TPG-Gerpex-System-Brochure-April-2015
GERPEX MultiLayer Composite Pipe & Press Fit Range Technical Product Guidewww.emmeti.co.uk

Engineered Water Solutions
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Gerpex PressFit Solutions Introduction
EMMETI-Gerpex PEXb/AL/PEXb 20×2 PER
On the 9th of January 2009 Emmeti Spa built and developed a dedicated PE-Xb/Al/PE-Xb multilayer pipe factory in Fontanafredda (PN), Italy covering 10,000m in order to accomodate two production lines, research and development facilities, post manufacture quality and stress test laboratory to ensure maximum reliabilty and safety of the nished product.The factory has the capacity to produce upto 30,000,000 metres per year. This along with the production facilty in Ponte S.Marco which produces the PressFit range and other brass ttings means that Emmeti can now offer a full PressFit solution including pipe, press ttings and tooling.
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The manufacturing process of Emmeti multilayer pipe is subject to stringent control checks which are carried out before, during and after production from the raw material analysis through to the nished product performance checks. The purpose built analytical laboratory is equipped to carry out the following tests:
Veries compliance of the Enlargement TestTest performed both in production and in the Ball TestTo ensure that there are noocclusions or deformations pipe by using compressed air to pass a ball through Dimensional control in productioncontrol of pipe dimensions.INK TestEnsure that the strip of aluminium is free of imper
Tests the resistance toPressure cyclesTests a system consisting of pressure cycles (from 1 frequency of 0.5 Hz.Thermal cyclesTests a system consisting of jected to 5000 temperature pressure of 10 bar.Resistance to internal pressureTests resistance to a specic internal pressure at 95°C; the pressure value is chosen in relation to the size of pipe (maximum diameter, 165h, 1000h), by referring to the relative regression curves.Verication of cross-Verication performed in correct level (%) of cross-Vibration TestVibration tests a systemalternating bending cycleswith an internal pressure of15 bar at room temperature.
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Types of ApplicationsGerpex is the Emmeti range of Multilayer pipe, press ttings and tooling developed for use with heating (Wall Hung The ttings are available in two different versions: press-ttings and compression. The wide range of ttings and complete and highly reliable product.The Gerpex System including the multilayer pipe that is cross • Chilled water air-conditioning systems• Compressed air systemsHigh resistance to pressureResistant to pressures up to a maximum of 10 bar (at 95 °C).The linear expansion in relation to a variation in temperature is comparable with that of copper.Thermal insulationthe following re safety standards:European Standard Class 1 (UNI 9177) – DL-s2-d2 (EN 13501-1).Low internal resistanceThe smooth interior surface of the pipe prevents limescale deposits and promotes the smooth ow of uid thus considerably reducing pressure drops across the system.High resistance to temperaturesResistance to temperatures up to a maximum of 95°C.This is due to the resistance of the aluminium layer and of the layers in PE-X used in the pipe’s construction.The aluminium layer makes the Gerpex pipe impermeable to oxygen that would cause corrosion of the system’s metallic components by providing a solid barrier.Resistance to external chemical agentsenvironments.Complete resistance to electrochemical corrosionThe materials used in the pipe’s construction and the adopthe ttings are fully resistant to elctromechanical corrosion.Thanks to its low specic weight and the ability to bend easily, the Gerpex System is extremely easy to install. Once bent into the desired position, the pipe remains in that position just like
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Classication of the conditions of use (UNI ISO 21003)
ApplicationclassDesigntemperature (°C)Durability (years)max(°C)Durabilitymax(years)malfunction(°C)Durability at malfunction(ore)Range ofapplication49100Hot water (60 °C)49100Hot Water (70 °C)402,52,5100100Floor heatingand low temperatureradiators14100100High temperatureradiators
Regression curves and linear thermal expansionExplanation of regression curve graphThe maximum pressure (Pmax) for a duration of 50 years at a given temperature is identied by intersecting the vertical line for 50 years with the colouredline for said temperature. Once the expected operating pressure is known (Pes), the safety coefcient will be equal to ks=Pmax/Pes.
1 10 100 1000 10000 100000 1000000
t (hours)P (bar)
110100
t (years)
1102550
20 °C
70 °C
95 °C
110 °C
Linear thermal expansion for pipes of 10 m in various materials
CopperPE-X polyethylene mesh PP polypropylenePB polybutyleneSteelInox Stee
Gerpex
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Bonding (Cross-linking)Bonding or cross-linking is the process by which the polyethylene achieves its chemical/mechanical characteristics following the formation of bonds between the polymer chains.The bonded polyethylene used in Gerpex multilayer pipes is of the PE-Xb type and is obtained with the silane method. In this process, high-density grafted polyethylene is used i.e. a silane additive is used with a small amount of peroxide being added to act as an initiator.There are 4 different bonding methods:
Designation PeroxidePE-Xa 70%EN 579SilanePE-Xb 65%EN 579Electron Beam WeldingPE-Xc 60%EN 579AzoPE-Xd 60%EN 579
Gerpex – The Full PressFit Solution
+ CH2=CH-Si-(OCH3)3CH30-Si-OCH3OCH3+ ROR’
polietilenesilanoperossidopolietilene graffato con silanometanolopolietilene gaffato con sianoionica silno
ionica acqua+ 3 2O+ 3 C3++ 3 + + 3O-+ 3 C3OH
