RAKtherm PPR and PEX Catalogue-Min
RAKtherm PPR and PEX Catalogue-Min
RAKtherm PPR and PEX Catalogue-Min
Piping Systems
We exist to be a leader in everything we do!
from
RAKtherm
to Worldwide. "
2
Welcome to
With over 50 years of experience in plastic pipe and fitting manufacturing in Saudi
Arabia, Egypt and Jordan, Tahweel™ has launched it’s first integrated PP-R and PE-X
pipes & fittings system for servicing a booming construction sector worldwide and in
the Middle East in particular under the trade name of RAKtherm® with 40,000 m man-
ufacturing complex based in Ras Al Khaimah and sales branch office based in Shar-
jah, Tahweel™ is well on its way to become the regional leader in water supply
and drainage systems.
RAKtherm is a versatile, and comprehensive system for delivery of water and other fluids, used
in applications of pressurized hot and cold water delivery as well as under floor heating in all
modern residential, commercial, and industrial buildings.
RAKtherm® offers the widest range of PP-R and it’s complimentary PE-X piping systems in
the Middle East and North Africa, including Multilayer oxygen barrier pipes and Aluminum
composite pipes in addition to the conventional piping systems.
We believe the quality of products and the support services provided at RAKthem® are our
main advantages. This is translated in a very wide range of products that are produced with
state-of-the-art machinery from the most reputed sources, and a very high-tech quality
control system which ensures that this quality is always maintained in addition to well trained
and highly motivated staff on all levels of the company that are always committed to premium
service at any time.
3
TABLE OF CONTENTS
1. SYSTEM... AN OVERVIEW..................................................................................8-17
Introduction.......................................................................................................................................8
RAKtherm piping system are used in...............................................................................................8
RAKtherm piping system are also used in.......................................................................................8
RAKtherm Materials.........................................................................................................................9
RAKtherm PP-R an ideal solution....................................................................................................9
Service life against hot water application........................................................................................10
An investment for your family’s health...........................................................................................14
RAKtherm your environment friendly choice..................................................................................14
Corrosion & chemical resistance....................................................................................................14
RAKtherm, Mechanical and thermal properties.............................................................................15
Raktherm aluminum composite pipe technology...........................................................................15
Easy reliable installation.................................................................................................................16
Service & support............................................................................................................................17
2. QUALITY ASSURANCE........................................................................................18-21
3. PRODUCT RANGE............................................................................................22-25
Pipe PN 10......................................................................................................................................22
Pipe PN 16......................................................................................................................................22
Pipe PN 20......................................................................................................................................23
Pipe PN 25......................................................................................................................................23
Stabi Pipe PN 20.............................................................................................................................23
Stabi Pipe PN 25.............................................................................................................................24
Stabi Pipe UV PN 20........................................................................................................................24
Stabi Pipe UV PN 25........................................................................................................................24
Larger Pipe Sizes............................................................................................................................25
4
TABLE OF CONTENTS
3. PRODUCT RANGE............................................................................................26-34
Socket.............................................................................................................................................26
Reducer Socket.........................................................................................................................26-27
Elbow 90o.......................................................................................................................................27
Elbow 45o........................................................................................................................................27
Elbow Reducer................................................................................................................................27
Spigot Elbow 90o.............................................................................................................................28
Equal Tee........................................................................................................................................28
Reducing Tee.................................................................................................................................28
End Cap...........................................................................................................................................29
Cross Tee........................................................................................................................................29
Female Union Both Ends Welding .................................................................................................29
Saddle Socket .............................................................................................................................29
Flanges Adaptor.............................................................................................................................30
End Plug.........................................................................................................................................30
Over Bridge Bow.............................................................................................................................30
(Smart) Over Bridge Bow..............................................................................................................30
Bracket For Pipe............................................................................................................................30
Clamp For Pipe...............................................................................................................................31
Bend..............................................................................................................................................31
PPR Manifold.................................................................................................................................31
PPR Ball Valve...............................................................................................................................31
Transition Piece Round-Female....................................................................................................32
Transition Piece Round-Female With Hexagon Socket...............................................................32
Transition Piece Round-Male.........................................................................................................32
Transition PPR Male Union Brass with Ribs.................................................................................33
Transition PPR Female Union Brass with Ribs.............................................................................33
Transition PPR Male Union............................................................................................................33
Transition PPR Female Union........................................................................................................33
Transition Piece Round-Male With Hexagon Socket...................................................................34
Transition Female Tee....................................................................................................................34
Valve Body ......................................................................................................................................34
Transition Elbow Female..............................................................................................................35
Wall Mount Elbow ..........................................................................................................................35
5
TABLE OF CONTENTS
3. PRODUCT RANAGE.........................................................................................35-40
Transition Elbow Male....................................................................................................................35
Horizontal Wall Mount Group.........................................................................................................36
Vertical Wall Mount Group............................................................................................................36
Female Socket with loose nut........................................................................................................36
Female elbow with loose nut..........................................................................................................36
Concealed Ball Valve.....................................................................................................................37
Stop Globe Valve ............................................................................................................................37
Concealed Valve..............................................................................................................................37
German Concealed Valve ..............................................................................................................37
Hidden Concealed Valve.................................................................................................................38
Ball Valve........................................................................................................................................38
New Ball Valve...............................................................................................................................38
Check Valve.....................................................................................................................................38
Concealed Valve Extension.............................................................................................................39
Brass Nipple Extension...................................................................................................................39
Angle Valve V8 ................................................................................................................................39
Angle Valve V5 ................................................................................................................................39
Angle Valve V6................................................................................................................................39
Concealed Shower Mixer................................................................................................................40
RAKtherm Italian Shattaf................................................................................................................40
Brass Bib Cock 1/2"........................................................................................................................40
Brass Bib Cock 1/2" ( Nickle ).........................................................................................................40
6. INSTALLATION.................................................................................................54-61
Introduction...........................................................................................................................54
RAKtherm pipes joint Assembles...................................................................................................54
Pipe joints with threaded fittings ...................................................................................................55
General Guidelines for the installation of pipe work inside building ............................................55
Linear Expansion.............................................................................................................................56
Formula For Calculation of linear expansion.................................................................................56
Linear Expansion calculation example...........................................................................................56
Insulation of RAKtherm pipes.........................................................................................................59
Insulation of RAKtherm pipes for cold water applications............................................................59
Protection of RAKtherm hot water pipes against heat loss .........................................................60
RAKtherm pressure test................................................................................................................60
Transport & storage........................................................................................................................61
Introduction...................................................................................................................................62
Your Unparalleled Advantage........................................................................................................63
RAKtherm PEX Piping System Features......................................................................................64
PEX Monolayer Pipes......................................................................................................................65
Adaptor..........................................................................................................................................66
Male & Female Adaptor.................................................................................................................67
Male Elbow ....................................................................................................................................67
Male Coupling.................................................................................................................................67
Pex union.........................................................................................................................................67
Pex Female Adaptor.......................................................................................................................68
Air Release Valve............................................................................................................................68
End Plug .........................................................................................................................................68
Female Elbow..................................................................................................................................68
Pex Ball Valve with Union (Red & Blue)..........................................................................................69
Ball Valve (Red/Blue)......................................................................................................................69
7
PIONEER IN PP-R AND PE-X PIPING SYSTEM
German Technology, with the widest range of PP-R piping system using the
latest innovation technique .
