INSTAFLEX Technical Manual 2006

Technical Manual
Polybutylene PB The complete piping system

for heating, hot and cold
water, chilled water and
compressed air systems
P aten
t pend
ing
INSTAFLEX
INSTAFLEX
Technical Manual
6th Edition November 2004
GEORGE FISCHER
Piping Systems
GEORGE FISCHER
George Fischer Company Profile

Inventiveness and enterprise, a
thirst for knowledge and a sound
understanding of his craft, these were
characteristics of Johann Conrad
Fischer, who began producing cast
steel in crucibles in a former herb mill
in Schaffhausen in 1802. This was
the beginning of a new era of iron
processing on the European continent
as well as the cornerstone of a large
industrial enterprise now operating
worldwide.
Actual industrial production began
in the second half of the last century
with the development of malleable
iron foundries in Schaffhausen and
Singen, as well as the large steel
foundry in Schaffhausen. The first
diversification into areas other than
casting occurred in the 1920s, when
the largest engineering factory in
Schaffhausen was incorporated
into the George Fischer Works. This
factory manufactured copying lathes
and subsequently fully automatic
turning machines.
A major step towards diversification
into other materials was taken some
45 years ago. The diversity and
especially the aggressiveness of
media conveyed in pipelines led to
the extension of the product range in
the early fifties to include fittings and
valves made of high-grade plastics.
George Fischer now employs a workforce of over 14,000 in numerous
factories in Europe and elsewhere.
Its activities are combined in four
divisions: the automotive products,
which handle a wide range of
materials and focus mainly on the
automotive and power engineering
sectors; metal and plastic piping
systems with the increasingly
important measurement and control
technology; manufacturing
technology, with the emphasis on
automated and system-integrated

metal processing machines; and

finally, plant engineering and
construction, which is concerned
with solving process engineering
problems in the chemical industry,
plastics production and processing,
food production and casting.
George Fischer is a company which
has earned a worldwide reputation
through the high technological
standard of its products and their
outstanding quality. The applied
engineering know-how which
George Fischer has acquired and
keeps up-to-date via its extensive
consulting activities, is utilized for
the benefit of users in the design of
products for maximum practicality
and ease of installation.
A whole series of innovative new
developments, such as a bead and
crevice free fusion jointing system,
or a secondary containment piping
system, highlight the pioneering role
played by George Fischer in the field
of piping systems.
Plant engineers in particular
appreciate the product consistency
and accuracy of tolerances,
maintained over many years.
Products from George Fischer
bearing the trademark have
become a byword with professionals
and cover a large part of the
range of metal and plastic products
necessary for pipeline construction
in industry, building services and
communal supply networks.
GEORGE FISCHER
George Fischer Piping Systems,

Schaffhausen.
George Fischer Distribution

Centre Coventry (DCC)
GEORGE FISCHER
Introduction
The technical data given in
this publication are for general information purposes only
and is liable to change. They
imply no warranty of whatever kind. Please consult our
General Conditions of Supply.
This manual contains all the essential

information on the George Fischer
plastic piping system INSTAFLEX
for use in commercial, industrial
and domestic hot and cold water
installations.
It has been written for use in the UK
market taking into account current
standards and regulations. Since
these are under regular review
the reader should ensure that their
application complies with the current
legislation.
The manual has been subdivided
into three main sections:
general,
materials,
technical.
The general section at the

beginning of the manual is an
introduction to hot and cold water,
potable water distribution in
domestic, industrial and commercial
installations as well as plastic
materials technology.
In the materials section the
plastic polybutylene (PB) and other
materials used in the system are
discussed.
In the technical section you will find
all the essential data for planning,
processing, installing and operating.
GEORGE FISCHER
Overview
Company Profile
Introduction/Overview/Table of Contents
List of abbreviations
General Information
Technical Regulations (Standards etc.)
Chemical Resistance
INSTAFLEX System Technology
Dimensional Information
Expansion & Contraction
Flow Characteristics
INSTAFLEX Jointing
GEORGE FISCHER
Contents
The INSTAFLEX System Philosophy
1 .02
What is INSTAFLEX? 1 .03
What is Polybutylene? 1 .04
Why polybutylene (PB)? 1 .05 - 1 .09
Comparison between different materials and jointing techniques 1 .10
Plastics and the environment 1 .11 - 1 .14
History of Polybutylene 1 .15
Characteristics of Polybutylene 1 .16 - 1 .17
Application range for INSTAFLEX pipe & fittings 1 .18 - 1 .19
Standards and Regulations

Tests and Quality Assurance
Legionella-proof Operation
Hygiene Standards
Fire Protection
Noise Protection
Insulation of Water Pipes
Heat loss from INSTAFLEX
Surface temperature of INSTAFLEX pipe
Insulation of Hot Water Pipes
Trace Heating
Heaters for Potable Water
Flushing Potable Water Pipes
Disinfection of Potable Water Systems
Pipework Additives
Approvals in Europe
2.02
2.03
2.04
2.04
2.05
2.06
2.07
2.07
2.07
2.08
2.09
2.09
2.10
2.10
2.10
2.11
Chemical Resistance
3.02
INSTAFLEX system technology

Multistorey Installations
Pipe Layout
Individual Pipeline
Continuous Pipeline
Ring Main
T-piece Branching
Continuous Pipeline with Circulation
Pipe Layout for Large Flow Rates
Pipe Layout in Screed Floors
Pipe Layout in the Masonry (Recessed Mounting)
Pipe Layout in Dry lined & Partition Walls
Frostproof Pipe Laying
Curvature Radius
4.02
4.03
4.03
4.03
4.03
4.04
4.04
4.04
4.05
4.05- 4.06
4.07
4.08
4.09
4.10
Comparison of pipe dimensions

z Dimension installation method
Application examples
Conclusions for practical use
Fitting combinations
5.02
5.03 - 5.04
5.05 - 5.07
5.08
5.09 - 5.15
GEORGE FISCHER
Contents (contd.)
Introduction
Change in length
Allowing for expansion or contraction
Bracket spacing
Determining Pressure Loss in Piping Systems Using the
INSTAFLEX Calculation Method
2.1 Determining Pipe Diameter
2.2 Manifold Distribution
2.3 Distribution Mains
2.4 Entire Installation
Blank INSTAFLEX Pressure Loss Table
British Method and Data
Calculation example based on C.I.B.S.E.
Excerpts from the C.I.B.S.E. guidelines
Simultaneous demand peak flow tables
Pressure loss and flow velocity tables
Equivalent pipe length tables
Flushing Times for Dead Legs
Terms, Symbols and Units
INSTAFLEX Jointing
Compression jointing
Fusion Jointing
Electrofusion Jointing
Cutting & joining INSTAFLEX sleeve
Cutting & preparing INSTAFLEX carrier
Handling & storage instructions for INSTAFLEX
COSHU Regulations for cleaning fluid
Safety considerations for machinery
Operational tests & ordinary maintenance
Common faults in fusion jointing
INSTAFLEX Installation Quick Reference Guide

GEORGE FISCHER
6.01
6.02
6.03
6.04 - 6.07
6.08 - 6.12
7.01
7.02
7.03
7.05
7.05
7.06
7.07
7.09
7.10
7.11 - 7.13
7.14
7.15
7.16 - 7.17
8.01
8.02
8.03 - 8.48
8.49 - 8.57
8.58 - 8.60
8.61
8.62
8.63 - 8.66
8.67 - 8.72
8.73
8.74 - 8.81
8.82
Abbreviations
The following is a list of abbreviations
used in this catalogue:
ABS Acrylonitrile-Butadiene-Styrene
ASA American Standards Association
BSP British Standard Pipe (Thread)
CSM Chlorine Sulphonyl Polyethylene
(e.g. Hypalon)
CR Chloroprene Rubber (e.g. Neoprene*)
DIN Deutsche Industrie Normen (German Industrial
Standards)
DN Nominal Bore (of pipe)
EPDM Ethylene Propylene Rubber
FPM Fluorine Rubber (e.g. Viton*)
g
Weight in grammes
GP Carton (Gross Pack)
GRP Unsaturated Polyester resin glass-fibre
reinforced
IIR Butyl Rubber
ISO International Standardisation Organisation
kg Weight in kilogrammes
NBR Nitrile Rubber
NP Nominal Pressure
NR Natural Rubber
PB Polybutylene
PE Polyethylene
POM Polyoxymethylene (e.g. Kematal**)
PP Polypropylene
PTFE Polytetrafluoroethylene (e.g. Teflon*)
PVDF Polyvinyliden Fluoride
PVC-C Chlorinated Polyvinylchloride
PVC-U Unplasticised Polyvinyl Chloride
R
Taper Thread
Rp Parallel Thread
SP Standard Pack
* Duponts registered trade name
** ICIs registered trade name
GEORGE FISCHER
INSTAFLEX
The modern versatile piping system
A full range of pipe and fittings makes the INSTAFLEX system highly versatile.
Allowing prefabrication and being

lightweight make the installation of an
INSTAFLEX system highly cost effective.
GEORGE FISCHER
INSTAFLEX the plastic piping

system for complete services
installations in one material
The efficient distribution of services in buildings is a

demanding undertaking. The plastic piping system INSTAFLEX
from George Fischer meets these high requirements.
Suitable for:
Application
Temp
Working pressure
Heating systems
82C
7bar
Hot water services
65C 10bar
Cold water services 10C 16bar
Chilled water systems
5C 16bar
Compressed Air
20C 16bar
Above figures based on 50 year lifespan and safety factor of 1 .5.

10
GEORGE FISCHER
General Information
Page
The INSTAFLEX System Philosophy
What is INSTAFLEX?
What is Polybutylene?
Why polybutylene (PB)?
Comparison between different materials and jointing techniques
Plastics and the environment
History of Polybutylene
Characteristics of Polybutylene
Application range for INSTAFLEX pipe & fittings
GEORGE FISCHER
1 .02
1 .03
1 .04 1
1 .05 - 1 .09
1 .10
1 .11 - 1 .14
1 .15
1 .16 - 1 .17
1 .18 - 1 .19
1 .0
The INSTAFLEX system philosophy

We offer various solutions for the
optimal installation of pipework
systems, but the designer and the
installer have the final say.
This manual is intended for both
designers and installers and
offers guidelines for the design
and installation of the INSTAFLEX
pipework system. George Fischer's
extensive knowledge in pipework
installations as well as in the
manufacturing of plastic piping
systems is the background for this
manual.
1 .0
It incorporates the experience

George Fischer has gained from
many years of active participation
in various national and international
standards and professional
associations. Our own accredited
testing facilities and close cooperation with the pipe and raw
materials manufacturers validates the
contents of this manual.
This manual in conjunction with the
current product range forms the basis
required for system layout.
GEORGE FISCHER
What is INSTAFLEX?
The versatile pressure piping
system for building services
For use on:
Hot & cold water services
Heating systems
Chilled water
Compressed airlines
The INSTAFLEX system has been

designed for use as a complete
building services piping system which
provides a solution to the problems
faced by traditional materials
namely:
No corrosion
No encrustation/limescale
No noise emmission
Long service life
High flexibility
Fast assembly
Lightweight
Launched in 1980 into mainland

Europe and into the UK in 1995
this system has provided installers
and designers with a flexible system
which meets the stringent demands
of modern building design and
construction.
Material
Manufactured from polybutylene
(PB), a high performance plastics
material, which was specifically
developed for use in piping systems
for potable water. Its inherent
charachertistics make it ideal for
this purpose and for other building
services applications.
Range
A full range of pipe and fittings are
available with adaptors to join onto
other piping system components.
GEORGE FISCHER
Pipe & fittings 16 -110mm

Pipe-in-sleeve
Accessories & jointing
equipment
Valves

Jointing & installation
The INSTAFLEX system utalises three
complimentary jointing techniques:
socket fusion
electrofusion
compression fittings
Each of which have advantages

depending on the installation in
question. Most installation tend to
incorporate more than one type of
jointing method.
Due to the flexibility of the system and
the material's lightweight significant
savings can be made on installation
time and costs.
Technical advice & support
George Fischer's expertise and
technical knowledge in the piping
system field is recognised worldwide.
In order to assist designers and
installers in the optimum use of the
INSTAFLEX system the following
support is available :
On-site support & advice
Design take-offs
Certificated jointing training
courses
Technical support
CAD
Custom products
1 .0
What is Polybutylene (PB)?

Polybutylene is a thermoplastic from
the polyolefine family. It is a semi-crystalline material. Its density is in the
range of other thermoplastics such
as PE or PP. It has good mechanical
properties and chemical resistance
making polybutylene an important
material for piping systems.
Flexibility, even at low temperatures,

high thermal stability make polybutylene a modern material. Not only for
hot and coldwater distribution but
also in
industrial applications and compressed air.
George Fischer are able to supply
metric socket and electro fusion pipe,
fittings and valves as well as mechanical joints in the following size range.
PB is created by polymerizing butylene (C4H8) and is, therefore, an ecologicaly safe hydrocarbon product.
The material which we use, may be
used with foodstuffs due to its safe
stabilizing agent. The fittings and
pipes are odourless and tasteless
as well as physiologically safe. It
is perfect for use in drinking water
installations.
socket fusion 16mm - 110mm o.d.

electro fusion 16mm - 110mm o.d.
Like PE and PP, PB belongs to the

group of co-valent materials, whose
surfaces do not swell and are not
soluable. Solvent cementing is,
therefore, not possible without special
surface treatment. PB is, however,
easily fused. Compression, socket
fusion and electrofusion jointing can
be used.
The physical values shown in the table below

are to be treated as guide values.
Properties of Polybutylene
1 .0
Property
PB
Density
0.93
g/cm3
Melt flow index MFI @90/5
0.4
g/@0 min
Yield strength
17
N/mm2 Testing
Elongation at fracture
>125
Bending-creep modulus (@ min.)
800
N/mm2
Impact strength 23 C
Impact strength 20 C
no failure
40
mJ/mm2
mJ/mm2
Crystalline fusion temperature
0.013
Coefficient of linear expansion
0.13
mm/mC
Thermal conductivity at 20 C
0.22
W/m . K
Surface resistance
0.007
Normal working temperature range
-15 to 95
Unit
speed
@25 mm/min
GEORGE FISCHER
At George Fischer every

plastic is used to the
best of its potential.
Why polybutylene (PB)?

Why did George Fischer choose the
plastic, polybutylene (PB) as a pipe
material for INSTAFLEX potable water
installations?
Crosslinked polyethylene PEX was
the first plastic to be used successfully
in Europe for hot and cold water
installations.
also started using this material
in 1982.
PP
PVC-C
PE
With the development of

Polybutylene PB 4137 by Shell
in collaboration with George Fischer,
the market had a new, modern pipe
material.
Both materials combine the following
characteristics, required for water
services installations:
high heat resistance,
good stress resistance,
high impact strength,
low creep behaviour,
high flexibility.
PEX and PB are both suitable as
pipe materials for compression
jointing. In addition, PB, a polyolefine
thermoplastic, is excellent for fusion
jointing of pipes and fittings.
PB
PEX
Polybutylene's strength and versatility also make it

suitable for:
GEORGE FISCHER
Hot & cold water services

70C, 10bar pressure based on a
design life of 50 years for continuous
use with a safety factor of 1 .5
Compressed air systems

design life of 50 years with a safety
factor of 2.
Heating systems
design life of 50 years for intermittent
use, with a safety factor of 1 .5
High temperature drainage

95C, low pressure, high life expectancy.
Chilled water systems

Down to -5C, 10bar pressure based
on a design life of 50 years for
continuous use with a safety factor of
1 .5.
Fan coil units Two pipe systems

Where temperatures may fluctuate
from below 0C in the summer (cooling) up to 85C in winter (heating)
at10bar pressure based on 50 years
life expectancy, with a safety factor
of 1 .5
1 .0
Density
PB
PEX
0.93
0.94
= Rho
The density of a body
is the ratio of its mass m
to its volume V.
PP-R
PVC-C
0.90
1 .55
= m
V
Water
Steel
Copper
1 .00
7.85
8.89
Thermal conductivity can

be defined as the energy
transmissability of a material,
in relation to the difference
between the pipe inner and
pipe outer temperatures and
the pipe wall thickness.
H2O
Thermal conductivity
PB
0.22
PEX
0.41
W/mK
= Lambda
g/cm3
(kg/dm3)
Why PB?
A comparison of PB and other plastics
PP-R
PVC-C
0.24
0.14
Water
Steel
Copper
0.58
42 to 53
407.10
100
Pipe length
10 m
Temp.-Difference
The heat expansion

coefficient refers to the
difference in length,
measured in mm, of a 1m
rod after heating it by1K.
Note: 1K (Kelvin) = 1C
Expansion & contraction a

PB
PEX
0.13
0.20
PP-R
PVC-C
0.18
0.08
Steel
Copper
Stainless Steel
0.012
0.018
0.026
65
40
6
St
PE
1 .0
50 C
mm/mK
= Alpha
90
9
Cu
PB
PEX PP-R PVC-C
GEORGE FISCHER
The E-modulus is the

ratio of stress to strain in
the elastic range of the
material.
Expansion loop comparison

Although the coefficient of
expansion for PB is not the lowest
due to the material's flexibility (i.e.
it's modulus of elasticity is by far
the lowest), the ability to cater for
any expansion or contraction is
most favourable
expansion
1
10m
Using a typical example, with

values
Temp difference
t =

50C
Pipe diameter
d = 40mm
Pipe length = 10m
The expansion of L of the different
materials is as follows:
PB
PEX
PVC-C
PP - R
Steel
Copper
Stl. Steel
L
L
L
L
L
L
L
= 65mm
= 100mm
= 40mm
= 90mm
= 6mm
= 9mm
= 9mm
using the formula

LBS = C x L x d
where LBS =

L =
expansion

d =

C =
Creep is the extension of a

material in relation to time
under constant load and
constant temperature.
expansion loop leg

primary pipe
outside dia.. of pipe
factor
Creep behaviour
Creep behaviour is an important
factor in plastic construction. It must
be given special consideration with
jointing and fastening techniques.
It can be seen from the adjacent
graph that with a creep test, where a
weight is hung from a piece of PB its
creep is slower than PEX
Therefore, under the same

conditions the expansion leg
required for the different materials
would be as follows:
Material
Expansion leg LBS
PB
PEX
PVC-C
PP-R
Steel
Cu
Stl. Steel
510
760
1360
1800
1450
1030
1150
As can be seen from the above the

expansion leg required for PB is
considerably less than all the other
materials.
PEX
20
Creep %
Determining the expansion

loop according to
CEN/TC. 155/WG 5
C for:
PB
10
PEX
12
PE 27
PVC-C 34
PP-R
30
Steel 94
Cu
54
Stl.Steel 61
LBS
10
PB
Tensile strength
8 MPa (8 Nmm2)
Temp. 20 C
10-3
100
103
Time in hours
GEORGE FISCHER
1 .0
= Sigma/Break
The hoop stress in the pipe
wall is the result of internal
pressure. If this pressure is
continuous the pipe will
fracture with time
Comparison of minimum breaking

strengths of PB, PEX, PP-R, PVC-C, applying to a material life expectancy
of one year at different temperatures.
Safety against breakage

due to stress from internal
pressure is given with the
relationship between pipe
wall stress to hoop stress.
1 MPa = 1 N/mm
100
90
80
70
60
50
Hoop stress in MPa
Minimum breaking strength

The minimum breaking strength is
given as the hoop stress .
40
30
20
PB
PVC-C
10
9
8
7
6
PEX
5
4
3
PP
20
30
40
50
60
70
80
90
100
Temperature in C
} {
MPa
50
40
30
20
Hoop stress in MPa
Long-term Behaviour
The long-term behaviour is the
relationship between the hoop
stress, the temperature and the life
expectancy of a material.
Allowable permanent internal
pressure in bar:

P perm = 20 s 6R

SF on a service
Hoop stress(d-s)
is based
life of 50 years and a constant
operating temperature of 70 C,
without considering the safety factor
Pperm Internal pressure
for:
s
Pipe wall thickness
PB
7.5
d
Pipe outer-
R
PEX
5.3
SF
Safety factor
PP-R
3.1

Minimum breaking

strength (R = Rupture) PVC-C
7.5
Long-term behaviour of pipes at 70C
PB
PEX
PP
1
0.9
0.8
0.7
0.6
0.5
0.1
10
Time in hours
1 .0
PVC-
10
9
8
7
6
5
4
102
103
104
105
106
50 years
GEORGE FISCHER
In reference to the 70C

curve with a service life of
50 years and safety factor
included, on page 1 .18
Comparison of potable water pipes used in domestic
installations.
Comparision of flow characteristics

The pipe wall thickness is determined
by the hoop stress, the pipe outer diameter and the allowable operating
pressure at 20C.
Example for pipes 40mm o.d., with DVGW/SVGW approval

Pipe Material
PB
PEX
PP-R
PVC-C
3.7
6.7
4.5 mm
Pipe inner diameter
32.6 29.0 26.6
31 .0 mm
Nominal pressure
GEORGE FISCHER
PN 16
5.5
Pipe dimension d 40 x
Pipe inner surface area 834
v = Velocity
Because at any given size the wall

thickness of PB pipe is less than the
other materials the flow velocity and
pressure drop will be best.
660
555
PN 20
PN 20
Flow velocity at
= 2.0 l/s 2.4
3.0
Pressure drop at
= 2.0 l/s
18.4
32.5

754 mm2
PN 25
3.6 2.7 m/s

49.5 23.6 mbar/m
1 .0
Jointing Techniques
The basis for selecting a jointing method for plastic pipes are the physical
characteristics of the various materials, e.g.:
type of plastic
creep behavior
brittleness
stability
flexibility
PB
Compression
Fusion
Solvent Cement
Electrofusion
PEX
PVC-C
Jointing Technique
PP-R
Advantages & disadvantages of each method:

Advantages

No power supply required

Easily made in-situ

No specialist tools
Disadvantages

Fittings generally more costly

Not suitable for larger pipe

sizes

Jointing time
Fusion jointing
Advantages

Jointing time fast

No solvents used

Flushing requirements reduced
Solvent jointing
Advantages

No power supply required
Disadvantages

Solvents need careful flushing

Solvent fumes

Drying Time

Electrofusion
Advantages

Easily made in-situ

Disadvantages

Power source required

Disadvantages

Power source required

1 .10
GEORGE FISCHER
Plastics and the Environment

Using plastics means saving energy
Plastics represent only 4 % of the crude
oil consumption in Europe. But as we all
know, crude oil reserves are limited. We
must already rely on raw materials which
can be renewed or expand our use of
alternative energy sources. This is often
referred to as re-usable raw materials.
All working processes require energy

(heat, pressure, motor-driven).
Manufacturing plastics requires less
energy than manufacturing metals. To
manufacture 1 litre 3 of material, the
amount of energy required is shown in
the chart below
Plastic, e.g.. polyolefine (PE/PP/PB)

Steel
Copper
Aluminium
0
10
5
(Kilograms oil-equivalent/litre material)
15
A Plastic's Second Life

Recycling
Plastics only represent 4 % of crude oil
consumption, but it is realistic to assume
that the energy value of plastic must be
utilized.
There are two recycling possibilities:
re-use, create new products,
incineration, create thermal energy.
In the re-using method, plastic waste is
returned to its original state via various
processes, such as hydrolysis, pyrolysis,
regranulation.
At George Fischer production waste is

ground (regranulated) and returned to
the manufacturing of products, which
have lower requirements for quality
and hygiene than pipes and fittings. For
instance, hand levers for valves, actuator
housings, etc.
Materials considered recyclable are
mainly thermoplastics, such as PE, PP, PB,
PVC, PVC-C.
PEX, crosslinked polyethylene, cannot be
recycled.
Recoverable heat energy of different materials

PE/PP/PB
Heating Oil
Coal
PVC-U/PVC-C
Paper
Wood
Household waste
Metals
GEORGE FISCHER
44000 kJ/Kg
44000 kJ/Kg
29000 kJ/Kg
19000 kJ/Kg
16800 kJ/Kg
16000 kJ/Kg
8000 kJ/Kg
0 kJ/Kg
1 .11
Recycling Possibilities
From production to end consumption
Tar
Coal
Refinery products
Crude oil/gas
Secondary
raw materials
Powder
New
materiGranules
Granules
Powder
Production
industry
Chemical
raw mate-
Granulate
Processing
industry
Using energy
Long-distance
energy/electricity
heating gas
Preparation
(e.g. wash,
crushing)
Finished products
Special operations
Pyrolysis
(simple fittings)
Refuse
power
plant
Sort re-usable
plastics
Mixed
plastic waste
Agriculture
Industry
Business
Households
Waste
dump
1 .12
GEORGE FISCHER
Ecological Analysis
Environmental analyses for determining
the environmental pollution produced
by a product, process or from a
service provides important information.
To be able to make a comprehensive
statement, it is important to include
all the aspects which influence the
product, process through its entire life
cycle.
Plastic and metal pipework systems
were analysed from the obtaining
of the raw material, via material
and component production, to
final installation, with regard to the
environmental effect.
VENOB
Comparative consideration
standardised as regards the
results.
VENOB is a development
from the Technical University of Berlin, by Professor
Dr.Kufer and colleagues
Pressure loss per storey

1800mbar
Supply pressure 4bar
The emission data determined for soil,
water and air pollution were converted
into dimensionaless values.
The material with the lowest amount of
total pollution emissions was evaluated
with the factor 1 and the other
materials correspondingly higher.
Soil Pollution Characteristics

45.0
44.0
A simplified, undistorted interpretation

of the data relevant to the environment
can only be obtained by the VENOB
process.
40.0
35.0
The VENOB process ensures that the

large amount of recorded emission
data from soil, water and oil
pollution studies can be included
and the results can be compared.
The pollution levels are recorded
as independent, dimensionless
characteristics. The emissions which
occur simultaneously for all pipework
systems are taken into account in the
process.
Pipeline systems made of the
following materials were subjected to
environmental analysis:
PB
Polybutylene
PEX
x linked polyethylene
PP-R
Polypropylene random

copolymer
PVC-C Polyvinyl chloride, post

chlorinated
Cu
Copper
St.
Galvanised steel
30.0
25.0
20.0
15.0
12.0
10.0
4.0
PB
Plastics
Cu
St
Water Pollution Characteristics

4.4
The pipeline systems shown were

judged according to the following
boundary conditions:
Drinking water installation
according to DIN 1988 Part 3
Block of flats with 16 individual
flats
Central hot water supply,
Insulation according to HeizAn
1V
3.5
3.0
2.0
PB
Plastics
GEORGE FISCHER
Cu
St
1 .13
Air Pollution Characteristics
Total Energy Characteristics

18.0
4.4
17.0
16.0
-15.0
-3.0
14.0
13.0
12.0
11 .0
10.0
9.0
8.0
7.0
6.0
4.0
3.0
2.0
PB
Plastics
Cu
St
The soil, water and air pollution

determined show higher values for
the metal systems (Cu & St) than for
plastics.
Soil, water and air pollution are,
however, only part of a comparative
ecological analysis. The energy
equivalent values and the installation
weights also have to be considered.
These two points of view were again
related to the complete installation of
the block of flats.
PB
Plastics
Cu
St
First, a comparative environmental

analysis for plastics and metal systems
was carried out by the VENOB
process. The environmental analysis
corresponds to the ideas of the
German Federal Environmental Ministry
for producing and balancing the
relevant data.
The result clearly shows greater
environmental pollution from metal
pipework compared to plastics. There
are also differences between the
plastic pipework systems.
The use of pipeline systems made of
plastics, above all of the materials PB
(polybutylene) therefore represents an
environmentally friendly solution.
Installation Weight
Characteristics
7.0
The environmental analysis was carried

out and the VENOB process was
developed in the Plastics Department
of the Technical University of Berlin,
by Professor Dr Helmut Kufer and
colleagues.
6.0
5.0
4.0
3.0
2.4
2.0
PB
Plastics
1 .14
Cu
St
GEORGE FISCHER
The History of Polybutylene (PB)

In the early 1970s, a polybutylene was
brought on the market by the Hls
Chemischen Werken under the name of
Vestolen BT 8000.
The material was intended for the
conveyance of hot media in piping
systems.
At this time George Fischer had also
prepared a fitting programme of
Vestolen BT 8000. Many domestic
and industrial systems constructed
with this material are still operating
satisfactorily today. In 1973, production
of polybutylene was terminated at Hls
due to the oil crisis and other reasons.
Independent of Hls, another
firm, Whitron Corp., developed a

polybutylene called Whitron 4121 .
Shell took over this product. In 1978
George Fischer tested polybutylene for
use in potable water distribution. Various
stabilizers were tested. Long-term tests
were carried out with the stabilizer 4137,
which met our requirements. Since 1987
George Fischer have been using the
material polybutylene 4137 by Shell for
INSTAFLEX potable water piping systems.
The Material Polybutylene (PB) 4137