CH30-Si-OCH3OCH3
O–Si-O-O-
HO-Si-OHOH
polyethylene
silane
peroxide
polyethylene grafted with silane
polyethylene grafted with silane
Ionic dissociation
Ionic dissociation
methanol
HO-Si-OHOH
OH
+HO-Si-OH
HO-Si-OHO–
HO-Si-OHHO-Si-OHO+ 2O
+HO-Si+-OH + H- + +
PE-Xb
+catalyst
water
The process begins with a combined extrusion of grafted polyethylene granules and a catalyst (max 5 %). Subsequently, thecross-linking process is achieved by placing the pipe in contact with water at high temperature (or steam).In the rst phase, the water acts as reagent (hydrolysis) and methanol is produced.In the second and last phase, water is produced (condensation) as a result of reactions triggered by the catalyst.This therefore creates intermolecular bridges inside the material that improvesthe characteristics of the pipe in terms of:• Resistance over time to temperature and pressure• Resistance to corrosion• Chemical resistance• The ability to use the pipe with both high and low temperatures
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ConstructionMultilayer pipe for plumbing systems made of composite material through a technologically advanced process with which a PE-Xb (cross linked polyethylene) pipe is combined to an aluminium core (minimum thickness 0.2 mm) welded on top, coated on the outside with another layer of PE-Xb (PE-HD, size 40-63).Gerpex pipes combine the processing and durability advantages of a plastic pipe to the sturdiness and dimensional stability to temperature and pressure of a metal pipeGerpex MLCP

The RangeAvailable in rolls with diameters of DN 16, 20, 26, 32 and in bars DN 16, 20, 26, 32, 40, 50, 63. The pipe on rolls is also available preinsulated with closed cell expanded polyethylene sheath, cross-link coating.1 Cross-linked polyethylene inner pipe (PE-Xb).Bonding layer connecting the inner pipe to the aluminium pipeButt-welded aluminium pipe, thickness min 0,3 mmBonding layer connecting the outer pipe to the aluminium pipeCross-linked polyethylene outer pipe (PE-Xb), size 16-32High-density polyethylene outer pipe (PE-HD), size 40-63
Dimensional data
Gerpex pipe internal ØOverall thickness3,54,5Weight (1)Kg/m0,130,150,28 (0,30)0,38 (0,41)0,580,881,32Water contentl/m0,110,200,310,530,851,382,29Isolation thickness (2)Packs nude pipe (roll)100100/200Packs nude pipe (bars L= 4m)96*96*40*40*Packs insulated pipe (roll)50/100(1) Brackets indicate weight in Kg/m for 4m bars(2) For insulated pipes only* packaged in rigid protective pipeTechnical data Gerpex pipeClasses of application (UNI ISO 21003 – see table “Classication of the conditions of use”): 2/10 bar, 5/10 barMax. operating temperature: 95 °CMax. operating pressure: 10 barCoefcient of linear expansion: 0,026 mm/m °CThermal conductivity: 0,45 W/m °CSurface roughness of internal pipe: 7 mFire reaction class: E (EN 13501-1)Technical data of insulating sheathMaterial: Closed-cell expanded polyurethane, covered with a lm in extruded LD-PE.Thermal conductivity (at 40 °C):  0,040 W/mK (UNI EN ISO 8497).Water vapour resistance factor : 5000 (UNI EN 13469)Fire reaction class of covering: 1 (UNI 9177); DL-s2-d2 (EN 13501-1)Admitted operating temperature of the covering: -45 °C ÷ +100 °C.
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Certication and qualityThe features and performance of Gerpex pipe is veried and certied by numerous quality marks and international standards.In particular, Gerpex pipe has obtained the DVGW certicate of quality regarding the prestigious German institution Technical Regulation W542, as well as KIWA in accordance with UNI EN ISO 21003. The Gerpex pipe is WRAS approved certicate number: 1404093Marking example of Gerpex pipe DN 16×2 (al 0.2)EMMETI-Gerpex PEXb/AL/PEXb 16×2 PER IMPIANTI TERMICI E SANITARI T=95°C P=10 bar KQ UNI EN ISO 21003 Class 2/10 bar, 5/10 bar DVGW DW8501BN0004 Made in Italy 14:28 14/04/14 4M111052 100 mKEY
PEXb/AL/PEXbInternal layer pipe in PE-Xb, intermediate layer in aluminum, external layer pipe in PE-Xb16x2External diameter and pipe wall thickness, expressed in millimeters (nominal dimensions)PER IMPIANTI TERMICI E SANITARIFields of application of the pipeT=95 °C Max. operating temperature=95 °C P=10 bar Max. operating pressure=10 bar KQ UNI EN ISO 21003 KIWA certication in accordance with Technical Standard UNI EN ISO 21003 Class 2/10 bar, 5/10 bar Application class in accordance with Technical Standard UNI EN ISO 21003 DVGW DW8501BN0004 N° certicate in accordance with German Technical Regulation DVGW W534 Made in Italy Pipe made in Italy 14:28 Time of manufacturing 14/04/14 Date of manufacturing 4M111052 Production batch 100 m Progressive roll length
EMMETI-GERPEX PEXb/AL/PEXb 16×2 PER IMPIANTI TERMICI E SANITARI T=95°C P=10 bar KQ UNI EN ISO 21003 Class 2/10 bar, 5/10 bar DV
GW DW8501BN0004 Made in Italy 14:28 14/04/14 4M111052 100
Drinking waterThe use of Gerpex systems in medical facilities is guaranteed by the certicate of suitability for drinking water according to the current national legislation in force (Ministerial Decree 174 of the Ministry of Health) as well as compliance with the requirements by the German institute KTW.
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FeaturesGerpex press-ttings have been designed to be installed with the connection technique based on the use of electric or manual pressing devices. This type of joint has become increasingly more popular due to its simple and quick installation, along with high working temperature and pressure capability. The Press Jaw, specic for every diameter of ttings, compresses a stainless steel sleeve, which secures the pipe onto the core of the tting. The hydraulic and mechanical sealing is guaranteed by the special prole of the tting and the double O-ring.After pressing, the tting produces a joint with maximum stability and duration.