INTRODUCTION
RAKtherm..a versatile, and comprehensive system for water and other fluid delivery, is used in applications of
pressurized warm or cold water in all modern residential, commercial, and industrial applications. The creative
solutions provided by RAKtherm in its product base renders it a leader in the construction industry.
Indoor and outdoor swimming pools, gyms and their water filtration circuits and water installations.
Piping networks for all types of irrigation and agriculture applications and pressurized networks.
Piping networks for all types for industrial applications for the delivery of aggressive chemicals including many
acidic, alkaline and other reactive and corrosive chemicals.
Piping networks for all types of chilled water application and cooling systems networks.
Piping networks for heating installations from the boiler outlets or water heating unit up to the individual
radiators or heat exchangers.
8
ENGINEERED PIPING
SYSTEM FOR YOUR
PLUMBING CHALLENGES
RAKTHERM MATERIALS
RAKtherm pipes and fittings are made with a material called polypropylene which is used extensively in food and
medical industries because of its safe properties.
A random copolymer grade of polypropylene called PP-R was especially developed for engineering applications
with certain stringent requirements. PP-R is characterized by excellent physical and chemical properties even at
elevated temperatures. Compression strength, elasticity, corrosion, chemical and heat resistance are just some
of these properties. RAKtherm PP-R system has proven its high resilience even at the most extreme conditions.
These factors and more, make RAKtherm PP-R the ideal material for the delivery of potable hot and cold water in
your home, office, or factory.
9
SYSTEM
SYSTEM
ANOVERVIEW
OVERVIEW
TABLE 1.1
SERVICE LIFE AGAINST HOT WATER APPLICATION
UNDER CONSTANT PERIOD ( SERVICE CONDITION)
PERMISSIBLE WORKING PRESSURES (BARS)/1.25 SAFETY FACTOR)
Years of
Temperature PN10 PN16 PN20 PN25
Service
1 Year 10°C 21.1 33.4 42.0 52.9
10
ULTIMATE PIPING SOLUTIONS
TABLE 1.1
SERVICE LIFE AGAINST HOT WATER APPLICATION
UNDER CONSTANT PERIOD ( SERVICE CONDITION)
PERMISSIBLE WORKING PRESSURES (BARS)/1.25 SAFETY FACTOR)
RAKtherm
RAKtherm RAKtherm Stabi Pipe RAKtherm Stabi Pipe
Standard Pipe
Standard Pipe RAKtherm standard pipe RAKtherm standard
SDR 7.4
SDR 11 SDR 6 pipe SDR 5
ISO S3.2
ISO S5 (ISO S2.5) (ISO S2)
Nominal Pressure Class
11
SYSTEM OVERVIEW TABLE 1.2
12
TABLE 1.2
RAKtherm
RAKtherm Stabi Pipe RAKtherm Stabi Pipe
Standard Pipe
RAKtherm standard pipe RAKtherm standard
SDR 7.4
SDR 6 pipe SDR 5
ISO S3.2
(ISO S2.5) (ISO S2)
Nominal Pressure Class
13
ANTI-CORROSIVE AND CHEMICAL RESISTANCE
Anti – corrosive and high chemical resistance properties ensuring durability
avoiding rapid breakage and expensive maintenance.
AN INVESTMENT
FOR YOUR FAMILY’S HEALTH
At the highest level of RAKtherm’s priorities is maintaining the quality of water that reaches your family , PP-R
as a material, is inert by nature and does not, in any way, react or affect potable water, as compared
with other materials used in conventional piping systems that can corrode, react chemically, or seep certain
contaminants into the water system, affecting the health and safety of the potable water. This ensures
continuous hygienic potable water for you and your family.
RAKTHERM,
YOUR ENVIRONMENT FRIENDLY CHOICE
Heavy metals such as nickel and chrome negatively impact the environment, plated metal inserts, previously used in
fittings, no longer find their way into the RAKtherm product line (consistant with BS 6920). In addition,RAKtherm
pipe and fitting materials can be 100% recycled, and used again in other products (consistant with DVGW
working sheet W270). These are just a few of the many ways that RAKtherm contributes to the welfare of
our environment.
RAKTHERM IS ENGINEERED
FOR HIGHER LEVEL OF PIPING
SERVICE PERFORMANCE
14
RAKTHERM
MECHANICAL
AND THERMAL
PROPERTIES
In accordance with its areas of application, RAKtherm piping systems is designed for continuous
temperatures of 0°C to 900 C, and short-term peak temperatures of up to 100° C and a service life of a
minimum of 50 years. Therefore RAKtherm piping system is suitable for all types of chilled and heating
water networks. More precise details are summarized in table (1.1 & 1.2)
For exposed and open air installations under direct sunlight or UV radiation, RAKtherm remains
physically stable through a specially developed external black layer (UV resistant), in adherence with
the aluminium layer.