Polybutylene is a thermoplastic from the
polyolefine family. It is a semi-crystalline
material. Its density is in the range of
other thermoplastics such as PE or PP.
It has good mechanical properties,
chemical resistance and its especially
high temperature behaviour, makes it an
important material for piping systems.
PB is created by polymerizing
butylene (C4H8) and is, therefore, an
ecologically favourable hydrocarbon
product.
The material type 4137, which we use,
is permitted according to food laws due
to its stabilizing agent. The fittings and
pipes are odourless and tasteless as
well as physiologically safe. It is perfect
for use in drinking water installations.
minimal creep (advantageous for

compression jointing)
resistance to hot water
high resistance to stress cracking
stabilization against UV damage
anti-algae pigmentation
high flexibility even at low
temperatures
low brittleness fracture temperature
high impact strength
high abrasion resistance
easy to use
due to high thermal stability, small
pipe wall thicknesses. Therefore, large
pipe inner diameter, leading to better
pipe hydraulics
lightweight
Like PE and PP, PB belongs to the group

of covalent materials, whose surfaces do
not swell and are not soluble. Solvent
cementing is, therefore, not possible
without special surface treatment. PB
is, however, easily fused. Compression,
socket fusion and electrofusion jointing
can be used.
Flexibility, even at low temperatures, plus
high thermal stability make polybutylene
a modern material. Not only for potable
water distribution but also in industrial
applications.
Polybutylene, the universal plastic for
compression and fusion jointing offers:
longevity and dimensional stability
GEORGE FISCHER
1 .15
Characteristics of Polybutylene
Mechanical and physical properties
Properties
Value
Unit
Density
0.93
g/cm
DIN 53479
Melt temperature
122128
DTA
Vicat softening point
113
DIN 53735
Glass transition point
18
ASTM D-746
Fusion heat
kJ/kg
DSC
0.22
W/mK
DIN 52612
Thermal expansion coefficient
0.13
mm/mK
DIN 53752
Modulus of elasticity
350
MPa
DIN 53457
Shore hardness
53
D-Scale
ISO 8608
Impact resistance
40
(0 C) kJ/m2 DIN 53453
Ultimate elongation
100
Standard
3
DIN 53457
Tensile strength
33
125
MPa
DIN 53455
Yield stress
17
MPa
DIN 53455
The ultimate elongation indicates

at what percentage of elongation a
material will tear.
The melt temperature is the

temperature range in which a material
will change from a solid to a liquid state.
The modulus of elasticity represents

the stress-strain relationship in the elastic
range of a material.
Fusion heat is the heat required to

convert 1 kg of a material from the solid
to the liquid state at melting temperature.
The impact resistance indicates the

amount of energy needed to break or
deform a sample by letting a pendulum
of known kinetic energy collide against
it.
Thermal conductivity represents the

energy transmission within a material
depending on the temperature and the
surface.
The Shore hardness is the hardness of a

material; the smaller the given value, the
softer the material is.
Values 3039 = leathery

4060 = medium - hard
The Vicat softening point indicates at
what temperature a test stylus with an
area of 1 mm2 and a load of
10 N will penetrate a materialby 1mm.
At glass transition point, a material is at
its hardest and most brittle state and has
the highest mechanical properties. When
the temperature increases, the material
becomes softer and more elastic, but
also loses stability.
The density of a body is the ratio of its
mass m to its volume V.
The thermal expansion coefficient

indicates in millimetres the change in
length of a 1m rod with 1C temperature
change.
The yield stress is the point at which
the slope of the stress-strain curve
first reaches zero when a material is
constricted.
The tensile strength is the greatest
amount of force a material can absorb
before breaking.
Melt flow index This single point

measurement characterizes the flow of
molten material under certain conditions
of pressure and temperature. It gives an
indication of the material's processing
properties.
1 .16
GEORGE FISCHER
Chemical Resistance
(see also Section 6)
The chemical resistance of polybutylene
is similar to that of other polyolefine
plastics, such as PE and PP, although
certain differences do exist.
resistant to
acids, alkalines,
weak solvents
not resistant to
oxidizing acids,
halogens
UV-Resistance
Compared to colourless plastics,
polybutylene is more resistant to UV
radiation due to its grey pigmentation.
Long-term exposure to UV radiation in
Curacao showed no material damage to
polybutylene pipes left unprotected over
a period of two months.
It is not necessary to protect the pipes
against UV light when they have been
laid inside a building.
WRAS Approval
Tests carried out in accordance with
the requirements of 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.
To be acceptable, a material must be
shown to give satisfactory results in tests
designed to determine that there is:
KTW recommendations:
Hygienic evaluation of plastics and other non-metallic
materials for use in potable
water systems in the framework of the Food and Consumer Products Act;1 . and
2. Report ff.; BGesundhBL
20 (1977), Vol.1, pg.10ff.
Plastics in the Food Industry, Recommendations of
the Federal Department of
Health: by R. Frank and H.
Mhlschlegel, Carl Heymanns Verlag KG, Kln, Berlin,
Bonn, Mnchen.
1)
GEORGE FISCHER
Fire Protection
Pipes made of polybutylene belong
to Flammability Class IV. 2 (normal
flammability) in the VKF classification and
are, therefore, permitted.
(a) no taste imparted to the water.

(b) no change in the appearance of
the water.
(c) no growth of micro-organisms in the
water in contact with the materials
or on the surface of the material.
(d) no release of substances into the
water that may be of concern to
public health.
(e) no release of metals into the water.
Hygienic Considerations
Shell has proven the absolute safety of
polybutylene 4137, regarding hygiene
for potable water pipes. The DVGM
research centre in the Engler-BunteInstitute at the University of Karlsruhe
has certified that polybutylene meets the
KTW recommendations1) of the German
Federal Department of Health.
1 .17
Application Range of INSTAFLEX PB Pipes

and Fittings
INSTAFLEX is used in installations for
hot and cold water pipes, heating
and chilled water systems and compressed airlines
The necessary operating criteria required for each country are not only
fulfilled, but exceeded.
Application Range of INSTAFLEX PB Pipes16 and 20mm o.d.
Continuous operating pressure in bar
PN 25
30
20
10
Life expectancy with SF = 1 .5
0
2
10
20
25
30
40
50
Years
Application Range of INSTAFLEX PB Pipes 25 to 110mm o.d.

30
Continuous operating pressure in bar
PN 16
20
10
Life expectancy with SF = 1 .5
0
2
1 .18
10
20
25
30
40
50
Years
GEORGE FISCHER
Temperature/Pressure rating
Example
The George Fischer INSTAFLEX system

is manufactured from polybutylene
which is a thermoplastic material. As
the name thermoplastic suggests, it is
affected by temperature. When the
temperature of the liquid in the pipeline
rises the material will soften and its
ability to withstand pressure reduces
correspondingly. To calculate the
pressure rating at any given temperature
the well known "vessel" formula is
used in conjunction with the long term
regression curves of the material.
SF for non-dangerous
liquids = 1 .5
SF for dangerous
liquids =2.0
or
Design life 50 years.
where

Safety Factor 1 .5
26
P=
x 20 x s
SF x (d-s)
SF =
x 20 x s
P x (d-s)
What is the maximum pressure for a

110mm pipe carrying water at 70C
with a working life of 50 years
s = for 110mm INSTAFLEX pipe is 10mm
SF = 1 .5
d = 7.5 MPa taken from long term

regression curve opposite.
P=
x 20 x s
SF x (d-s)
P=
7.5 x 20 x10
1 .5 x (110-10)
P = 10 bar
P = pressure in bar
= hoop stress of material at
any given temp. in M Pa
s = pipe wall thickness in mm
d = pipe o.d. in mm
SF = safety factor
Temperature/Pressure chart
24
16 & 20mm o.d. pipe
22
maximum allowable pressure rating in bar
20
18
16
25 & 110mm o.d. pipe
14
12
10
8
6
4
Note:
Size 16 & 20mm is
25 bar
25 to 110mm is
16 bar.
2
0
0
10
20
30
40
50
60
70
80
90
100
Temperature in C
GEORGE FISCHER
1 .19
1 .20
GEORGE FISCHER
Technical Regulations
Hygiene Standards
Fire Protection
Noise Protection
Insulation of Services
Heat loss from INSTAFLEX
Trace Heating
Flushing Potable Water Pipes
Pipework Additives
Approvals in Europe
GEORGE FISCHER
Page
2.02
2.03
2.04
2.04
2.05
2.06 2
2.07
2.07
2.07
2.08
2.09
2.09
2.10
2.10
2.10
2.11
2.0

The standards and regulations specific
to each country are the Bible of the
Water Installation Specialist.
The actual standards for water
installations are intended for both
mechanical services designers and also
for manufacturers. This is to ensure they
comply with the requirements for parts
and for materials.
Until uniform European Technical
Regulations for Water Installation
are established, the specific country's
Recognized Technical Guidelines are
valid.
Technical Regulations for Water
Installation are in:
UK

Water Byelaws &

British Standards
BS & WRAS
Germany

DVGW
DIN 1988 (TRWI)
Switzerland

SVGW
Guidelines W3
Austria

Standard in preparation
based on DIN 1988
BS 7291
Class S
Thermoplastic pipes
and associated fittings

for hot and cold water

for domestic purposes

and heating, chilled

water and compressed
air installations in
buildings

Part 1: General

requirements

Part 2: Specifications

for polybutylene (PB)

pipes and associated

fittings.

UK Water Fittings Scheme Listing
Germany DVGW
DIN 1988 (TRWI)
DIN 4109 Noise protection in
buildings
DIN 4102 Behaviour of construction
materials in fire
HeizAnlV
Heating installation
regulation
Switzerland SVGW
W3
Guidelines for the
installation of water
systems
SIA 181
Noise protection in
residential buildings
With these regulations in mind, the legal

requirements for hygienic and technical
suitability of parts and materials have
to be met. For the purposes of product
identification, the manufacturer is
required to label his products and the
installer is required to use only clearly
marked products.
For the construction of water systems, the
following standards and regulations must
be considered:
United Kingdom BS & WRAS
BS 5955 Specification for the
Pt 8
installation of thermo
plastic pipes and

associated fittings

for use in domestic hot

and cold water

services and heating

systems.
2.0
GEORGE FISCHER

SKZ Southern Germany

Plastics Center,

Wrzburg
Quality assurance has top priority at

George Fischer!
Standard guidelines on internal
and external tests, are set out in the
requirements for quality assurance of
pipes, fittings and other piping system
accessories.
The objective of the tests, besides
checking dimensional accuracy, is to
determine and monitor quality, which will
guarantee safe operation over a period
of 50 years.
The hygienic suitability of pipes and
components for the conveyance of
the foodstuff, drinking water, is
independently tested in accordance with
the appropriate standards. Only pipes
and fittings which have been successfully
tested and monitored for quality by
recognized, independent testing centres
may carry the seal of approval.
INSTAFLEX pipes and fittings are tested
and monitored for quality by the
accredited tests centres in the relevant
countries. The proof of suitability is
based on a service life of 50 years,
with reference to the specific country's
operating requirements (see 2.04).
GEORGE FISCHER
Under ISO and DIN standards as

well as existing test guidelines, the
manufacturer is obliged to continuously
evaluate the product through prescribed
tests, throughout the production
process. This is in accordance with
George Fischer's Quality Assurance
Manual, and is supported by periodic
external monitoring conducted by the
SKZ and others. This continuous and
stringent in-house supervision is the
basis of George Fischer's quality control
procedure.
Test Guidelines:
DVGW Worksheet
W 532/I

Worksheet
W 534 E
SVGW Construction and test
regulations

W/TPW 129
VGW NORM
B 5155

Guideline
W 38
KIWA Criteria
44
DIN 16968 and 16969 Pipes of
Polybutylene (PB)
KTW
Recommendations by the
Federal Department of Health
(BGes. BL. Jg. 1977, 1 . and 2.
Mitt. ff.)
BS/
Approval to British Standard
WRAS BS6920 and BS7291
2.0
Legionella are bacteria, which are
naturally present in many environments.
They multiply rapidly in hot water systems
where the temperature range is between
30 to 50C. Experiments have shown that
the material of the piping system has no
specific influence, which means, there
is no discernible difference between
copper, steel, galvanized steel and
plastic*.
The operating conditions, specified
by the DVGW, permit INSTAFLEX hot
water installations to be operated in
such a way as to prohibit the growth
of legionella. The INSTAFLEX ring main
makes it possible, via pumped circulation
with a corresponding hydraulic switching
system, to maintain an operating
temperature of 60C at 10 bar up to the
outlet.
In addition, periodic temperature
increases of up to 85C are possible at

this pressure (duration: approx. 1 hour
per week). Alternatively operating
temperatures may be maintained at
70C without compromising safety as
long as the operating pressure does
not exceed 10 bar.
INSTAFLEX layouts enables thermal
disinfection, thus preventing
legionella bacteria from accumulating
*) Dr. K. Seidel, Berlin: The Occurrence
and Significance of Legionella; 6.
Seminar of the DVGW 1988 New
Technologies in Potable Water Supply;
gwf 129 (1988), Vol. 2, pg. 105.
Hygienic Standards
For UK
INSTAFLEX pipes have been proven
hygienically sound; they are equally
suited for use in hot and cold water
systems. By WRAS according to BS6920
suitability of non-metallic products for
use in contact with water intended for
human consumption with regards to their
effects on the quality of water.
the Food and Consumer Products Act;

1st and 2nd Report ff.; BGesundhBL 20
(1977), Vol. 1, pg. 10 ff.
For Germany
The DVGW research centre in the
Engler-Bunte Institute at the University
of Karlsruhe has certified that
INSTAFLEX PB pipes meet the KTW
recommendations of the German Federal
Department of Health.
LMBG
Food and Consumer Products Act of 15.
8.1974; BGesundhBL Part 1, pg. 1945 ff.
INSTAFLEX is certified as being a suitable

material for use as a consumer product
in accordance with the Food and
Consumer Products Act.
Plastics in the Food Industry,

Recommendations by the Federal
Department of Health; by R. Frank and
H. Mhlschlegel, Carl Heymanns Verlag
KG, Kln, Berlin, Bonn, Mnchen.
For Austria
According to Decision ZI. IV-445.850/26/86 of the Federal Department of
Health and Environmental Protection
as well as the Report kl.1399/6-87 of
the Environmental Protection Institute,
Corporation for Public Rights.
KTW recommend.
Hygienic evaluation of plastics and other
non-metallic materials for use in potable
water systems within the guidelines of
2.0
GEORGE FISCHER
Fire Protection
Wherever INSTAFLEX pipe passes
through a fire resistant wall it must
be sleeved in a suitable intumescent
material.
This recommendation is in accordance
with Building Regulations sub section
10/AD B3
Class D Materials
In order to obtain a high product
performance classification, Building
Regulations sub section 10/AD B3
recommends that materials in these
areas be protected by 'Class D'
insulation or lining.
Burning Behaviour
When exposed to an open fire,
polybutylene will burn brightly and will
continue to burn after the source of fire
is removed. The fire gases and smoke
will smell similar to wax or paraffin. It
produces low smoke emmissions. When
the fire is extinguished, it will smell similar
to a blown-out candle.
Polybutylene has no harmful toxic or
corrosive bi-products of combustion since
there are no halogens in its molecular
structure.
GEORGE FISCHER
2.0
Noise Protection
Providing noise protection in water
services is best achieved by careful
planning and design. This is the most
effective method, least susceptible to
faulty installation and is cost effective.
The arrangement of the rooms is
important to optimise acoustics and
the corresponding layout of sanitary
equipment, fittings and pipes can
compliment this.
Furthermore, if the wall to which pipes

(supply or drainage), fittings or sanitary
equipment are to be connected to is
adjacent to a room which needs to
be protected from noise, then this wall
should have a surface density of 220
kg/m2 , in the absence of more suitable
information.
If the wall on which pipework (supply

or drainage) or sanitary fittings are to
be connected to is adjacent to a room
which needs to be protected from
noise, then this wall should be constructed from a suitable sound absorbant material
For sound conduction through solids, the
sound insulation of the material is an
important criteria. This is in relation to
the density and the modulus of elasticity
of the material.
In plastic pipes, the sound insulation
is high, which is why INSTAFLEX
polybutylene pipes are excellent for
noise prevention in water installations.
Sound velocity in materials
2.0
Density
kg/dm3
E-Modulus
N/mm2
Sound velocity
m/s
Copper
7.20 110 000
PB
0.93
350
620
PVC-C 1 .56
3 500
2350
3900
PEX
0.95
600
800
Soft rubber
0.90
90
320
GEORGE FISCHER
Insulation of Services
All pipe services must be insulated in
accordance with the current standards
of thermal efficiency as governed by the
project specification
INSTAFLEX has a very high sound and
thermal insulation property and therefore
careful consideration must be given
to the insulation thickness to gain the
maximum advantage from its use.
temperature of all sizes of tube and

can be used to determine the insulation
thickness
It is recommended that closed cell
flexible insulation is considered , such as
Armaflex for example, to permit
pre-insulation prior to installation to gain
the maximum advantage of flexibility of
the pipework during erection.
The following charts indicate both

the thermal heat loss and surface
Heat loss from INSTAFLEX pipe

(Watts per metre)
Temp. Difference Pipe size (mm)
C 16 20 25
32
40
50
63
75
90 110
10
4
5
7
9 11 13 15 18 20 23
15
7
8 11 13 16 20 23 26 30 34
20
9 11 14 17 21 26 31 35 40 46
25 11 14 18 22 26 33 38 44 50 57
30 13 16 21 26 32 39 46 53 60 69
35 16 19 25 31 37 48 54 61 70 80
40 18 22 28 35 42 52 61 70 80 92
45 20 25 32 39 48 59 69 79 90 103
50 22 27 35 44 53 65 77 88 100 115
55 25 30 39 48 58 72 84 97 110 126
60 27 33 42 52 63 78 92 105 120 128
65 29 35 46 57 69 85 99 114 130 149
70 31 38 49 61 74 91 107 123 140 161

(Based on ambient temperature of surrounding air 20C)
Fluid temp.
Pipe size (mm)
C 16 20 25
32
40
50
63
75
90 110
6
9 10
9 10 10 11 12 12 13 14
8 11 11 11 11 12 12 13 13 14 15
10 12 13 12 13 13 13 14 15 15 15
12 14 14 14 14 14 15 15 16 16 16
60
51 49 51 49 48 47 44 42 40 38
62
53 51 53 51 49 48 45 43 41 39
70
59 57 59 57 55 54 49 47 45 43
80
67 64 67 64 61 60 55 53 50 47
82
68 66 69 66 63 62 58 54 51 48
GEORGE FISCHER
2.0

Multistorey distributors for pipe-in-sleeve
hot water systems 16 and 20 mm o.d.)
need not be insulated , as long as it is
not used for secondary circulation.
Pipe
Protective sleeve
Need not be insulated
2.0
GEORGE FISCHER
Trace Heating
Self-regulating trace heaters whose
surface temperature does not exceed
65C may be used with INSTAFLEX
pipes. The trace heating limits the water
temperature to 60C.
For better heat transmission the trace
heating should be attached as flatly
as possible along its entire length of
the pipe by means of wide aluminium
adhesive tape. For pipes with carriers,
the strip heater must be attached to the
carrier and not between the pipe and
the carrier.
Insulation
Aluminium
Adhesive
Tape
Trace Heater
Power Source
The installation instructions of the manufacturer

should also be observed.
Pipe
Carrier
Trace
Heating
Insulation

The maximum temperatures compatible
with constant operation of the system can
be found in the operating requirements.
Continuous flow heaters which heat
water as it passes through a specific
length of pipe have been tested and
approved for use with INSTAFLEX pipes.
They should be thermostatically not
hydraulically controlled, this is because
with hydraulically controlled devices
there is a danger of overheating from
uncontrolled boosted heating.
To protect pipe and joints, temperature

controllers or safety temperature limiters
must be used to ensure that at no time
or location will the water temperature
exceed 95C .
For hydraulically controlled devices, the
shut-off mechanism must ensure that the
pressure can never exceed 10 bar with
booster heating effects.
Hot water heaters should be located as

near as possible to the hot water output.
The length of the pipe from the heater
essentially determines the flushing time for
the dead leg to each outlet.
GEORGE FISCHER
2.0
Flushing Water Pipes

Water pipes must be flushed thoroughly
to remove any rust, shavings, cutting oil
residue and fluxing agents.
The pipes should be flushed with drinking
water in an intermittent air-water mixture
under pressure.
Due to corrosion reasons this type of
flushing is mandatory for metal pipes.
it does not corrode, no solvents, fluxes

or cutting oils are used. The assembly
methods employed are clean using only
compression or fusion joints.
A flushing of the system must nevertheless
be carried out for hygienic reasons. This
is easily achieved by filling the system
with drinking water and opening the
drainage valve to thoroughly rinse the
pipework system.
With INSTAFLEX there is no need for

this costly flushing procedure, because

The consequences of drinking water being
contaminated with pathogenic germs
could be so serious that it is essential that
such risks are avoided.
Correct disinfection of potable water
systems is an important step in ensuring
that the strict microbiological standards in
the potable water regulations are met.
Disinfectants are hazardous materials
for health and the environment. Their
use must be carefully planned taking
into consideration industrial safety and
environmentally safe disposal after use.
Lfd.
Description
Permissible
Nr.
Addition

mg/l
Limit value
calculated
Reaction products
after
as
Limit value
calculated
preparation
after prep.
as
mg/l
mg/l
Chlorine 1 .2
0.3
Sodium-,
Calcium-,
Magnesium-,
hypochlorite
Bleach
free
0.01
chlorine
Trihalogen
methane
Chlorodioxide 0.4
CIO2
Chlorite
0.2
0.2
3
Ozone 10
0.05
O 3
0.01
Trihalogen

methane

Pipework Additives
Its is a standard requirement for additives

to be used in all closed circuit piping
systems.
With INSTAFLEX no treatment is required,
however, the other elements of the
installation will require protection with a
commercially available inhibitor. Due to
the extensive range of products available
we would recommend that if a technical
specification sheet on the product is sent
to our Coventry sales office (address
on the back cover) we shall advise the
10
2.010
Possible Disinfectants
Sodium hypochlorite
Hydrogen peroxide
Potassium permanganate
Chlorine
NaOCl
H2O2
KMnO4
Cl2
The disinfection of pipes can be carried

out with or without the water circulating
but the disinfectant solution must remain
in the pipework system for no less than
12 hours. If the pressure test is done
with water containing disinfectant, the
increased pressure forces the solution
into the pores and crevices of the
pipework achieving a more effective
result.
The pipes must be rinsed thoroughly
after disinfection. Before putting the
system into operation, it must be made
certain that the disinfectants present
in the drinking water do not exceed
acceptable concentrations.
Guidelines for the Disinfection of Potable
Water according to EG Guidelines from
July 15, 1980.
suitability with polybutylene

At the time of printing this manual
we have received no information on
products which should not be used with
INSTAFLEX.
GEORGE FISCHER
Approvals in Europe
Keuringsinstituut
voor waterleidingartikelen
Kiwa nv
2

DVGW
Deutscher Verein des Gasund Wasserfaches e. V.

sterreichische Vereinigung
fr das Gas- und Wasserfach

SVGW
Schweiz. Verein des Gasund Wasserfaches
SSIGE
Socit Suisse de lindustrie
du Gaz et des Eaux
SOCOTEC
DIRECTION TECHNIQUE
Dpartement des
Equipements Techniques
The comprehensive INSTAFLEX

approvals in the respective countries
include:
compression joints from 16 to 63mm
o.d. inclusive,
socket fusion joints from 16 to 63mm
o.d. inclusive,
as well as system accessories.
GEORGE FISCHER
Sddeutsches
Kunststoffzentrum
Officially recognized test
institute
for plastics
AGREMENT
TECHNIQUE
AVEC
CERTIFICATION
TECHNISCHE
GOEDKEURING
MET
CERTIFIKAAT
11
2.011
12
2.012
GEORGE FISCHER
Chemical Resistance List

for Polybutylene (PB)
Page
General
Classification
Pipe Joints
Sealing Materials
Metallic Materials
3.02
3.02
3.02
3.02
3.03
GEORGE FISCHER
3.0
General
Pipe Joints
The Chemical Resistance List is only intended as a guide. Changes in the composition of the medium or special working conditions could lead to deviations.
If there is any doubt, it is advisable to
test the behaviour of the material under
the specific operating conditions.
No guarantees can be given regarding
the information contained in this manual.
The data is based on the information
available at the time of printing.
It will occasionally be revised in the light
of subsequent research and experience.
Fusion Joints
In the case of PB, fusion joints have practically the same chemical resistance as
the pipe material. However, for media
which could cause stress cracking, the
fusion joints can be susceptable to increased residual stresses.
Classification
Sealing Materials
The customary classifications, resistant,

conditionally resistant and not recommended are depicted by the signs +, O
and repectively . This makes presentation and application easier. These classifications are defined as follows:
The life expectancy of sealing materials

can differ greatly from that of the pipe
material determined by the operating
conditions and stress involved.
Resistant: +
The material is not significantly affected
by the medium within the acceptable
operational limits of pressure and temperature.
Conditionally resistant: O
The medium can be aggressive to the
materials or causes swelling. Restrictions must be made regarding pressure
and/or temperature, taking the expected
service life into account. The service life
can be noticeably reduced. Further consultation with George Fischer is recommended.
Flange and Threaded Unions

For flange and threaded union connections, the material of the sealing element
must be considered.
Material:
EPDM
Ethylene-Propylene-Rubber
Good ozone and weather resistance,
potable water quality. Especially suitable
for aggressive media. Not
recommended for oils and fats. Temperature, 90 C constant, 120 C shortterm.
NBR
Nitrile-Rubber
Good resistance to oils and gasoline.
Temperature, 90 C constant, 120 C
short-term.
Not recommended:
The material cannot be used with the
medium, or only under special conditions.
Chemical Resistance Lists
Can be made available upon request

or visit www.georgefischer.co.uk
3.0
GEORGE FISCHER
Metallic Materials
The metallic materials mostly used in INSTAFLEX systems are:
Brass (Ms)
according to DIN 17660
in the quality
CuZn 39 Pb 3
and
CuZn 39 Pb 2
These materials correspond to the requirements for potable water installations

according to DVGW and SVGW Guidelines.
For other, non-domestic potable water systems, the use of these materials should be checked.
Bronze
G-CuSn 5 Zn Pb
Stainless Steel
12 NiCr 18/8
GEORGE FISCHER
3.0
3.0
GEORGE FISCHER
System Technology
Multistorey Installations
Pipe Layout
Individual Pipeline
Continuous Pipeline
Ring Main
T-piece Branching
Pipe Layout for Large Flow Rates
Pipe Layout in the Masonry (Recessed Mounting)
Pipe Layout in Dry lined & Partition Walls
Curvature Radius
GEORGE FISCHER
Page
4.02
4.03
4.03
4.03
4.03
4.04
4.04
4.04
4.05
4.05- 4.06
4.07
4.08 4
4.09
4.10
4.0

Pipe longitudinal line
alignment marks (every 45), for

component assembly
Marks for insertion depth (welding length)
Description with:
name of manufacturer
dimension
material
product code
Alignment markings on the fittings
and the pipe longitudinal line make
it easier to assemble components and
alleviate the time-consuming process
of pre-marking the fitting and the pipe
in order to ensure they are aligned
properly. Work becomes quicker and
more precise.
Insertion depth marking
(Welding length)
Marking the insertion depth on the pipe,
ensures the pipe is not inserted to far into
the fitting, this will prevent the formation
of inner beads in the fusion zone,
when the fusion procedure is followed
correctly.
PB risers, the change of direction used as an

expansion loop
Multistorey distribution, in
concrete floor or ceiling.
4.0
GEORGE FISCHER
Multistorey Installation
The efficient distribution of water in
buildings is a difficult task. INSTAFLEX
meets this challenge and provides a
solution for installations in both new and
in refurbished buildings.
Whether in single family homes,

luxurious apartment buildings, public
housing, offices or commercial buildings,
INSTAFLEX offers the best possible
solution.
Pipe Layout
It is possible to install INSTAFLEX piping
with either the traditional layout of Tpiece branches or use the reliable pipe
- in - sleeve technique. This is achieved
by using flexible PB pipe which comes in
straight lengths or in coils, with or without
protective sleeves.
Individual lines, continuous lines, ring

mains, T-piece branches and continuous
lines with circulation as well as the
associated fittings make for optimal
water distribution, possible at every floor
of a building.
Individual Pipeline
R HW CW
Easy planning
Simple pressure loss calculation and
size selection
Every tap is supplied by a separate
line
Low pressure losses, short flushing time,
maximum comfort
Single tap connections
With pipe-in-sleeve installation, replacement of pipe is very simple
Continuous Pipeline
R HW CW
GEORGE FISCHER
More taps are supplied with a single

pipe
Fewer pipes are required
Increased pressure losses (largest
water consumer should be located at
beginning of pipeline)
Single and double tap connections
4.0
Ring Mains
R
HW CW
T-Piece Branches
R HW CW

R HW CW
4.0
Every tap is supplied with water from

two sides
No stagnated water
Pressure loss usually reduced by 1/3 of
that for continuous lines
Double tap connections
Several taps can be supplied with one

line
Less space is required for pipes
When renovating, installation in existing recesses may be possible
Fittings in fusion and/or compression
versions
Single tap connections
Legionella-proof operation
Maximum efficiency.
HW available up to tap
GEORGE FISCHER
Pipe Layout for Large

Flowrates
Flowrates with a flow volume of
E 0.4 l/s can be connected with parallel supply pipes of 16mm o.d..
For parallel supply lines (2 x 16mm o.d.)
the pressure loss is about 20% less than
that for a single supply pipe in the next
highest size (20mm o.d.). Parallel supply
pipes are especially useful where only
low supply pressures are available.
Example:
Outflow valve
E = 0.6 l/s
Single line 20mm o.d.
R = 110 mbar/m
Dual line 2 x 16mm o.d.
(E = 0.3 l/s each)
R = 90 mbar/m
Difference
20 %
R HW CW

