70C. The total thermal length variation in this case is:L = 10 mm/m x 30 m = 300 mm.

LB = 12x 50x300 = 1470 mm


Chapter 6General directions

Wirsbo-PEX pipes are supplied in various dimensions, lengths and packages. Product information including some installation recommendations and sets of special end plugs are included in the packaging.

To ensure a long-term service life, pipes should be stored in a clean, dry environment and away from exposure to UV radiation (sunlight). They should also be kept in their packaging as long as possible in order to avoid dirt accumulation.

Pipes should be kept clean from dirt, grease, mortar etc. To avoid the introduction of dirt into the system during installation, end plugs should be fi xed to the pipes and retained for as long as possible. With Wirsbo Pipe-in Pipe, no concrete or mortar should force its way between the water pipe and conduit. If this happens any future substitution of the water pipe will be made more diffi cult.

A Wirsbo pipe uncoiler can be used to facilitate uncoiling. The uncoiler should be positioned as close to the current working area as possible. In this way, the length of pipe pulled over the fl oor is kept short and the number of corners around which the pipe is pulled are kept to a minimum.

Wirsbo-PEX pipes are manufactured to close dimensional tolerances and fi ttings are provided to meet those tolerances. A pipe cutter purposely designed for use with plastic pipes is recommended. However for larger pipe dimensions a cutter with large cutting discs should be used. When cutting the pipes, always ensure that the cut is straight and square. No excess material or burrs should remain that might affect the fi tting connection.

Storage and general care

Uncoiling the pipe

Method of cutting

Figure 33 Wirsbo pipe uncoiler


Assembling procedure:1. Cut the pipe.2. Fit the Q&E ring to the pipe.3. Use the expander tool to expand the pipe end with the ring. It is important

to rotate the tool slightly before the segments of the tool are pushed further into the pipe, prior to the next expanding. Rotate the tool alternating to the right and to the left between each expansion.

4. Push the pipe onto the fi tting nipple. The Q&E ring and pipe will strive to resume their original shape and in so doing will grip the coupling.

Assembling a Wirsbo Q&E fi tting

Figures 34-37 Methods of cutting a pipe

Figures 38 and 39 Assembling a Wirsbo

Q&E fi tting steps 1 and 2

Figures 40 and 41 Assembling a Wirsbo

Q&E fi tting steps 3 and 4


A correctly fi tted Wirsbo Q&E joint can be pressurised after 30 minutes at temperatures above +5C. At room temperature the joint will be as strong as the pipe itself after six hours. However ambient temperature affects the time it takes for the pipe and ring to shrink fi rmly on to the fi tting nipple to make a watertight seal; the lower the temperature, the slower the contraction.

Useful tips Keep the number of expansions to a minimum. Expand just enough to

allow the pipe to slip comfortably onto the fi tting nipple. Warming up the fi ttings and expander rings speeds up contraction time.

Heat the pipe for a maximum of about 30 seconds until it reaches 40-50C, which is the temperature at which you can hold the pipe in your hand without discomfort. Never use a naked fl ame for heating.

If uncertain as to how long the pipe will take to contract on to the fi tting a small test using a short piece of pipe can be made. When correctly mounted the pipe should grip the fi tting nipple within 3 seconds although for dimension greater than 16 mm this may tale from 3-10 seconds. If it takes longer, the number of expansions may have been too many or the duration of each expansion too long.

Note Approximate waiting times before pressurising a joint are presented in the

assembly instructions enclosed with the Wirsbo Q&E toolbox. Wirsbo recommend the steps taken and illustrated in the assembly instructions in order to ensure a secure and correctly fi tted Wirsbo Q&E joint.

Wirsbo Quick & Easy is a fi tting intended and designed only for Wirsbo pipes. Only genuine Wirsbo fi ttings, rings and expander tools should be used.

When Wirsbo Q&E fi ttings are used with pipes in concealed runs, they should be insulated to prevent condensation.