15
SYSTEM OVERVIEW
Pipe networks for industry and applications where transport of aggressive fluids is
required
ADVANTAGES:
Length extension reduced by at least 80% compared with standard pipes.
Higher flow rate increased by 20% with the same external diameter and wider flow area insde the
pipe.
Supports intervals can be increased wiht less of mounting clips are used compared with
plastic pipes.
16
HIGH-END QUALITY
FOR INTENSIFIED
BRAND INTEGRITY
17
MAINTAINS THE HIGHEST
STANDARD OF QUALITY
Maintains comprehensive quality control system from
designing the required specifications, sourcing the
highest quality raw materials to manufacture the
product, careful packing and proper storage up to
shipping to the customer
It is our mission at RAKtherm to maintain the highest levels of quality through clear operating
procedures, work instructions, forms and records throughout the company. Statistical quality control and
sound documentation ensures traceability is maintained anytime in the future. This means that all
corporate and plant functions within RAKtherm, whether commercial, or operational, are required
to be clearly stated and documented, ensuring that the quality of your product is never compromised
or been left to chance.
DIN 1988 DVGW Code of Practice (Drinking water supply systems; materials, components, appliances,
design and installation).
DIN 8078 Polypropylene (PP) pipes; general quality requirements testing &
chemical resistance of pipes and fittings.
DIN 169621Ptl Pipe joint assemblies and fittings for type 1 & 2 polypropylene (PP) pressure
pipes; bends produced by segment inserts for buff welding dimensions.
18
DVS 2207 Welding of thermoplastic pipes and fittings.
DVS 2208 Welding machines & devices for thermoplastic pipes and fittings.
BS 6920 Suitability of non-metallic products for use in contact with water intended
for human consumption with regard to their effect on the quality of the water.
OHSAS 1 8001 British standard for Health and safety management system.
QUALITY GUARANTEE
RAKtherm always maintains the highest standards of quality for its users. To support this, RAKtherm
warrants a 15-year guarantee for all its piping network components from the date of purchase. (Please
ask your local representative for details)
19
QUALITY ASSURANCE
RAKtherm is fully equipped with quality control laboratories that include state-of-the-art
measurement and performance evaluation instrumentation to aid in controlling and achieving specification
compliance. Our engineers utilize these ultra-modern high-tech equipment to run dimensional, physical
and chemical property tests. For example, accelerated hydrostatic testing on samples taken from production
runs, using technically advanced equipment, is just one of many tests that is conducted on a continuous basis
to simulate the aging of piping systems under working conditions.
We also strongly believe and always nourish the environment of continuous quality improvement in every
aspect of our business and the enhancement of our employee knowledge and skills to achieve their best in
individual performance and teamwork. This is just a glimpse of the meaning of quality at RAKtherm, which
is committed to your complete satisfaction through consistently exceeding your expectations through the
understanding of your needs and requirements.
20
INTELLIGENT QUALITY
MANAGEMENT SYSTEMS
FOR PRODUCT COMPETENCY
21
GROUNDBREAKING PIPING
APPROACH THROUGH INNOVATION
RAKtherm Pipe SDR 7.4 PP-R PN 16 Pipe Series 5 According To DIN 8077/78
Outer
Wall Thickness Intrernal Diameter Water content
Art-.No. Dimension Packing Unit Diameter Kg / mt
(S) (ID)mm I/mt
(OD)mm
P16-20 20 mm 100 mts 20 2.8 14.4 0.163 0.148
P16-25 25 mm 100 mts 25 3.5 18 0.254 0.230
22
RAKtherm Pipe SDR 6 PP-R PN 20 Pipe Series 6 According To DIN 8077/78
Outer
Wall Thickness Intrernal Diameter Water content
Art-.No. Dimension Packing Unit Diameter Kg / mt
(S) (ID)mm I/mt
(OD)mm
P20-20 20 mm 100 mts 20 3.4 13.2 0.137 0.172
P20-25 25 mm 100 mts 25 4.2 16.6 0.216 0.266
Outer
Wall Thickness Intrernal Diameter Water content
Art-.No. Dimension Packing Unit Diameter Kg / mt
(S) (ID)mm I/mt
(OD)mm
P25-20 20 mm 100 mts 20 4.1 11.8 0.111 0.198
P25-25 25 mm 100 mts 25 5.1 14.8 0.178 0.307
23
PRODUCT RANGE
24
LARGER PIPE SIZES
NOW AVAILABLE
25
FITTINGS & ACCESSORIES
26
PRODUCT RANGE
Elbow Reducer
27
Spigot Elbow 90°
Cross Tee
Female Union
both ends welding
End Plug
30
PRODUCT RANGE
Bend
PPR Manifold
31
SPECIALLY DEVELOPED BRASS INSERTS
Innovative brass inserts specially designed to provide better brass connections
to ensure modified strength to withstand higher tightening torque without breakage
or deformation.