The introduction of flexible pipe-in-sleeve
installation systems (e.g. INSTAFLEX with
PB pipes) had a dramatic impact on installation techniques. New layout techniques, which not only improved efficiency
but also provide increased design flexibility for the installer and designer.
The pipe-in-sleeve installation in screed
floors, similar to the installation of electric

cables in the coiled protective tube, has
simplified and accelerated installation
techniques. Laying pipes in the screed
has proved to be one of the best installation methods now available.
Repair/replacement of damaged pipework

One of many innovative aspects of this
method of installation is the ability to
easily replace a water carrying pipe
which has been accidently damaged by
drilling or nails. A major advantage of
the pipe-in-sleeve installation is that the
water-conveying pipe is separated from
the building structure by the protective
sleeve.
GEORGE FISCHER
When the installation is carried out properly (observing the minimum curvature
radius) using the installation fixtures provided, mechanical damage of the pipes
is practically impossible. The pipes can
be replaced at any time.
4.0
Pipe layout on the concrete

floor in the insulation layer
with deformation-resistant
covering.
Pipe Layout on Concrete Floor

If pipes are laid on a supporting base
(concrete floor), which serves as a floating floor.
Sound penetration and/or fluctuations in
the floor thickness should be avoided.
Pipe layout on the concrete

floor in the insulation or
screed layer with deformation-resistant bedding.
Pipes which are laid in the supporting

base (normally 75mm deep - of which
50mm represents the distance between
the top of the pipe and the surface of the
support base) or in the insulation must
be imbedded for stability or securely
fastened. By filling in any gaps, an even
surface can be re-established for the insulating layer.
When two pipes are laid parallel in the
insulation with deformation-resistant covering, the requirements for sound insulation from footsteps are fulfilled.
Pipe layout entirely within

the insulation layer with deformation-resistant bedding.
If recesses are planned in the concrete

floor for laying pipes, they can easily be
run across the floor slab in this conduit.
Pipes which are laid in the pipe conduit
in the concrete floor or in the insulation must be in protective sleeves. Pipes
which are imbedded directly in the floor
or floor heating over the insulation can
be laid without protective sleeves.
For other floor coverings, e.g. hot asphalt, it must be made certain that the
plastic pipes laid in or under the insulation are not damaged.
Pipe layout in the floor

recesses with deformationresistant bedding.
Floor
Concrete
floor
Insulation
layer
Bedding
Cover
4.0
GEORGE FISCHER
Pipe Layout in the Masonry

(recessed mounting)
Although there are regulations in some
countries against recessed mounting, it
can still be found in renovation and modernizing work.
In new constructions, especially when the
pipes are laid on or in the concrete floor,
recessed mounting is recommended.
Horizontal wall recesses should be avoided where possible.
Purpose made installation systems

enable fittings to be attached efficiently
in wall recesses.
The pipe-in-sleeve installation makes
insulation or protection of the pipe in the
masonry unnecessary.
GEORGE FISCHER
4.0
metal bars with plaster

boards
1)
Pipe Layout in Lightweight Construction Walls

For the installation of multistorey pipes
in dry lined & partition walls1) or wood
walls, the stresses arising from the fittings
and their operation will be transmitted to
the supporting structures.
The pipe fittings can be attached with a
combination of INSTAFLEX mounting
accessories and those supplied by wall
manufacturers.
4 2
INSTAFLEX
Distance plate
Plate
Pipe fitting
Wall Manufacturer
Mounting rail
Mounting plate
4.0
GEORGE FISCHER

An important rule in frostproof pipe
laying in heated buildings is to locate
the pipes in parts of the building where
the temperature will always be above
0C. If this rule is even partially violated,
there is an increased danger of water
freezing in the stagnation points.
Out-
Insulation
Inside
For those parts of the building where the

temperature may fall below 0C , e.g.
edges of basement floor, garages and
driveways, the pipes should be laid in
a frost-free zone to prevent danger of
freezing.
Wrong
The wrong installation. The pipe could
be exposed to frost via the cold bridge.
Cold
bridge
Out-
Insulation
Inside
Installations which are exposed to frost

should be drained normally. Ice crystals
in water pockets is not a problem for INSTAFLEX polybutylene (PB) pipes.
GEORGE FISCHER
Right
The correct installation. The pipe has
been laid in the warm zone.
Frozen pipes can be de-iced according

to the INSTAFLEX defrosting method, see
Section 8 Repairs.
4.0
Curvature Radius
INSTAFLEX PB pipes 16, 20 and
25mm o.d. must always be bent
cold. The materials require a minimum curvature radius of
R 8 x o.d.
Conveying pipe
Protective
sleeve
o.d.
Fastening the pipes

in curves
Pipe

16mm o.d.
20mm o.d.
25mm o.d.
R = 130 mm
R = 160 mm
R = 200 mm
Pipes from dimension 32 to 63mm

o.d. can be bent up to a 30 angle
with a curvature radius
R 15 x mm o.d. cold.
Bending INSTAFLEX PB pipes
warm on the construction site is
not permitted.
When moving from the floor

to the wall or within wall
channels, it is necessary to
ensure that the minimum
curvature radius is observed.
4.10
GEORGE FISCHER
Dimensional information
Comparison of pipe dimensions
z Dimension installation method
Application examples
Conclusions for practical use
Fitting combinations
Page
5.02
5.03 - 5.04
5.05 - 5.07
5.08
5.09 - 5.15
GEORGE FISCHER
5.0
Comparison of Pipe Dimensions

Due to the smooth internal bore of
INSTAFLEX pipe similar flow velocities
produced by traditional materials
can achieved with a smaller internal
diameter INSTAFLEX pipe. The tables
below provide a guide for the selection of pipe size x size i.e.
INSTAFLEX = 20 mm o.d.
Steel
= 1/2" o.d.
Copper
= 18 mm o.d.
INSTAFLEX PB Pipes
o.d. (mm)
16,6 20,6 25,6 32,6 40,6 50,6 63,6 75,6 90,6 110
ID (mm) 11 .6 14.4 20.4 26.0 32.6 40.8 51 .4 61 .2 73.6 90.0
Steel Pipes galvanized DIN 2440/44
1
3
o.d. (inch)

/2
/4
1
11/4 11/2
2
ID (mm)
16.0 21 .6 27.2 35.9 41 .8 53.0
21/2
68.8
3
80.8

4,6
105.3
Copper Pipes DIN 1786/ISO 274

o.d. (mm)
15
18
22
28
ID (mm) 13 16 20 25
5.0
35
32
42
39
54
50
76.1 88.9 108

72.0 85.0 103
GEORGE FISCHER
z-Dimension Installation
Introduction
The z-dimension assembly method is
used to aid the measurement of pipe
lengths between fittings, developed
by George Fischer together with experienced installers in the domestic
and industrial installation sector. It
has proven to be very successful for
many years.
As a basis for efficient design, factory
preparation and pre-assembly, this
method saves the enterprising contractor a considerable amount of time
and money. It makes:
efficient use of employees
administration easier
calculations and accounting easier
efficient use of machinery
reduced stocks of fittings and pipes
transportation easier, less material
distribution time.
thod
z-dimension and a uniform measuring method are at the core of this
assembly method by George Fischer.
The z-dimension is the construction
measurement of the installer. This allows him to calculate easily the exact
pipe length between fitting and/or
valves.
The basis for the calculation and application of the z-dimension is
The z-dimension method requires

exact planning of pipe layout
knowing the dimensions of valves,
appliances and their location
coordination of architect, designer,
contractor as well as any others
involved in the construction whose
work could effect the pipe layout
use of fittings with constant dimensional and axis accuracy, as those
manufactured by George Fischer
standard pipe connections, which
can be easily installed with George
Fischer fittings and pipes.
z-Dimension and Measuring Me-
In order to work out the length the

pipe needs to be cut to you need:
the centreline to centreline pipe
section, indicated by M
the z-dimension for fittings and
valves
the construction height h for fittings
with outer joint ends
to take into consideration the jointing length x for pipe sections
The exact pipe length L can then be
easily calculated.
x1
z2
Uniform Measuring
Centreline - Centreline =
M
x2
z1
GEORGE FISCHER
5.0
Measurement of Fitting
Fitting with outer joint end

C
Fitting with inner joint end

C
h = height of fitting
L =centreline
l = length of fitting from centreline

z = z-dimension
x = length of joint
Elbow 90 with inner and outer joint

ends (socket spigot)
The z-dimension is the difference between the construction length L and

the joint length x.
z = lx
Elbow 90 with two inner joint ends

(sockets)
l
Inner joint ends are referred to as

sockets and outer joint ends as spigots.
Type of joints available in pipe construction are:
plug connections
compression joints
threaded unions
soldered joints
fusion joints
solvent cement joints
flange adaptors
5.0
GEORGE FISCHER
Application Examples
z
z2
z1
z2
/2 seal
z1
M = h + z
M = l + z1 + z2 + 1/2 seal
M
M = h + z 1 + z2
GEORGE FISCHER
5.0
M2
z2
l
z1
z2
l
z1
h
M1
M = l + z 1 + z2
l = M (z1 + z2)
5.0
M1 = h + z
M2 = l + z1 + z2
GEORGE FISCHER
a
z
h
z
45
M = z + h
b = M x 0.707
a = M x 0.707 + (z + h)
h
z
a
45
M = h + z
a or b = M x 0.707
a
z
b
z
b
45
M = z + h
a or b = M x 0.707
45
M = a or b x 1 .414
M = l + 2z
l = M 2z
GEORGE FISCHER
5.0
Conclusions for Practical Use

The z-dimension assembly method by
George Fischer is the proven basis for
small-scale and industrial pre-assembly of threaded pipe installations.
It combines various processes to produce a fast and efficient way of using
materials, labour and of avoiding
unnecessary assembly steps. It makes
economic and high-quality solutions
possible .
This requires :
Dividing the piping system and installation into manageable sections.
Dividing installation into pre-assembly (in the workshop or on site)
and site assembly work. It is advantageous to prepare as much as
possible before going on site in the
workshop.
Preparing all the important pipe dimensions, so that pre-assembly can
be done in quick succession.
The most important rule is:
Use as much information on pipe
sections as possible from the installation drawings.
Attention: pre-assembled pipe

combinations should never be so
bulky that they cannot be easily
transported or installed on site.
When sections must be prepared on

site (to compensate for variations in
the structure):
Always measure along the path of
the pipes.
The z-dimension assembly method by
George Fischer enables:
pre-assembly
efficient use of materials, labour
and machinery
shorter assembly times
quick adjustments to construction
progress and site conditions
independence of construction schedules
better control of outside contracts
better conditions for renovation
work
more accuracy with less effort
consistent quality
To be able to exploit these advantages to the fullest, installation planning must be given equal priority in
project planning. Efficient construction begins in the planning stage with
complete details and coordinated
information.
Note: The z-dimension method is

not synonymous with prefabrication; it can be used wherever pipes
with fittings are installed.
z-dimension method for different materials

Taking into consideration the varying
characteristics of metal or plastic piping systems, the z-dimension method
by George Fischer can also be used
with all of them.
5.0
GEORGE FISCHER
Fitting Combinations
Fittings with socket fusion joints
Elbow 90
All dimensions
in mm
Dimension
M
o.d. mm
16
44
20
49
25
58
32
68
40
80
50
96
63 116
T-equal
a
Elbow 45
5
Dimension
a/b
o.d. mm
16 27
20
30
25
35
32
41
40
48
50
56
63
68
Elbow 90 / T-equal
M
Elbow 90
Dimension
M
o.d. mm
16
44
20
49
25
58
32
68
40
80
50
96
63 116
Elbow 90
a
Elbow 45
Dimension
a/b
o.d. mm
16 25
20 26
25
30
32
35
40
41
50
47
63
56
Elbow 45
GEORGE FISCHER
5.0
Elbow 90
T-red
a
Elbow 45
T-red
Minimum Distance between Fittings
a
z
Elbow 45
z
L
z
T-equal or Elbow 90
Elbow 45
L
a
b
T-equal or Elbow
90 & Reducer
5.10
Dimension
o.d. mm
20-16
25-16
25-20
32-16
32-20
32-25
40-25
50-25
63-25
Dimension
o.d. mm
20-16
25-16
25-20
32-16
32-20
32-25
40-25
50-40-25
63-40-25
a/b
47
51
53
57
59
64
70
77
88
30
32
33
37
37
39
43
48
56
Dimension
a/b
o.d. mm
16
39
20
42
25
47
32
55
40
64
50
71
63
85
75
99
90
117
110
138
M
L
min.
55
40
60
40
66
45
78
50
90
55
100
60
120
70
140
80
165
93
195 107
Dimension
a/b
o.d. mm
20-16
52
25-16
54
25-20
55
32-25
66
40-32
74
50-40
92
63-50
103
75-63
120
90-75
138
110-90
163
M
min.
73
77
78
94
105
130
145
170
195
230
L
39
39
39
47
51
59
64
72
85
97
GEORGE FISCHER
Elbow 45
z
L
Elbow 45
Elbow 90
L
M
T-equal or Elbow 90
& Reducer
M
L
min.
50
38
52
38
60
46
70
50
80
56
85
57
100
66
120
84
135
93
160 110
Dimension
o.d. mm
20-16
25-16
25-20
32-25
40-32
50-40
63-50
75-63
90-75
110-90
M
L
min.
78
40
82
40
85
40
102
48
115
53
140
59
160
67
195
80
225
91
270 107
Dimension
o.d. mm
16
20
25
32
40
50
63
75
90
110
M
L
min.
60
40
66
40
76
48
88
52
100
56
115
63
140
72
165
81
195
93
230 104
L
M
Elbow 90
Dimension
a/b
o.d. mm
16
35
20
37
25
42
32
50
40
57
50
60
63
71
75
85
90
95
110
113
T-equal or Elbow
90
GEORGE FISCHER
5.11
Minimum Distance between Centers M for Socket Fusion Machine*

Jointing
130
130
136
140
144
150
156
100
T-equal
Dimension
M
o.d. mm
min.
16

150
20

156
25

164
32
176
40
188
50
202
63
224
* Fusion Machine 5120
Elbow 90
Fitting Combinations with PB Manifold
5.12
GEORGE FISCHER
Pipe Lengths for

Position Change
16
20
60
80
100
130
160
190
230
54
74
94
124
154
184
224
Dimension o.d. mm
25 32 40
50
63
Pipe Lengths L
52
44

72
64
56

92
84
76
68

122 114 106
98
82
152 144 136 128 112
182 174 166 158 142
222 214 206 198 182
75

96
126
166
90 110

108
148
124
Elbow 90

M
80
100
120
150
180
210
250
Elbow 90
Elbow 45
L
M
z
T-equal / Elbow
90
Elbow 45
z
L
GEORGE FISCHER
Elbow 45

a/b
80
100
120
150
180
210
250

a/b
80
100
120
150
180
210
250
16
97
125
154
196
238
281
337
16
101
129
158
200
242
285
341
20
97
121
150
192
224
277
333
20
99
127
156
198
240
283
339
25
92
120
149
191
233
276
332
25
99
127
156
198
240
283
339
Dimension o.d.
32 40 50
Pipe Lengths
85 79 73
113 107 101
142 136 130
184 178 172
226 220 214
269 263 257
325 319 313
mm
63
L

90
119
161
203
246
302
Dimension o.d.
32 40 50
Pipe Lengths
93 89 85
121 117 113
150 146 142
192 188 184
234 230 226
277 273 269
333 329 325
mm
63
L
79
107
136
178
220
263
319
75

110
152
194
237
293
75

105
134
176
218
261
317
90 110

140
182
225
281

124
166
209
265
M
113
141
170
212
254
297
353
90 110

99
128
170
212
255
311

120
162
204
247
303
M
113
141
170
212
254
297
353
5.13
z-Dimension
Dimension
Elbow 90
Elbow 90 Socket-spigot o.d. mm
T-equal 90
16
20
25
32
d
40
h
z
50
l
63
75
90
d
110
D
z
10
13
14
18
22
26
34
42
51
63
Measurements
h
l
34
25
36
28
44
32
50
38
58
44
70
51
82
62

75

88

106
D
22
26
32
40
51
64
81
92
114
134
All dimensions
in mm
z
l1
Elbow 45
Dimension
Elbow 45 Socket-spigot o.d. mm
16
l
20
25
32
40
50
16 110mm
o.d.
63
75
90
110
d
z
6
7
7
10
12
14
17
18
21
25
Measurements
h
l
29
21
30
22
35
25
40
30
46
34
53
39
62
45

51

58

68
D
22
26
32
40
51
64
81
92
114
134
D
16 63 mm o.d.
T-reducing. 90
a
l
b
d
l
5.14
Dimension
o.d. mm a-b-c
20-16-20
13
20-16-16
13
20-20-16
13
25-16-25
14
25-20-25
14
25-20-20
14
25-25-20
17
32-16-32
18
32-20-32
18
32-25-32
18
40-25-40
22
50-25-50
26
63-25-63
34
Measurements
z1
z2
13
28
13
28
13
28
17
32
17
32
17
32
17
32
23
38
23
38
20
38
26
44
33
51
44
62
l
28
28
28
32
32
32
32

44
51
62
l1 D
26
26
26
32
32
32
32
40
40
40
51
64
81
GEORGE FISCHER
d1
Reducer
d1
z
l
Dimension
o.d. mm
20-16
25-16
25-20
32-20
32-25
40-20
40-25
40-32
50-20
50-25
50-32
50-40
63-20
63-25
63-32
63-40
63-50
75-63
90-75
110-63
110-75
110-90
Measurements
z
l
15
30
18
30
18
33
25
40
22
40
27
42
24
42
22
42
40
55
37
55
35
55
33
55
43
58
40
58
38
58
36
58
33
58
39
67
40
72
58
86
53
86
50
86
Flange adaptor flat

Flange adaptor with groove
Flange adaptor with spigot
z
l
Dimension
o.d. mm
16
20
25
32
40
50
63
75
90
110
z
5
5
5
5
5
5
5
4
6
7
flat
l
20
20
23
25
27
30
33
35
42
49
with groove with spigot

z
l
h
8
23
42
8
23
42
8
26
8
28
10
32
10
35
10
38
9
40
11
47
13
55
z
l
GEORGE FISCHER
5.15
5.16
GEORGE FISCHER

Expansion & Contraction Introduction
Change in length
Allowing for expansion or contraction
Bracket spacing
Page
6.02
6.03
6.04 - 6.07
6.08 - 6.12
GEORGE FISCHER
6.0
Expansion and Contraction

All materials expand or contract
with the increase or decrease
in temperature. The amount of
this expansion or contraction is
dependent on the coefficient of linear
expansion . This coefficient is very
rarely linear for a material, however
for most calculations a good average
is used.
L = change in length
L = pipe length
Example
How much will a 10m length of PB
(INSTAFLEX) expand if the working
temperature is 60C and the
installation temperature is 15C?
t = working temperature -
installation temperature
t = 60C 15C
t = 45C
Therefore
L = 0.13 x 10 x 45
L = 58.5mm
The average linear expansion

coefficient of polybutylene (PB):
= 0.13 mm/mC
Therefore
L = x L x t
Important
Please note that t is the
difference between the
installation temperature and
the working temperature.
Where L = change in length in mm

= coefficient of expansion

L = original length in m

t = temperature difference

in C
Change in length L in mm for PB pipes
Pipe l.
in m
Temperature difference t in C
10
20
30
40
50
60
70
80
0.1
0.1
0.3
0.4
0.5
0.7
0.8
0.9 1.0
0.2
0.3
0.5
0.8 1 .0
2.0
2.3
2.7
3.1
0.3
0.4
0.8 1 .2 1 .6
2.0
2.3
2.7
3.1
0.4
0.5 1 .0 1 .6
2.1
2.6
3.1
3.6
4.2
0.5
0.6 1 .3
2.0
2.6
3.3
3.9
4.6
5.2

0.6
0.8 1 .6
2.3
3.1
3.9
4.7
5.5
6.2
0.7
0.9 1 .8
2.7
3.6
4.6
5.5
6.4
7.3
0.8 1 .0
2.1
3.1
4.2
5.2
6.2
7.3
8.3
0.9 1 .2
2.3
3.5
4.7
5.9
7.0
8.2
9.4
1 .0 1 .3
2.6
3.9
5.2
6.5
7.8
9.1 10.4

2.0
2.6
5.2
7.8 10.4 13.0 15.6 18.2
20.8
3.0
3.9
7.8 11 .7 15.6 19.5
23.4
27.3
31 .2
4.0
5.2 10.4 15.6
20.8
26.0
31 .2
36.4
41 .6
5.0
6.5 13.0 19.5
26.0
32.5
39.0
45.5
52.0
6.0
7.8 15.6
23.4
31 .2
39.0
46.8
54.6
62.4
7.0
9.1 18.2
27.3
8.0 10.4
20.8
31 .2
9.0 11 .7
23.4
35.1
10.0 13.0
26.0
39.0
11 .0 14.3
28.6
42.9
12.0 15.6
31 .2
46.8

36.4
41 .6
46.8
52.0
57.2
62.4
45.5
52.0
58.5
65.0
71 .5
78.0
54.6
63.7
72.8
62.4
72.8
83.2
70.2
81 .9
93.6
78.0
91 .0 104.0
85.8 100.1 114.4
93.6 109.2 124.8
Example from table

A 5m long pipe working at a
temperature of 50C will expand or
contract by 32.5mm.
6.0
GEORGE FISCHER
Change in length L in mm for PB pipes
Temperature Difference t in C
Pipe length L in m
0 10 20
30 40 50 60 70
80 90 100 110 120 130
Change in length L in mm
GEORGE FISCHER
6.0
Allowing for Expansion or Contraction

1 . General
Being a member of the thermoplastic

family, INSTAFLEX PB is subject to
greater thermal movement than
metals. As all materials expand or
contract and since the modulus of
elasticity (E) of INSTAFLEX is very
Method 1
low, at 350N/mm2, overcoming the

effects of expansion or contraction is
generally easier than with metals.
There are three principal methods
to overcome the effects of thermal
movement.
By optimising the flexibility of PB by

using the changes of direction found
in most installations or to install
expansion loops. This method is most
commonly used in places where the

pipework is not visible, i.e. in ceiling
voids or riser ducts.
Flexible expansion leg
Pipe lateral yielding in riser
Expansion
Fixed point
bracket
Sliding
bracket
Flexible Leg
Expansion Loop
Expansion
Fixed point
bracket
Sliding
bracket
Sliding
bracket
Flexible Leg
Fixed point
bracket
Flexible Leg
Fixed point
bracket
6.0
GEORGE FISCHER
Method 2
Similar to Method 1 but using

pipe carrier to continually support
the pipe. The advantage of this
approach is that pipe is continually
supported and the bracket centers
can be much further apart.

Ideal for use in areas where the pipe
is visible.
Typical Pipe Carrier
Pipe in Riser Carrier
Pipe ties
Pipe carrier
Flexible Leg
Flexible Expansion Leg

with carrier
Pipe carrier
Expansion L
Pipe ties
Fixed point
bracket
Sliding
bracket
Flexible Leg
GEORGE FISCHER
Fixed point
bracket
6.0
Method 3
This method utilises the unique feature

of INSTAFLEX, namely its ability to
absorb any thermal movement within
itself without detriment to the material
or system. This is achieved by rigidly
Fixed point
bracket
Sliding bracket
fixing the pipework to prevent any

thermal movement.
This system is commonly used where
there are long pipe runs with laterals.
Fixed point
bracket
Pipe carrier
Pipe ties
Calculating the Flexible Leg for

Methods 1 and 2.
a = k x L x od
where a = flexible leg in cm

k = constant PB = 10

L = Expansion or Contraction in
Sliding
Bracket
Fixed Point
Bracket
Flexible Leg
Example
How long should leg a be if the expansion L is 3.25cm
on a 6.3cm od pipe?
a = 10 x 3.25 x 6.3
6.0
45cm
GEORGE FISCHER
Graphical method for Determining the Flexible Leg a

For methods 1 and 2
1 . Control the direction and

amount of thermal movement
by careful positioning of fixed
points.
2. Take care to ensure the
pipe can move freely within
the loose brackets.
3. Never create a fixed point
by tightening the bracket to
squeeze the pipe.
4. Ensure that the positioning
of loose bracket does not
inadvertently create a fixed
point.
110
d110
100
d90
90
d75
80
d63
d50
70
d40
60
d32
50
d25
45
Flexible Leg a
General Guidelines
40
30
20
10
Change in length L in cm
9
2 1
Temperature difference t in C
10
10
length of pipe run in m

GEORGE FISCHER
6.0
Method 1 Bracket Spacing

Pipe size
d
20C
70
75
Pipe bracket intervals in cm
30C
70
80
40C
65
75
60C
80C
60
70
60
70
16
20
25
80
80
80
75
75
70
32
90
90
90
90
85
80
40 105 100 100
95
95
90
50 115 115 110 110 105 100
63 130 130 125 120 120 110
75 140 140 135 130 130 120
90 155 150 150 145 140 130
The pipe bracket spacing may be

increased by 30% in the case of
vertical pipes. i.e. multiply the values
given by 1 .3.
65
75
50C
The bracket spacings above are

based on a maximum deflection of
0.25cm between the brackets.
Method 2 Loose Bracket Spacing with support tray

Pipe size
d
6.0
All Temperatures
Tie Spacing
16 to 75mm 1 .5 to 2m maximum
approx. every 30cm
90 & 110 1 .5 to 2m maximum

No support tray
approx. every 30cm
GEORGE FISCHER
Pre-stressing
An alternative solution for Methods 1
and 2 is to cut the pipe short by the
amount that it is calculated that it will
expand or contract, such that when it
Position at ambient temperature
is at its normal operating temperature

the expansion leg or loop is straight.
Position at operating temperature
Note
There must be a
Flexible Leg a
Flexible leg a
Fixed point assembly Method 3 Bracket Spacing
Bracket distances for hot water pipes

Pipe dim
d mm
16
20
25
32
40
50
63
75
Fixed point distances

L
Loose bracket
distances
L1
Pipe binder distances

L2
maximum
6m between
fixed points
1 .5 to 2m max.
approx every 30cm
last fixed point brackets.
For fixed installations the expansion

force of the pipe is transferred to the
expansion force
Force on bracket
= expansion force
2
GEORGE FISCHER
Force on bracket
=0
expansion force
Force on bracket
=0
expansion force
Force on bracket
= expansion force
2
6.0
Temp. Difference t in C.
Expansion Forces generated by PB pipes for Temperature Differences
Expansion Force FR in N
To calculate the expansion force, the following formula may be used;

FR = A x E x x tC.
2
= 1 .3 x 10-4mm/mmC
A = (D2 - d2)
where
A = pipe cross section area mm2

E = modulus of elasticity 350N/mm2
= coefficient of linear expansion
= 0.13mm/mC
t = temperature difference C
FR = expansion force

2
Example
What is the force acting on an end bracket for a 63 mm od pipe with a
temperature difference of 50C?
FR = (63 2 - 51 .42) x 350 x 1 .3 x 10-4 x 50

4x2
FR = 1185 N
6.10
GEORGE FISCHER
Forces due to expansion of various

sizes of PB pipe which would be
transferred to a fixed point pipe
support clamp, can be read from
the graph on page 11 . Depending
on how far the centerline of the pipe
needs to be from the supporting
structure will effect the required

diameter of the fastening rod used
to hold the fixed point in place. This
can be determined using the graph
below and the expansion forces on
page 11 .
Hanger length H in cm
Choosing the Diameter of the Fastening Rods for the Pipe Clamp
and Bass Plate
Expansion Force Fz in N
Calculating the Fixed Point Support Clamp
D

H

L
X

FR
FZ

Diameter of the fastener

rods
Distance to ceiling or
wall from the pipe
Distance between screws
Number of screws with
tensile strength
Fixed point forces (N)
Screw or dowel retention

force (N)
2-hole base plate

x=1
4-hole base plate
x=2
GEORGE FISCHER
Fz =
FR x H
LxX
[N]
Example:
Fz =
1200N x 20cm
= 1000N
12cm x 2
Retention force per screw:

Fz = 1000N
6.11
Fixed Point and Sliding Brackets

Arrangement of fixed point
support brackets
Fixed points direct thermal expansion
of the pipe in the desired direction.
Fixed points should ideally be
installed at a fitting and should
support it on both sides or be
installed in between the two fittings.
Attention!
Pipe brackets for fixed point

and sliding support should
be lined with suitable rubber
inserts or of such a design to
prevent any damage
to the pipe.
Elbow
Tee
Connecting socket
Valve connection
Typical fixed point assembly
Sliding support brackets

Sliding brackets allow an axial
movement of the pipe. The bracket
must be in line with the pipe. Sliding
brackets should be lined with rubber
inserts suitable for plastic pipe, or
of such a design to prevent any
damage to the pipe.
All commercially available pipe
clamps and fastening materials,
which are suitable for plastic pipe
installations can be used as fixed
points or sliding pipe supports for
INSTAFLEX.
6.12
GEORGE FISCHER
Page
Determining Pressure Loss in Piping Systems Using the
INSTAFLEX Calculation Method
2.1 Determining Pipe Diameter
2.3 Distribution Mains
Blank INSTAFLEX Pressure Loss Table
British Method and Data
Calculation example based on C.I.B.S.E.
Excerpts from the C.I.B.S.E. guidelines
Simultaneous demand peak flow tables
Pressure loss and flow velocity tables
Equivalent pipe length tables
Flushing Times for Dead Legs
7.01
7.02
7.03
7.05
7.05
7.06
7.07
7.09
7.10
7.11 - 7.13
7.14
7.15
7.16 - 7.17
GEORGE FISCHER
7.0
Determining Pressure Loss in Piping Systems Using

the INSTAFLEX Calculation Method
Pressure loss calculation is based on
the determination of pipe diameters
directly from the load units.
Approximate pipe diameters can be
determined using section 2.1
approx. 1 .5
bar
If pipe diameters are correctly calculated, pressure loss of 1 .5 bar