For further product information about the Wirsbo Q&E fi tting, please see the separate Wirsbo Q&E catalogue.

The fi ttings used with Wirsbo-PEX pipes must be approved connection fi ttings recommended by either Wirsbo or one of our retailers. Pipe inserts must always be used.

Assembling procedure:1. Slide the nut and the compression ring over the end of the pipe.2. Push the pipe insert into the pipe by hand. Ensure that the insert is pressed

in as far as the fl ange in order to get a secure joint. If manual pressure is insuffi cient a rubber hammer may be used.

3. Fit the pipe to the connector and tighten fi rstly by hand and then with the aid of a spanner, until the tightening torque increases noticeably.

Assembling a compression fi tting

Figures 42 and 43 Assembling a

compression fi tting, steps 1 and 2


Note When using compression fi ttings, pipe inserts must always be used. Tighten the nut in line with manufacturers recommendations. If for any reason the fitting is dismantled, a new compression ring

should be fi tted.

The WIPEX coupling is an excellent pipe fi tting, intended mainly for use with Wirsbo pipe dimensions greater than 32 mm.

Assembling procedure:1. Chamfer the square cut pipe end with a deburring tool or knife. Ensure that

the pipe end is clean and that any external burrs are removed.2. Unbolt the clamping sleeve, prise it apart as shown with pliers and remove

it from the coupling.3. Mount the sleeve on to the end of the pipe. Note that the clamping sleeve is

strong and will resist being prised apart. Therefore, once the bolt has been removed and the sleeve forced open, place the head of the bolt into the gap before removing the pliers, in order to keep the lugs apart.

4. Connect the pipe to the coupling pressing it as far as the locking groove.5. Reunite the clamping sleeve with the coupling ensuring that the locking

groove on the support sleeve of the coupling engages with the clamping sleeve.

6. Lubricate the threads on the bolt and the washer with a suitable lubricant and insert the bolt into position. Tighten until the lugs on the outer sleeve are drawn together.

Figures 44 and 45 Assembling a

compression fi tting, steps 3 and 4

Assembling a WIPEX coupling

Figures 46 and 47 Assembling a WIPEX

fi tting


Note Because the nut, bolt and washer are made of acid-resistant stainless steel,

the threads and the washer must be lubricated. For a correctly fi tted, secure connection follow the instructions enclosed

with the WIPEX coupling. O-rings are used for sealing all joints in the WIPEX assortment and are

supplied with the fi ttings. If a coupling is to be fi tted to some other component, seal the threaded joint with linen yarn, fl ux or a linseed oil based compound.

For further product information please consult the WIPEX catalogue.

Because cross-linked polyethylene cannot be welded or repaired with adhesives, if a pipe is accidentally sliced or punctured, the safest and simplest repairing method is to cut away the damaged area and replace it with a Wirsbo Q&E joint.

However if a pipe has been buckled, after for example being bent too far, an alternative repair method, which actually reforms the pipe and takes advantage of cross-linked polyethylenes unique thermal memory (see chap 1 above), can be applied as shown below. Reforming method: 1. Straighten the damaged section by hand2. Carefully heat the damaged area with a hot-air gun, rotating the gun

around the pipe throughout the process for an even application. Heat until the pipe has returned to its original shape or until the material begins to become transparent round its whole circumference. This will happen at around 130C. However see note below.

Figures 48-50 Assembling a WIPEX fi tting

Minor repairs


3. Allow the pipe to cool to room temperature before use. Using cold water or blowing cold air on the repaired section will accelerate cooling. Once cooled it will return to its original appearance and regain all of its strength. However see note below.

Note Do not use an open fl ame for heating. Use a hot-air gun. Do not heat Wirsbo-pePEX or Wirsbo-evalPEX pipes. They have an outer

oxygen diffusion barrier which, if heated, will be damaged. Keep heating to a minimum. It is not always necessary to heat the pipe

until it is transparent before it resumes its original shape. Note any change in the pipes surface. If heating has discoloured the pipe, this indicates that the material has been damaged and the pipe needs replacing.