Transition Piece
Round-Female
Art-.No. Dimension Packing Unit Kg / Piece
AF-201/2 20 mm x 1/2” 10 pcs 0.058
AF-203/4 20 mm x 3/4” 10 pcs 0.072
Transition Piece
Round-Female With
Hexagon Socket Art-.No. Dimension Packing Unit Kg / Piece
AF1-321 32 mm x 1” 5 pcs 0.236
AF1-401 40 mm x 1” 5 pcs 0.240
Transition Piece
Round-Male
Art-.No. Dimension Packing Unit Kg / Piece
AM-201/2 20 mm x 1/2” 10 pcs 0.068
AM-203/4 20 mm x 3/4” 10 pcs 0.081
32
FITTINGS & ACCESSORIES
33
FITTINGS & ACCESSORIES
Transition Piece
Round-Male
With Hexagon Socket Art-.No. Dimension Packing Unit Kg / Piece
AM1-321 32 mm x 1” 5 pcs 0.227
AM1-401 40 mm x 1” 5 pcs 0.231
Tank Connector
Art-.No. Dimension Packing Unit Kg / Piece
TCM-321 32mm x 1 3/4 5 pcs 0.289
Valve Body
V4-321 32 mm x 1” 1 pc 0.141
V4-4011/4 40 mm x 1.1/4” 1 pc 0.254
34
PRODUCT RANGE
35
PRODUCT RANGE
36
Concealed Ball Valve
V1-32 32 mm x 1” 1 pc 0.295
V1-40 40 mm x 1.1/4” 1 pc 0.549
Y Globe Valve
37
PRODUCT RANGE
Concealed Valve
V2-32 32 mm x 1” 1 pc 0.433
V7-32 32 mm 1 pc 0.378
Ball Valve
Art-.No. Dimension Packing Unit Kg / Piece
BV-20 20 mm 1 pc 0.350
BV-25 25 mm 1 pc 0.500
BV-32 32 mm 1 pc 0.655
BV-40 40 mm 1 pc 0.900
BV-50 50 mm 1 pc 1.313
BV-63 63 mm 1 pc 2.530
38
PRODUCT RANGE
Check Valve
Concealed Valve
Extension
39
PRODUCT RANGE
Angle Valve V8
Angle Valve V5
Angle Valve V6
40
RAKtherm Itallian
Shower Mixer
41
WELDING ACCESSORIES
Marking Tool
Welding Device
42
WELDING ACCESSORIES
Peeling Tools
Art-.No. Dimension Packing Unit Kg / Piece
P-WT2-2025 20 - 25 mm 1 pc 0.340
P-WT2-3240 32 - 40 mm 1 pc 0.470
P-WT2-5063 50 - 63 mm 1 pc 1.060
P-WT2-7590 75 - 90 mm 1 pc 1.160
P-WT2-110 110 mm 1 pc 1.660
Repair Pin
43
Professional Pipe Cutter
Pipe Cutter
Pipe Cutter
Pipe Cutter
44
RAKTHERM UV SYSTEM
THE FIRST PPR PIPING SYSTEM INTEGRATED WITH ANTI-UV
TECHNOLOGY
RAKtherm is versatile and comprehensive piping systems for water and other fluid delivery
applications used for pressurized hot and cold water in modern residential, commercial,
and industrial piping installations.
The creative solutions delivered by RAKtherm towards its’ products makes them the global
leader in the construction industry.
RAKtherm has proven its’ high resilience even at the most extreme conditions; these factors
and more makes RAKtherm as the ideal system for delivery of potable hot and cold water.
RAKtherm pipes and fittings are extensively used in food and medical industries owing to its’
harmless and safe properties.
We came up to the new generation pipes to serve the continuous development and meet the
demand of the construction industry.
45
PRODUCT RANGE
With widest range of brass fittings for PEX, from sizes 16mm to 32mm
46
FEATURES
The creation of RAKtherm anti-UV fittings came up to supply the demand for outdoor piping
applications; this will complete the entire selection of anti-UV piping systems of the industry.
And now, RAKtherm has introduced one of the very first integrated full systems with anti-UV
protection for fittings. It will administer a full network of anti-UV pipes integrated with anti-UV fittings for
maximum outdoor piping performance.
Our influential approach which redefined the piping service performance has initiated
towards new level of excellence setting the highest standard of credibility and authenticity.
The Safest and Longest Lasting Piping Solution for Outdoor Applications
We have carefully blended and formulated our own PP-R resins (polypropylene-random), integrated
with special technology of black anti-UV layer for higher resistance against UV sunlight. Absolutely free
from heavy metals and toxic chemicals; proven to be non-toxic and chemically stable even at elevated
temperature. This is the safest piping solution in the market excellent for outdoor applications of hot
and cold water applications.
PP-R engineered with black anti-UV layer, is a material with excellent chemical resistance which
does not react to most chemicals, with non-corrosive properties, proven to be physiologically and
microbiologically harmless.
PP-R 80 is engineered with black anti-UV component were developed to withstand hot and cold water
applications under extreme temperatures of 0°C to 90°C at service life of minimum 50 years. Therefore,
RAKtherm anti-UV system is a superior piping solution for hot and cold water outdoor installations. The
anti-UV black technology for lower linear expansion rate and contraction, that remains physically stable
under controlled expansion.
47
FEATURES
The revolutionary black component reduces expansion and contraction for longer piping service
performance.
A fully integrated piping network designed for maximum anti-UV resistance caused by the bad effects
of UV sunlight.
The longest-lasting piping solution with anti-UV properties available in the global piping market.
The welding process is easy, the same with the normal PPR fittings.
RAKtherm is the very first and the only manufacturer of anti-UV fittings that has been
registered in German laboratory.
48
WELDING
RAKtherm’s Welding
Devices and Tools
Our welding devices and tools are equipped to
establish proper fusion of pipes and fittings
and get the benefit of full service warranty.
Assembly of the RAKtherm system is easily done by electric heating tools (threaded inserts), mounted on the
RAKtherm welding device...a process called fusion welding.
Fusion Welding requires the heating of the pipe and its respective fitting socket simultaneously to the right fusion
temperature. A homogeneous melt between two parts occurs and a uniform layer is formed. These parts are there-
after joined easily by inserting the male part into the female part. This combination is held in place till the parts cool
down to ambient temperature and become one. This process is repeated throughout the network of pipes and fit-
tings at the construction site and combined with other units until a closed efficient water delivery system is formed.
This technique permits joining to be carried out with simple equipment supplied by your local RAKtherm
agent or representative. Needless to say, parts to be welded must have the same properties, and therefore, to avoid
failures in the network and guarantee a long and trouble-free service life, never mix RAKtherm pipes or fittings
with other brands.
It is widely acknowledged that, in order to establish a consistent and structurally sound joint, it is necessary to fol-
low RAKtherm fusion welding preparation procedure. If the appropriate procedures are followed, contamination
and disturbance effects that might weaken the fusion mechanism will be avoided.
49
USING RAKTHERM WELDING DEVICE & TOOLS
Only use original RAKtherm welding devices and welding tools to ensure proper fusion
of pipes and fittings.
Take out the device and other required equipment from the portable storage box.
Before heating up the device, mount and fi nger tighten the threaded inserts so as to hold
the tools firmly.