(150,000N/m2) should not be exceeded for the entire installation, from
the water meter or the pressure reducing valve to the last outlet.
2.1 Determining the pipe diameter

The pipe diameter is determined
using Tables 1a on page 7.03
The load units of the individual pipeline sections are the basis for determining pipe diameter.
The load unit LU corresponds to the
flow rates of outlets and appliances
specific to each country (see guidelines or technical regulations). For the
UK see
Table B4.21
p7.09
The total load unit of a pipeline section are the sum of individual load
units in the section, without consideration of simultaneous use.
If the pipe diameter is not sufficient,

pressure losses must be determined
for manifold distribution according to
section 2.2 and for general distribution using section 2.3. & 2.4
7.0
GEORGE FISCHER
Table 1a: Load units (LU) and pipe diameters for INSTAFLEX polybutylene
pipes and plastic fittings
max. number
LU (LV)
14
17
25
55
180
500
1100
Pipe o.d. (mm) 16
20
25
32
140
550
1163
20.4
26.0
132.6 540.8
Pipe ID (mm) 11 .6 14.4

1151 .4
Manifold Pressure drop
/4"
No. of
Ports
K value
5.08
7.6
4.23
drop = K x 10-1 x Qm
drop = mm H2O
Q = l/h
m = 2.026
2.2.2 Continuous line
Piping systems and pressure loss determination for manifold distribution

in the pipe dimensions 16 and 20mm
o.d. .
Pressure loss as a function of flow
rate in manifold distribution systems,
it can be determined using Tables 2
and 3 on pages 7.04 and 7.05. Only
the least favourable flow path, i.e. the
index pipe with the greatest pressure
loss, is considered when determining
pressure loss.
The load units (LU) for outlets and
appliances are given in the relevant
technical regulations or guidelines,
see page 7.09
2.2.1 Individual lines
Individual lines supply only one outlet

from the manifold. The pressure loss
can be read directly from Table 2 or
3 on pages 7.04 and 7.05.
GEORGE FISCHER
Continuous lines supplying more than

one outlet from each pipeline on the
manifold. The fact that the tapping
points are connected in series means
that their pressure losses are cumulative.
By installing the outlet with the largest
load units at the beginning of the
pipeline, rather than at the end, considerably lower pressure losses can
be obtained.
The pressure loss in continuous lines is
calculated with peak flow. This reduced simultaneous use, which means
that not all outlets on a flow path are
used at the same time or for the same
duration.
The peak flow (Vs) is determined from

the total load units using the relevant
diagrams and charts for simultaneous
use or calculation formulae from the
appropriate technical regulations
see page 7.10.
7.0
If high pressure losses prevent the

connection of all draw offs to a single
line, then two or more pipelines may
be necessary.
Pressure loss in a ring main is about

70 % less than in a continuous line.
For calculating pressure loss, the ring
main is treated as a continuous line
with only one inlet. The pressure loss
calculated is multiplied by 0.3; the
result is the pressure loss of the ring
main.
2.2.3 Ring mains

Ring mains supply more than one
outlet from the manifold. The outlets
are supplied by water from two directions.
This prevents water stagnation.
2.2.4 Pressure losses in

INSTAFLEX pipeline loops
The pressure losses in Table 2 and
3 include the individual resistances
caused by changes of direction, pipe
joints and manifolds.
Table 2: Pressure losses in 16mm o.d. pipeline loops

V
V
in
in

11
l/s m/s

Loop length l in meters

11 .5 12
12.5 13
14
15
16
17
18
19
110
111
112
113
114
115
116
117
118
119
120
Pressure loss in pipeline loop in mbar
0.07 0.7
17
21
24
28
31
38
0.10 0.9
32
38
45
51
57
70
0.13 1 .2
54
64
74
84
94 114
0.15 1 .4
72
85
98
45
52
57
66
72
79
86
83
96
109
121
134
147
160
134
154
174
194
214
234
254
93
100
107
114
121
128
135
141
148
173
185
198
211
224
237
249
262
275
274
294
314
334
354
374
394
414
434
111
124 150
177
203
229
255
281
307
333
359
385
411
438
464
490
516
542
568
0.20 1 .9 129 150 172
194
216 259
303
346
390
433
477
520
564
607
651
694
738
781
825
868
912
955
0.22 2.1 156 182
208
234
259 311
363
415
467
518
570
622
674
726
777
829
881
933
985 1036 1088 1140
0.25 2.4 200
232
265
297
329 394
459
524
589
653
718
783
848
913
977 1042 1107 1172 1237 1301 1366 1431
0.30 2.8 274
319
364
409
454 544
634
723
813
903
993 1083 1173 1263 1353 1443 1533 1622 1712 1802 1892 1982
0.35 3.3 375
434
494
553
612 731
850
969 1088 1206 1325 1444 1563 1682 1800 1919
0.40 3.8 490
566
642
717
793 944 1096 1247 1398 1549 1700 1852 2003
0.50 4.7 746
860
973 1087 1200 1428 1655 1882
7.0
GEORGE FISCHER
Table 3: Pressure losses in 20mm o.d. pipeline loops

V
V

in
in

l/s m/s

Loop length l in metres

11 1 .5
12 12.5
13
14
15
16
17
18
19
110
111
112
113
114
115
116 117
118
119
120
Pressure loss in pipeline loop in mbar
0.07 0.4
10
11
14
16
19
21
24
26
29
31
34
36
39
41
44
46
49
51
54
0.10 0.6
12
14
17
19
21
26
31
35
40
44
49
54
58
63
67
72
77
81
86
90
95
100
0.13 0.8
20
24
27
31
35
42
49
57
64
71
78
86
93
100
108
115
122
130
137
144
151
159
0.15 0.9
26
31
36
40
45
54
64
73
82
91
101
110
119
129
138
147
157
166
175
184
194
203
0.20 1 .2
46
53
61
69
76
92
107
123
138
153
169
184
200
215
230
246
261
277
292 307
323
338
0.22 1 .4
55
64
73
82
91
110
128
146
165
183
201
220
238
256
274
293
311
329
348
366
384
403
0.25 1 .5
70
81
93 104
116
138
161
184
207
230
252
275
298
321
344
366
389
412
435
458
480
503
0.30 1 .8 100 115 131 147
163
194
226
258
289
321
352
384
416
447
479
510
542
574
605
637
668
700
0.35 2.1 134 155 176 196
217
259
300
342
384
425
467
508
550
592
633
675
716
758
800
841
883
924
0.40 2.5 174
226 253
279
332
385
438
491
544
597
650
703
755
808
861
914
967 1020 1073 1126 1179
742
821
900
980 1059 1138 1217 1296 1375 1454 1533 1612 1691 1771
200
0.50 3.1 268
307
347 386
426
505
584
663
0.60 3.7 384
439
494 549
604
714
824
934 1045 1155 1265 1375 1485 1705 1815 1925
0.70 4.3 516
589
661 734
807
953 1099 1245 1391 1536 1682 1828 1974
0.80 4.9 666
759
852 946 1039 1225 1411 1597 1783 1969
7
2.3 Distribution mains
Determining pressure losses in distribution mains of polybutylene (PB)

pipe dimensions 25, 32, 40, 50, 63,
75, 90, &110mm o.d.
Pressure loss in the entire installation

comprises manifold pressure loss
PST and distribution mains pressure
loss PVL .
The pressure loss PVL in the distribution mains is calculated by adding

the pressure losses PTS of the individual sections of the index run.
Only the manifold and distribution

mains with the largest pressure loss
are taken into account here, this is
the index run.
In order to calculate pressure loss,

peak flow VS must be calculated from
the total number of load units in each
section of pipe, see page 7.09.
The total pressure loss PInst. is the

maximum pressure loss in the index
run from the water meter, pressure
reducing valve or cistern to the last
outlet.
The pressure loss in the individual

sections is determined by adding
the fitting supplements (equivalent
pipe lengths) from the information
on page 7.14 to the given pipeline
length. Multiplying the total length by
the pressure loss per
meter run of the
corresponding pipe, as a function of

peak flow volume VS from Tables on
pages 7.11 -13
GEORGE FISCHER
To adjust the pressure reducing valve,

the required flow pressure at the most
distant outlet and the altitude difference between the pressure reducing
valve and the highest outlet point
must be added to the total pressure
loss PInst..
7.0
Job Reference
Apartment
Project Name
Distribution
hIfomIatIon from the Drawmgl

1
2
~
load
ReferencesUnIt.
P...ur.
3
Row
Rote
~
length
m
1.0
1.1
V.
0.15
Date
!fxample
xxxxx
Drop CakuIatIonsl
0.3
1.5
16
---319
0.3
2.0
16
---364
1.4
14
0.3
1.5
16
---319
9
10
11
PresslWe PresSloe
loss
lossToial
(pascoIs) !pascals)
niJor
mbor
guide B4:17 on page

or from Table B4:20
~
the
0.15
3.0
16
---124
124"
12
0.3
3.0
16
---454
454
11
0.3
2.5
16
---409
409
"
""
\
'\:
"""
,
}
to:S
~:i
t
'c'
~ ~ -9-0
Mi
5 ~
Column 9. Determining the

total pressure loss for
the section.
including all
bends. From tables 2 {, 3
on pages 11.04 {, 11.05
~
~ ~
~ ~ ..
~m 0;;
E
2
.s
t.'! u (3
lower
value
~ J i:s
-i v
~
!! i
~
~
11.29
on
1G
't m
~ ~
page 11.30 which ever is

the
1074
Exploootion
Colwnn 2 Determining the

demand units from
C. I .B. S. E. Guide B4 Table
B4:21 on page 11.29
Colwnn 3. Determining
1 of 2
value
of simultaneous
demand
from
C.I.B.S.E.
1.2
Sheet
XXXXX
Notes
5
6
7
8
~
Pressure Fittings 'bid
SiZe loss/metreEquivdent Pipe
lposcas/mI length length
o.d.mm mbor/m
m
m
16
---72
1.3
Name
~
'"
Section 1
Section 2
Section 3
Section 4
.~
5.1
0.15
1.0
16
---72
5.2
0.25
2.5
16
---297
B t
r.:'"
~ c
c~
-"
,
369
Section
'"~
.l.
o.~
-r Po low f ow fi ures ta en
dire tly frpm Tab e B4:17 page 1 .29
"'
j 8 ~ .a
~!"']
~~8.~
N";8..;
~~ 1
.a
13
Total PressureDrop (Section No.)
6. P -lO74mbar.lO7400Pa --(pascals)
"e~
80
GEORGERSOfER+GF+ INSTAFLEXCK>
George Fischerpermit photocopyingof thissheet for usein sizingINSTAFlEXPipingSchemes

t.;.L6').t.
Job Reference
Manifold
and
Project Name
Risers
Example
Infonnatlon from the Drawingl

1
Pipe
Row
References
PressureDrop ColculatlOlll1
7
Ilti'
P"ope
RoM length
Dote
Name
xxxx
XXXX
Sheet
2 of 2
Notes
8
Toiol
Exploinalion
enl PIpe
ength length
8'm
Value: INSTAFLEXDN 20-'/,.

see valve chart on page
11.22
~ !
'" ~ ~ B
~ .v li
-i
'"
"0
c~
.~
Co1wnn2. Determining the

demand units from
C.I.B.S.E.
Guide B4. Table
B4.21 page 11.29
II
I
I.
Column 3. Determining
value of simultaneous
.0 ~ !
~ ~ !
demand from C.I.B.S.E.

Guide B4. Table B4.20
the
~ ~
~~
:s ~
v]-
on
page 11.30
Colwnn 6. Selecting
suitable
pipe size
fluid
flow
(usually
a
for
under
3m/s velocity)
Record
pressure losses from
tables on pages 11.31 -33
8
=
~
~
:z=
$; j
...'"

~ ~
total value for equivalent
.g -g
length for all items in
].~
the pipe section. From;
j
table 4a or 4b, page 11.33 '6 Y g
Co1wnn 10. SUllWnerisethe
pipe pressures pressures
from the furthest point
back to the pwnp
Total PressureDrop (SectIon No.)
6. p -32190
~
::;
~
~
~ OI"'~
a ! 8. ~
N ,.; 8..;
~ ~1 ~
~ ~ ~ ~
oRIbGr(pascals) GEORGERSOiER+GF+ INSTAFLEX<!>
George Fischerpermitphotocopying of thissheetfor usein sizingINSTAFlEXPipingSchemes
r!
~~otal
s stem ressureloss = 107;400+ 32,190= 139,590pas-
ca s
I
.-Within
anticipated
Z08
working
pressures
GEORGEFISCHER+GF+
Calculation Example 3: based on the Chartered

Institute of Building Services Engineers Guide B4
Apartment Distribution
3DU/0.15l/s
5 DU/0.1 l/s
5.1/3
16/1
5 DU/0.15
3 DU/0.15
l/s
l/s
5 DU/0.1 l/s
3 DU/0.15 l/s
11DU/0.3 l/s
5.2/8
16/2.5
4/11
16/2.5
48 DU
DN 20
1 .4/14
16/1 .5
Section/number of DU( VR)

Pipe / section length
1 .3/9
16/2
1 .2/6
16/1 .5
1 .1/3
16/1
2/5
16/3
12 DU/0.3
l/s
3/12
16/3
1 LU equal to 3 DU
Manifolds and Risers

6m
48 DU
3m
3m
3m
48 DU
48 DU
24 DU
24 DU
0.5 m
48 DU
24 DU
24 DU
48 DU
48 DU
48 DU
1 .2/96
25/3
48 DU
1 .3/144
32/3
48 DU
1m
48 DU
1 .1/48
25/3.5
48 DU
2m
6m
8m
1 .4/192
40/5
4m
1 .5/624
40/2
TWE
312 DU
1 .6/936
50/5
5m
GEORGE FISCHER
Section / number of DU( VR)

Pipe / section length
7.0
Example
Apartment Distribution
Name
XXXXX
XXXXX
Explaination
1
Pipe
References
Load
Units
Flow
Rate
Pipe
Length
Pipe
Size
1.1
0.15
1.0
o.d.mm
16
1.2
0.3
1.5
16
319
1.3
0.3
2.0
16
364
1.4
14
0.3
1.5
16
319
l/s
Pressure
Fittings
Total
Loss/metre Equivalent Pipe
(pascals/m) Length Length
mbar/m
m
m
-
10
Pressure
Loss
(pascals)
mbar
72
Pressure
Loss Total
(pascals)
mbar
11
Column 2 Determining the

demand units from
C.I.B.S.E. Guide B4 Table
B4:21 on page 11.29
guide B4:17 on page 11.29
or from Table B4:20 on
page 11.30 which ever is
the lower value
1074

total pressure loss for
the section, including all
bends. From tables 2 & 3
on pages 11.04 & 11.05
0.15
3.0
16
124
124
12
0.3
3.0
16
454
454
11
0.3
2.5
16
409
409
Section
Section
Section
Section
369
Section 5
5.1
0.15
1.0
16
72
5.2
0.25
2.5
16
297
For
1
2
3
4
low flow figures taken

directly from Table B4:17 page 11.29
p = 1074mbar
= 107400Pa
mbar (pascals)
C.I.B.S.E.
Manifold and Risers
Example
XXXX
Name
XXXX
Explaination
1
Pipe
References
Load
Units
Flow
Rate
Pipe
Length
Pipe
Size
o.d.mm
Value
48
0.3
1.1
48
0.3
3.5
25
617
1.2
96
0.5
3.0
25
1500
1.3
144
0.6
3.0
32
1.4
192
0.8
5.0
1.5
624
1.8
2.0
1.6
936
2.5
5.0
l/s
Pressure
Fittings
Total
Loss/metre Equivalent Pipe
(pascals/m) Length Length
mbar/m
m
m
DN 20
10
Pressure
Loss
(pascals)
mbar
Pressure
Loss Total
(pascals)
mbar
8100
8100
1.8
5.3
3270
11370
3.0
4500
15870
640
3.0
1920
17790
40
360
2.8
7.3
1228
20418
40
1500
1.8
3.8
5700
26118
50
920
1.6
6.6
6072
32190
11
For higher flows figures

taken from Table B4:20 page 11.30
Value: INSTAFLEX DN 20-3 /4"

see valve chart on page
11.22
demand units from
C.I.B.S.E. Guide B4. Table
B4.21 page 11.29
Guide B4. Table B4.20 on
page 11.30
Column 6. Selecting a
suitable pipe size for
fluid flow (usually under
3m/s velocity) Record
pressure losses from
tables on pages 11.31 -33
total value for equivalent
length for all items in
the pipe section. From
table 4a or 4b, page 11.33
Column 10. Summerise the
pipe pressures pressures
from the furthest point
back to the pump
p =
32190
mbar (pascals)
Total system pressure loss =107,400 + 32,190= 139,590pascals

p inst 1 .4 bar - Within anticipated working pressures
7.0
GEORGE FISCHER
Excerpts from C.I.B.S.E. Guide, Section B4

The C.I.B.S.E. guides are the basis for
selecting the size of the pipes and
for determining the pressure losses,
within the scope of the application
shown.
Table B4.17. shows the guidelines for
approximate water demand at each
outlet.
Table B4.21 . Shows the guidelines for

demand units at each type of outlet
Table B4.17. Approximate demand required of water points (hot and cold).
Table B4.21 . Practical demand units for

use with data listed in Table B4.20
Sanitary appliance

Flow rate
Fitting
Type of application
(litre/second)
Congested Public Private
Basin (spray)
Basin (tap)
Bath (private)
Bath (public)
Flushing system
0.05
0.15
0.3
0.6
0.1
Shower (nozzle)
Shower (100mm rose)*
Sink (15mm tap)
Sink (20m tap)
Wash fountain
0.15
0.4
0.2
0.3
0.4
* The use of shower roses results in wasteful

consumption of water, but emergency drench
showers require high discharge rates.
Basin* 10
Bath
47
Sink
43
Urinal**
WC (13.5 litre)
WC (9 litre)
5
3
25 12
22 11

35 15
22 10
8
5
* These data apply to conventional taps only.

If spray taps are used, demand may be continuous at 0.05 litre/s per tap
If a shower spray nozzle is used over the
bath, demand may be continuous at 0.1
litre/s per nozzle.
Demand will be continuous at 0.003 litre/s
per stall
Table B4.20 on page 7.09 shows the

anticipated flow rates for simultaneous usage as a result of the total
demand units in each pipe section.
Information reproduced from
C.I.B.S.E. Guide Section B4
by permission of the Chartered Institute of Building Services Engineers
GEORGE FISCHER
Note: For approximate pipe sizes using tables 1a and 1b on page 7.03.
1 Load Unit (LU) equals 3 Demand Units from Table B4.21 above
7.0
7.10
GEORGE FISCHER
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
4000
5000
6000
7000
0
1000
2000
3000
Demand
units
0.3
2.7
4.7
6.5
50
0.5
2.8
4.8
6.6
100
22.0
23.7
25.3
27.0
15.3
17.0
18.7
20.3
28.5 28.6
30.2 30.3
31 .8 31 .9
33.5 33.5
21 .9
23.6
25.2
26.9
15.2
16.9
18.6
20.3
28.7
30.3
32.0
33.6
22.1
23.8
25.4
27.1
15.4
17.1
18.8
20.4
8.3
8.3 8.4
10.0 10.1 10.2
11 .8 11 .9 11 .9
13.5 13.6 13.7
0.0
2.6
4.6
6.4
28.8
30.4
32.1
33.7
22.2
23.8
25.5
27.1
15.5
17.2
18.8
20.5
8.5
10.3
12.0
13.7
0.6
2.9
4.9
6.7
150
0.9
3.1
5.1
6.9
250
28.9
30.5
32.1
33.8
22.3
23.9
25.6
27.2
15.5
17.2
18.9
20.6
29.0
30.6
32.2
33.9
22.3
24.0
25.7
27.3
15.6
17.3
19.0
20.7
8.6 8.7
10.4 10.5
12.1 12.2
13.8 13.9
0.8
3.0
5.0
6.8
200
Table B4.20. Simultaneous demand data for design
29.0
30.7
32.3
33.9
22.4
24.1
25.7
27.4
15.7
17.4
19.1
20.8
8.8
10.5
12.3
14.0
1 .0
3.2
5.1
7.0
300
29.1
30.8
32.4
34.0
22.5
24.2
25.8
27.5
15.8
17.5
19.2
20.8
8.9
10.6
12.4
14.1
1 .2
3.3
5.2
7.1
350
29.2
30.8
32.5
34.1
22.6
24.3
25.9
27.6
15.9
17.6
19.3
20.9
9.0
10.7
12.5
14.2
1 .3
3.4
5.3
7.2
400
1 .5
3.6
5.5
7.4
500
1 .6
3.7
5.6
7.4
550
1 .7
3.8
5.7
7.5
600
1 .9
3.9
5.8
7.6
650
29.3
30.9
32.6
34.2
22.8
24.5
26.2
27.8
22.9
24.6
26.2
27.9
23.0
24.7
26.3
28.0
29.4 29.4 29.5 29.6
31 .0 31 .1 31 .2 31 .2
32.6 32.7 32.8 32.9
34.3 34.3 34.4 34.5
22.7 22.8
24.4 24.5
26.0 26.1
27.6 27.7
16.0 16.0 16.1 16.2 16.3

17.7 17.7 17.8 17.9 18.0
19.3 19.4 19.5 19.6 19.7
21 .0 21 .1 21 .2 21 .3 21 .3
9.1
9.1
9.2
9.3
9.4
10.8 10.9 11 .0 11 .1 11 .2
12.5 12.6 12.7 12.8 12.9
14.3 14.3 14.4 14.5 14.6
1 .4
3.5
5.4
7.3
450
Design demand
(litre/s)
2.1
4.1
6.0
7.8
750
2.2
4.2
6.1
7.9
800
29.7
31 .3
33.0
34.6
23.1
24.7
26.4
28.0
16.4
18.1
19.8
21 .4
29.8
31 .4
33.0
34.7
23.2
24.8
26..5
28.1
16.5
18.2
19.8
21 .5
29.9
31 .5
33.1
34.8
23.3
24.9
26.6
28.2
16.6
18.2
19.9
21 .6
9.5 9.6 9.7

11 .2 11 .3 11 .4
13.0 13.1 13.1
14.7 14.8 14.9
2.0
4.0
5.9
7.7
700
2.4
4.4
6.3
8.1
900
2.5
4.5
6.4
8.2
950
23.4
25.1
26.7
28.4
29.9 30.0
31 .6 31 .7
33.2 33.3
34.8 34.9
23.3
25.0
26.6
28.3
16.6 16.7
18.3 18.4
20.0 20.1
21 .7 21 .8
30.1
31 .7
33.4
35.0
23.5
25.2
26.8
28.5
16.8
18.5
20.2
21 .8
9.8
9.8 9.9
11 .5 11 .6 11 .7
13.2 13.3 13.4
14.9 15.0 15.1
2.3
4.3
6.2
8.0
850
Table:
Pressure Loss per meter run of INSTAFLEX PB Pipe
Pressure Velocity Pipe Size

Velocity Pressure
Drop
Volumetric Flow L/S
Drop
(pascals) (m/s)
16mm 20mm 25mm 32mm 40mm 50mm 63mm 75mm 90mm 110mm (m/s) (pascals)
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
12.5
15.0
17.5
20.0
22.5
25.0
27.5
30.0
32.5
35.0
37.5
40.0
42.5
45.0
47.5
50.0
52.5
55.0
57.5
60.0
62.5
65.0
67.5
70.0
72.5
75.0
77.5
80.0
82.5
85.0
87.5
90.0
92.5
95.0
97.5
100.0
120.0
140.0
160.0
0.003
0.004
0.004
0.004
0.004
0.005
0.005
0.005
0.005
0.006
0.006
0.006
0.007
0.007
0.008
0.008
0.009
0.009
0.010
0.010
0.011
0.011
0.012
0.012
0.013
0.013
0.014
0.014
0.015
0.015
0.016
0.016
0.017
0.017
0.018
0.018
0.019
0.019
0.020
0.020
0.021
0.021
0.022
0.022
0.023
0.023
0.024
0.027
0.030
0.032
0.5
GEORGE FISCHER
0.006
0.007
0.007
0.008
0.008
0.008
0.009
0.009
0.010
0.010
0.010
0.011
0.012
0.014
0.015
0.016
0.018
0.019
0.020
0.021
0.022
0.023
0.024
0.025
0.026
0.027
0.028
0.029
0.030
0.031
0.031
0.032
0.033
0.034
0.034
0.035
0.036
0.037
0.037
0.038
0.039
0.039
0.040
0.040
0.041
0.041
0.042
0.046
0.050
0.054
0.013
0.014
0.015
0.016
0.017
0.017
0.018
0.018
0.019
0.019
0.020
0.023
0.025
0.028
0.030
0.033
0.035
0.038
0.040
0.043
0.045
0.048
0.050
0.053
0.055
0.058
0.060
0.063
0.065
0.068
0.070
0.073
0.075
0.078
0.080
0.083
0.085
0.088
0.090
0.093
0.095
0.098
0.100
0.103
0.105
0.108
0.110
0.120
0.130
0.140
0.030
0.033
0.036
0.039
0.042
0.045
0.047
0.049
0.051
0.053
0.055
0.060
0.066
0.074
0.080
0.085
0.090
0.095
0.100
0.105
0.110
0.115
0.120
0.125
0.130
0.135
0.140
0.144
0.148
0.152
0.156
0.160
0.164
0.168
0.172
0.176
0.180
0.184
0.188
0.192
0.196
0.200
0.204
0.208
0.212
0.216
0.220
0.240
0.260
0.285
0.065
0.070
0.075
0.079
0.082
0.085
0.088
0.091
0.094
0.097
0.100
0.110
0.120
0.130
0.140
0.150
0.160
0.170
0.180
0.190
0.200
0.210
0.220
0.229
0.238
0.247
0.256
0.264
0.272
0.280
0.287
0.294
0.301
0.308
0.315
0.322
0.329
0.336
0.342
.0348
0.364
0.370
0.376
0.382
0.388
0.394
0.40
0.44
0.48
0.51
0.13
0.14
0.15
0.16
0.17
0.17
0.18
0.18
0.19
0.19
0.20
0.22
0.24
0.26
0.28
0.30
0.31
0.33
0.34
0.36
0.37
0.39
0.40
0.41
0.42
0.44
0.45
0.47
0.48
0.50
0.51
0.53
0.54
0.55
0.57
0.58
0.59
0.61
0.62
0.64
0.65
0.66
0.67
0.69
0.70
0.71
0.72
0.80
0.87
0.94
0.34
0.36
0.38
0.40
0.41
0.43
0.44
0.46
0.48
0.49
0.50
0.52
0.55
0.57
0.60
0.62
0.65
0.67
0.70
0.72
0.75
0.77
0.80
0.82
0.85
0.87
0.89
0.92
0.94
0.96
0.99
1 .01
1 .03
1 .06
1 .08
1 .10
1 .13
1 .15
1 .17
1 .20
1 .22
1 .24
1 .26
1 .28
1 .30
1 .32
1 .34
1 .48
1 .61
1 .74
0.42
0.44
0.46
0.48
0.50
0.52
0.54
0.56
0.58
0.60
0.62
0.70
0.78
0.86
0.92
0.97
1 .02
1 .07
1 .12
1 .18
1 .23
1 .28
1 .32
1 .37
1 .41
1 .45
1 .49
1 .53
1 .56
1 .59
1 .62
1 .66
1 .69
1 .72
1 .75
1 .79
1 .82
1 .85
1 .88
1 .91
1 .94
1 .97
2.00
2.03
2.06
2.09
2.12
2.35
2.57
2.79
0.70
0.74
0.78
0.82
0.85
0.88
0.95
0.98
1 .01
1 .04
1 .14
1 .24
1 .24
1 .34
1 .44
1 .53
1 .62
1 .71
1 .80
1 .88
1 .96
2.04
2.12
2.19
2.26
2.33
2.40
2.47
2.53
2.60
2.66
2.72
2.78
2.84
2.90
2.95
3.00
3.50
3.10
3.15
3.20
3.25
3.30
3.35
3.40
3.45
3.50
3.85
4.20
4.55
1 .10
1 .16
1 .21
1 .27
1 .33
1 .38
1 .43
1 .48
1 .53
1 .54
1 .62
1 .84
2.04
2.22
2.39
2.55
2.70
2.85
2.99
3.12
0.5
3.25
3.37
3.50
3.62
3.75
3.87
4.00
4.12
4.25
4.37
4.50
4.62
4.75
4.87
5.00
5.12
5.25
5.37
5.50
5.62
5.75
5.87
6.00
6.12
6.25
1 .0
6.37
6.50
7.00
8.00
9.00
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
12.5
15.0
17.5
20.0
22.5
25.0
27.5
30.0
32.5
35.0
37.5
40.0
42.5
45.0
47.5
50.0
52.5
55.0
57.0
60.0
62.5
65.0
67.0
70.0
72.0
75.0
77.5
80.0
82.5
85.0
87.5
90.0
92.5
95.0
97.0
100.0
120.0
140.0
160.0
1 .5
7.11
1 .0
0.5
1 .5