Construction DetailsThe stainless steel sleeve is connected onto the tting by blue plastic ring.Each sleeve has the indication of the diameter and production data engraved (year week).The plastic ring has four important functions:it prevents electric contact between the layer of aluminium of the pipe and the brass body of the tting, thus preventing the risk of possible corrosionit provides sight holes to ensure that the pipe has been fully inserted into the ttingit guides the correct positioning of the jaws around the tting�xes the sleeve to the �ttingThe Gerpex range of ttings are constructed with a brass nickel plated body (nickel plating is only on surfaces not in The blue plastic collar has sight holes which allow the installer to be sure that the pipe has been inserted fully into The stainless steel collar is marked with the tting size and Emmeti branding and when crimped onto the pipe and The two O-ring system gives greater condence when tting, these are made from EPDM peroxide 70SH.
Pressing Prole OptionsProle and dimensions of the jaws that can be used with Multi-Jaw Gerpex Fittings
16202632405063THOKOKOKOKOKOKOKBOKOKOKOK—UOKOK—–HOKOK—–FOKOK—–
TH – KSP 11
B – KSP 1U – KSP 5H – KSP 7F – KSP 2
TH – KSP 11B – KSP 1U – KSP 5H – KSP 7F – KSP 2
TH – KSP 11B – KSP 1U – KSP 5H – KSP 7F – KSP 2
TH – KSP 11B – KSP 1
U – KSP
5H – KSP 7F – KSP 2
TH – KSP 11B – KSP 1U – KSP 5H
– KSP
7F – KSP 2
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Gerpex Pipe
16 x 2100 / 200 / 50020 x 2100 / 20026 x 332 x 3Gerpex pipe coilsGerpex insulated pipe coilsClosed cell cross-linked polyethylene isolating sheath, coated.Isolating thermal conductivity at 40 °C: 0,040 W/m °C
16 x 2 red6 mm10016 x 2 blue6 mm10020 x 2 red6 mm20 x 2 blue6 mmGerpex pipe straight lengths4 mt bars
16 x 220 x 226 x 332 x 340 x 3,550 x 463 x 4,5
16 x 26 mm50/10020 x 26 mm20 x 29 mm26 x 39 mm32 x 39 mmClosed cell cross-linked polyethylene isolating sheath, coated.Isolating thermal conductivity at 40 °C: 0,040 W/m °C
Gerpex insulated pipe coilsClosed cell cross-linked polyethylene isolating sheath, coated.Isolating thermal conductivity at 40 °C: 0,040 W/m °C
16 x 210 mm20 x 213 mm26 x 313 mm32 x 313 mmGerpex insulated pipe coils
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Female elbow
B
A
CH
16 x 1/2″23,520 x 1/2″23,520 x 3/4″26 x 3/4″32 x 1″38
Wall mounted female elbow
B
C
A
E
=
=
DCH
16 x 1/2″16 x 1/2″20 x 1/2″20 x 1/2″20 x 3/4″26 x 3/4″
Male elbow
A
B
CH
16 x 1/2″20 x 1/2″20 x 3/4″31,526 x 3/4″31,532 x 1″383440 x 1″1/469,550 x 1″1/275,563 x 2″65Equal elbow
A
A
16 x 1620 x 2026 x 2632 x 3240 x 406650 x 5074,563 x 63(**) Compatible prole F (KSP2)
Equal elbow 45°
40 x 4050 x 5059,563 x 63(**) Compatible prole F (KSP2)
A
CH
Ø 16 – 24×1945,5Ø 20 – 24×1945,5Ø 16 – Eurocone 3/4″45,5Ø 20 – Eurocone 3/4″45,5
Female union adaptors to 24 x 19 manifold connection
A
A
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Female union adaptors
A
16 x 3/8”16 x 3/4”20 x 1/2”20 x 3/4”26 x 3/4”26 x 1”32 x 1”32 x 1”1/459,540 x 1”1/250 x 2”63 x 2”1/2
Equal tee
B
B
B
A
16 x 16 x 1618 x 18 x 1842,520 x 20 x 2026 x 26 x 2632 x 32 x 3210640 x 40 x 401326650 x 50 x 5014974,563 x 63 x 6316475 x 75 x 75TH (**)201100,5(**) Compatible prole F (KSP2)
Male branch tee
B
B
A
C
CH
16 x 1/2″ x 1620 x 1/2″ x 2020 x 3/4″ x 2031,526 x 3/4″ x 2631,5Reducing tee
B
B
B
A
16 x 20 x 1620 x 16 x 1620 x 16 x 2020 x 20 x 1620 x 26 x 2020 x 32 x 2010626 x 16 x 2026 x 16 x 2626 x 20 x 1626 x 20 x 2026 x 20 x 2626 x 26 x 1626 x 26 x 2026 x 32 x 2610632 x 16 x 3210632 x 20 x 2010632 x 20 x 2610632 x 20 x 3210632 x 26 x 2010632 x 26 x 2610632 x 26 x 3210632 x 32 x 1610632 x 32 x 2010632 x 32 x 2610640 x 26 x 32TH (¹)/(²)124,557,540 x 26 x 40TH (¹)13257,540 x 32 x 32TH (²)124,558,540 x 32 x 40TH (¹)1326640 x 40 x 32TH (²)124,56650 x 26 x 50TH (¹)14950 x 32 x 50TH (¹)14963,550 x 40 x 4014974,550 x 40 x 5014972,550 x 50 x 32TH (²)139,574,550 x 50 x 4014963 x 50 x 63164(¹) Takeoffs prole 26×3: TH(²) Takeoffs prole 32×3: TH