When a hot-air gun is used, the factory calibrated tolerances are lost. Therefore the reheated section should not be used for joining to a fi tting. However Wirsbo Q&E joints, if mounted as recommended, can still be used.

The conduit and the PE-X pipe can be installed together or separately. If the conduit is installed on its own, check before it is concealed that it has not been deformed or otherwise obstructed. Also check that clamping has been carried out properly before inserting the water pipe (see also Chapter 5).

Useful tips The water pipe will be easier to

insert into the conduit, if the pipe end is cut into a sharp tongue about 150 mm long.

If insertion is found to be diffi cult, a drawing wire, attached to the pipe end and then threaded through the conduit beforehand, can be used to pull the pipe through.

Figure 51 Reforming a Wirsbo-PEX pipe

Inserting a PE-X pipe into a conduit

Figure 52 Pipe end with sharp tongue


One of the advantages of using Wirsbo-PEX Pipe-in-Pipe is that, if required, the water pipe can be replaced without causing structural damage to the building. Replacement is made easier if the conduit has been correctly installed. It should have been well secured, be one seamless run from manifold to draw-off point, and should have as few bends as necessary with bends being as gradual as possible (see chapter 5).

Before removing the pipe see useful tips below.Normally it is possible to pull out the pipe by hand but sometimes this

may prove diffi cult, for example in an installation where there are many sharp bends. If this is the case, having once disconnected the pipe from the manifold and faucet/mixing tap, and having removed the fi ttings from the manifold end of the pipe, take the following steps: 1. Pull out the termination elbow in order to expose more of the PE-X pipe.2. Mount the forked extender supplied by Wirsbo on a crowbar end as

shown.3. Insert protection in the form of, for example a piece of plywood, between

the crowbar and the wall. 4. Press the exposed pipe end into the fork and lock it with pliers if

necessary.5. Lever the crow bar downwards and pull out a section of pipe.6. Relocate the extender next to the wall and repeat steps 4 and 5. Repeat as

necessary or until the pipe has been totally removed from the conduit.

Replacing a damaged pipe

Figures 53-56 Replacing a damaged pipe



Once the pipe has been removed the new pipe can be inserted (see section above).

Useful tips Removing the old pipe is made easier if it is fi rst softened either by blowing

warm air or by running warm water through it. Installing a new Wirsbo-PEX pipe can be done at the same time as

removing the old one by connecting the pipes to each other and then pulling both pipes through at once. Connect the pipes, for example, with a 100 mm length of close-fi tting electrical cable using a staple gun as shown. Make sure that the pipe ends are as close to each other as possible and that the staples do not stick out on the other side of the pipe, as in both cases this could cause the pipe to catch on the inside of the conduit.

Taping the join to give it extra strength is permitted since it will be cut away later.



Pipe bending Wirsbo-PEX pipes are normally bent without the need for any special tool. If bends with small radii are necessary, a bending support should be used.

Alternatively, the pipes can be bent after being heated up in accordance with the procedure described below.

1. Heat the pipe carefully with a hot-air gun. Move the gun around the pipe throughout the process for an even application.

2. Heat the pipe until the material begins to become transparent where the pipe is to be bent, which will occur at around 130C.

3. Bend the pipe at once to the required angle. 4. Hold the pipe at the required angle and cool it with water or air. The

pipe will maintain the new shape. If it is heated once more it will resume its original shape.

Useful tips Where a sharp bend with a narrow radius is required, a fl exible support

should be placed in the pipe at the bending point prior to bending (step 3), in order to prevent the pipe from folding.

Note An open fl ame must not be used for heating the pipe. Do not heat more than necessary. If heating has discoloured the pipe,

this indicates that the material has been damaged and the pipe must be replaced.