Velocity Pressure
Drop
Volumetric Flow L/S
Drop
(pascals)

(m/s)
16mm 20mm 25mm 32mm 40mm 50mm 63mm 75mm 90mm 110mm
(m/s)
180.0
200.0
220.0
240.0
260.0
280.0
300.0
320.0
340.0
360.0
380.0
400.0
420.0
440.0
0.5
460.0
480.0
500.0
520.0
540.0
560.0
580.0
600.0
620.0
640.0
660.0
680.0
700.0
720.0
740.0
760.0
780.0
800.0
820.0
840.0
860.0
880.0
900.0
920.0
940.0
960.0
980.0
1000.0
1100.0
1200.0
1300.0
1400.0
1 .0
1500.0
1600.0
1700.0
1800.0

7.12
0.034
0.036
0.037
0.039
0.041
0.042
0.043
0.045
0.046
0.047
0.049
0.050
0.051
0.053
0.054
0.055
0.057
0.058
0.059
0.061
0.062
0.063
0.065
0.066
0.067
0.069
0.070
0.071
0.073
0.074
0.075
0.077
0.078
0.079
0.080
0.082
0.083
0.084
0.085
0.087
0.088
0.089
0.094
0.098
0.102
0.106
0.110
0.114
0.118
0.122
1 .5
0.058
0.061
0.064
0.067
0.070
0.074
0.078
0.089
0.084
0.087
0.090
0.093
0.096
0.098
0.100
0.103
0.105
0.107
0.109
0.111
0.113
0.115
0.117
0.199
0.121
0.123
0.125
0.127
0.129
0.131
0.133
0.135
0.137
0.139
0.141
0.143
0.145
0.147
0.149
0.151
0.153
0.155
0.164
0.173
0.181
0.189
0.197
0.204
0.211
0.218
0.150
0.160
0.168
0.176
0.184
0.192
0.200
0.207
0.214
0.221
0.228
0.235
0.241
0.247
0.253
0.259
0.265
0.271
0.277
0.283
0.289
0.295
0.301
0.307
0.313
0.319
0.325
0.331
0.337
0.343
0.349
0.355
0.360
0.365
0.370
0.375
0.380
0.384
0.388
0.392
0.396
0.400
0.420
0.440
0.460
0.480
0.500
0.520
0.540
0.560
2.0
0.300
0.315
0.330
0.345
0.360
0.375
0.390
0.405
0.420
0.435
0.450
0.465
0.480
0.495
0.51
0.52
0.53
0.54
0.55
0.56
0.57
0.58
0.59
0.60
0.61
0.62
0.63
0.64
0.65
0.65
0.67
0.68
0.69
0.70
0.71
0.72
0.73
0.74
0.75
0.76
0.77
0.78
0.82
0.86
0.90
0.94
0.97
1 .01
1 .04
1 .08
2.5
0.54
0.57
0.59
0.62
0.65
0.68
0.71
0.74
0.77
0.80
0.82
0.84
0.86
0.88
0.90
0.92
0.94
0.96
0.98
1 .00
1 .02
1 .04
1 .06
1 .08
1 .10
1 .12
1 .14
1 .16
1 .18
1 .20
1 .22
1 .24
1 .26
1 .28
1 .30
1 .32
1 .34
1 .36
1 .38
1 .40
1 .42
1 .44
1 .52
1 .60
1 .67
1 .73
1 .80
1 .86
1 .92
1 .98
1 .00 1 .86 3.00 4.90

1 .06 1 .98 3.15 5.20
1 .12 2.09 3.30 5.50
1 .18 2.20 3.45 5.75
1 .23 2.30 3.60 6.00
1 .29 2.40 3.74 6.25
1 .32 2.49 3.88 6.50
1 .38 2.58 4.02 6.75
1 .43 2.67 4.16 7.00
1 .48 2.76 4.30 7.20
1 .52 2.85 4.44 7.40
1 .56 2.94 4.58 7.60
1 .60 3.02 4.72 7.80
1 .64 3.10 4.86 8.00
1 .68 3.18 5.00 8.20
1 .72 3.25 5.13 8.40
1 .76 3.32 5.26 8.60
1 .80 3.39 5.37 8.80
1 .84 3.46 5.48 8.98
1 .88 3.52 5.59 9.15
1 .92 3.58 5.70 9.32
1 .96 3.64 5.80 9.50
2.00 3.70 5.90 9.67
2.04 3.76 6.00 9.84
2.07 3.82 6.10 10.01
2.10 3.88 6.20 10.18
2.14 3.95 6.30 10.35
2.17 4.02 6.40 10.51
2.20 4.08 6.50 10.67
2.24 4.14 6.60 10.83
2.27 4.20 6.70 10.99
2.30 4.26 6.80 11 .15
2.34 4.32 6.90 11 .30
2.37 4.38 7.00 11 .45
2.40 4.44
7.10 11 .60
2.44 4.50 7.20 11 .75
2.47 4.56 7.30 11 .90
2.50 4.62 7.38 12.05
2.53 4.68 7.46 12.19
2.56 4.73 7.54 12.33
2.59 4.78 7.62 12.47
2.62 4.83
7.70 12.60
2.75 5.09 8.10 13.30
2.88 5.34 8.50 13.90
3.01 5.58 8.90 14.50
3.14 5.81 9.30 15.10
3.26 6.03 9.60 15.70
3.38 6.25 9.90 16.25
3.50 6.46 10.30 16.80
3.61 6.66 10.60 17.30
3.0
3.5
4.0
4.5
9.50
1 .5
9.90
10.50
10.85
11 .20
11 .50
11 .70
12.00
12.35
12.65
2.0
13.00
13.30
13.65
14.00
14.25
14.50
14.75
15.00
15.35
15.70
2.5
16.00
16.30
16.60
16.90
17.20
17.50
17.75
18.00
18.25
18.50
18.75
19.00
3.0
19.30
19.60
19.85
20.10
30.35
20.60
20.90
21 .20
21 .50
21 .75
3.5
23.00
24.20
24.90
4.0
25.80
26.90
27.75
28.50
4.5
29.10
180.0
200.0
220.0
240.0
260.0
280.0
300.0
320.0
340.0
360.0
380.0
400.0
420.0
440.0
460.0
480.0
500.0
520.0
540.0
560.0
580.0
600.0
620.0
640.0
660.0
680.0
700.0
720.0
740.0
760.0
780.0
800.0
820.0
840.0
860.0
880.0
900.0
920.0
90.0
960.0
980.0
1000.0
1100.0
1200.0
1300.0
1400.0
1500.0
1600.0
1700.0
1800.0
5.0
GEORGE FISCHER
1 .5
2.0
2.5
3.0
3.5
4.0
4.5
5.0

Velocity Pressure
Drop
Volumetric Flow L/S
Drop
(pascals) (m/s)
16mm 20mm 25mm 32mm 40mm 50mm 63mm 75mm 90mm 110mm (m/s) (pascals)
1900.0
2000.0
2250.0
2500.0
2750.0 1 .5
3000.0
3250.0
3500.0
3750.0
4000.0
4250.0
4500.0
4750.0 2.0
5000.0
5250.0
5500.0
5750.0
6000.0
6250.0
6500.0
6750.0
7000.0
7250.0 2.5
7500.0
7750.0
8000.0
8250.0
8500.0
8750.0
9000.0
9250.0
9500.0
9750.0 3.0
10000.0
12000.0 3.5
14000.0
16000.0 4.0
18000.0
20000.0 4.5
22000.0
24000.0
26000.0 5.0
28000.0
30000.0 5.5
32000.0
34000.0 6.0
36000.0
38000.0
40000.0
GEORGE FISCHER
0.126 0.224 0.580 1 .11

2.04 3.72
6.86 10.90 17.80 29.65 19.00.0
0.130 0.230 0.600 1 .15
2.10 3.83
7.06 11 .25 18.30 30.15
5.0 2000.0
0.140 0.245 0.640 1 .23
2.25 4.07
7.53 12.00 19.55 2250.0
0.150 0.260 0.680 1 .30
2.40 4.31
7.98 12.70 20.70 2500.0
0.157 0.275 0.715 1 .37
2.52 4.54
8.41 13.35 21 .75 2750.0
0.164 0.290 0.750 1 .43
2.64 4.76
8.82 14.00 22.70 3000.0
0.173 0.305 0.780 1 .49
2.76 4.97
9.21 14.60 23.55 3250.0
0.180 0.320 0.810 1 .55
2.88 5.18
9.58 15.15 3500.0
0.187 0.335 0.840 1 .61
3.00 5.38 10.03 3750.0
0.193 0.350 0.870 1 .67
3.09 5.55 10.36 4000.0
0.200 0.360 0.900 1 .73
3.18 5.75 10.66 4250.0
0.206 0.370 0.930 1 .79
3.27 5.93 4500.0
0.212 0.380 0.960 1 .85
3.36 6.11 4750.0
0.218 0.390 0.990 1 .90
3.45 6.29 5000.0
0.224 0.400 1 .020 1 .95
3.54 6.45 5250.0
0.230 0.410 1 .050 2.00
3.63 6.61 5500.0
0.235 0.420 1 .075 2.05
3.72 6.76 5750.0
0.240 0.430 1 .100 2.10
3.81 6.90 6000.0
0.245 0.440 1 .125 2.15
3.90 7.03 6250.0
0.250 0.450 1 .150 2.20
3.98 7.15
5.5 6500.0
0.255 0.458 1 .170 2.24
4.06 7.26 6750.0
0.260 0.466 1 .190 2.28
4.14 7.36 7000.0
0.265 0.474 1 .210 2.32
4.22 7250.0
0.270 0.482 1 .230 2.36
4.30 7500.0
0.275 0.490 1 .250 2.40
4.38 7750.0
0.280 0.500 1 .270 2.44
4.46 8000.0
0.285 0.508 1 .300 2.48
4.54 8250.0
0.290 0.516 1 .310 2.52 8500.0
0.295 0.524 1 .330 2.56 8750.0
0.300 0.532 1 .360 2.60 9000.0
0.305 0.540 1 .380 2.64 9250.0
0.310 0.550 1 .400 2.68 9500.0
0.315 0.560 1 .420 2.72 9750.0
0.320 0.570 1 .440 2.76 10000.0
0.355 0.630 1 .600 12000.0
0.380 0.680 1 .750 14000.0
0.405 0.730 1 .900
6.0 16000.0
0.430 0.780 18000.0
0.455 0.820 20000.0
0.480 0.870 22000.0
0.505 0.910 24000.0
0.530 0.950 26000.0
0.555 0.990 28000.0
0.580 1 .030 30000.0
0.600 1 .070 32000.0
0.620 1 .110 34000.0
0.640 36000.0
0.660 38000.0
0.680 40000.0
7.13
Table 4b: Equivalent pipe lengths for socket fusion & electro fusion fittings

PB pipe dimension o.d. mm

16
20
25
32
40
50
63
75
90
110
Item Equivalent pipe lengths m

Elbow 90
0.3
0.4
0.6 0.8
1 .0 1 .2 1 .7
2.1 2.6 3.2
Elbow 45
0.2
0.3
0.4 0.5
0.7
0.9 1 .2
1 .5 1 .9 2.4
1 3 0.6
1 2 0.7
0.8
0.9
1 .1 1 .5
1 .2 1 .7
1 .8
2.1
2.3 3.2
2.7 3.7
4.2 5.4 6.6

4.8 5.9 7.0
T-equal
1
3
2
Stop cock
Non return valve
Tap
4.0 7.0 10.0 13.0 16.0 22.0 34.0

2.5 4.3 5.6 6.0
7.9 11 .5
3.7 11 .8 22.0
T-reduced

Always consider the loss factor of the outlet in

flow direction (12 or 13) from T-equal.
Straight-through tees, sockets, reducers, unions are not included because their equivalent pipe length values are to low
Mechanical and physical properties

Properties
Value
Unit
Density
0.93
g/cm
DIN 53479
Melt temperature
122128
DTA
Vicat softening point
113
DIN 53735
Glass transition point
18
ASTM D-746
kJ/kg
DSC
0.22
W/mK
DIN 52612
Thermal expansion coefficient
0.13
mm/mK
DIN 53752
Modulus of elasticity
350
MPa
DIN 53457
Shore hardness
53
D-Scale
ISO 8608
Impact resistance
40
(0 C) kJ/m2 DIN 53453
Fusion heat
100
DIN 53457
Tensile strength
33
MPa
DIN 53455
Yield stress
17
MPa
DIN 53455
Ultimate elongation
7.14
Standard
3
125
GEORGE FISCHER
Flushing times for dead legs

Pipeline
16 mm o.d.
Water content per m of pipeline

0.10 l
Flow in l/s
10.07
10.10
10.15
10.20
10.25
10.30
0.50
Flushing times in seconds

2.8
2.0
1 .3
1 .0
5.7
4.0
2.7
2.0
1 .6
1 .3
8.6
6.0
4.0
3.0
2.4
2.0
1 .2
11 .4
8.0
5.3
4.0
3.2
2.7
1 .6
10
14.3
10.0
6.7
5.0
4.0
3.3
2.0
Medium content V per m

INSTAFLEX PB pipe
12
17.1
12.0
8.0
6.0
4.8
4.0
2.4
14
20.0
14.0
9.3
7.0
5.6
4.7
2.8
16
20
25
32
40
50
63
16
22.8
16.0
10.7
8.0
6.4
5.6
3.2
18
25.7
18.0
12.0
9.0
7.2
6.0
3.6
20
28.6
20.0
13.3
10.0
8.0
6.7
4.0
22
31 .4
22.0
14.7
11 .0
8.8
7.3
4.4
24
34.3
24.0
16.0
12.0
9.6
8.0
4.8
26
37.1
26.0
17.3
13.0
10.4
8.7
5.2
28
40.0
28.0
18.7
14.0
11 .2
9.3
5.6
30
42.8
30.0
20.0
15.0
12.0
10.0
6.0
mm
mm
mm
mm
mm
mm
mm
o.d.
o.d.
o.d.
o.d.
o.d.
o.d.
o.d.
= 0.10 l/m
= 0.16 l/m
= 0.33 l/m
= 0.53 l/m
= 0.83 l/m
= 1 .31 l/m
= 2.07 l/m
Calculation of
flushing time t
VL
t =
V
V = pipe content l/m
L . = pipeline length m
V= flow l/s
t = flushing time s
Pipeline length in m

2

4
Pipeline
20mm o.d.
Water content per m of pipeline

0.16 l
Flow in l/s
10.07
10.10
10.15
10.20
10.25
10.30
10.50
10.60
11 .00
Flushing times in seconds
4.6
3.2
2.1
1 .6
1 .3
1 .1
9.1
6.4
4.3
3.2
3.6
2.1
1 .3
1 .1
13.7
9.6
6.4
4.8
3.8
3.2
1 .9
1 .6
1 .0
18.3
12.8
8.5
6.4
5.1
4.3
2.6
2.2
1 .3
10
22.8
16.0
10.7
8.0
6.4
5.3
3.2
2.7
1 .6
12
27.4
19.2
12.8
9.6
7.7
6.4
3.8
3.2
1 .9
14
32.0
22.4
15.0
11 .2
9.0
7.5
4.5
3.7
2.2
16
36.6
25.6
17.1
12.8
10.2
8.5
5.1
4.3
2.6
18
41 .1
28.8
19.2
14.4
11 .5
9.6
5.8
4.8
2.9
Pipeline length in m
GEORGE FISCHER
20
45.7
32.0
21 .3
16.0
12.8
10.7
6.4
5.3
3.2
22
50.3
35.2
23.5
17.6
14.1
11 .7
7.0
5.9
3.5
24
54.8
38.4
25.6
19.2
15.4
12.8
7.7
6.4
3.8
26
59.4
41 .6
27.7
20.8
16.8
13.8
8.4
6.9
4.2
28
64.0
44.8
29.9
22.4
18.0
15.0
9.0
7.5
4.5
30
68.6
48.0
32.0
24.0
19.2
16.1
9.6
8.0
4.8
7.15

Term
Symbol
Unit
Calculated flow velocity

m/s

Average flow velocity at

peak flow
Volume
m3
Flow area
m2
Cross sectional internal area of pipe
Flow, Volume flow

V
l/s

m3/h

Quantity of water volume, which

flows through a certain flow area,
in a specific amount of time
Outlet flow
VE
l/s

Flow through an open tap

including outlets (jet
regulator, shower, etc.) at the
actual flow pressure
Highest
V0
l/s
outlet flow

Outlet flow for a specific

flow pressure according to
DIN 52 218 Part2
Least
Vmin
l/s
outlet flow

The smallest outlet flow

which suffices for use of the tap
Calculated flow
VR
l/s

The presumed outlet flow

for the calculation:
VR =
Total flow
VR
l/s

7.16
Definition
minall
+calculated
V0
The sumVof
flows
2 water consumption
of the supplied
devices in an open cross-section
Peak flow
Vs
l/s

The flow which is decisive in hydraulic

calculations taking into consideration
the probable simultaneous use of
water outlet during
operation.
Stationary pressure
pR

bar,
mbar,
Pa
Static atmospheric pressure at a

measurement point in the system,
when water is not flowing
Flow pressure
pFI

bar,
mbar,
Pa
Static atmospheric pressure at a

measurement point in the potable
water system, when water is flowing
Minimum flow pressure

pmin FI
bar,

mbar,

Pa

Minimum supply pressure
pmin V
bar

mbar
Required static atmospheric pressure

at the connecting point of a water
outlet at the least outlet flow

Pa

connecting line to the supply line

according to the specifications of the
respective water supply company
(WVU)
Pressure difference, pressure loss

p

bar
mbar
Pa
Difference between two pressures in

a potable water system (see also
table 2)
Pressure loss from geodetic

pgeo
height difference

bar
mbar
Pa
geo hgeo = g
Minimum static atmospheric pressure

at the connecting point of the
GEORGE FISCHER
Term
Symbol
Available pressure difference
pverf

Pipe friction pressure drop
R

Unit
bar,
mbar,
Pa
bar/m,
mbar/m,
Pa/m
Pressure loss from pipe friction

l R
bar,

mbar,

Pa
Available pipe friction
Rverf
bar/m,
pressure drop
mbar/m,

Pa/m
Pressure loss from fitting
Z
bar,

mbar,

Pa
Pipe length
l
m
Pipe inner diameter
di
mm
Resistance value,

1
pipe friction value
Pipe roughness
PB roughness factor

rf = 0.007

Loss value

1

Density

kg/m3
Reynolds number
Re
1
Kinematic viscosity

m2/s
.
Pump flow
VP
m3/h

Pump pressure
pP
mbar,

bar,
pump

Pa

GEORGE FISCHER
Definition
The available pressure difference
for pipe friction and fittings
Pressure loss per unit length from
pipe friction
p
R= l
Pressure loss from pipe friction
in a calculated section
The approximated value used in
the calculation for pipe friction
pressure drop
2
Z=
2
The presumed absolute roughness

of the pipe inner wall in use
(empiric probability)
Characteristic flow parameter
(constant) for a fitting; required for
calculation of the local pressure
loss
Ratio of mass and volume
di
Re =
The usable
volume flow conveyed
by the pump
(from: DIN 4046/09.83)
Difference between ultimate
pressure side of the circulation
and the pressure before
. the pump
with a pump flow of VP
7.17
7.18
GEORGE FISCHER
INSTAFLEX Jointing
GEORGE FISCHER
Page
INSTAFLEX Jointing
Fusion Jointing
Hand held fusion joints 16 - 63mm
Preparing the hand held fusion tool for use
Preparing the fitting
Preparing the pipe
Fusing the pipe and fitting together
Hand held fusion jointing in situ
Bench mounted fusion jointing machine 25 - 110mm
Preparing the bench mounted fusion machine for use
Preparing the pipe
Fusing the pipe and fitting together
Special fusion jointing using bench mounted socket fusion machine
Fusing reducing bushes into fittings
Fusing electrofusion spigots onto fitting
Preparing the electrofusion control unit for use
Preparing the fittings
Preparing the pipe
Electrofusing the pipe and fittings together
Jointing electrofusion fittings to the pipe
Cutting & joining INSTAFLEX sleeve
Joining the sleeve to the fittings
Cutting & preparing INSTAFLEX carrier
8.01
8.02
8.03
8.04 - 8.06
8.07 - 8.10
8.11
8.11 - 8.15
8.16 - 8.20
8.21 - 8.22
8.23 - 8.24
8.25 - 8.31
8.32
8.32 - 8.36
8.37 - 8.44
8.45
8.46 - 8.47
8.47 - 8.48
8.49
8.50 - 8.51
8.51
8.52 - 8.53
8.54 - 8.55 8
8.55 - 8.57
8.58 - 8.59
8.60
8.61
Handling & storage instructions for INSTAFLEX

Operational tests & ordinary maintenance
INSTAFLEX Installation Quick Reference Guide
8.62
8.63 - 8.66
8.67 - 8.72
8.73
8.74 - 8.81
8.82
8.0
Compression
Cross section of compression
joint
Gripping spigot
Introduction
A compression joint is a brass fitting
comprising of a number of parts,
into which the prepared PB pipe is
inserted. As the pipe is inserted into
the fitting it is pushed over an internal
gripping spigot.
When the pipe is fully inserted,
the locking mechanism of the
compression fitting is then tightened.
This compresses the pipe against the
gripping spigot achieving the water
tight seal without the use of any
sealing material. It also secures the
pipe firmly in place.
There are two methods of preparing
PB pipe for compression joints.
For 16 to 25mm a calibrating tool is
used to stretch the pipe so it will go
onto the gripping spigot.
For 32mm and above the pipe needs
to have a layer of PB reemed from
the inside to enable it to fit onto the
gripping spigot.
There are two mechanisms for
compressing the pipe against the
gripping spigot.
For 16 to 20mm a nut, containing a
split ring, is tightened with a spanner.
This compresses the split ring which
then grips the pipe.
For 25mm and above a clamping
loop is tightened around the pipe, by
screwing an allen key bolt until it is
tight, thus gripping the pipe.
8.0
GEORGE FISCHER
Fusion Jointing
Cross section through a fusion joint
Introduction
A fusion joint is where two pieces
of plastic (usually the pipe and
the fitting have been heated by a
heating tool until their surfaces melt.
Then the two molten surfaces are
brought together and joined. As
they cool the two molten surfaces
join together into one homogeneous
component.
This can be accomplished with either
hand held fusion tools, which are
suitable for pipe sizes 16 to 63mm
Both pipe and fitting are

heated on a heater tool.
They are then brought together and held for a preset

time
Or bench mounted fusion machines

which are suitable for pipe sizes 25
to 110mm but normally only used on
75-110mm sizes.
GEORGE FISCHER
8.0
Hand held fusion joints 16 to 63mm

This section covers;
the tools required for hand held
fusion jointing,
setting up the tools for use,
preparing the pipe and fittings for
jointing,
fusing the pipe and fitting together on
a bench and
fusing the pipe and fitting together in
situ.
Hand held heating element
Tools
The hand held fusion kit may be
hired or purchased, please contact
George Fischer Sales Ltd. Tel: 01203
535535,
Equipment required is:Hand held heating element:
110 volt used to heat the bushes.
Heating bushes:
16 to 63mm, these are used to melt
the pipes and fittings.
Heating bushes
Temple sticks:
These are wax crayons which melt
at specific temperatures. They are
used to check the heater bushes are
operating at the correct temperature.
Temple sticks
8.0
GEORGE FISCHER
Template:
Used to mark the pipe to check it is
inserted the correct depth into the
fittings.
Template
Gloves:
Heat resistant, used to prevent burns
when the heater bushes are changed
or cleaned.
Heat resistant gloves
Timer:
This must be used for every fusion
joint to check that the exact
heating time for fusion joints is used.
Timer
Pipe shear:
For snipping through pipe sizes 16 to
25mm o.d. at a 90 angle
Pipe Shears
Pipe cutter:
For cutting the 25 to 63mm pipe
by rotating around the pipe and
tightening the handle until the cutting
wheel slices through the pipe at a
90 angle.
Roller pipe cutters
Chamfering tool:
For chamfering the end of the pipes
for 25 to 63mm pipe.
Chamfering tools
GEORGE FISCHER
8.0
Cleaning fluid & lint free cloth:

Apply the cleaning fluid to cloth to
clean the pipe and fittings.
The G clamp is secured to the bench
and the hand held heating element is
slipped into it.
Cleaning fluid & cloths
Support base to hold the hand held

heating element upright when being
used to do jointing around the site.
Support base
Plastic support handle
Either Plastic support handle

This is screwed into the hand held
heating tool and is used to hold it
steady as joints are being made in
situ.
Or
Wooden support handle
This is used to hold the heater plate
of the hand held heating tool steady
when joints are being made in situ.
Wooden support handle
8.0
Note
When the hand held fusion tool
is hired most of the above tools
come as standard. They are also
sold as a complete package with a
new hand held fusion tool. (Except
cleaning fluid and lint free cloth,
which must be purchased separately.)
GEORGE FISCHER
Preparing the hand held fusion tool for use

Although the hand held fusion tool is
portable and suitable for use in situ,
it is best to use it at a fixed location
with the tool mounted on a bench.
Hand held fusion tool
HOT
DANGER
Secure fixing plate to the

bench
Warning
The hand held fusion tool is hot
when in use, it should not be
located where untrained staff can
accidentally knock into it. It should
ideally be marked with a clearly
visible warning signs identifying
that it is hot. It may be required by
the Safety Officer on the building
site, to cordon off the working area
around this tool.
Mount the fusion tool on a firm,
suitable, work surface. The fixing
method depends on the type of tools
which come with the hand held fusion
tool
Either
8
Flat plate
This should be secured near the edge
of a working surface
The plate is placed on a clean flat
part of the work surface.
G clamps are then used to fix the
plate to the surface. (G clamps are
not supplied by George Fischer)
The metal end of the hand held

fusion tools is placed into the flat
plate and secured in place with the
winged bolt.
Secure fusion tool to the fixing
plate
GEORGE FISCHER
8.0
Or
The support G clamp is secured to
one edge of a working surface. By
rotating the handle below the clamp
until it is tight.
Secure the clamp to the
bench
The plastic end of the hand held

fusion tool is slipped into the support
clamp. This will firmly hold the fusion
tool in place and does not need any
securing.
Slip the fusion tool into the

clamp
The fusion tool heater plate has two

holes in it and can maintain two
sets of heater bushes, at the correct
temperature, at the same time.
The hole furthest from the handle can
take heat bushes from sizes 16 to
25mm.
The hole closest to the handle can
take heat bushes from sizes 16 to
63mm.
When the hand held fusion tool has
been secured, the heating bushes can
be attached to it.
Insert the bolt through the

bush
The allen key bolt is inserted through

the bush socket, with the screw thread
facing out.
The screw and the bush socket are
put onto the fusion tool, through the
appropriate hole.
and through the heating

element
The other end of the bush set is

screwed onto the protruding bolt.
Screw the other bush onto

the bolt
8.0
GEORGE FISCHER
The bolt is tightened with an allen

key, to ensure there is a good surface
contact between the bush and the
heater plate. The bush heats up
through conduction from the heater
element. It is important to have
good surface contact between the
bush and the heater plate.
Tighten the bolt
Yellow temple stick is used

to check the element has
reached the correct temperature _It should melt
The fusion tool is plugged into a 110

volt supply and allowed to heat up
for about 5 mins The temperature is
checked using the temple sticks to
confirm the heater bushes are at the
correct working temperature. Firstly
the yellow temple stick is gently
marked on the outside of the bush
socket, this should melt at 253C.
Note
Wax from the temple sticks must
not come into contact with any
surface on the bushes which will
be in contact with the pipe or
fittings, as this could effect the
quality of joints and lead to leaks.
If the wax melts and maybe smokes
a little, we can tell that the bushes
are above the minimum temperature
required for socket fusion jointing.
If the wax does not melt the bush
is not yet up to the correct working
temperature, which is 265C.
Check the fusion tool has power to it
(its lights are on) and try again in 5
-10 mins.
Temperature controller
If it still doesnt melt the heater bush

is not reaching the correct working
temperature. The thermostatic control
may need to be turned up a fraction
(one millimetre clockwise on the
scale).
If the above steps is performed
several times and the thermostatic
control cannot be further adjusted,
there may be a fault with the fusion
tool and George Fischer should be
contacted Tel: 02476 535535
When the bushes are above the
minimum working temperature they
must then be checked to ensure they
are below the maximum working
temperature.
GEORGE FISCHER
8.0
Red temple stick is used to

check the element has not exceeded the correct temperature. It should not melt
The red temple stick is gently marked

on the outside of the bush, the wax
will melt at 253C.
If the wax does not melt the bush
is within the correct working
temperature.
If the wax is left on the bushes for
more than 5 seconds it will start to
bake. This is not an indication that
the temperature is too high.
If the wax melts quickly and maybe
smokes a little, then the fusion
tool is above the correct working
temperature.
Adjust if necessary
The thermostatic control on the side

of the fusion tool needs to be turned
down a fraction (one millimetre anticlockwise on the scale).
Allow the tool about 5 mins to cool
a little and check the temperatures
again with both the yellow and red
temple sticks.
Clean outside of bush
If the above steps is performed

several times and the thermostatic
control cannot be further adjusted,
tool and George Fischer should be
contacted Tel: 02476 535535
Check the bushes are clean, using
a piece of dry lint free cloth to
rub off any debris. To clean inside
the smaller bushes the cloth can
be wrapped around a piece of
dowelling or wooden pencil.
Clean inside of bush
Warning
Do not use a screwdriver or metal
object as this will damage the
Teflon coating on the bushes.
The hand held fusion tool should now
be firmly fastened on the working
surface, the heater bushes in place
and the tool at the correct working
temperature.
Fusion tool ready for jointing
8.10
The fusion tool is now ready to begin