Gerpex Press Fittings
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Female branch tee
C
C
A
B
CH
16 x 1/2″ x 1623,588 44 24 16 x 3/4″ x 1696 48 30 20 x 1/2″ x 2023,588 44 24 20 x 3/4″ x 2096 48 30 26 x 1/2″ x 2021,526 x 1/2″ x 2621,526 x 3/4″ x 2696 48 30 32 x 3/4″ x 3233 106 53 38 32 x 1″ x 3233 106 53 38 40 x 3/4″ x 4035,5130 65 38 40 x 1″ x 4039 130 65 38 40 x 1″1/4 x 4048,5140 71,547 50 x 3/4″ x 5040 133 66,538 50 x 1″ x 5041 133 66,538 50 x 1″1/4 x 5048,5143 71,547 63 x 1″ x 6346,5143 71,547 63 x 1″1/4 x 6348,5143 71,547 (**) Compatible prole F (KSP2)
Straight coupling
B
B
A
CH
16 x 1673 34,516 18 x 1833,520 x 2073 34,520 26 x 2671 35,523 32 x 3274 37 29 40 x 4095 47,540 50 x 50101 50,548 63 x 63103 51,560 (**) Compatible prole F (KSP2)Reducing coupling
B
B
A
CH
20 x 1673 34,520 26 x 1671 35,523 26 x 2071 35,523 32 x 1673 36,529 32 x 2073 36,529 32 x 2673 36,529 40 x 26TH (¹)86,547,540 40 x 32TH (²)86 43 40 50 x 32TH (²)91,550,548 50 x 4099 49,548 63 x 40101 50,560 63 x 50103 51,560 Takeoffs proleTakeoffs prole
Straight male
A
CH
16 x 1/2″50,818 x 1/2″53,520 x 1/2″50,820 x 3/4″54,526 x 3/4″54,526 x 1″59,53432 x 1″60,53432 x 1″1/466,540 x 1″71,540 x 1″1/450 x 1″1/263 x 2″82,265(**) Compatible prole F (KSP2)
Gerpex Press Fittings
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Straight female
A
CH
16 x 1/2″49,520 x 1/2″49,520 x 3/4″26 x 3/4″26 x 1″3832 x 1″38
Tee with chromed copper pipe
A
B
B
C
D
16 x Ø15 x 1646,529020 x Ø15 x 2046,5290Distance Tee 25 mm, chromed pipe 290 mm long.
Chromed copper pipe
L
Ø 15 x 1/2” M 175
Chromed elbow
B
L
16 x Ø 15165,5
Backplate female tee
A
B
=
D
=
C
=
=
16 x 1/2″ x 1620 x 1/2″ x 20
Right hand terminal elbow
=
=
C
D
=
=
A
B
16 x 1/2”20 x 1/2″
Left hand terminal elbow
=
=
C
=
=
D
A
B
16 x 1/2”20 x 1/2″
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15
Bracket for female T with elbow
Plug for circuit test with o-ring
1/2″ (blue or red)3/4″ (blue or red)
Leakage test plug for multi-layer pipe
Size16 x 220 x 2Complete with 1/2” F tting for release valve (provided standard)
Gerpex Press Fittings
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Compression FittingsUsesThe 24×19 thread allows for a single type of fitting which can be – Monoblocco Fittings is supplied with it components (nut, olive, ofto CW614N (DNIEN12164)The rangeTo suit and
PATENTPENDING
SizeThread16 x 224×1916 x 2,2524×1917 x 224×1920 x 224×1920 x 2,2524×1920 x 2,524×1926 x 3M32x1,5Fitting Female 24×19 – Male M32x1,5SizeF 24×19 – M 32×1,5Straight Male fitting 1/2” – M32x1,5SizeM 1/2” – M 32×1,5
UsesThe use of the compression pipe ttings makes installing the multi-layer pipe quick and simple with existing ttings.The 24×19 thread allows for a single type of tting which can be matched with Emmeti seals 24×19 for multi-layer pipe. The hydraulic seal is ensured by means of a system with three O-rings and a barbed insert to ensure a secure connection.All the ttings are equipped with a special PTFE ring that insulates the aluminium of the pipe from the brass tting.Construction details – Monoblocco FittingsThe single body tting is supplied with it components (nut, olive, adaptor) pre assembled and ready for insertion of the pipe.The sight hole on the nut makes it possible to verify if the tting has been inserted all the way down to the seat.Nut in CW617N (UNI EN 12165)Adapter in CW614N (UNI EN 12164)Washer in PTFESplit Olive to CW614N (UNIEN12164)Sealing O-Ring in EPDMThe rangeTo suit Gerpex pipe DN 16 and 20: seal and ttings with 26 x 19 thread For Gerpex pipe DN 26: seal and ttings with 32 x 1.5 thread.