Never install a tool in a location on the device which makes it extend outside the edge of
the tongue of the device! Always place the larger size diameter tools on the inner positions of
the welding device. This is especially true for diameters over 40 mm
Plug in and switch on welding device. At this point,both thermostat and control lamps will
light up. Adjust the thermostat to the correct fusion temperature at 26cFC. The thermo-
stat lamp goes off when the temperature reaches the set temperature. Depending on the
ambient temperature, the heating-up process should take between 5 to 25 minutes. Allow
a few more minutes in extreme cold cases.
Note that DVS-Welding Guidelines state that the temperature of the welding device has to
be checked at its application area before starting the welding process or whenever a new
tool is to be changed. It is recommended that this is done through the use of RAKtherm
temp-pen or another qualified surface thermometer.
Use an Allen Key to tighten up the tools. Do not use pliers or any other tools for this job.
This can scratch or damage the stick-free coating on the device and insert.
After finishing the welding process and the device has been switched off, wait until it has
cooled down before reusing or storing it away.
50
WELDING GUIDELINES
Instruction set for installation of RAKtherm pipes and fittings
Always keep the device in a dry and clean place. The device need to be used when
completely dry.
To avoid shock hazards, never use a device that has been exposed to water or other
fluids or in rain. Moreover, never clean the device with water or handle the device with wet
hands.
Never use water to cool down the device temperature, even after it has been unplugged.
This could damage the thermostat.
It is necessary to maintain the device clean at all times, especially in the locations where
the threaded inserts (tools) are mounted. Failure to do so may result in improper contact
between the inserts and device, and a resulting ineffi cient heating of the inserts and
inadequate welding thereof. Cleaning should be done with a paper or non fibrous cloth and
alcohol.
Durable and proper joining with the device can only be guaranteed when the tools and the
tongue are assured of perfectly good condition. It is recommended to replace any defective
device or tool.
Never attempt to open a defective device. Let the expert hands of RAKtherm’s engineers
help in assessment of the device’s qualification and if possible make the necessary
repairs.
51
WELDING
20 14 5 4 2
25 15 7 4 2
32 16.5 8 6 4
40 18 12 6 4
50 20 18 6 4
63 24 24 8 6
75 26 30 8 8
90 29 40 8 8
110 32 50 10 8
125 40 60 10 8
When the outdoor temperature is below 5°C, the heating time according to DVS 2207 part 11 should be
increased by 50%.
1. Use RAKtherm pipe cutter to cut the pipe. Make sure that a straight and clean pipe end results
and not at a skewed angle. This is to ensure that the welding adheres to the right conditions.
The joining process during RAKtherm fusion welding can be divided into three stages:
For successful joining of pipes, at least three preparation stages must be followed:
Firstly, pipe ends must have properly fi nished squared ends as apposed to
having a chamfered or broken edge. This ensures that the central cold zones come in full
contact with the welding tools and proper heat conduction will accordingly be achieved.
Before welding Stabi composite pipes peel-off the aluminum polypropylene layer
completely.
Finally, the pipe and fitting should be clamped during welding to eliminate relative
movement. This ensures that the molten polymer is allowed to fuse fully at the fusion
interface, developing a strong joint.
52
WELDING
2. Mark the welding depth with a pencil and measurement plate which are provided with the
RAKtherm welding kit.
3. Enter the end of the pipe into the tool upto the marked depth without twisting it and
simultaneously and also without twisting, push the fitting onto the heating tool,observing the
general guidelines for heating up times outlined in table 4.1.
Timing for heating should not start until the pipe and fitting reaches to the marked welding depth.
Both fitting and pipe should be heated for a set time, known as the heating time. When heating
time is complete, the pipe and fitting should be removed from the heating tool, and pressed
together to the marked welding depth for a few seconds without twisting a homogeneous
structure of the same material is thereupon formed.
The major alignment should be done before insertion of the pipe and fitting. Use fusion time for
minor alignment before fusion is complete and the assembled parts have cooled. Never
mechanically stress the welding joint before cooling time.
A cross-section of a properly welded RAKtherm joint will normally show a smooth transition
between the two initial parts. This is because the components have uniformly melted and fused
into each other to form one single piece.
Drill out the pipe at the welding point with a spiral drill bit. If necessary, clean the hole from any burrs.
Caution is to be taken in drilling the correct depth and diameter see table 4.2. When drilling, make sure
that the opposite pipe wall is not reached, otherwise, the pipe will be damaged.
After drilling, remove the remaining aluminum at the entrance of the hole with a chamfering device.
Heat up the pipe with the tool for 30 seconds. Subsequently, heat the saddle along with the external
surface of the pipe for another 20 seconds, total of 50 sec for the pipe. Make a light pressure with the
saddle on the tools. Make sure that the entire surface is in contact with the heating tool.
After finishing the heating phase, remove the welding unit and insert the welding saddle nozzle into the
heated drilled pipe hole. Fix under light pressure, avoiding rotation for an additional 30 sec.
53
For RAKtherm Stabi pipe
The system may be exposed to full load after 15 minutes of welding.
TABLE 4.2:
SDS1-7525 30 20 20 30 20
SDS1-7532 30 20 20 30 25
SDS1-9025 30 20 20 30 20
SDS1-9032 30 20 20 30 25
54
INSTALLATION GUIDE
Complete installation guide with photo illustration for engineers and plumbers that leads through
the easiest process of installation.
INTRODUCTION
Water service lines are connections that lead from the water mains to the building plumbing network. The service
line consists of all pipes, valves, and fittings between the main water cabinet through the meter, and ending at
the individual outlets or endpoints.
DIN 1988 Parts 1 &3 apply to drinking water supply systems inside buildings and their networks. It specifies
requirements for design, installation, operation and maintenance of such systems in addition to alterations
to these systems. It also gives particular attention to materials, components and appliances installed to
supply a building with potable water. Designers and installers should make sure that only such required
equipment and appliances are installed ensuring proper economic and technically qualified functioning of the
system is maintained.