fusion jointing.
GEORGE FISCHER

Clean the polybutylene fittings
internally with Tangit KS. Reiniger,
cleaning fluid.
Apply the cleaning fluid to a clean,
dry lint free cloth.
Moisten cloth with cleaning
fluid
Clean inside of fitting
Rub the moist cloth firmly around the

inside of the fitting on all faces to be
fusion joined.
Place the cleaned fitting carefully
on the working surface, avoid any
moisture or dirt getting inside the
fitting.
Note:
Do not touch the inside of the
fitting with your hands since this
will dirty the fitting and it will need
to cleaned again.
Several fittings can be pre-cleaned
in this way, so long as the cloth is
dampened with fluid and clean, and
the assembly area is not dusty or wet.
Preparing the pipe
The pipe must be cut at right angles

using the appropriate pipe cutters.
Shears for pipes from 16 to 25mm.
Use pipe shears to cut pipe

up to 25mm
Roller cutter for cutting pipes from 25

to 63mm.
The pipe should not be cut with a
hacksaw or similar serrated blade as
this will leave unacceptable burrs.
Use roller cutters on pipe

above 25mm
GEORGE FISCHER
8.11
The pipe must be free from deep

scratches and burrs.
16 and 20mm o.d. pipes do not need
chamfering.
Chamfering pipes from 25 to
63mm o.d.
Check pads are clean.
Check the pads on the chamfering

tools are free from grit, as this will
scratch and damage the pipe when it
is being chamfered.
Check the blade on the chamfering
tool is in contact with the pipe and
will remain in contact with the pipe
throughout its chamfer.
Put pipe up to the blade.
Put the centre spindle on the inside

of the pipe wall, the blades (which
are at an angle) should be in contact
with the pipe about half way down
the blades and be able to remain
in contact for at least half the pipes
width as the pipe is chamfered.
Places pipe over central
spindle.
If the above situation is not true the

relative position of the blades can be
adjusted, by loosening the nut on the
central spindle and moving it closer
or further away from the blades as
required.
Spindle may need adjusting.
Loosen nut to adjust spindle
and then re-tighten it.
8.12
Then firmly tightening the nut on the

spindle to grip it in its new position.
(this adjustment should not be
required often, but it is occasionally
necessary).
GEORGE FISCHER
When the cutting blades are

correctly adjusted for wall thickness
the guidance pads on the chamfering
tool need to be adjusted to suit the
pipe size.
Loosen the guide pads
Twist the black lever on the

chamfering handle, anti-clockwise,
this should loosen the guidance pads.
Put the central spindle roller inside the
pipe and push the chamfering pads
firmly up to the wall of the pipe.
Push pads firmly against pipe

wall
Whilst holding the pads and spindle

roller firmly against the pipe, tighten
the black lever on the chamfering
tool.
Tighten pads in position
When the lever has been tightened, it

may be in a difficult position to allow
easy chamfering, it can be moved
to a different position, by pulling
the lever away from the chamfering
tool about 5mm, at this point it
disengages the tightening bolt and
will move freely to a more suitable
position.
GEORGE FISCHER
8.13
The chamfering tool spindle is

inserted into the pipe, and then
pushed firmly against the end of the
pipe.
Push and turn chamfering tool
Whilst still pushing the chamfering

tool firmly onto the end of the pipe,
rotate the tool clockwise
As the tool rotates, pipe swarf should

start to be pealed from the pipe,
if the pipe is not being pealed the
chamfering tool must be pressed
more firmly onto the end of the pipe.
Remove swarf
The pipe must be chamfered until the

end of the pipe wall is down to about
half its original thickness. The chamfer
should be at an angle of about 15.
Chamfer pipe to 1/2 wall

thickness
8.14
GEORGE FISCHER
The chamfered pipe now needs to

be cleaned externally with Tangit K.S
Reiniger, cleaning fluid.
dry, lint free cloth.
Moisten the cloth with cleaning fluid

outside of the pipes about 50mm up
the pipe. This should remove any dirt
and the printed markings on the pipe
(if it does not you may be using the
wrong cleaning fluid).
Note:
Remember not to handle the
outside of the cleaned pipe with
your hands as it will require
cleaning again.
Clean the pipe
If you have to put the pipe down,

ensure the clean end does not come
into contact with the surface.
Support the pipe ends
Mark the insertion depth of the pipe

with a template after the pipe has
been cleaned.
Pipe size o.d.
Mark the insertion depth
GEORGE FISCHER
Insertion depth
16mm
17mm
20mm
17mm
25mm
20mm
32mm
22mm
40mm
24mm
50mm
28mm
63mm
32mm
The pipe is now ready for fusion
jointing
8.15
Fusing the pipe and the fitting together
Pipe longitudinal line
alignment marks (every 45), for

component assembly
Marks for insertion depth (welding length)
Description with:
- name of manufacturer
- dimension
- material
- product code
The pipe has a line down one

side and the fittings have external
markings every 45. These are to
enable installers to pre-fabricate the
pipes and fittings whilst keeping them
in true alignment.
Alignment line on the pipe
Alignment marks on the fitting
8.16
The fittings also have a mark showing

the insertion depth of the pipe into
the fitting. This enables the installers
to measure the centre to centre
distances of branches on site or
from drawings and cut the pipes to
exactly the right length. This subject is
covered in more detail elsewhere and
is call the Z dimension method
it makes pre-fabricating pipework
simple.
GEORGE FISCHER
Long lengths of pipe will need to be

supported during the fusion process,
approximately at the same height of
the fusion tool, to keep them straight
as the joint is made. This can be
achieved with a bench or boxes or
similar support. This will be required
on both sides of the fusion tool.
The timer has to be set for the
required fusion time according to
the pipe size being jointed. (See the
times listed to the left).
The timer can be reset to zero by
pressing both the second and the
minutes buttons simultaneously, the
seconds button is then pressed to set
the correct fusion time on the timer.
The fusion time varies for the pipe
size being used
Pipe Size o.d.
16mm
20mm
25mm
32mm
40mm
50mm
63mm
Time
6 secs
7 secs
7 secs
10 secs
14 secs
18 secs
22 secs
Note
These times are critical and should
always be measured with a timer
GEORGE FISCHER
The start button will start the timer

and also stop the alarm, although the
alarm will automatically stop after 10
seconds. The timer will then return to
the original time (just set) for repeats
of the same pipe size, do not reset
the timer.
8
Check the fusion temperature of the
bushes is within limits with the temple
sticks, described earlier.
The pipe is held in one hand and the
fitting is held in the other hand.
The alignment of the pipe and fitting
must be checked before you start
jointing.
8.17
The pipe and fitting are pushed

simultaneously onto the heater
bushes, in a steady motion. Larger
pipe sizes will require more effort and
the pipe will be harder to push onto
the bush than the fitting.
Simultaneously push the pipe
As they are pushed onto the bushes

they will start to melt.
and the fitting onto the heater

bush
The pipe is pushed into the bush

socket until the insertion depth mark is
about 2mm short of the bush socket.
If you push any further, the mark will
disappear under the bead of the
melting PB.
2-3mm short of the mark on
the pipe
The fitting is pushed onto the bush

until it reaches the first ridge on the
bush.
and up to the edge of the

fitting
The timer is started when both the

pipe and fitting are fully inserted onto
the bushes.
Start timer
8.18
The operator will have to briefly take

one hand off either the pipe or the
fitting to press the start button on the
timer. It is normal to take your hand
off the fitting.
GEORGE FISCHER
The pipe and fitting must both be

held in place throughout the fusion
process. Gentle pressure should be
maintained to help them stay fully
inserted onto the fusion tool. Also
keeping them straight and level.
Pipe & fitting fully on heater
being held in position
Simultaneously withdraw
both pipe and fitting from
heater bushes
Quickly insert pipe into the

fitting
When the timer beeps withdraw

the pipe and fitting from the fusion
tool, this should be done in a fluid
movement not too fast or slow.
It will be difficult to withdraw the
pipe and fitting at first as they will
tend to stick to the bushes, as they
are withdrawn further they will move
more freely, so less pressure will be
required. It is important to withdraw
them in a gradual movement as
this reduces the amount of molten
material left on the bushes and results
in better joints (this will come with
practice).
Quickly align the pipe and fitting and
bring them together.
Note:
8
It is important to bring the pipe
and fitting together quickly to
prevent their surfaces cooling and
drying
As you bring the pipe and fitting
together you will have to push the
pipe into the fitting. This must be
done quickly and firmly.
Push together without twisting
Push up to the insertion mark
Note:
Do not twist the pipe when
pushing together as this will
weaken the bond and may lead to
failures.
Push the pipe into the fitting up to
the end of the weld. i.e. Where the
insertion mark is, stopping just short
of the insertion mark.
Normally there will be two beads of
soft P.B one on the fitting and one on
the pipe. This demonstrates a perfect
joint.
You need to maintain slight pressure
holding them together otherwise they
will tend to push apart.
GEORGE FISCHER
8.19
You will have to maintain this pressure

for the holding time which is listed
below for different pipe sizes.
Maintain pressure on joint for

holding time
Lay joint on a flat surface for

cooling time
Pipe o.d.
Holding Time in secs
16mm
15
20mm
15
25mm
15
32mm
20
40mm
20
50mm
30
63mm
30
After the holding time has elapsed the
pipe and fitting can be put gently to
one side, on a level surface, to cool.
Note:
It is important to handle the newly
made joint with care, to avoid
putting a strain on it, as it is still
very soft, until the cooling time has
elapsed.
The newly made joint must be left
undisturbed for minimum of the times
listed below to cool
Pipe o.d.
Cooling Time in mins.
16mm
2
20mm
2
25mm
2
32mm
4
40mm
4
50mm
4
63mm
6
Clean both bushes with a dry

lint free cloth
Inspect joint
8.20
After each joint is made rub a dry/

clean cloth over the bush and socket
to check they are free from any
deposits of P.B.
After the joint has been made,
especially when you are using
INSTAFLEX for the first time, check
your workmanship. Learn from any
mistakes and improve your jointing
techniques.
A reference list is given at the end of
the section of common fusion jointing
faults to check and learn from.
After the cooling time the pipe and
fitting are strongly fused together and
can be handled normally
After 1 hour after the last joint has
been made a full system pressure test
up to 15 bar can be undertaken.
GEORGE FISCHER
Hand Held fusion jointing in situ
!
HOT
DANGER
So far in this section we have dealt

with using the hand held fusion tool
bench mounted, it can also be used
in situ. The fusion process is the same,
here we examine the ways in which
the hand held tool can be used in
situ.
Hand held tool
Hand held tool on stand with

insulation cover
Note
The hand held fusion tool is hot.
When it is being transported
around the site it must have its
cover in place. When it is not
being held it must be placed in a
suitable support (provided with
each fusion tool) not laid on its
side on the floor. It must be located
where it will not cause an accident
or hazard. It must not be left
unattended when switched on.
Making joints in situ will normally
involve 2 people, one to hold the
fusion tool and one to hold the pipe
and fitting
Warning
It is important to remember that the
whole heater plate is hot, not just
the bushes. When jointing in situ it is
important to prevent the heater plate
coming into contact with nearby
plastic pipes and fittings as it will melt
them.
If any components are damaged
in this way, although they may not
instantly leak, they will have a shorter
life expectancy and should be
replaced.
Note: Very Important
Because of the short heating times
it is not recommended for 16 and
20mm joints, electrofusion is safer
GEORGE FISCHER
8.21
When using the hand held fusion

tool for joints in situ attach the spare
handle
either
The plastic handle, is screwed onto
the heater plate
Using the plastic handle
or
The wooden handle is hooked over
the end of the pipe
Using the wooden handle
In order to make hand-held fusion

joints in-situ two installers are required. The fusion tool is held in both
hands by one fitter and pushed into
the pipe, which is supported by the
other fitter who at the same time
pushes the fitting onto the fusion tool.
After the correct fusion time the fusion
tool is pulled off the pipe and the
fitting is simultaneously pulled off the
fusion tool.
The fusion tool is withdrawn from
between the pipe and the fitting. The
fitting is then quickly pushed onto the
pipe and held in place for the holding and cooling time.
Note:
It is important to use the timer. The
timer provided by George Fischer
can be attached to a belt or pocket. It can normally be operated by
the fitter holding the fusion tool
after pushing it into the pipe.
8.22
GEORGE FISCHER
Bench mounted fusion jointing machine 25 to 110mm

This section covers the tools required
for bench mounted fusion jointing;
setting up the tools for use; preparing
the pipes and fittings for joining;
fusing the pipes and fittings together
with the bench mounted fusion
machine.
Tools
Prisma 110 bench mounted
socket fusion machine
The bench mounted fusion kit may be

hired or purchased. Please contact
George Fischer Sales at Coventry Tel:
02476 535535.
The equipment required is a
Prisma 110, bench mounted socket
fusion machine (110 volts) which has
wheels at one end and handles at
the other, to enabled it to be moved
around similar to a wheel barrow.
Heating bushes 25mm to 110mm
these are used to melt the pipe and
fittings.
Temple sticks
Heater bushes
Temple sticks, these are wax crayons

which melt at specific temperatures,
they are used to check the heater
bushes are operating at the correct
temperature.
Template is used to mark the pipe, to
ensure that it is inserted to the correct
depth into the fittings. For pipe sizes
16mm to 63mm only.
Gloves
Template
Gloves. Heat resistant gloves must

be used to prevent burns when
the heater bushes are changed or
cleaned.
Timer This must be used for every
fusion joint to check that the exact
heating time for fusion jointing is
used.
Timer
Roller cutters
GEORGE FISCHER
Pipe cutters for cutting the pipe by

rotating them around the pipe and
tightening the handle, until the cutting
wheel slices through the pipe at 90
angles, to the pipe
One size for 25 - 63mm pipes
One size for 75 - 110mm pipes.
8.23
Chamfering tools for chamfering the

end of the pipe in preparation for
fusion jointing.
One size for 25 - 63mm pipes
One size for 75 - 110mm pipes.
Cleaning fluid and cloth

Chamfering tools (right)
Cleaning fluid & Lint free cloth

Apply the cleaning fluid to cloth to
clean the pipe.
Pipe clamps. These are attached to
the Prisma 110, and are reversible for
supporting different pipe sizes.
One side holds pipes from 25mm
to 63mm. the other side holds pipes
from 75mm to 110mm.
These supports come in pairs for
different purposes, one set holds the
pipe, the other set holds the fitting.
It is important not to get the two sets
mixed.
Pipe clamps
Bench rotating handle
Bench rotating handle. This is a

loose handle which must be removed
when the bench mounted fusion
jointed machine is being moved
around the site. It is used to operate
the insertion mechanism on the
machine.
Pipe support stand. This is used to
support a length of pipe at the pipe
clamping side of the bench mounted
fusion machine to prevent the pipe
slipping out of the machine as fusion
joints are made.
Backing plate. This is put over
the rear fitting clamps when fusing
elbows above 50mm to provide back
support to the elbows and stop them
slipping out of the clamps during
jointing
Pipe support stand
Backing plate
8.24
Note:Most of the above tools come as

standard with the hired bench
mounted fusion jointing machine
They can also be sold as a
complete package with a new
bench mounted fusion jointing
machine. With the exception
of cleaning fluid and lint free
cloth, which must be purchased
separately.
GEORGE FISCHER
Preparing the bench mounted fusion jointing

machine for use
!
HOT
DANGER
The fusion machine is mobile
Attach the handle
The Prisma 110, bench mounted

fusion machine is provided with
wheels to make it suitable for moving
around site, to different locations as
necessary.
Note
The bench mounted jointing
machine has components which
get very hot when it is in use.
It should not be located where
untrained staff can accidentally
come into contact with it. It should
be marked with clearly visible
warning signs identifying that it
is hot. It may be required by the
Site Safety Officer to cordon off the
working area around this tool.
Locate the bench rotating handle

8
onto the steel shaft protruding
from the side of the machine, this is
achieved by pushing it onto the shaft.
Set the pipe size dial, located at one
end of the machine, to the size of the
pipe being jointed.
Set the pipe size dial
Fix the pipe clamps to the Prisma 110.

For pipe sizes 25 to 63mm have the
small pipe grips facing into the centre
of the machine.
For pipe sizes 75 to 110mm have the
large pipe grips facing into the centre
of the machine.
Clamp grips for small diameter pipework
Clamp grips for large diameter pipework
GEORGE FISCHER
8.25
Fix the front fitting support clamp to

the bench mounted fusion machine.
This clamp is the only clamp which
is fixed in the same position every
time. It can not be moved forward or
backward on the fusion machine like
the other clamps
Front clamp for fittings
There are two depressions under the

clamp for shims to be inserted and
aligned with the depressions on the
bench. Checking the shims are in the
correct place and the clamps are flat
on the guide rails, the bolts are then
firmly tightened to hold them in place.
Front clamp alignment shims
Slide the clamps onto the rail
Tighten the front clamps
The clamps are fixed onto the guide

rail on the fusion machine, with
locking bars, which are held loosely
to the pipe clamps with bolts and
slipped into the guide rails.
The front clamps are secured by

tighten the fixing bolt with an allen
key.
Fix the rear fitting supporting

clamps to the bench mounted fusion
machine
The pair of rear fitting support
clamps have larger jaws than the 2
pairs of pipe support clamps.
Do not get them mixed up as this
will result in joints which are out of
alignment.
Do not get the clamps mixed

up. Pipe support clamps are
smaller.
8.26
GEORGE FISCHER
Slide the clamps to the required

position and tightened up.
Fit the rear clamps
A quick release mechanism on the

bolts enables them to be easily
tightened or loosened. To operate
the mechanism, lift the black handle,
this will disconnect it from the bolt,
the handle can then be moved freely
without tightening or loosening the
bolt to get it out of the way.
Lowering the handle will make it grip
the bolt, which can then be tightened
or loosened as required.
The 2 clamps should be set up
opposite each other when holding
a fitting to ensure it is supported
squarely.
Tighten with lever
Slide the clamps forward or

backward on the side rails to suit
different fitting types and sizes.
Set clamps up in pairs
Fix the front and back pipe support

clamps on the bench mounted fusion
machine.
Clamps may be moved on

the rail
This comprises of two pairs of

identical support clamps. Before
fitting check the two clamps on the
left are exactly the same as each
other and the two clamps on the right
are exactly the same as each other,
and the exact mirror of the left hand
clamps.
There should now be eight clamps
fitted to the machine set out in four
pairs directly opposite each other.
All 8 clamps need positioning

GEORGE FISCHER
8.27

Always ensure clamps are
aligned
Slide the clamps to the required

position and tightened up using the
quick release mechanism described
earlier.
Correct!
Each pair of clamps should be
directly opposite each other, to
ensure the pipe is held straight.

Wrong!
Clamps should not be positioned
like this. They should always
be opposite their matching
counterpart
Do not misalign clamps
Slide the pairs of clamps closer

together or further apart depending
on the item being assembled.
Clamps can be placed close

together...
or far apart
8.28
GEORGE FISCHER
When the support clamps are

attached the heater bushes can be
fixed to the heater plate.
The heater plate can heat bushes
from 25 to 110 mm, which are the
sizes the clamps supplied are suitable
for. (Extra bushes will be required for
16 - 20mm jointing)
The heater plate
The allen key bolt is inserted through

the bush socket with the screw thread
facing out.
Push the bolt through the

bush
Position the bush on the

heater plate
The bolt screw, with the bush socket

attached, is pushed through the hole 8
in the heater plate. Check the heater
bush is facing the same side as the
clamps for holding the fittings and
the heater socket is facing the clamps
which will grip the pipe.
The other end of the bush set

is screwed onto the bolt screw
protruding through the heater plate.
Screw the other bush onto the

heater plate
The bolt is tightened with an allen

key to ensure there is a good surface
contact between the bush set and the
heater plate. The bush set heats up
through conduction from the heater
plate.
Tighten the bolt with an allen
key to secure the bushes in
place
GEORGE FISCHER
Note:
When handling the bushes or
heater plate always wear heat
resistant gloves
8.29
The fusion tool is plugged into

110volt supply and switched on,
allowing about 5 mins. to heat up.
A red light will be illuminate to
indicate the power is on and a green
light will illuminate to indicate when
there is power going to the heater
plate.
Switch on the machine
The heater plate is thermostatically

controlled and the green light will
switch on and off as it maintains the
heater plate temperature.
The temple sticks are used to confirm
the heater bushes are at the correct
working temperature. The temple
sticks are made of wax which will
melt at specific temperatures.
The red and green lights

should illuminate
First the yellow temple stick is

socket, this should melt at 253C.
If the wax melts and possibly smokes
a little, we can tell that the bushes
are above the minimum temperature
required for socket fusion jointing.
Tap the bush with the yellow

temple stick
Note
It is important that no wax from
the temple stick falls onto the
surfaces of the bushes, which
will be in contact with the pipe
or fittings, as this could effect the
quality of joints and lead to leaks.
If the wax does not melt, the bush

is not yet up to the correct working
temperature. Check the fusion
machine is still switched on and has
power to it, then leave it 5-10 mins,
and then try again.
If it still doesnt melt the heater bush

is not reaching the correct working
temperature. The thermostat control,
situated by the On switch, may
need to be turned up slightly (one
millimetre clockwise on the scale).
If it does not melt increase the
temperature gradually
8.30
If the above step is performed several

times and the thermostat control can
not be adjusted any higher, then
machine and George Fischer should
be contacted, Tel: 02476 535535.
GEORGE FISCHER
When the heater bushes are above

the minimum working temperature we
must then check that they are below
the maximum working temperature.
To do this the red temple stick is
socket, the wax will melt at 253C.
Tap the bush with the red

temple stick
If the wax does not melt, the

bush is within the correct working
temperature. If the wax is left in the
bushes for more than 5 seconds,
it will start to bake. This is not an
indication that the temperature is too
high.
If the wax melts quickly and possibly
smokes a little, then the fusion
tool is above the correct working
temperature and needs adjusting.
The thermostat control on the side
of the fusion machine needs to be
turned down slightly (1 mm anticlockwise on the scale).
Lower the temperature if the

wax melts
Allow the fusion machine about 5

mins to cool a little and check the
temperature again with both yellow
and red temple sticks.
If the above task is performed several
times and the thermostatic control
can not be adjusted any further,
machine and George Fischer Sales
should be contacted, Tel: 02476
535535.
Pipe supports stands must be

used to support long lengths
of pipe
The pipe support stand is used to

support the pipe whilst jointing and
can be placed where it counter
balances the pipes weight. It is useful
when assembling long lengths of
pipe to support them from both sides.
Boxes or conventional pipe supports
can achieve this.
Check the bushes are clean, using
a piece of dry lint free cloth to
rub off any debris. To clean inside
the smaller bushes, the cloth can
be wrapped around a piece of
dowelling or a wooden pencil.
Clean the bushes with dry lint
free cloth
GEORGE FISCHER
Note:
Do not use a screwdriver or metal
object as this will damage the
Teflon coating on the bushes
The fusion machine is now ready to

begin fusion jointing.
8.31
Preparing the Fitting

internally with the Tangit KS, Reiniger,
cleaning fluid.
Moisten the cloth with cleaning fluid

inside of the fitting on all faces to
be fusion joined. Place the cleaned
fitting carefully on the working service
surface, avoid any moisture or dirt
getting inside the fitting.
Note:
Remember not to handle the inside
of the fittings with your hands as
you will make them dirty and you
will need to clean them again.
Clean the inside of the fitting

in this manner, at any one time,
provided the cloth is still clean and
moist with cleaning fluid, and the
assembly areas is not dusty or wet.
Preparing the pipe

The pipe must be cut at right angles
using the appropriate pipe roller
cutters.
Cut the pipe with roller cutters
For pipes below 40mm the pipe can

be held by hand as the roller cutter is
rotated around it.
For pipes above 50mm it is easier
to cut them if you use the clamps on
the fusion machine to hold the pipe
steady whilst you use the roller cutter
to cut the pipe.
Large pipe diameters can be

held in the machine
8.32

hacksaw or similar serrated blade as
this will leave unacceptable burrs.
GEORGE FISCHER
Select chamfering tool checking that the pads are clean
Chamfering pipes from 25 to

110mm o.d
Two tools are required, the smaller
tool is used to chamfer pipes 25 to
63mm, diameter, the larger tool is
use to chamfer pipes 75 to 110mm
diameter.
Check the pads on the chamfering

tools are free from grit, as this will
scratch and damage the pipe when it
is being chamfered.
Check the blade on the chamfering

tool is in contact with the pipe and
will remain in contact with the pipe
throughout its chamfer.
Push the pipe up to the
blades
Put the centre spindle on the inside

8
of the pipe wall, the blades (which
are at an angle) should be in contact
with the pipe about half way down
the blades, and be able to remain
in contact for at least half the pipes
width as the pipe is chamfered.
If the above situation is not true the

relative position of the blades can
be adjusted, by loosening the nut on
the central spindle and moving the
spindle closer or further away from
the blades as required.
Then firmly tightening the nut on the
spindle to grip it in its new position.
(This adjustment should not be
required often, but it is occasionally
necessary)
GEORGE FISCHER
8.33
Put the pipe over the spindle

and loosen the guidance
pad holder
When the cutting blades are

correctly adjusted for the pipe wall
thickness, the guidance pads on the
chamfering tool need to be adjusted
to suit the pipe size.
Twist the black lever on the
chamfering handle anti-clockwise,
this should loosen the guidance pads.
Put the central spindle roller inside the

pipe and push the chamfering pads
firmly up to the wall of the pipe.
Hold the pads tight to the

pipe wall and tighten
Whilst holding the pads and spindle

roller firmly against the pipe, tighten
the black lever on the chamfering
tool.
When the lever has been tightened,
it may be in an awkward position
to allow easy chamfering, it can
be moved to a different position by
pulling it away from the chamfering
tool handle by about 5mm. At this
point it disengages the locking
bolt and will move freely to a more
suitable position.
Move the lever out of the

way
8.34
GEORGE FISCHER
Once the guidance pads are set

up for a particular pipe size, they
can chamfer many pipes of that size
without being adjusted again.
Push and rotate chamfering

tool
Larger pipe diameters can be

held in the machine
The chamfering tool spindle is

inserted into the pipe, and the
chamfering tool is pushed firmly
against the end of the pipe.
For pipes above 50mm it is easier
to chamfer if you use the clamps on
the fusion machine to hold the pipe
stationary while you chamfer the end.
Still pushing the chamfering tool
firmly onto the end of the pipe, rotate
the tool clockwise.
As the tool rotates, pipe swarf should
start to be peeled from the pipe.
If the pipe is not being peeled the
chamfering tool must be pressed
more firmly onto the end of the pipe.
The pipe must be chamfered until

the end of the pipe wall is down to
about half its original thickness. The
chamfering should be at an angle of
about 15.
Chamfer pipe to 1/2 wall

thickness
GEORGE FISCHER
8.35
The chamfered pipe now needs to

be cleaned externally with Tangit KS.
Reiniger, cleaning fluid.
Apply cleaning fluid to cloth

Clean the pipe

outside of the pipe, about 50mm up
the pipe. This should remove any dirt
and the printed markings on the pipe
(if it does not, you may be using the
wrong cleaning fluid).
Note
your hands as this will make it
dirty and it will need cleaning
again.
Keep the clean pipe end off

the surface
If you have to put the pipe down,

ensure the clean end does not come
into contact with the surface.
Mark the insertion depth of the pipe
with a template after the pipe has
been cleaned.
Mark the insertion depth
Pipe o.d.
16mm
20mm
25mm
32mm
40mm
50mm
63mm
75mm
90mm
110mm
Insertion depth
17mm
17mm
20mm
22mm
24mm
28mm
32mm
36mm
42mm
48mm
Below 63mm this can be done with a

template
Above 63mm you will need to use a
tape measure
The pipe is now ready for fusion
jointing.
8.36
GEORGE FISCHER
Fusing the pipe and fittings together