Note any change in the surface of the pipe during the heating operation. Do not heat Wirsbo-pePEX or Wirsbo-evalPEX pipes. They have an outer

oxygen diffusion barrier which, if heated, will be damaged.

The fi gures below give the minimum bending radius for pipe dimensions used in the Wirsbo Tap Water System. D

o = outer diameter.

Cold bending 8 x DoCold fi xture bending 5 x DoHot bending 5 x Do

Note It is not practical to manually bend dimensions larger than 32 mm to

the minimum bending radius. The radius with which Wirsbo-PEX pipes can be bent, depends on the

installation temperature, pipe wall thickness and type of pipe.

All pipe systems should be fi lled slowly in order to expel as much air as possible. In order to remove any remaining air pockets, venting the system afterwards is recommended. Examine the coupling points and pipe runs whilst fi lling the system.

Note In extremely cold areas the system should be protected at all times

from freezing.

PE-X systems can be pressure tested in accordance with the local standards and regulations which apply to metal pipes. However there is a more appropriate method of testing, which takes into account the fact that a PE-X system expands and contracts radially when pressure is applied. This is as follows:

Filling the system

Pressure test

Minimum bend radius


Vent all air from the system and pressurise the system to 1.5 x operating pressure. Maintain this pressure for 30 minutes and inspect the joints and pipe runs. Quickly drain off water to reduce the pressure to 0.5 x operating pressure and close the drain valve. If the pressure rises to a value higher than 0.5 x operating pressure and remains constant, this indicates that the system is watertight. Leave the system pressurised for 90 minutes keeping it under continued inspection. If the pressure drops during this period, this indicates leakage in the system.

Fire protection

Diagram 8 Pressure testing

When pipes are installed in a fi re-resistant construction/structure, fi re-resistance ratings must be maintained.

In general:

Pipes should be run within one continuous length of conduit through a hole in a construction.

The space between the water pipe and the conduit must be sealed to prevent the spread of fumes caused by fi re between fi re cells. This seal may conveniently be mounted at the end of the conduit.

The gap between conduit and wall must be fi lled with an incombustible homogenous material such as mortar.

In order to prevent the spread of fumes, spaces between building structures and pipes and between separate pipes should be large enough to allow each conduit to be sealed separately.

Note All fire precaution has to be carried out according to regulations by

local authorities.

Operating pressure

1.5

1.0

0.5

00 20 40 60 80 100 120

Time (min)


Material Properties

Table 13 Material properties

Mechanical properties Value Unit Standard Den sity 0.938 g/cm3 Ten sile strength (at 20C) 1926 N/mm2 DIN 53455 (at 100C) 913 N/mm2 Mod ulus of elas tic ity E (at 20C) 800900 N/mm2 DIN 53457 (at 80C) 300350 N/mm2 Elongation on failure (at 20C) 350550 % DIN 53455 (at 100C) 500700 % Im pact strength (at 20C) No failure kJ/m2 DIN 53453 (at 140C) No failure kJ/m2 Mois ture ab sorp tion (at 22C) 0.01 mg/4d DIN 53472 Co ef fi cient of fric tion with steel 0.08-0.1 Sur face en er gy 34 x 103 N/m Oxy gen perme abil ity (at 20C) 80 m3 mm/m2 x day x atm ASTM D1434 (at 55C) 250 m3 mm/m2 x day x atm ASTM D1434

Thermal properties Tem per a ture range 100 to +110 C Co ef fi cient of linear ex pan sion (at 20C) 1.4 x 104 m/mC Co ef fi cient of linear ex pan sion (at 100C) 2.05 x 104 m/mC Sof ten ing tem per a ture +133 C Spe cifi c heat 2.3 kJ/kgC Coeffi cient of ther mal con duc tiv ity 0.35 W/mC DIN 4725

Electrical properties Spe cifi c internal re sis tance (at 20C) 1015 m Die lec tric con stant (at 20C) 2.3 Die lec tric loss fac tor (at 20C/50 Hz) 1 x 103 Rupture voltage (at 20C) 6090 kV/mm

Forces of expansion and contraction

These can appear when a pipe has been installed at an ambient tempe-rature of about 20C and is then sud-denly exposed to a water temperature of 90C. Forces can appear during both expansion and contraction. However if the temperature changes gradually or if the pipe can give sideways, the strength of the forces will diminish. Naturally sideways movement can be infl uenced by pipe length and by clamping, but note that the length of the pipe has no bearing on the size of the force.