When installation is executed, RAKtherm instructions should be strictly followed. Additionally, the fol-
lowing must be readily available:
A building site plan; engineering drawing of each floor including cellars (plan view), with simplified
pipe work diagram and sectional drawings;
A detailed pipe network diagram showing length of pipe runs,pipe nominal sizes, bore diameters, material,
draw-off points (type, number and sizes or bore diameter), minimum flow pressure required, and the
fitting group as defi ned in the of DIN 4109 series of standards, where necessary.
55
TABLE 5.1
OPERATING CONDITIONS FOR PIPES & PIPE JOINT ASSEMBLIES
Rnage of Working
Frequency
Pressure Temperature
of use
(fluctuating) in 0C
(hours per year)
in bar
The arrangement of pipes should facilitate their identification. Mounting plates should be
used where required.
Pipes should be laid so as to prevent the formation of air locks. Where pipes are likely to
suffer from frost damage,drainage fittings should be provided at the lowest points of the
system.
Where pipes are laid above one another, exposed cold water pipes should be on the lowest
level in order to minimize the risk of condensation.
Where a system provides water to two or more buildings, a riser should be installed in each
building.
Where draw-off points on a storey require backflow prevention but are not individually
isolated (DIN 1988 part 4), the main branch pipe should branch off from the riser not less
than 300 mm above the maximum possible water level on the storey.
56
TECHNICAL DEPARTMENT
Raktherm’s highly competent technical department are ready to resolve all your
sanitary problems 24/7.
LINEAR EXPANSION
Linear expansion of pipes is directly proportional to the heat subjected to the pipe material. Hence, cold water pipes
have practically no linear expansion and could be neglected in the installation design. On the other hand, expansion
of pipes is significant in warm water and heating installations and in extreme temperature varying environments,
and therefore needs to be considered.
That means you can expect a linear expansion of 10.8 mm for this segment of pipe if the
Alternatively, you can quickly obtain the result from the following table for different
types of pipe:
57
TABLE 5.2: STANDARD PIPE LINEAR EXPANSION CHART (METERS)
∆T(0X)**
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
0.1 0.15 0.23 0.30 0.38 0.45 0.53 0.60 0.68 0.75 0.83 0.90 0.98 1.05 1.13 1.20
0.2 0.30 0.45 0.60 0.75 0.90 1.05 1.20 1.35 1.50 1.65 1.80 1.95 2.10 2.25 2.40
0.3 0.45 0.68 0.90 1.13 1.35 1.58 1.80 2.03 2.25 2.48 2.70 2.93 3.15 3.38 3.50
0.4 0.60 0.90 1.20 1.50 1.80 2.10 2.40 2.70 3.00 3.30 3.60 3.90 4.20 4.50 4.80
0.5 0.75 1.13 1.50 1.88 2.25 2.63 3.00 3.38 3.75 4.13 4.50 4.88 5.25 5.63 6.00
Length of segment (meters)
0.6 0.90 1.35 1.80 2.25 2.70 3.15 3.60 4.05 4.50 4.95 5.40 5.85 6.30 6.75 7.20
0.7 1.05 1.58 2.10 2.63 3.15 3.68 4.20 4.73 5.25 5.78 6.30 6.83 7.35 7.88 8.40
0.8 1.20 1.80 2.40 3.00 3.60 4.20 4.80 5.40 6.00 6.60 7.20 7.80 8.40 9.00 9.60
0.9 1.35 2.03 2.70 3.38 4.05 4.73 5.40 6.08 6.75 7.43 8.10 8.78 9.45 10.13 10.80
1.0 1.50 2.25 3.00 3.75 4.50 5.25 6.00 6.75 7.50 8.25 9.00 9.75 10.50 11.25 12.00
2.0 3.00 4.50 6.00 7.50 9.00 10.50 12.00 13.50 15.00 16.50 18.00 19.50 21.00 22.50 24.00
3.0 4.50 6.75 9.00 11.25 13.50 15.75 18.00 20.25 22.50 24.75 27.00 29.25 31.50 33.75 36.00
4.0 6.00 9.00 12.00 15.00 18.00 21.00 24.00 27.00 30.00 33.00 36.00 39.00 42.00 45.00 48.00
5.0 7.50 11.25 15.00 18.75 22.50 26.25 30.00 33.75 37.50 41.25 45.00 48.75 52.50 56.25 60.00
6.0 9.00 13.50 18.00 22.50 27.00 31.50 36.00 40.50 45.00 49.50 54.00 58.50 63.00 67.50 72.00
7.0 10.50 15.75 21.00 26.25 31.50 36.75 42.00 47.25 52.50 57.75 63.00 68.25 73.50 78.75 84.00
8.0 12.00 18.00 24.00 30.00 36.00 42.00 48.00 54.00 60.00 66.00 72.00 78.00 84.00 90.00 96.00
9.0 13.50 20.25 27.00 33.75 40.50 47.25 54.00 60.75 67.50 74.25 81.00 87.75 94.50 101.30 108.00
10.0 15.00 22.50 30.00 37.50 45.00 52.50 60.00 67.50 75.00 82.50 90.00 97.50 105.00 112.50 120.00
70
∆T (K)
60
50
40
30
20
10
0
0 0 1 2 3 5 6 7 8 9 10 11 12
Linear expansion ∆L in mm/m
58
INSTALLATION
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
0.1 0.03 0.05 0.06 0.08 0.09 0.11 0.12 0.14 0.15 0.17 0.18 0.20 0.21 0.23 0.24
0.2 0.06 0.09 0.12 0.15 0.18 0.21 0.24 0.27 0.30 0.33 0.36 0.39 0.42 0.45 0.48
0.3 0.09 0.14 0.18 0.23 0.27 0.32 0.36 0.41 0.45 0.50 0.54 0.59 0.63 0.68 0.72
0.4 0.12 0.18 0.24 0.30 0.36 0.42 0.48 0.54 0.60 0.66 0.72 0.78 0.84 0.90 0.96
0.5 0.15 0.23 0.30 0.38 0.45 0.53 0.60 0.68 0.75 0.83 0.90 0.98 1.05 1.13 1.20
Length of segment (meters)
0.6 0.18 0.27 0.36 0.45 0.54 0.63 0.72 0.81 0.90 0.99 1.08 1.17 1.26 1.35 1.44
0.7 0.21 0.32 0.42 0.53 0.63 0.74 0.84 0.95 1.05 1.16 1.26 1.37 1.47 1.58 1.68
0.8 0.24 0.36 0.48 0.60 0.72 0.84 0.96 1.08 1.20 1.32 1.44 1.56 1.68 1.80 1.92
0.9 0.27 0.41 0.54 0.68 0.81 0.95 1.08 1.22 1.35 1.49 1.62 1.76 1.89 2.03 2.16
1.0 0.30 0.45 0.60 0.75 0.90 1.05 1.20 1.35 1.50 1.65 1.80 1.95 2.10 2.25 2.40
2.0 0.60 0.90 1.20 1.50 1.80 2.10 2.40 2.70 3.00 3.30 3.60 3.90 4.20 4.50 4.80