All the pipes have a line down one
side and the fittings up to 63mm
have external markings every 45.
These are to enable installers to prefabricate the pipes and fittings whilst
keeping them in perfect alignments.
Alignment line on pipe
Alignment mark on fitting
Support the pipes
Place fitting up to edge of

clamp
Adjust rear clamps to grip

fitting
GEORGE FISCHER
The fittings below 63mm also have a

mark showing the depth to which the
pipe is inserted into them. This is to
allow installers to measure the centre
to centre distance of branches on site
or from drawings and cut the pipes to
exactly the right length. This subject
is covered in more details elsewhere
and is called the Z Dimension
Method it makes pre-fabrication of
pipework easy.
Long lengths of pipe will need to be
supported during the fusion process,
approximately to the same height
of the fusion machine, keeping them
level as the joints are made. The pipe
support clamps will help achieve
8
this, supporting the pipes on both
sides of the fusion tool. This may be
insufficient on its own and extra pipe
support stands or boxes should be
used.
The fitting must be placed squarely
into the fitting support clamps. The
face of the fitting must be placed
flush with the lips at the edge of
the clamps, checking all four points
where fitting is gripped by the clamp.
Note:
Ensure the support clamps are the
correct way around on the fusion
machine, for the fitting sizes being
used, see section preparing the
bench mounted fusion jointing
machine for use, for more details
on this. (Page 38)
The rear fitting support clamps may
be moved backwards or forwards
to grip a suitable point on the fitting
(you must not try to hold the pipe with
the rear support clamps since they
will be to large for the pipe).
8.37
The fitting is then clamped in the

support clamp by rotating the clamp
opening/closing handle until the
fitting is held firmly.
As the clamp grips the fitting, its
alignment must be checked to ensure
it is straight.
Tighten the hand wheel
When fusing an elbow or tee outlet,

the rear fitting support clamps will not
be able to grip it. Place the backing
plate on the rear fitting support
clamps.
For small fittings put the backing plate on clamps
Move both clamps forward so that

they push the backing plate up
against the back of the fitting and
then tighten the quick release bolts.
Push backing plate up to fitting and tighten the lever
When the heater bushes are in

place check the pipe size selection
dial is set to the correct size for the
pipe you are jointing.
Rotating knob for adjusting

size dim
Fit the pipe into the pipe clamps,

by rotating the clamp opening/
closing handle, until the pipe loosely
gripped.
Hold the pipe in the clamps
8.38
GEORGE FISCHER
Push and hold the stop button in.
Push and hold button
Rotate the large bench rotating

handle clockwise until the pipe and
fitting supports touch the stop button.
Rotate hand wheel
Release the stop button.
Release button
Loosen the pipe support clamps

and push the pipe forwards in the
clamp so that the edge of the pipe is
between 1- 2mm within the fitting.
Push pipe forward
Tighten the pipe support clamp,

so the pipe is held firmly in place
checking the pipe is accurately
centred within the fitting.
Tighten support clamps
GEORGE FISCHER
8.39
Check the timer has been set for the

required fusion time of the pipe size
being joined. See list below
Fusion times vary for each pipe size
being used.
Pipe o.d. Fusion time
Use the timer for all joints
16mm
5 secs
20mm
6 secs
25mm 6 secs
32mm
10 secs
40mm 14 secs
50mm 18 secs
63mm
22 secs
75mm 26 secs
90mm 30 secs
110mm 35 secs
Check the fusion temperature of the

bush is within limits with the temple
sticks, as described earlier, just before
jointing.
Prior to jointing check the

temperature of the bushes
Set the timer
The timer can be reset to zero by

pressing both the second and minute
buttons simultaneously. The seconds
button is then pressed to set the
correct fusion time on the timer. The
start time button will start the timer
and also stop the alarm, although the
alarm will automatically stop after 10
seconds. The timer will then return to
original time set. For repeats of the
same pipe size do not reset the timer.
Turn the large bench rotating handle
anti-clockwise, until the pipe and
fitting are as far apart as possible.
Turn the bench rotating handle anticlockwise until pipe

and fitting are as far apart as
possible.
8.40
GEORGE FISCHER
Lower the heater plate between the

pipe and fitting.
Lower the heater plate
Turn the bench rotating handle

clockwise to bring the pipe and fitting
onto the heater bushes.
Rotate the handle clockwise
Keep turning the handle until it

cannot be rotated any further. The
heater plate will move during the last
part of insertion as it is automatically
self centring.
Push pipe and fitting onto

heater bush
When the pipe and fitting are fully

inserted start the timer.
Start timer
When the timer beeps gently turn the

bench rotating handle anticlockwise
with drawing the pipe and fitting
from the heater bushes. When the
pipe and fitting are free of the heater
bushes continue turning the handle
quickly until it reaches the stop.
When the timer beeps
withdraw pipe and fitting
GEORGE FISCHER
8.41
Quickly lift the heater plate from

between the molten pipe and fitting.
Lift heater plate
Quickly turn the bench rotating

handle clockwise to bring the pipe
and fitting close together.
As they come into contact slowly
continue to rotate the handle so the
pipe inserts gently into the fitting until
it can go no further.
Quickly bring pipe and fitting
together
The mark indicating the insertion

depth should be near the molten
bead of PB or half covered. If it is
4mm or more away from the fitting
the pipe or fitting may have slipped
within the clamps.
Quickly release one of the clamps
and manually push the pipe or fitting
up to the insertion mark, then retighten the clamp when the pipe is
fully inserted into the fitting.
Push up to the insertion mark
A slight pressure needs to be

maintained on the hand wheel
throughout the to prevent the
materials natural tendency to push
apart. This is just for the holding times
listed below.
Maintain slight pressure on

the handle
o.d. pipe
16mm
20mm
25mm
32mm
40mm
50mm
63mm
75mm
90mm
110mm
8.42
Holding time
20 secs
20 secs
20 secs
20 secs
20 secs
30 secs
30 secs
60 secs
75 secs
90 secs
Note
It is important when moving the
pipe and fitting in and out of the
bushes, or into each other, to move
them firmly but gently to achieve
the best joint.
It is also important to move them
quickly between the heater plate
and jointing to minimise the time
they are exposed to free air and
cooling.
GEORGE FISCHER
After the holding time, the pipe and

fitting may be carefully released
from the clamps by turning the hand
wheels anti-clockwise.
Undo support clamps

Release fitting first (support
when releasing)
Note: It is important to avoid

any strain on the fittings until the
cooling time has elapsed.
The fitting should always be released

first and the clamp opened wide
enough so that it is clear of the fitting
just in case the pipe moves when
released.
Then release the pipe

(support when releasing)
The pipe is then released. As the pipe

clamp is opened the pipe should be
supported with one hand to reduce
movement.
The pipe and fitting can be gently put
to one side, on a flat surface to cool
for the required cooling times listed
below.
Set aside to cool
o.d pipe
16mm
20mm
25mm
32mm
40mm
50mm
63mm
75mm
90mm
110mm
Cooling time
4 mins
4 mins
4 mins
4 mins
4 mins
4 mins
6 mins
6 mins
6 mins
6 mins
After which they can safely be

handled normally.
If the fitting already has a pipe in one
end before jointing, more care will
have to be taken to avoid straining
the new joint when releasing the
fitting and pipe and setting it aside.
This can normally be achieved by
two people working together.
Use two people for long
lengths
GEORGE FISCHER
Alternatively if the pipe and fitting is

left in the bench clamps for the full
cooling time, it can then be handled
normally by one man.
8.43
When each joint is made rub a

clean, dry cloth over the bush and
socket in the fusion well to check they
are free from any residue of P.B.
Clean outside the bush
Clean inside the socket
After the joint has been made,

especially when you are using
INSTAFLEX for first time, check
your workmanship, learn from any
mistakes to improve your fusion
jointing technique.
At the end of this section there is a list
of faults to check and learn from but
three common examples are given
below.
Inspect your own workmanship
Uneven bead
1/ If the bead of P.B around the

external junction between pipe &
fitting is uneven, i.e there is a high
build up in 2 or 4 locations and a
low build up in 2 or 4 locations, this
indicates the fitting has been gripped
too tightly by the clamp in the fusion
machine, tighten the clamps less next
time.
2/ If the insertion mark is not visible,
then the pipe is over inserting into the
fitting. This is either the result of the
pipe size dial being set for the wrong
pipe size or the pipe being inserted
too far into the fitting when the stop
was in place.
Identify cause and correct.
Over insertion
Under insertion
3/ If the insertion mark is clearly

visible by 4mm or more, then the
pipe is being under inserted in to the
fittings. This is either the result of the
pipe size dial being set for the wrong
pipe size, or the pipe not being
brought close enough to the fitting
when the stop was in place, or the
pipe or fitting slipping in the clamps
when they are being joined.
Identify cause and correct.
Wait one hour after the last joint has
been made before filling the system
with water and pressure testing up to
15 bar pressure.
8.44
GEORGE FISCHER
Special Fusion jointing using the

bench mounted socket fusion machine
With difficult assemblies like small
pipes, awkward shapes or reducing
bushes, the bench mounted fusion
machine can still be used to assemble
these items, except it has to be used
slightly differently.
Hand held fusion joints

with the bench mounted
Heater plate lowered
The bench mounted fusion tool can

be used to do joints as if it was a
hand held fusion tool.
This can be done with either the
heater plate in its lowered position,
with all the clamps and slide fully
open and as far away from the
heater plate as possible.
or with the heater plate in its raised
position.
Fusing small pipes with

the bench mounted fusion
machine
Heater plate raised
The bench mounted fusion machine,

does not come supplied with bushes
for fusing 16mm and 20mm pipes
and fittings. These will have to be
ordered separately in order to use
this machine for joining pipes and
fittings of these sizes.
Since 16 and 20mm pipes are too
small to fit in the clamps of the
bench mounted fusion machine the
only method to jointing these sizes
is to fuse them by using the hand
held jointing technique. Refer to the
section for hand held fusion jointing
for more information.
GEORGE FISCHER
8.45
Fusing reducing bushes into fittings

What follows is a summary of
additional instructions for fabrication
of reducing bushes fused into fittings.
For full details of bench mounted
fusion jointing please refer to earlier
instructions.
Fuse the pipe into a reducer
The simplest method of fusing a

reducer into a fitting is to fuse the
reducer onto the pipe first, then
continue as detailed below.
Hold the pipe with the reducer
already fused onto the end in the
small pipe clamps.
The fitting will be held with the large
fitting clamps.
Hold the pipe in the clamp...
Continue the fusion process as

normal.
...and join as normal
To produce a fusion joint between

a fitting and a reducer without first
fusing the reducer to the pipe can be
achieved by holding the reducer in
the hand
The fitting is held in the

clamps while the reducer is
held by hand.
The fitting is still held in the clamps

but you manually push the reducer
into the heater bush as you rotate the
handle to bring the fitting onto the
bush.
You can support your arm on the pipe
clamp to aid withdrawing the fitting.
8.46
GEORGE FISCHER
Remove the heater plate...
Tilt the heater plate out of

the way.
... and manually push the reducer into

the fitting.
Push the reducer into the

fitting
Hold the reducer in the fitting for the

holding time. Remember to check its
alignment before it cools.
8
Hold reducer in place
Fusing Electrofusion
spigots onto fitting
It is easier to put the electrofusion
spigot onto a piece of pipe prior to
fusing. Tighten the screws to hold it in
place.
Place spigot on pipe
Carry on with a normal jointing

procedure to make the joint.
Push spigot with pipe into

heater bush
GEORGE FISCHER
8.47
Alternatively reducers can be fused

onto the pipe as if a hand held joint
is being made. Refer to the section
for hand held fusion jointing for more
information.
When fusing 16 and 20mm pipes
into a reducer, this operation can
only be performed by using the hand
held jointing technique. Refer to the
section for hand held fusion jointing
for more information.
The reducer has no insertion mark.
The correct insertion mark is up to the
end of the reducer.
Note.
With small reduction changes
i.e. 25mm reduced to 20mm it is
difficult to tell which side of the
fitting is reducing. Do not melt
the side of the fitting with printed
writing on. The other side has a
pre-moulded chamfer.
It is necessary to hold the
electrofusion spigot as you withdraw
it from the heater bush.
Hold spigot whilst withdrawing
Push the electrofusion spigot into the

molten fitting.
Push spigot into fitting
After the holding time release the

screws and withdraw the pipe from
the electrofusion spigot.
Withdraw pipe
8.48
GEORGE FISCHER
for electrofusion jointing, setting up
the tools for use, preparing the pipes
and fittings for jointing. Fusing the
pipes and fitting together with the
electrofusion machine.
Important:
It should be noted that electrofusion
and socket fusion fittings are not
always compatible. The length of the
spigot does not permit a joint to be
made.
Tools
Electrofusion control unit is a fully

automatic unit for fusing pipe and
electrofusion fittings together, it
can operate at either 240 volts or
110 volts. This is suitable for fusing
all electrofusion joints from 16mm
110mm.
Welding cable this has a plug at
each end, one end is screwed onto
the top socket of the electrofusion
control unit, the other in is plugged
into an electrofusion fitting to make
joints.
Electrofusion control unit
Primary cable 110v
welding cable
Primary cable 240v
Pipe shears
Primary cable 110v This has

a plug at each end. One end is
screwed onto the bottom socket of
the electrofusion control unit, the
other end is plugged into a 110 volt
building site power transformer, to
provide power to the electrofusion
control unit.
Primary cable 240v. This has a plug
at each end. One end is screwed
onto the bottom socket of the
electrofusion control unit, the other
end is plugged into a 240v socket to
provide power to the electrofusion
control unit.
Pipe shears for snipping through
pipes 16 to 25mm o.d.
Pipe roller cutters
Cleaning fluid and cloth
Pipe roller cutters for cutting the

pipe at right angle.
One size for 25-63mm pipes.
One size for 75-110mm pipes.
The pipe must not be cut with a saw
or serrated blade since this will leave
unacceptable burrs.
Cleaning fluid for cleaning the pipe
Lint free cloth Apply the cleaning
fluid to the cloth to clean the pipe.
GEORGE FISCHER
8.49
Note:
The new
electrofusion control
unit is now supplied
with 3 outputs.
Note:
Only the cables come as standard
with the electrofusion control unit.
The other tools can be obtained
separately or are available as
standard tools with INSTAFLEX socket
fusion machinery. Cleaning fluid and
lint free cloth must be purchased
separately.
Preparing the
electrofusion control unit
for use
The electrofusion control unit

is portable
The electrofusion control is small and

relatively light weight device and is
designed for ease of transportation
around site.
Internally it is a complicated electrical
device and can easily be broken
or develop a fault if dropped. Care
must be taken when in use to always
place it on a flat and level surface
where it is unlikely to be knocked off
or damaged.
To operate select whether you will
be using a 240 volt domestic power
supply or a 110 volt building site
power source and select the lead
with the appropriate plug.
Attach the power cable

(110v Primary cable shown)
Attach the primary power cable to

the control unit by plugging it into the
socket at the bottom of the box, then
rotating the outer plastic ring on the
plug clockwise. The thread will secure
the cable to the control unit.
Attach the welding cable to the
control unit by plugging it into
the socket at the top of the box,
then rotating the outer plastic ring
clockwise the thread will secure the
cable to the control unit.
Attach the welding cable
8.50
GEORGE FISCHER
Note:
The new
with 3 outputs.
Plug in and check that all
lights come on
Plug the control unit primary cable

into a power source. All the lights on
the front of the control panel should
illuminate briefly while the control unit
conducts a self diagnostic test.
When this is completed the power
light in the bottom right hand corner
should remain illuminated, this
indicates the control unit is ready to
begin welding.
If the alarm light comes on, there
may be a fault with the unit and
George Fischer Sales Ltd. should be
contacted Tel: 02476 535535.
The electrofusion control unit will
operate satisfactorily within the
conditions listed below.
Ready light on

Mains voltage
Mains frequency
Temperature
110v
Min Max
88v
127v
47Hz 65Hz
15C 40C
240v
Min
185v
47Hz
15C
Max
264v
65Hz
40C
Preparing the fittings

internally with Tangit KS. Reiniger,
cleaning fluid.

fluid

inside of the fitting, on all faces to be
joined
Place the cleaned fitting carefully
on the working surface. Avoid any
moisture or dirt getting inside the
fitting.
Clean the fitting
Note
Do not handle the inside of the
fitting after cleaning it as your
hand will dirty the fitting and it
will need to be cleaned again.
at one time, so long as the cloth is
still moist with cleaning fluid and the
assembly area is not dusty or wet.
GEORGE FISCHER
8.51
Preparing the pipe.
The pipe must be cut at right angles,

using the appropriate pipe cutters.
Shears for pipe 16 up to 25mm and
roller cutter for pipes above 25mm.
Snip the pipe sizes 25mm

and below.

hacksaw or similar serrated blade
as this will leave unacceptable burrs,
and probably result in a cut which is
not at right angles to the pipe, which
is very important.
Cutting pipe sizes 25mm and

above.
Note
The pipes in all sizes must NOT be
chamfered
Apply the cleaning fluid to a clean


fluid

outside of the pipe about 100mm
up the pipe for fittings below 63mm
and about 200mm up the pipe for
fittings above 63mm. (It is necessary
to clean the pipe this far, because
when making electrofusion joints it is
standard practice to slip the fitting
fully onto one end of the pipe).
This should remove any dirt and the
printed marks on the pipe (If it does
not you may be using the wrong
cleaning fluid)
Clean the pipe
Note
your hand as this will make
it dirty, and it will need to be
cleaned again.
If you have to put the pipe down
ensure the clean end does not
come into contact with any
surfaces.
Keep cleaned pipe off

surfaces
8.52
GEORGE FISCHER
Mark the insertion depth on the pipe

after it has been cleaned.
Do not use a wax pencil to mark
the insertion depth.
Mark insertion depth with a

tape measure...
Pipe o.d.
16mm
20mm
25mm
32mm
40mm
50mm
63mm
75mm
90mm
110mm
Insertion depth
27mm
30mm
34mm
37mm
40mm
44mm
50mm
67mm
73.5mm
80mm
The insertion depths shown above

are the distance from the centre to
the edge of the electrofusion fitting,
so a fitting of the appropriate size
which has a mark showing its centre
can be used as an aid for marking
...or mark insertion depth
from centre mark on fitting
Note
It is important to mark both ends
of pipe which will be inserted into
the electrofusion fittings, to avoid
errors.
The pipe is now ready for
electrofusion jointing.
GEORGE FISCHER
8.53
Electrofusing the pipe and

fittings together
All the pipes have a line down one
side and the fittings have external
marks every 45 these enable
installers to keep prefabricated pipes
and fittings in the correct alignment
when doing electrofusion joints on
site.
Alignment line on pipe
The pipes will touch in the centre of

the electrofusion sockets, the other
fittings have a Z dimension shown in
the product guide, to help calculate
what lengths to cut pipes to. So it
is easy to calculate the lengths of
the pipes required for electrofusion
installations. The Z dimension
method is described elsewhere.
The electrofusion fittings are usually
used to join pre-fabricated pipework
sub-assembled together on site.
Marks at 45 intervals to aid

alignment
Electrofusion spigots, elbows, tees

and reducers
The electrofusion spigots sizes from
16 to 63mm o.d. are usually fused
with socket fusion into the end of a
fitting, typically an elbow or tee.
When jointing in situ the prepared

pipe end is then inserted its full
distance into the spigot, elbows,
tees or reducers and the 2 screws
on either side of the fitting are firmly
tightened to prevent the pipe from
slipping out.
The electrofusion fitting will now be
ready for jointing.
Electrofusion socket
The electrofusion sockets are
available in all sizes from 16 to
110mm. They normally have the full
length of the socket slipped onto one
pipe end.
8.54
GEORGE FISCHER
The other pipe end is brought

up flush to the pipe end with the
electrofusion socket.
The socket is slipped over both pipe
ends, so the insertion marks on both
pipe ends are just disappearing
this confirms the pipe ends are
positioned exactly in the centre of the
electrofusion fitting.
The 4 screws around the electrofusion
socket are tightened to hold the
pipes firmly in place.
Note: Electrofusion fittings now use an allen key fixing and not screwdriver fixing
as illustrated in these examples.
The electrofusion socket is now ready

for jointing
Jointing electrofusion
fittings to the pipe
The fusion joint occurs between the

outside wall of the pipe and the
inside surface of the electrofusion
fitting.
As a result the electrofusion fittings
will be a permanent part of the pipe
work system.
The screws on the fittings only hold
the pipe and fittings together when
prior to and during electrofusion
jointing process. They do not add
mechanical strength or extended life
expectancy.
Cross section through an
electrofusion joint
GEORGE FISCHER
8.55
To make an electrofusion joint simply

plug the welding cable from the
electrofusion control unit, into the
electrofusion fitting.
Plug in welding cable
Note:
The new
with 3 outputs.
The Ready light should

be on
You will hear a beep as the cable is

plugged in and the ready light, on
the electrofusion control unit should
come on.
If the alarm comes on, do not use this
fitting and return it George Fischer for
examination/replacement.
Note
With 75, 90 and 110mm
electrofusion sockets and all
electrofusion tees and elbows
each end is joined separately. It
is important to plug the welding
cable into all ends of the fitting
before starting any joints. So
the electrofusion control unit
can perform its diagnostics on
the fitting to check that no faults
exist. (If you do not do this you
could find you have fused one
end. But the other end has a
fault and you need to cut the half
fused electrofusion fitting out and
replace a length of pipe).
If the fitting does not have a fault,
simply press the start button.
No timer has to be set.
Press Start
The electrofusion process is fully

automatic, it will recognise the fitting
being fused and automatically fuse
it for the correct time, but the fusion
times are listed below for reference.
Pipe o.d.

mm
16mm
20mm
25mm
32mm
40mm
50mm
63mm
75mm
90mm
110mm
8.56
Total fusion time

seconds
45
50
65
75
85
105
120
105 each end
110 each end
120 each end
GEORGE FISCHER
As the electrofusion control unit is

fusing the pipe and fitting together, a
little indicator pip will rise from within
the fitting to indicate a joint has been
successfully made.
Joint indicator starts to show
Joint indicator fully showing
Although the electrofusion fitting

gets warm during the electrofusion
process, it is never unsafe, or too hot
to handle.
If for any reason the indication pip
does not rise or you are uncertain
the joint had been made (someone
may have switched off the power)
or a fault develops during the fusion
process. Leave the fitting for a
minimum of 1 hour, then you can go
back and re-make the joint safely.
When the joint has been completed
a beeper will sound and the end
light will come on. This indicates that
a successful joint should have been
made.
Hold the joint in place
Note:
The new
with 3 outputs.
End light will show when the
joint is complete
Remove the welding cable
GEORGE FISCHER
During electrofusion jointing the pipe

and fitting should not be moved, or
subjected to unnecessary stresses.
The pipe and fitting should be
allowed to cool for a few minutes
after each joint has been made,
before being moved or subjected to
stress.
Minimum cooling times before moving
pipe and fittings
Pipe o.d. Minimum cooling time
16mm
4 mins
20mm
4 mins
25mm
4 mins
32mm
4 mins
40mm
4 mins
50mm
6 mins
63mm
6 mins
75mm
6 mins
90mm
6 mins
110mm
6 mins
Wait one hour after the last joint has
been made before filling the system
with water and pressure testing, up to
15 bar pressure.
8.57
Cutting and joining the INSTAFLEX sleeve

for the INSTAFLEX sleeve cutting and
joining.
Tools
Pipe shears
Pipe shears for cutting through the

pipe and sleeve together from 16 to
25mm o.d.
Sleeve Cutters for cutting the sleeves
for 16 to 25mm pipe, with the pipe in
place without damaging the pipe.
These tools can be purchased from
George Fischer, when ordering the
pipe and fittings
Sleeve cutter
Applications for sleeve

The sleeve is usually used as a carrier
duct for INSTAFLEX pipework, where
the pipework is to be buried in the
floor and screeded over or in the wall
and plastered over
Because of its flexible nature,
INSTAFLEX pipes can easily be
withdrawn from its sleeve thereby
meeting the Building Regulations that
a buried pipe should be accessible
through its length.
To ensure the pipe can be withdrawn,
from the sleeve, the sleeve should
have as few bends as possible no
sharper than 8 pipe diameters radius
Minimum bending radius for different
pipe sizes is
Pipe size o.d.
16mm
20mm
25mm
Min bend radius

130mm
160mm
200mm
diagram showing min

bend
8.58
GEORGE FISCHER
Cutting the sleeve

The pipe shears can be used to cut
through the pipe and sleeve together
The pipe shears can also be used to
cut through the sleeve if there is no
pipe within it.
Pipe shears can cut through
pipe and sleeve
If you wish to cut the sleeve without

cutting the pipe within the sleeve the
sleeve cutter must be used.
Note
Do not attempt to cut the sleeve
with a bare blade, like a knife as
this will inevitably lead to the pipe
being nicked which will reduce its
life expectancy.
Sleeve safely cuts the sleeve
Pipe
internal parts of pipe sleeve

cutter
Position the guides on the
sleeve as shown
Press the cutter jaws to close

on each other
Pipe sleeve
Guide
Blade
The cutter is a valuable aid in the

safe cutting of the pipe sleeve
containing a pipe. The pipe cannot
be damaged with this tool
Sleeves for 16, 20 and 25mm o.d
pipes can be cut with the pipe sleeve
cutter.
Place the cutter into the protective
pipe groove.
Press the cutting jaws lightly together
and twist back and forth over 90.
Remove the cut-off pipe sleeve piece
from the cutter by hand.
Twist the cutter forward and

backward whilst holding the
sleeve stationary
GEORGE FISCHER
8.59
Joining the sleeve to

fittings
There are a variety of fittings which
include a cover which holds the pipe
sleeve.
The pipe is inserted into the
fitting (see Section 2, Assembling
compression joints).
Insert the pipe into the fitting
The sleeve is brought into place

The sleeve gripping part of the fitting
cover is fastened around the sleeve.
Checking the mechanism grips the
grooves in the sleeve.
Push the sleeve up
No specific cleaning or sealing is

required for the sleeve.
The cutting lengths of the protective

pipe are, 35mm for single valve
connections, 80mm for double valve
connections.
Fix the cover in place
Insertion depths for compression

joints

16mm o.d = 25mm

20mm o.d = 29mm
which are marked on the pipe cutter.
16mm o.d =25mm

20mm o.d. =29mm
Insertion
depth
35mm
80mm
8.60
GEORGE FISCHER
Cutting and preparing

INSTAFLEX carrier.
It is not compulsory to use pipe

support carrier, but where it is used
it must be used properly. This section
gives a little advice for preparing
INSTAFLEX pipe support carrier for
use, so that it will not damage the
pipes.
Tools
Hacksaw for cutting the carrier.
File For smoothing rough burrs from
the edge of the carrier
Hacksaw and file
Method
The carrier is used to reduce the
quantity of the pipe supports used on
8
hot and cold water installations.
The carrier is cut with a hacksaw.
Cut to length with hacksaw
The rough edges are smoothed with

a file to prevent them damaging the
pipe.
File the edges smooth
GEORGE FISCHER
8.61
Handling and Storage Instructions for INSTAFLEX

INSTAFLEX must be stored properly on site
Handling pipes.
INSTAFLEX pipes are very flexible,
they will bow when carried. It
is important to prevent the pipe
from rubbing on the floor, which
will damage them when they are
transported around site.
When moving 6m lengths of pipe, use
2 men to carry them.
When moving 3m lengths of pipe,
one man can carry the pipe, but he
must hold the pipe in the centre, high
enough from the ground to prevent
it from scuffing. Do not drag pipes
across the floor.
Small sizes may be coiled to make
transporting easier. Do not leave the
pipes coiled for long periods of time
as this can lead to a permanent bow.
Care should be taken to ensure
the pipes do not come into contact
with any sharp objects as this may
damage the pipes surface.
When mechanical handling is used,
metal hooks must not come into
direct contact with the pipes.
No more than 8 pipes should be

placed directly on top of each other.
Pipes should be protected from
sunlight. Long periods of time in the
sun can lead to oxidisation of the
surface of the pipes, which will affect
jointing.
Pipes should be kept reasonably
clean i.e. not left on the floor or in the
mud.
Storing fittings.
INSTAFLEX fittings are usually
provided in sealed plastic bags. The
fittings should be kept in these bags
until they are required. This will keep
the fittings clean and prevent them
from being damaged.
Storing pipes.
INSTAFLEX pipes can develop a
permanent bow if stored incorrectly.
This will make pipes difficult to install.
INSTAFLEX should be stored flat at
all times (not vertically or allowed to
sag).
INSTAFLEX should be stored on a soft
surface, like wood (clean scaffolding
boards), this will prevent the pipes
being scratched while they are stored
and when they are withdrawn for
use.
Pipes should be stored in neat stacks.
Pipes of different sizes should be
stacked separately. Where this is
not possible, larger pipes should be
stacked on the bottom.
8.62
GEORGE FISCHER

Date of issue: September 1995
Health and Safety at Work Act 1974
GEORGE FISCHER SALES LIMITED
Paradise Way, Coventry CV2 2ST

Tel 02476 535535 Fax 02476 530450/1
Hazard Data Sheet

The Product:
Tangit KS Reiniger (Special Cleaner)

Cleaner based on Ethanol.

Declaration according 91/155/EEC:

90% Ethanol

Symbol: F

R-Phrases: 11

CAS No. 64-17-5
Hazards:
R11 highly flammable

The solvents contained in the product evaporate during
drying time and the vapours may form explosive highly
inflammable vapour-air mixtures.
First Aid Procedures:
Inhalation:
Skin contact:
Eye contact:
Ingestion:
Remove to fresh air. Intensive inhalation: remove to fresh

air, give oxygen, seek medical advice in hospital.
Rinse with running water and soap. Skin care. Remove
contaminated clothes.
Immediately flush eyes with copious amounts of running
water (for 10 minutes), put on a bandage with sterile
gauze, see an oculist.
Flush oral cavity, drink plenty of water, see a physician.
Fire Fighting measures:

Do not inhale combustion gases
Extinguishing media: Suitable for all regular extinguishing materials. In case of
fire, cool endangered containers with water spray.
Extinguishing media which must not be used for safety reasons: none known.
Special exposure hazards arising from the product itself, from combustion
products or from resulting gases: can form explosive gas-air mixtures.
Special protective equipment for firefighters: wear protective equipment. Wear
self-contained breathing apparatus.
Accidental release measures:
Personal precautions: Ensure adequate ventilation. Keep away ignition sources.
Wear protective equipment.
Environmental precautions: Do not allow to enter drainage system, surface or
ground water.
Methods of cleaning up/removing: Remove with liquid absorbing material
(sand, peat, sawdust). Dispose of contaminated material as waste - see
Disposal considerations.
GEORGE FISCHER
8.63
Handling and Storage:

Handling:

Storage:
Ventilate working rooms thoroughly. Avoid naked flames,

sparking and sources of ignition. Switch off electrical
devices. Do not smoke. Do not weld. Do not empty waste
into waste water drains.
Avoid open flames and sources of ignition. No smoking.
Ensure adequate ventilation. Close the container carefully
after use and store it at a good ventilated place. Store
protected from heat influence. Store at temperatures under
50C. Store only in the original container.
Do not store together with edibles or other consumable
substances.
Storage class: VCI-storage Class: 3A (BRD)
Exposure Controls/Personal Protection:
Information on the system design: Ensure for good ventilation/suction. Draw off
vapours directly at the point of generation and exit. In the case of regular
work, provide bench mounted extraction equipment.
Components with specific control parameters:

Ethanol

CAS No. 64-17-5

MAK 1000ppm (1900mg/m3)
Personal protection;

Do not breathe dust and vapours. Avoid skin contact.