12 x 1,624×1914 x 224×1916 x 224×1916 x 2,2524×1917 x 224×1920 x 224×1920 x 2,2524×1920 x 2,524×1926 x 3M32x1,516 x 2Eurocone20 x 2EuroconeFitting Female 24×19 – Male M32x1,5
F 24×19 – M 32×1,5
Straight Male fitting 1/2” – M32x1,5
M 1/2” – M 32×1,5Monoblocco seal 24×19 and Eurocone for multi-layer pipeMLCP to Copper connectors
16×2 – 15mm20x2 – 22mm26x3 – 28mm
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Straight male – female BSP
MisuraABCh.Attacco
1/2″24×193/4″24×19313/4″M32x1,534M32x1,528,538
Straight male – male joint BSP
MisuraABCCh.Attacco
1/2″24×1928,53/4″24×1929,5313/4″M32x1,534M32x1,531,513,534
Straight male – male joint
ABCCh.MisuraMisura
24×1927,5M32x1,534
Elebow male – female BSP
MisuraA
B
Attacco
1/2″24×19313/4″24×1933,53/4″M32x1,531M32x1,538,5
Size
Thread
Size
Thread
Size
Size
Size
ThreadElbow male – male BSP
MisuraABAttacco
1/2″24×19293/4″24×19293/4″M32x1,5M32x1,5
Elbow male – male
AMisura
B
Misura
24×1927,5M32x1,53131,5
Tee joint male-male-female BSP
MisuraAAttaccoBAttacco
1/2”24×19313/4”24×195833,5
Tee joint male – male – male BSP
MisuraAttaccoAttaccoAB
1/2”24×193/4”24×195831
Size
Thread
Size
Thread
Thread
Size
Thread
Thread
Size
Size
Compression Fittings
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18
Tee joint male – male -male
AttaccoAttaccoBAttaccoA
24×1927,5
Size
Size
Thread
Thread
Thread
Elbow joint femaleBSP – male with ange
MisuraAAttacco
DEBC
1/2”24×1931
Gerpex Tooling
Ultra compact, one handed, battery operated press tool capable of pressing up to 40mm. Supplied with 1 or 2 x 14.4v 1.6Ah batteries and sturdy steel case with slots for press jaws. Compatible with all REMS jaw proles up to 40mm. Includes a battery charge status indicator and integrated LED work light. 360 rotatable head with Automatic Circuit Control.REMS Mini-Press ACC 14.4V Press Tool (with 1 or 2 Battery option)
TH prole pressing jaws for use with REMS Mini-press tool.Mini-Press TH Jaws
Compact battery operated press tool capable of pressing up to 110mm. Supplied with 1 or 2 x 14.4v 3.2Ah batteries and sturdy steel case with slots for press jaws. Compatible with all REMS jaw proles up to 110mm. Includes a battery charge status indicator and integrated LED work light. 360rotatable head with Automatic Circuit Control.REMS Akku-Press ACC 14.4V Press Tool (with 1 or 2 Battery option)
TH prole pressing jaws for use with REMS Akku-press tool.Akku-Press TH Jaws
16mm20mm26mm32mm40mm
16mm20mm26mm32mm40mm50mm63mm
19
19
Flarer and calibratorShear for multi-layer pipe
Ø 14Ø 16Ø 18Ø 20Ø 26Ø 32Ø 40Ø 50Ø 63Ø 75Ø 16 – 20 – 26
Ø 14 – 26Ø 26 – 40
Internal spring for bending pipe
Pipe cutter
Ø 14 – 32
Pipe cutter
Ø 6 – 75
External spring for bending pipe
Hydraulic bending machine for Gerpex pipe
Ø 26 – 32Complete with case, shape Ø 26 and Ø 32
Ø 16Ø 20Forms and Shapes for bending machine
Ø 16 L=500 mmØ 20 L=500 mmØ 26 L=1000 mm
Ø 16 L=500 mmØ 20 L=500 mm
Gerpex shear
Ø 14 – 32
Gerpex Tooling
20
20
Installing the systemAll installation operations must be carried out at temperatures above -10 °C and below 45 °C to avoid any possible damage to the materials.In case of temperatures below 0 °C, store the materials (pipes and ttings) at a higher temperature before use.Removal of packaging from the pipePay attention to not damage the pipe when removing the packaging tape from the roll.For insulated pipe, make sure you do not cut into insulating sheath.Surface mounted installationIn surface mounted installations, in false ceilings, in the gaps of dry wall systems (e.g. plasterboard) and in shafts, the pipes must be adequately secured with suitable collars placed at a distance of no more than a certain value that depends on the size of the pipe.Maximum distance “S” for bracketing surface mounted pipes (see following gure):
Pipe dimensionMaximum Distance (S) 14 x 210016 x 210020 x 212526 x 315032 x 320040 x 3,520050 x 425063 x 4,525075 x 5250
Surface embedded installationIn surface embedded installations, the pipes must be suitably secured with ties and there must be a minimum distance between them of 80 cm on straight lengths, and placed 30 cm before and after each bend. For this type of installation it is preferable to lay insulated pipe that has a foam sheath covering or pass the pipe through exible tubing.Press ttings: in laying concealed piping, the press ttings must be protected from corrosion that can result from contact with chemicals contained in plasters and mortars. It is possible to use boxing, adhesive tapes specically adapted for such applications, or coverings in an expanded
ADCA = max 80 cmB = 30 cmB
Gerpex Installation
SS
21
21
It is preferable to use elbow unions to form curves on pipes with a diameter greater than 26mm.In bending the pipe you must also avoid putting pressure on the unions already installed and the distance between a union and the beginning of the bend must be greater than 5xØ, where Ø is the external diameter of the pipe.
RØSx
L = 5 x Ø
Thermal expansionDuring the installation phase, pay particular attention to thermal expansion that can particularly affect multilayer pipes. The elongation a pipe undergoes as a result of a variation in temperature can be calculated with the following formula:where: is the coefcient of linear expansion, equal to 0.026 mm/m K for insulated pipes;is the initial length of the pipe (m);is the temperature difference (K).Example:Length of pipe: 12 mTemperature difference: 50 KL = 0.026 x 12 x 50 = 15.6 mmL = Length (m)T = Temperature difference (K)L = Longitudinal expansion (mm)Minimum radius of bendsThe bending of pipes must be carried out in accordance with the minimum values provided by the following table.
Pipedimension(Ø x S)Minimum radiusof bend RMinimum radius of bend Rwith spring pipe benderMinimum radiusof bend Rwith hydraulic bender14 x 25 x Ø3 x Ø16 x 25 x Ø3 x Ø20 x 25 x Ø3 x Ø26 x 38 x Ø4 x Ø4 x Ø32 x 34 x Ø40 x 3,54 x Ø50 x 44 x Ø63 x 4,54,5 x Ø
T10203040506070LL0,10,0260,0520,0780,1040,1300,1560,1820,20,0520,1040,1560,2080,2600,3120,3640,30,0780,1560,2340,3120,3900,4680,5460,40,1040,2080,3120,4160,5200,6240,7280,50,1300,2600,3900,5200,6500,7800,9100,60,1560,3120,4680,6240,7800,9361,0920,70,1820,3640,5460,7281,9101,0921,2740,80,2080,4160,6240,8321,0401,2481,4560,90,2340,4680,7020,9361,1701,4041,6381,00,2600,5200,7801,0401,3001,5601,8202,00,5201,0401,5602,0802,6003,1203,6403,00,7801,5602,3403,1203,9004,6805,4604,01,0402,0803,1204,1605,2006,2407,2805,01,3002,6003,9005,2006,5007,8009,1006,01,5603,1204,6806,2407,8009,36010,9207,01,8203,6405,4607,2809,10010,92012,7408,02,0804,1606,2408,83010,40012,48014,5609,02,3404,6807,0209,36011,70014,04016,38010,02,6005,2007,80010,40013,00015,60018,200
Gerpex Installation
22
22
In order to guarantee the free movement of pipes in an installation inside a vertical shaft with horizontal branches, the branches must have a minimum free length Ls and the passage through the side wall of the shaft should be free and the pipe protected with a sheath (Fig. A and B).Where pipes are concealed or embedded in screed (laid in the oor), thermal expansion can be compensated for by creating an insulated curve at least every 10m (for example with an insulating foam sheath or by passing the pipe through exible tubing).Note: where the pipes are being used in radiant circuits (spiral or serpentine for underoor heating/cooling), these guidelines do not apply!