3.0 0.90 1.35 1.80 2.25 2.70 3.15 6.30 4.05 4.50 4.95 5.40 5.85 6.30 6.75 7.20
4.0 1.20 1.80 2.40 3.00 3.60 4.20 4.80 5.40 6.00 6.60 7.20 7.80 8.40 9.00 9.60
5.0 1.50 2.25 3.00 3.75 4.50 5.25 6.00 6.75 7.50 8.25 9.00 9.75 10.50 11.25 12.00
6.0 1.80 2.70 3.60 4.50 5.40 6.30 7.20 8.10 9.00 9.00 10.80 11.70 12.60 13.50 14.40
7.0 2.10 3.15 4.20 5.25 6.30 7.35 8.40 9.45 10.50 11.55 12.60 13.65 14.70 15.75 16.80
8.0 2.40 3.60 4.80 6.00 7.20 8.40 9.60 10.80 12.00 13.20 14.40 15.60 16.80 18.00 19.20
9.0 2.70 4.05 5.40 6.75 8.10 9.45 10.80 12.15 13.50 14.85 16.20 17.55 18.90 20.25 21.30
10.0 3.00 4.50 6.00 7.50 9.00 10.50 12.00 13.50 15.00 16.50 18.00 19.50 21.00 22.50 24.00
80
70
∆T (K)
60
50
Please see the details of
40
Linear expansion and Installation
30 Types in RAKtherm Technical
Manual
20
10
0
0 0 1 2 3 5 6 7 8 9 10 11 12
59
INSULATION OF RAKTHERM PIPES
A major advantage of the use of polypropylene pipes is its low coefficient of conductivity. In other words,
PP-R systems, in comparison to steel piping systems, offer superior insulating properties, and require
much less insulation, if further heat loss is to be prevented.
insulating material should ensure that the water is maintained at the designed operating temperature.
Legal and other obligations (in building regulations) should also be complied to.
The insulating effect is mainly a function of the thickness of insulation and its thermal conductivity. It
increases in direct proportion to the temperature. Moisture can impair the performance of insulating
material. Hence open cell and fibrous insulating materials should be supplemented with a vapor barrier
attached to the outer surface of the insulation.
Condensation can form on any insulating material if the pipe carr ying cold water is inadequately
lagged. Furthermore, it can lead towards moisture penetrating to the pipe in case of using unsuitable
materials. Obviously, closed cell material with a high moisture resistance should be used to insulate
cold water pipes. All butt joints, cuts, and ends should be properly sealed.
Considering the areas where frost damage is common, even insulation would prove insufficient in
preventing the freezing if the system is out of service. Pipes should hence be drained or protected.
*For other values of the thickness is to be obtained by conversion, on the basis of pipe diameter of 20mm
Under required circumstances, cold water pipework should be adequately protected against
condensation and sources of heat. The installation of cold water pipes should be done avoiding heat
sources (hot pipes, chimneys, boilers), unless the pipes are equipped with proper insulation so as to
retain the water temperature.
60
INSTALLATION
For residential applications, assuming normal service conditions, the insulation thickness specified in
table 5.4 should be used. However, insulation will not provide permanent protection of the water against
warmth.
The specifications of Technical Manual table 5.10 are also applicable where the protection against
condensation on the outer surface of the insulation is concerned, assuming that the water temperature
is 10 °C.
PROTECTION OF
RAKTHERM
HOT WATER PIPES
AGAINST HEAT LOSS
The minimum requirements specified (Heating System Regulation) should be complied with for
restricting the heat loss of hot water pipes.
RAKtherm pipes and fittings have to be protected by insulation to prevent heat loss. Pipes and fittings
made of PP-R have heat conductivity constant of 0.15 W/mK. This indicates a significantly higher degree
of self-insulation compared to metal pipes, meaning that in terms of heat transfer RAKtherm pipes and
fittings offer superior natural insulating properties.
Where pipes and fittings have been welded, the pressure test should not be performed before two hours
have elapsed after the last welding operation.
61
THE PRESSURE TEST CONSISTS OF TWO STAGES:
For the first stage, a test pressure equal to the permissible working pressure plus 5 bar should
be applied twice within 30 minutes at 10 minute intervals. Then the pressure should be checked.
In case more than a 0.6 bar drop occurs over a period of 30 minutes at a rate of 0.1 bar/min, then
a leakage is reported.
The second stage should follow the first stage without interval and should last minimum of 2
hours. Then the Pressure drop should be checked. If the pressure drop is more than 0.2 bar and
the pipe work shows signs of leakage, then the network should be corrected and the test must
be repeated.
Additionally, a solid base is recommended to avoid any deformation of pipes during transportation
and storage. Even though RAKtherm pipes are extremely robust it is recommended to treat the material with
care.
62
RAKTHERM PEX PIPING SYSTEM
Raktherm PEX Piping A wide range of plumbing and under floor-heating systems
have been developed and produced by RAKTherm
INTRODUCTION
A wide range of plumbing and under - floor heating systems have been developed and produced by Gulf
Plastics and Converting Industries (Tahweel) under the brand name of RAKtherm.
Central heating.
Air-conditioning systems.
District heating.