Dimension Max force mm N 22x3.0 250 25x2.3 200 25x3.5 300 28x4.0 400 32x2.9 400 32x4.4 500 40x3.7 600 40x5.5 800 50x4.6 900 50x6.9 1300 63x5.8 1500 63x8.7 2100 75x6.8 2100 90x8.2 2900 110x10.0 4400

Table 14 Forces of expansion and contraction

Chapter 7Wirsbo-PEX Technical data


Chapter 8Quality Assurance, tap water approvals

Wirsbo-PEX approvals for hot and cold water installations have been issued in:

Germany The NetherlandsSweden DenmarkNorway AustriaSwitzerland BelgiumFrance PortugalGreat Britain SpainFinland PolandUSA CanadaChina AustraliaIceland HungaryBulgaria EstoniaLithuania LatviaCroatia SlovakiaRumania KazakhstanRussia The UkraineMalaysia JapanHong Kong

Standards and other quality guidelines relating to Wirsbo-PEX

The following published guidelines are available at present:

1) DIN 16892 - 2000 (Germany)2) DIN 16893 - 2000 (Germany)3) DVGW Arbeitsblatt W 544 - 1988 (Germany)4) DVGW Arbeitsblatt W 534 - 2000 (Germany)5) Australian Standard 2537 - 1994 (Australia)6) Australian Standard 2492 - 1994 (Australia)7) Guide Technique Specialis TE Q/1 No 30142 (France)8) UNE 53381 (Spain)9) ASTM F 876 -8410) F877 -84 (USA)11) KIWA CRITERIA No. 41 (Netherlands)12) NORM B 5153 (Austria)13) Type approval requirements for hot water pipes - NKB Product rule 3 (Nordic countries) 14) Type approval requirements for mechanical fi ttings of metal for PEX and PB pipes for tap water installations - NKB Product rule 18 (Nordic countries) 15) UNI 9338 (Italy)16) UNI 9349 (Italy)

The following standards are under preparation:

17) prEN 1231818) ISO/DIS 15875


Production of Wirsbo-PEX is monitored by the following bodies:

1) MPA Darmstadt (Germany)2) Statens Provningsanstalt (Sweden, Norway, Denmark, Finland)3) Centre Scientifi que et Technique du Btiment (CSTB) (France)4) KIWA (Netherlands)5) National Sanitation Foundation (NSF) (USA)6) Plastico y Caucho (Spain)7) sterreisische Kunststoff Institut (KI) (Austria)8) Laboratrio Nacional de Engenharia Civil (LNEC) (Portugal)9) BCCA Belgium10) QAS Australia


Chapter 9Conversion tables

1.06299 27 685.8 1.10236 28 711.2 1.14173 29 736.6 1.1811 30 762.0 1.22047 31 787.4 1.25984 32 812.8 1.29921 33 838.2 1.33858 34 863.6 1.37795 35 889.0 1.41732 36 914.4 1.45669 37 939.8 1.49606 38 965.2 1.53543 39 990.6 1.5748 40 1016.0 1.61417 41 1041.4 1.65354 42 1066.8 1.69291 43 1092.2 1.73228 44 1117.6 1.77165 45 1143.0 1.81102 46 1168.4 1.85039 47 1193.8 1.88976 48 1219.2 1.92913 49 1244.6 1.9685 50 1270.0 2.00787 51 1295.4

2.04724 52 1320.8 2.08661 53 1346.2

Documents

Basic Tapwater Manual