In surface mounted installations or installations in false ceilings and shafts, longitudinal thermal expansion can be compensated for through careful arrangement of xed and sliding brackets (points), depending on the type of installation, thus providing suitable thermal expansion compensators.Where:= External diameter of pipe (mm)WithL = 15,6 mm (previous example),the result will be:
FP
FPFP
LL
LL
FPSPSPL
FPSP
LLFP: Fixed point
Ls
Ls
In case the size of the shaft doesn’t allow for a compensator of length Ls, the hole in the side wall should be increased in size and at the same time the tube should be protected with an
Gerpex Installation
23
23
Multi-jaw press ttingsCuttingCut the multilayer pipe with a pipe cutter or shears, verifying that the cut is perpendicular to the pipe axis. Calibration – FlaringCalibrate the cut end using the relevant calibrator, which calibrates and ares the ends of the pipe (Fig. C).This operation is essential, as it ensures the correct internal diameter of the pipe and creates the rounded end that eases insertion of the tting. Insertion the ttingInsert the tting into the pipe fully home; the sight hole in the plastic ring ensures correct insertion can be seen (Fig. D).PressingPlace the jaws around the plastic ring (Fig. E) by matching the collar of the plastic ring with the groove of the jaws (Fig. F). Start the hydraulic press-tting tool until it clicks, signalling the completion of the press-tting operation (Fig. G). The operation must be done carefully so that the pipes are kept free of any tension. Once the tting has been pressed, avoid placing the joint under any tension.Completion of pressingRemove the pressing device and open the jaws again.
Fig. CFig. D
Fig. G
Fig. EFig. F
Fig. AFig. B
24
24
CuttingCut the multilayer pipe with a pipe cutter or shears, verifying that the cut is perpendicular to the pipe axis.
Calibration – FlaringCalibrate the cut end using the relevant calibrator, which calibrates and ares the ends of the pipe (Fig. C).This operation is essential, as it ensures the correct internal diameter of the pipe and creates the rounded end that eases insertion of the tting.
Inserting the ttingInsert the pipe into the monoblocco tting, checking correct insertion through the slot in the nut (Fig. A). ScrewingScrew the nut and tighten using a hexagonal wrench, without excessive force. (Fig. B).
Fig. A
Fig. B
Compression fittings
25
25
7
8
6
9
9
4
7
6
7
Distribution with manifold
1
2
9
Distribution with ‘T’ ttingSeries distribution in a wall
3
44
3
44
9
9
5
Examples of installation
1
2
34
5
67
9
9
8
26
26
Gerpex – Water at 10 °C
1200,291581500,214000,351158000,421300,321821700,234400,391368600,451261400,342081900,264800,421589200,481421500,372342100,291085200,461829800,511591600,392622300,321265600,5020710400,541761700,422912500,351466000,5323411000,581941800,443222700,371676400,5726211600,612131900,473542900,401896800,6029112200,642332000,493873100,432137200,6432212800,672532100,524223300,462377600,6735413400,702752200,543500,482638000,7138714000,732962300,564953700,512908400,7442214600,763192400,595333900,543188800,7845715200,803422500,615724100,573479200,8149415800,833662600,646134300,593779600,8553316400,863912700,666554500,6240810000,8857217000,894162800,696984700,6544110400,9261317600,924432900,717424900,6847410800,9565518200,954693000,747885100,7050811200,9969818800,984973100,768345300,7354411601,0374219401,015253200,798825500,7658012001,0678720001,055533300,819305700,7961712401,1083420601,085833400,849805900,8265612801,1388121201,116133500,8610316100,8469513201,1793021801,146443600,8810846300,8773613601,2098022401,176753700,9111370,9014001,24103123001,207073800,9311916700,9381914401,27108323601,237393900,9612466900,9586314801,31113624201,277734000,9813037100,9890715201,34119124801,308064101,0113607301,0195215601,38124625401,338414201,0314197501,0499816001,41130226001,36876
4301,0614797701,06104516401,45136026601,399124401,0815397901,09109316801,49141827201,429484501,1116018101,12114217201,52147827801,459854601,1316648301,15119217601,56153928401,4910224701,1517281,17124318001,59160029001,5210604801,1817938701,20129418401,63166329601,5510994901,2018588901,23134718801,66172730201,5811385001,2319259101,26140019201,70179230801,6111785101,2519939301,28145419601,73185831401,6412195201,2820629501,31151020001,77192532001,6712605301,3021329701,34156620401,80199232601,7113015401,3322039901,37162320801,84206133201,7413445501,35227510101,40168021201,87213133801,7713865601,38234810301,42173921601,91220234401,8014305701,40242210501,45179922001,95227435001,8314745801,42249610701,48185922401,98234735601,8615185901,45257210901,51192022802,02242136201,8915636001,47264911101,53198223202,05249536801,9316096101,50272711301,56204523602,09257137401,9616556201,52280511501,59210924002,12264838001,991702
Distributed pressure drops
27
27
Gerpex – Water at 10 °C