Transport of industrial gases, compressed air and fluids (Including fuel oil, gases,
acids and alkalis)
63
Cross linked polyethylene (PE-X) results from chemically adjoining polyethylene molecules in order
to improve their properties especially at high temperatures. This results in a structure that does not
soften when high temperature is applied, thus raising the thermal stability of the material under load,
which greatly increases the environmental stress crack resistance and the resistance to slow crack
growth due to deterioration of the material under continuous temperature use. The Molecule Structure
of Polyethylene and Cross linked Polyethylene.
Improved impact strength Reducing Raid Crack Propagation (RCP), even at low
temperatures.
No corrosion in the system, especially through the use of Multilayer and Aluminum
RESISTANCE TO TEMPERATURE
RAKtherm PEX piping system Cross linking polyethylene changes the polymer from a thermoplastic
to a thermo setting polymer. Once it is fully cross linked, polyethylene tends not to melt but merely to
become more flexible at higher temperatures. Low density polyethylene film grades which have been
designed for medical applications.
For example, have been autoclaved at 130°C without losing their properties.Although high
temperature resistance of RAKtherm PEX piping system makes it particularly suitable for hot and
cold interior plumbing applications, it also makes an excellent underground water service piping.
The maximum continuous application temperature is 95°C. The permanent operating pressure is 10
bars at 70°C, which far exceeds any water delivery application.
In rare instances during the lifetime of the piping system and due to malfunctioning under abnormal
circumstances in the installation, the highest temperature that can be withstood in the piping system
for a short time during operation is 110 degrees celsius. This can be sustained for a maximum of 100
hours per 50 years.
RAKtherm PEX piping system piping system is designed for indoor and buried applications only and is
not recommended for outdoor aboveground use. Short exposures to sunlight not to exceed 30 - 45 days
are however permissible when storing RAKtherm PEX piping system. However, it is recommended that
the pipes if stored outside be shielded from direct sunlight.
64
RAKTHERM PEX PIPING SYSTEM FEATURES
RESISTANCE TO CHEMICALS
The basic cross linked structure physically is resistant to the attack of aggressive chemicals. The
material is thus rendered more resistant to permeation and softening by these chemicals.
RESISTANCE TO PRESSURE
RAKtherm PEX piping system cross linking improves the resistance to pressure at room
temperature reducing tendency to creep. At high temperatures this is achieved by reducing relative molecular
movement.
At elevated temperatures cross linking allows the properties of the original base polyethylene to be
preserved. Moreover cross linked high density polyethylene which has closer packing of the chains and
an intrinsically higher pressure resistance is used for higher pressure applications than cross linked
low density polyethylene.
According to DIN 16892 standards and in order to meet the pressure regulations for flexible under floor
heating pipes a minimum density of 0.935 to 0.940 is necessary.
As for hot sanitary water pipes which have to meet more stringent requirements, a minimum density
of 0.945 to 0.950 is required. All RAKtherm PEX piping system cross linked polyethylene pipes have a
density in excess of 0.95, and therefore meet or exceed DIN 16892 standards.
The following diagram shows the service life expectancy which depends on the installed system
pressure and pressure changes. Under normal circumstances, however the service life expectancy of
the pipes is more than 50 years.
RAKtherm pex Piping System for sanitary and heating systems, and floor radiating panel system.
65
PEX Monolayer Pipes External Wall Internal
Art-.No. Diameter Thickness Diameter
(mm) (mm) (mm)
PX-1620 16 mm 2.0 12
PX-1622 16 mm 2.2 11.5
PX-2020 20 mm 2.0 16
PX-2022 20 mm 2.25 15.5
PX-2525 25 mm 2.5 20
PX-3230 32 mm 3 26
PEX Aluminum
Composite Multilayer
Pipes
External Wall Internal
Art-.No. Diameter Thickness Diameter
(mm) (mm) (mm)
PML1-1620 16 mm 2.0 12
PML1-1622 16 mm 2.2 11.5
PML1-2020 20 mm 2.0 16
PML1-2022 20 mm 2.25 15.5
PML1-2525 25 mm 2.5 20
PML1-3230 32 mm 3 26
PXO-2020 20 mm 2.0 16
PXO-2022 20 mm 2.25 15.5
PXO-2525 25 mm 2.5 20
PXO-3230 32 mm 3 26
Pex Blue/Red
Protective Sleeve
Blue Red
Internal Internal
Art-.No. Art-.No.
Diameter(mm) Diameter(mm)
CP1-25 25 CP2-25 25
CP1-32 32 CP2-32 32
CP1-40 40 CP2-40 40
66
ADAPTERS
Manifold
PRODUCT RANGE
PEX Piping System designed to offer a very
long service life, made under very strict
quality control conditions, superior in
mechanical and thermal performance
showing very good resistance to crack
propagation, notching, scratching, during
stage, transport, and pipe installation.
67
Male Adaptor
Art-.No. Dimension
AMP1-161/2 16mm x 1/2"
AMP1-201/2 20mm x 1/2"
Female Adaptor
Art-.No. Dimension
AFP1-161/2 16 mm x ½”
AFP1-201/2 20mm x 1/2"
Male Elbow
Art-.No. Dimension
EM1-201/2 20mm x 1/2 "
EM1-253/4 25mm x 3/4 "
Male Coupling
Art-.No. Dimension
MMC1-1/2 1/2"
MMC1-3/4 3/4"
MMC1-3/41/2 3/4"x1/2"
MMC1-1 1”
MMC1-11/4 11/4"
Pex union
Art-.No. Dimension
P-PU2-161/2 16mm x 1/2
68
PRODUCT RANGE
Art-.No. Dimension
ARV1-1/2 1/2"
END Plug
Art-.No. Dimension
EP1- 1/2 1/2"
EP1- 3/4 3/4"
EP1-1 1"
EP1-11/4 11/4"
Female Elbow
Art-.No. Dimension
EF2-201/2 20mm x 1/2 "
EF2-253/4 25mm x 3/4 "
69
Pex Ball Valve
with Union (Red)
Art-.No. Dimension
RBV1-3/4 3/4"
RBV1-1 1"
RBV1-11/4 11/4"
RBV2-1/2 1/2"
Art-.No. Dimension
EF1-161/2 16mm x 1/2"
EF1-201/2 20mm x 1/2"
70
71
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