10000,325320000,4030000,3611000,3622000,4435000,4212000,3924000,4840000,4913000,4226000,5245000,5514000,4528000,5610250000,6115000,4910830000,6011555000,6710116000,5212132000,6412960000,7311817000,5513434000,6814465000,7913518000,5814836000,7215970000,8515419000,6216338000,7617475000,9117420000,6517840000,8019180000,9719521000,6819442000,8420885001,0321622000,7121144000,8822590001,0923923000,7522846000,9224495001,1526324000,7824548000,96263100001,2128725000,8126450001,00282105001,2731326000,8428252001,04302110001,3334027000,8830254001,08323115001,3936728000,9132156001,12344120001,4639529000,9434258001,16366125001,5242530000,9736360001,20388130001,5845531001,0138462001,24411135001,6448632001,0440664001,28434140001,7051833001,0742866001,32458145001,7655134001,1045168001,36483150001,8258435001,1447570001,40508155001,8861936001,1749972001,44534160001,9465437001,2052374001,48560165002,0069038001,2354876001,52587170002,0672739001,2757478001,56614175002,1276540001,3060080001,60642180002,1880441001,3362682001,64670185002,2484442001,3665384001,68699190002,3043001,4068186001,72728195002,3792544001,4370988001,76758200002,4396745001,4673790001,80789205002,49101046001,4976692001,84820210002,55105347001,5379694001,88851215002,61109748001,5682596001,92883220002,67114249001,5985698001,96915225002,73118850001,62886100002,00948230002,79123551001,66918102002,05982235002,8512825200
1,69949104002,091016240002,91133053001,72982106002,131050245002,97137954001,751014108002,171085250003,03142955001,791047110002,211121255003,09147956001,821081112002,251156260003,15153057001,851115114002,291193265003,21158258001,881149116002,331230270003,27163559001,921184118002,371267275003,34168860001,951220119502,401295280003,401742
28
28
Gerpex – Water at 50 °C
1200,291261500,214000,358000,421300,321451700,234400,391088600,451001400,341651900,264800,421269200,481131500,371862100,295200,461459800,511261600,392082300,321005600,5016510400,541401700,422312500,351166000,5318611000,581541800,442562700,371336400,5720811600,611691900,472812900,401506800,6023112200,641852000,493083100,431697200,6425612800,672012100,523353300,461887600,6728113400,702182200,543633500,482098000,7130714000,732352300,563933700,512308400,7433514600,762532400,594233900,542528800,7836315200,802722500,614544100,572759200,8139315800,832912600,644874300,592999600,8542316400,863112700,665204500,6232410000,8845417000,893312800,695544700,6535010400,9248717600,923512900,715894900,6837610800,9552018200,953733000,746255100,7040411200,9955418800,983943100,766625300,7343211601,0358919401,014173200,797005500,7646112001,0662520001,054393300,817395700,7949012401,1066220601,084633400,847785900,8252112801,1370021201,114873500,868196100,8455213201,1773921801,145113600,888606300,8758413601,2077822401,175363700,919030,9061714001,2481923001,205613800,939466700,9365114401,2786023601,235873900,969906900,9568514801,3190224201,276134000,9810357100,9872015201,3494524801,306404101,0110807301,0175615601,3825401,336684201,0311277501,0479316001,41103426001,36696
4301,0611747701,0683016401,45108026601,397244401,0812227901,0916801,49112627201,427534501,1112718101,1290717201,52117427801,457824601,1313218301,1594617601,56122228401,498124701,1513721,1798718001,59127129001,528424801,1814238701,20102818401,63132129601,558734901,2014768901,23106918801,66137130201,589045001,2315299101,26111219201,70142330801,619365101,2515839301,28115519601,73147531401,649685201,2816379501,31119920001,77152832001,6710005301,3016939701,34124320401,80158232601,7110335401,3317499901,37128820801,84163733201,7410675501,35180610101,40133421201,87169233801,7711015601,38186410301,42138121601,91174834401,8011355701,40192310501,45142822001,95180535001,8311705801,42198210701,48147622401,98186335601,8612055901,45204210901,51152522802,02192236201,8912416001,47210311101,53157423202,05198136801,9312776101,50216511301,56162423602,09204137401,9613146201,52222711501,59167524002,12210238001,991351
Distributed pressure drops
29
29
Gerpex – Water at 50 °C
10000,3220000,4030000,3611000,3622000,4435000,4212000,395824000,4840000,4913000,4226000,5245000,5514000,4528000,5650000,6115000,4930000,6055000,6716000,5232000,6410360000,7317000,5510734000,6811465000,7910718000,5811836000,7212670000,8512219000,6212938000,7613875000,9113820000,6514240000,8015280000,9715421000,6815442000,8416585001,0317222000,7116744000,8817990001,0919023000,7518146000,9219395001,1520924000,7819548000,96208100001,2122825000,8120950001,00224105001,2724926000,8422452001,04240110001,3327027000,8823954001,08256115001,3929128000,9125556001,12273120001,4631429000,9427158001,16290125001,5233730000,9728860001,20308130001,5836131001,0130562001,24326135001,6438632001,0432264001,28345140001,7041133001,0734066001,32364145001,7643734001,1035868001,36383150001,8235001,1437770001,40403155001,8849136001,1739672001,44424160001,9451937001,2041674001,48445165002,0054838001,2343576001,52466170002,0657839001,2745678001,56487175002,1260840001,3047680001,60510180002,1863841001,3349782001,64532185002,2467042001,3651984001,68555190002,3070243001,4054186001,72578195002,3773444001,4356388001,76602200002,4376845001,4658590001,80626205002,4980246001,4960892001,84651210002,5583647001,5363294001,88676215002,6187148001,5665596001,92701220002,6790749001,5967998001,96727225002,7394350001,62704100002,00753230002,7998051001,66729102002,05780235002,8510185200
1,69754104002,09807240002,91105653001,72779106002,13834245002,97109554001,75805108002,17862250003,03113455001,79832110002,21890255003,09117456001,82858112002,25918260003,15121557001,85885114002,29947265003,21125658001,88913116002,33976270003,27129859001,92940118002,371006275003,34134060001,95968120002,411036280003,401383
30
30
Gerpex – Water at 80 °C
1200,291171500,214000,358000,421300,321351700,23554400,391018600,451400,341541900,264800,421179200,481051500,371732100,295200,461359800,511181600,391942300,325600,5015410400,541301700,422162500,351086000,5317311000,581441800,442382700,371246400,5719411600,611581900,472622900,401406800,6021612200,641722000,492873100,431577200,6423812800,671882100,523123300,461767600,6726213400,702032200,543393500,481958000,7128714000,732192300,563663700,512158400,7431214600,762362400,593943900,542358800,7833915200,802532500,614244100,572579200,8136615800,832712600,644544300,592799600,8539416400,862892700,664854500,6230210000,8842317000,893082800,695174700,6532610400,9245417600,923282900,715494900,6835110800,9548518200,953473000,745835100,7037611200,9951618800,983683100,766175300,7340211601,0354919401,013883200,796535500,7642912001,0658320001,054103300,816895700,7945712401,1061720601,084313400,847265900,8248512801,1365221201,114543500,867636100,8451513201,1768821801,144763600,888026300,8754413601,2072522401,174993700,918410,9057514001,2476323001,205233800,938816700,9314401,2780223601,235473900,969226900,9563814801,3184124201,275724000,989647100,9867115201,3488124801,305974101,0110077301,0170515601,3892225401,336224201,0310507501,0473916001,4196426001,36648
4301,0610947701,0677416401,45100626601,396754401,0811397901,0980916801,49105027201,427024501,1111858101,1284517201,52109427801,457294601,1312318301,1588217601,56113928401,497574701,1512791,1792018001,59118529001,527854801,1813278701,2095818401,63123129601,558134901,2013758901,2399718801,66127830201,588435001,2314259101,26103619201,70132630801,618725101,2514759301,28107619601,73137531401,649025201,2815269501,31111720001,77142432001,679325301,3015789701,34115920401,80147532601,719635401,3316309901,37120120801,84152633201,749945501,35168410101,40124421201,87157733801,7710265601,38173710301,42128721601,91163034401,8010585701,40179210501,45133122001,95168335001,8310915801,42184810701,48137622401,98173735601,8611245901,45190410901,51142122802,02179136201,8911576001,47196011101,53146723202,05184736801,9311916101,50201811301,56151423602,09190337401,9612256201,52207611501,59156124002,12196038001,991260
Distributed pressure drops
31
31
Gerpex – Water at 80 °C
10000,3220000,4030000,3611000,3622000,4435000,423412000,3924000,485840000,494313000,4226000,526645000,5514000,4528000,5650000,6115000,4930000,6055000,6716000,5232000,6460000,738717000,559934000,6810665000,7910018000,5811036000,7211770000,8511419000,6212138000,7612975000,9112920000,6513240000,8014180000,9714421000,6814442000,8415485001,0316022000,7115644000,8816790001,0917723000,7516946000,9218095001,1519424000,7818248000,96194100001,2121325000,8119550001,00209105001,2723226000,8420952001,04223110001,3325127000,8822354001,08239115001,3927228000,9123856001,12254120001,4629329000,9425358001,16271125001,5231430000,9726860001,20287130001,5833731001,0128462001,24304135001,6436032001,0430064001,28321140001,7038333001,0731766001,32339145001,7640834001,1033468001,36357150001,8243335001,1435170001,40376155001,8836001,1736972001,44395160001,9437001,2038774001,48414165002,0051138001,2340676001,52434170002,0653839001,2742578001,56454175002,1256640001,3080001,60475180002,1859541001,3382001,64496185002,2462442001,3684001,68517190002,3065443001,4050486001,72539195002,3768544001,4352588001,76561200002,4371645001,4654690001,80584205002,4974746001,4956792001,84607210002,5577947001,5358994001,88630215002,6181248001,5661196001,92653220002,6784549001,5963398001,96678225002,7387950001,62656100002,00702230002,7991451001,66679102002,05727235002,859495200
1,69703104002,09752240002,9198453001,72727106002,13245002,97102154001,75751108002,17803250003,03105755001,79775110002,21829255003,09109556001,82800112002,25856260003,15113257001,85825114002,29883265003,21117158001,88851116002,33910270003,27121059001,92877118002,37938275003,34124960001,95903120002,41966280003,401289
32
32
To determine localised pressure drops of plants with Gerpex ttings, it is possible to refer to the following values for the loss coefcient (), which can be obtained from technical literature.v²/2p = pressure drop (Pa = 0.01 mbar)= loss coefcient= volume mass of the uid (kg/m³)
°ρ [kg/m³]200,99820,99220,998320,9718= speed of the uid (m/s)
Fitting figure
1,8
1,6
2,4
2,2
2,4
2,2
1,8
3,2
3,0
Pressure drops fittings
33
33
Quality Certifications
34
34
Notes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….
35
35
Notes………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….
6 Tannery YardWitney Street Burford Oxfordshire www.emmeti.co.ukRespect the environment!For a correct disposal, the different materials must be divided and collected according to the regulations in force.All rights are reserved. This publication nor any of its contents can be reproduced or publicised without Emmeti’s written authorisation.The data contained in this publication are subject to change at any time, for technical and commercial requirements.Emmeti are not responsible for eventual errors or inexactitudes
Technical Product Guide
For more information please call us on www.emmeti.co.uk
CERT
Gerpex Press Fit Solutions
Technical Product Guide
For more information please call us on www.emmeti.co.uk
CERT
Gerpex Press Fit Solutions