Do not eat, drink or smoke while working. Avoid
alcohol consumption when working with the product.
Wash hands before work breaks and after finishing
work.
Respiratory protection: When processing large amounts wear suitable

breathing mask when there is inadequate ventilation.
Hand protection: Solvent proof protective gloves
Eye protection:
Wear protective glasses in the event of spray hazard
Skin protection: Suitable protective clothing.
Physical and Chemical Properties:

Physical state:
Liquid
Colour
Colourless
Odour
Alcohol-like
pH
Not applicable
Boiling Point
78C
Flash Point
+ 12C Abel Pensky
Autoflammability: Product is not self-igniting
Limits of explosion: Lower 1 .8 Vol % Upper 19 Vol % (literature)
Vapour pressure: (20C) 58 mbar (highest partial vapour pressure)
Relative density: (20C) 0.789 g/cm3
Solubility:
(20C) miscible in water
Viscosity:
Watery
Ignition temperature + 425C DIN 51794
8.64
GEORGE FISCHER
Stability and Reactivity:

Conditions to avoid:
No decomposition if used according to specification
Materials to avoid:
None known is used for its intended purpose
Hazardous decomposition products:
None if used for intended purpose
Toxicological information:
Inhalation:
The toxicity of the product is due to its narcotic
effect after inhalation. Injuries to health cannot be
excluded after longer or repeated exposure.
Ecological Information:
Based on the components contained in the product and/or structurally
comparable substances the following ecological data are to be expected:
Persistence
and Degradability
Aquatic Toxicity

The material is degraded quickly. The total of the

organic substances contained in the product reach
at least 60% BOD28/COD in the closed bottle test
or at least 70% DOC removal in the modified OECD
screening test. (OECD limits for classification readily
biodegradable; at least 60% BOD28/COD resp.
at least 70% DOC).
Acute fish toxicity: EC50 100 mg prod./1 (golden
orfe, DIN 38412T15 or zebra fish, ISO 7346)
Acute bacterial toxicity: EC50 100 mg prod.1
(oxygen consumption test with Ps. putida)
Keep from entering waste water, soil or surface
waters.
Disposal Considerations:
Special waste incineration with the approval of the responsible local authority.
Only emptied packages with traces of dried product and without solvent
vapours are to go for recycling.
GEORGE FISCHER
8.65
Regulatory information:
Classification and labelling according to Hazardous Materials Statutes:
Symbols of danger:

R-Phrases:

S-phrases:

Further Advice:

Highly flammable
R11
Highly flammable
Further advice:
R18
In use, may form flammable/explosive

vapour-air mixture
S2
Keep out of reach of children
S7
Keep container tightly closed
S16
Keep away from sources of ignition no

smoking
S23
Do not breathe vapour
S29
Do not empty into drains
S46
If swallowed seek medical advice

immediately and show this
container or
label
S37/39

S51
Wear suitable gloves and eye/face

protection
Use only in well ventilated areas.
Other information:
This information is based on our current level of knowledge and relates to the
product in the state in which it is delivered. It is intended to describe put
products from the point of view of safety requirements and is not intended to
guarantee any particular properties.
For further information contact:

01606 593933 - Manufacturer - Henkel Home
Improvement & Adhesive Products

02476 535535 - Distributor - George Fischer Sales
Limited
8.66
GEORGE FISCHER

Comply with the requirements of the
current health and safety as work
act. At all times, when using any
machinery.
If you notice a problem attend to it
yourself or point it out to a supervisor
to have it attended to.
Safety recommendations
When using all plastic pipe welding

apparatus, tools, the fundamental
premises for reducing the risk of
accident are careful and scrupulous
handling and compliance with
the instructions for their use and
with current accident prevention
regulations.
Negligence and failure to
comply with accident prevention
regulations can cause accidents at
work.
Electric wiring to the power supply
The electrical distribution board
where the apparatus is to be
connected must be of the ASC type
and therefore comply with the safety
requirements of the CEI 17-13/1 and
17-13/4 standards; in particular, it
contain one or more highly sensitive
differential circuit-breakers that are
triggered within 0.4 sec in the event
of dispersions to earth, so as to
protect the operator of the apparatus
in the event of direct or indirect
contact with any live parts (e.g. in the
case of a faulty earthing connection),
plus thermal and magneto-thermal
protection devices sized according to
the output of the equipment requiring
protection (fig.1).
Power takeoffs and their relevant
protection devices must be identified
by means of suitably worded stickers.
The power takeoffs on the distribution
board must have a protection rating
of at least IP 44 (fig.2).
GEORGE FISCHER
Electric wiring to the apparatus

The electric wiring between the
job-site distribution board and
the apparatus must be achieved
using H07RN-F or similar abrasion
and chemical-resistant cables; any
extension leads must be made of
the same type of cable and have a
conductor cross-section suited to the
power output of the apparatus, or
preferably greater according to the
length of the extension lead.
.
The cables must not be laid in areas
traversed by vehicles or pedestrians
in order to avoid their being
damaged and becoming potentially
dangerous; when this is unavoidable,
special protection must be provided
against mechanical damage or
accidental contact with job-site
machinery. The direct laying of cables
underground is to be avoided: in
such cases heavy-duty PVC cable
8
ducts must be used.
Earthing
There must be a single earthing
connection for the whole job-site:
the earthing resistance value must
be suited to the protection devices
used and must ensure that no metal
part liable to come into contact with
an electric conductor can reach an
electric potential in excess of 25 V.
The earthing system must be
prepared and tested by qualified
staff and the installation must
be reported to the authorities
concerned.
It is only when the standards for a
proper earthing system have been
complied with that Class I apparatus
can be considered safe from the
point of view of the risk of electric
shock.
8.67
Recommendations for the proper use and storage of

electrical apparatus:
To reduce the risks (of electric shock) to a minimum, the apparatus must be used
and stored properly: in particular: Avoid using temporary power
connections that have not been
made in compliance with the
standard requirements.
Always avoid physical contact
with any live parts.
Do not disconnect the plug from
the socket by pulling on the cable.
Check at least once a month that the

differential circuit-breaker trips
properly.
Do not drag, carry or lift the

apparatus by means of the cable.
Get the earthing system checked by

qualified staff.
Do not step on the cable or stand

heavy or sharp objects, or objects
at a temperature which may be
critical for the resistance of the
insulation (70C) on the cable.
Clean the apparatus carefully,

paying particular attention to ensure
that the substances used are suitable
and cannot damage the insulation
do not use solvents, petrol or
abrasive .
It is absolutely forbidden to use

electrical apparatus in wet areas:
ensure that gloves, shoes, any
protective gear and the apparatus
itself are always dry.
Do not spray water or any other
liquids in the direction of the
apparatus.
Periodically (of after any abnormal
situation) check the insulation of
the electric cable and all the
insulated parts of the apparatus;
bear in mind that any infiltration of
dirt combined with a high degree
of humidity turns materials which
were originally valid electrical
insulators into conductors
Check the conditions of the cable
insulation, especially in line with
the fair lead and cable grip, or in
any other places liable to
particular mechanical strain.
Avoid using the apparatus in
critical environmental conditions
(e.g. extreme temperatures, high
relative humidity, lightning etc.)
If the apparatus is used in restricted
spaces, with a high level of humidity,
8.68
in ship-yards or in areas surrounded by

metal, make sure that the equipment is
powered by means of a SELV (Security
Extra Low Voltage 48v) system or through
electrical separation with added
equipotential link.
Store all the electrical equipment in a

dry place and out of the reach of
persons unauthorized to use the
apparatus.
Avoid using electrical apparatus in
the presence of inflammable gases,
steam, fumes or dust unless the
apparatus involved carries the
special symbol certifying that it has
been designed and made with
specific materials and methods which
make it explosion-proof.
On completion of the welding jobs,
or during interruptions, make sure
that the apparatus is disconnected
from the power supply (by means of
an omnipolar circuit breaker with
suitable electrical contacts or by
disconnecting the plug from the
power supply socket).
Before operating the apparatus
again, make sure that it has not been
damaged or man-handled in such a
way as to make it dangerous to use.
It is only when the above

recommendations and current
regulations (particularly the CEI
standards 64-8 and 64-8/7 (fig
GEORGE FISCHER
5), 17-13/1 and 17-13/4) have

been scrupulously complied with
the necessary steps will have
been taken to prevent accidents
at work. It is always advisable for
specialized personnel to provide
an accurate training, information
and updating of the operators of
electrical appliances.
What to avoid doing

Do not use tools or machines with
housing or grips that are cracked
or deformed, particularly if they are
made of plastic; any dirt and damp
penetrating in cracks can carry
electricity, consequently causing an
electric shock if there is any damage
to the insulation of the machine or
apparatus.
Avoid accidentally turning on the
machine
Before connecting it to the power
supply, make sure that the machine
and all its accessories are switched
off.
Avoid working in dangerous
environments
In the event of having to use the
machine in an excavated pit, make
sure that the walls of the excavation
are properly supported by means
of stays or barriers to avoid any
earth or stones falling away and
damaging the machine and any of
its component parts or creating a
hazard to the operator.
In the event of welding
operations in narrow spaces (e.g.
excavations, pits, boiler rooms,
etc.) it is essential for the operator
to be supervised by somebody
on the outside; also make sure that
inside the pit there is no infiltration of
water or other fluids that might come
GEORGE FISCHER
into contact with the apparatus and

thus place the operator at risk (of
electric shock).
Avoid using the machine or
apparatus in the presence of
inflammable or explosive liquids
or mixtures (Class C1 and C3Z1
areas) as this could cause an
outbreak of fire or an explosion,
with the consequent risk of injury for
the operator and damage to the
surrounding environment.
If a crane is used for transporting
or positioning the machine inside
an excavation, make sure that the
machine is well attached by means
of hooks, belts or ropes suited to the
weight of the apparatus (check the
weight of the machine); should the
machine drop, even from not very
high, it could injure the operator
(by squashing him) and damage
the apparatus. In any case, avoid
standing or working under the
suspended machine (fig. 6).
In the event of having to work on jobsites in the vicinity of water or other
liquids, or alongside barges, boats,
ships or the like, it is compulsory to
use low-voltage (48 V) machinery
and equipment in order to safeguard
the operator from the risk of electric
shock.
8.69
Do not perform welding on pipes

which contain or have previously
contained materials which, in
combination with heat, give off
explosive or toxic gases that would
prove dangerous for the operator.
Fumes and gases that are inevitably
caused by the welding process
may become dangerous if they are
breathed in over a period of time,
so it is advisable to provide suitable
ventilation in the working area; if
this is impossible, it is compulsory to
provide breathing apparatus and a
supply of air or adopt other methods
to enable proper breathing and
ventilation in the working area.
Avoid working with the machine in
environments saturated with fumes
from varnishes, de-greasers, fuels
or the like, irritation to the eyes
and respiratory tract are the first
symptoms of intoxication; in such
cases, it is essential to stop the work
and provide better ventilation of the
working area.
Do not place the equipment in areas
which are particularly dirty or dusty.
Maintenance of tools
Sharp, clean tools produce better
results and are safer to use.
Immediately replace any worn,
broken or lost parts; it is not
permitted to use a machine with
components which are either no
longer capable of functioning
properly or missing; worn, broken or
lost components can be a source of
danger to the operator: the machine
could suddenly fail, placing the
safety of the surrounding environment
at risk.
Check that the accessories are
coupled safely to the machine: if a
clamp or reduction fitting is not well
attached to the machine, it could
drop (together with the pipe) as a
result of the welding process.
For any replacement operations, use
only spares which can be obtained
through George Fischer Sales Ltd.
8.70
Tel: 024 7653 5535.

Use suitable working clothing
(fig.7)
Do not wear baggy clothing or
jewellery, as these can become
caught up in moving parts of the
machine and become a hazard to
the operator.
The operator must always wear:

protective gloves, mittens or

other suitable means for
protecting his hands
a boiler suit or work overalls
anti-accident footwear
suitable for use on the job-site
Avoid keeping any rags or other

items hanging from pockets as they
could become caught up in the
moving machine tools and prove
dangerous for the operator.
Avoid wearing loose belts or shoes
with the laces undone as these could
become caught up in moving parts of
the machine and prove a danger for
the operator.
The operator should not have long
hair or a long beard to avoid the risk
of getting caught up in the moving
parts if the machine; alternatively,
operators must use appropriate
protective coverings which safely
contain their hair or beard.
Keeping the work place clean and
tidy
Untidy and dirty work places and
work benches are not only a sign
of inefficiency, but also a source of
accident; it is essential to keep the
work place clean and tidy.
Mud and grease could cause the
tools being used to slip, with a
consequent risk of injury for the
operator; it is essential to provide
clean resting surfaces, such as panels
or tables of some kind, which will give
protection from dirt; it is essential
to make sure that the surface on
which the machine is operated
GEORGE FISCHER
has the necessary stability to

guarantee the performance of
good-quality welding and avoid
the danger of it toppling over, as
this would be a source of danger
for the operator (squashing or other
injury) and would cause damage to
the machine parts.
Keep visitors away
Keep visitors at a safe distance from
the work place: outsiders coming
close to the machine may obstruct
the work in progress and become
a danger to themselves and to the
operator.
USE GLOVES
HIGH
TEMPERATURE
ELECTRICITY
Make sure that the job-sites where

work is in progress are protected and
suitably signposted, as required by
accident prevention regulations, so
as to impede access to unauthorized
persons (fig.8).
Make sure that the barriers used
to prevent access to visitors on the
job-site are at a sufficient distance
to guarantee the safe transit of any
passers-by.
Always avoid the machine being
used by untrained staff (fig.9).
ANALYSIS OF POTENTIAL RISKS
AND SAFETY MEASURES
The machines must be used only by
trained staff; the use of the machine
by unqualified staff may place both
the operator and the surrounding
environment in danger.
The operator takes up the position
in front of the machines and must
always have a full view of the
operations being performed.
Always remove the plug from

the socket when the jointing
operation has been completed
Never touch the heating

surfaces of the heaterplate
with bare hands, to check the
temperature (during tests), use
only temple sticks or special
contact thermometers .
The basic machine

Check that the pipes and/or fittings
to be welded are securely locked
in place so that the welding can
be done with the utmost precision,
without the risk of the parts falling
out, which would be hazardous for
the operator.
During the welding process, the
operator must have enough work
space around the machine so that
no part of their body comes into
accidental contact with the machine.
Attached to the machine is a table
indicating all the risks for which it
is impossible to provide adequate
safety precautions during the design
stage (fig. 10).
GEORGE FISCHER CANNOT
TAKE RESPONSIBILITY FOR
ANY DAMAGE TO PERSONS
OR PROPERTY THAT ARE
CAUSED BY FAILURE TO READ
AND COMPLY WITH THIS
MANUAL BY AUTHORIZED OR
UNAUTHORIZED STAFF.
The heater plate

The heating element can reach
temperatures of about 300C; it is
essential to take the utmost care in its
handling and to rigidly comply with
the following recommendations:
GEORGE FISCHER
Use protective gloves
Always grasp the heater

exclusively by means of the
grips provided.
8.71
On the basis of an analysis of the

technical features of the welding
machines in terms of the aspects
of machines safety and operation,
the following table has been drawn
up to indicate each type of danger
deriving inevitably from the proper
use of the machine, together with an

evaluation of the risk, a description
of the safety device provided at the
design stage and any particular
indications on the machine or
supplementary information.
Danger
Electrocution (electric shock)

Risk evaluation
moderate risk with a low probability
of occurrence
Squashing between clamps

mild risk with a low probability of
occurrence
Squeezing between carriages

moderate risk with a low probability

of occurrence
Burning due to fire or explosion

severe risk with a very low
probability of occurrence
Scorching due to contact with
the thermoplate
moderate risk with a modest

probability of occurrence
Getting caught up in the machines

moving parts

occurrence
Squashing due to falling machine

occurrence
8.72
Safety device or warning signal
Supplementary information
Highly-sensitive differential
circuit-breaker

Warning signs attached to machine
(see Fig. 10)
See safety recommendations
Warning signs attached to machine (

see Fig. 10)
Analysis of danger
Suitable clothing
Tripod support
Analysis of danger
GEORGE FISCHER
Operational tests and

ordinary maintenance
Before proceeding with welding
operations, perform the following
tests, making any necessary
adjustments to the machine.
Check that the rated voltage for the
machine and all its component parts
corresponds to the mains power
supply.
The machines sliding-carriages and
heaterplatess guides must always be
kept clean.
With each welding cycle, clean
the non-stick surfaces of the heater
bushes at working temperature, using
soft paper soaked in spirit (use heat
resistant gloves).
Check the quality of the Tefloncoated surface on the sockets; any
deep or severely scored surfaces are
not permitted.
Check the proper operation of the

thermostat by measuring the surface
temperature of the sockets with a
contact thermometer.
Check the locking capacity of the
clamp jaws.
If any defects are detected in any
one or more of the above aspects,
it is essential to call George Fischer
Sales Ltd. Tel 024 7653 5535 for
advice.
GEORGE FISCHER
8.73
Section 9

The purpose of this section is to
illustrate typical common faults which
can occur when fusing INSTAFLEX
joints. This will enable corrective
action to be taken to prevent the
re-occurrence of these faults and
therefore maintain a high quality of
workmanship and avoid problems in
the future.
External view of perfect joint
Internal view of perfect joint
Perfect Joint
Firstly we should identify what is a
perfect joint. Externally there should
be two roughly even beads of P.B. at
the junction of the pipe and the fitting
and the insertion mark should be
clearly visible.
Internally there should be a sharp
pipe edge and a small even bead of
material, which does not exceed the
visible pipe wall thickness
Over Insertion
This is caused when jointing the pipe
is inserted too far into the heater
bush and/or too far into the fitting.
In both cases the insertion mark on
the outside of the pipe will have
disappeared.
Over insertion
- no mark visible
Over insertion
- intruding into pipe bore
If the pipe is inserted too far into the

heating bush it may cause the end
of the pipe to melt inwards, this will
result in even amount of intrusion
around the pipe bore.
If the pipe is inserted too far into the
fitting, it will cause the small bead of
material inside the fitting to intrude
into the pipe bore.
Over insertion will not mean that a
joint will leak, it will simply interfere
with fluid flow. If only a few of these
occur it will have no noticeable effect
on fluid flow. It becomes a problem
if this is a regular occurrence when it
may reduce fluid flow rates.
The solution is to keep to the insertion
markings visible when making a joint.
Keep insertion mark visible
8.74
GEORGE FISCHER
If making a joint with the fusion

jointing machine ensure the depth
dial is correctly adjusted for the
appropriate pipe size being jointed.
Check depth dial.
Under insertion - mark short

of fitting.
Under insertion of pipe into

heater bush.
Under Insertion
This occurs in the fusion process when
the pipe is not inserted far enough
into the heater bush and/or too little
into the fitting.
In both cases the insertion mark on
the outside of the pipe will be over
3mm away from the fitting.
If the pipe is not inserted far enough
into the heating bush, but is inserted
its full distance into the fitting, there
will only be one bead of excess P.B.
on the outside of the fitting.
If the pipe is inserted the correct
distance into the heater bush, but not 8
far enough into the fitting (or not held
firmly in place during the holding
time). There will be a grove between
the 2 beads of molten material of the
pipe and fitting.
Under insertion will not always mean
a pipe will leak straight away. It
will probably mean a joint has a
reduced life expectancy, this will be
proportional to the degree of under
insertion.
Under insertion of pipe into

fitting.
The solution is to check the fusion

mark is only 12 mm short of the
heater bushes when fusing the pipe.
And about 2-3 mm short of the fitting
when joining the pipe.
It is important to maintain the
pressure on the pipe and fitting for
the duration of the holding time.
Keep holding the pipe and

fitting together during the
jointing time.
GEORGE FISCHER
Check the pipe size dial on the

bench mounted fusion machine is
correctly set for the appropriate pipe
size being joined since this dictates
8.75
Under chamfering.
Leads to excess PB in
fitting
Chamfer to 1/2 wall

thickness
Over chamfering
No bead within the

fitting
Chamfer to 1/2 wall

thickness
Over heating causes

the pipe to collapse
Check the temperature
8.76
Adjust temperature if
necessary
Under chamfering
This is where insufficient P.B. is peeled
away from the INSTAFLEX pipe
when it is chamfered. Sometimes the
chamfer can be uneven (less P.B. is
taken from one side of the pipe than
the other).
After fusion jointing there is excess
and often uneven build up of molten
P.B. inside the pipe.
This will not cause a joint to leak. It
will simply interfere with flow of fluid
to a small degree. It should have no
overall effect on fluid flow throughout
a system.
The solution is to chamfer the pipe
slightly deeper, until the pipe wall is
half of its original thickness.
Over chamfering
This is where excessive P.B. is peeled
away from the INSTAFLEX pipe when
it is chamfered.
After fusion jointing there is no
discernable P.B. molten bead within
the pipe.
Over chamfering will not result in
instant leaks within the pipes. It may
reduce the life expectancy and
strength of the joint.
The solution is to chamfer the pipe a
little less, so the end of the pipe after
chamfering appears to have a wall
thickness half of the original thickness.
Over heating
This is usually where INSTAFLEX is left
in the heating bushes for too long, or
the heater plate is running at too high
a temperature.
It can be seen that the pipe wall
within the fitting it no longer smooth
and round because it has started to
collapse.
Over heating will not normally
cause a joint to leak. It will simply
interfere with fluid flow. It may
become a problem if this is a regular
occurrence, as it could reduce fluid
flow rates.
Check the temperature of the heater
bush with the temple sticks, to see if it
is running too hot. If it is turn it down.
Allow 5 minutes to cool and re-check.
If it is not, check the timer is set at
GEORGE FISCHER
Check timer & pipe

size chart
You may need to speed

up the insertion
the correct time for size of pipe and

fitting.
If both of the above are correct, you
may be inserting and withdrawing
the pipe too slowly, resulting in the
ends being in the bushes too long.
Try and speed up the insertion and
withdrawal process a little and see if
this improves the joint quality.
Under heating
This usually occurs where INSTAFLEX
is not heated long enough in the
heater bushes. It can also occur when
the heater plate is not hot enough.
It should be noticed during assembly
that it is more difficult that normal
to push the molten pipe and fitting
together.
Under heated fitting The bead is too small
The bead that normally occurs on the

outside of the pipe will be smaller.
If only the fitting is heated and not
the pipe (or visa versa) there will only
be one molten bead. The bushes may
not be tight enough on the heater
plate. These fitting will always fail.
8
Single bead fitting or pipe

not heated at all
Under heating will frequently

cause a joint to leak. If you think
a fitting and pipe is under heated,
dont risk it, throw it away and try
again.
Check heater is
switched on
Check heater bush temperature
Adjust temperature if necessary

GEORGE FISCHER
Check the bush is tight
Check there is still power to the

heater plate (i.e. the power on
red light will be on and the green
thermostat light will be flicking on
and off.) Check all connections and
switch back on.
Check the allen key bolt, securing the
bushes, is fully tightened to ensure
there is good conductivity between
the heater plate and bushes. Check
the temperature of the bushes,
with the temple sticks. Adjust the
temperature if necessary, wait 5
minutes to heat up.
If all of the above were OK, check
the timer is set for the correct time for
the pipe size being jointed.
If none of the above are wrong,
contact George Fischer Sales Ltd Tel:
02476 535335 for advice.
8.77
Dirty bushes
Excessive residue on the bushes

This usually occurs on old and
worn bushes, or dirty bushes, but
it can occur if the pipe/fitting are
withdrawn too fast.
If the bushes are old and worn,
contact George Fischer Tel:
02476 535535, and arrange for
replacement /recoated bushes.
If the bushes are dirty, clean them
thoroughly with spirit and a lint free
cloth wrapped around a pencil.
Clean bushes thoroughly
Dirty joints are visible externally
8.78
Withdrawing the pipe too quickly,

is a common problem when partly
trained staff are becoming familiar
with hand held fusion jointing. They
have to take more care to withdraw
the fitting more gradually. This will
come with experience. Until then the
bushes must be thoroughly cleaned
between every joint.
Sometimes withdrawing the pipe and
fitting too fast will leave P.B. in the
bush and create a web P.B. strands.
Ignore this, and quickly re-join the
pipe and fitting as normal. (The P.B.
web of strands will re-melt in the
molten joint and not effect the joint
quality). More gradual withdrawal
of pipe and fitting is required. Clean
excess residue from the pipe and
fittings.
This will not cause joints to fail in
the short or long term. It will simply
take more time to clean the bushes
between each joint. If the bushes are
not cleaned properly between each
joint and residue is left on the bushes
this could cause long term problems
with dirty joints see the section below.
Dirty joints
Dirty joints are visible after a joint has
been made because the external and
internal beads of molten P.B. will be
slightly or noticeably brown.
Dirty joints are an indication that a
residue of P.B. is being left on the
bushes after each joint (this is not
always noticeable at a glance). This
P.B. residue is then baking on the hot
bushes and turning brown or even
black.
GEORGE FISCHER
Dirty joints are visible internally
Clean bushes thoroughly
When the next joint is made the

baked P.B. is sticking to the molten
P.B. and becoming trapped in
between the joint.
Dirty joints are weaker joints and
they may take weeks or even months
before they fail.
As soon as it is noticed that joints are
slightly brown, the bushes must be
cleaned thoroughly with spirit and
lint free cloth wrapped around a
pencil.
If the above does not prevent the
problem, then replace the bushes
with new /recoated bushes. Contact
George Fischer Sales Ltd. Tel: 02476
535335.
Misalignment
This usually occurs with hand held
joints. As they are brought together
sometimes it is difficult to bring the
pipe exactly into the centre of the
joint.
This is noticeable within the fitting
by a small amount of extra material
occurring on one side of the pipe.
Slight misalignment when

bringing pipe and fittings
together
Check alignment from two

plains from the top and from
the front. Slight misalignment
can be corrected during the
holding time
GEORGE FISCHER
This will not cause a joint to leak. It

will simply interfere with fluid flow
to a small degree. It should have no
overall effect on fluid flow through a
system.
Note:
It is far more important to ensure
that the two molten surfaces
of pipe and fitting are brought
together quickly rather than to
spend time trying to get the joint
alignment perfect when they
should be cooling down.
Aligned joints will become easier
for installer, the more joints they
make by hand.
During the hold time, there is a time
to ensure the pipe and fitting are
straight compared to each other. This
is done visually in 2 plains. From the
front and from the top. The pipes can
be moved slightly, when soft to bring
them into alignment. But they must
not be twisted.
8.79
Misaligned bench mounted

fusion joint
If pipes are misaligned when being

joined on the bench mounted fusion
machine this could be due to:
The clamps may be loose, check and
tighten the bolts. If they are not loose
check the clamps are in the correct
position as detailed in the section for
setting up the bench mounted fusion
machine.
Uneven fusion bead around the
pipe and fitting
With a hand held tool. This is usually
because the pipe and/or fitting is
being held in the fusion tool at an
angle (i.e. not at 90 to the face of
the heater tool). This will heat the
pipe and/or fitting too much on one
side.
Misaligned bench mounted

fusion joint
This will not cause a joint to leak or

affect its life expectancy. It is simply a
poor appearance.
This can be overcome by holding the
pipe and fitting straight in the fusion
tool. Often it will help if the pipe is
supported through its length by pipe
supports to the same height as the
fusion tool.
Uneven fusion joint
With the bench mounted fusion

machine. An uneven bead is normally
the result of over tightening of the
pipe clamp or fitting clamp. This will
cause areas where the bead is thick
and areas where the bead is thin.
This will not normally cause leaks,
only if there is no bead in the areas
which should have a thin bead. It
can be resolved by not tightening the
clamps as much next time.
8.80
GEORGE FISCHER
With the bench mounted fusion

machine. If the bead is more on one
side than the other, it is likely that the
pipe clamps are loose on the slide.
Check and tighten the bolts. If they

are not loose, check the clamps are
in the correct position as detailed in
the section for setting up the bench
mounted fusion machine.
Please Note.
If you continue to have difficulties
please contact the George Fischer
Sales Office who will be able to
provide further advise.
GEORGE FISCHER
8.81
INSTAFLEX Installation
Quick Reference Guide
For full details refer to full INSTAFLEX Training Manual
Socket Fusion Jointing

1 .
2.
3.
4.
5.
6.
7.

8.
9.
Chamfer pipe ends

Clean pipe & fittings
Check heater bushes temperature
Check and clean heater bushes
Set timer to correct heating time
Mark fusion depth with gauge
Make joint but Do Not Twist after insertion only
adjust for squareness
Hold pipe & fitting together for required holding time
Carefully put pipe and fitting down for cooling time
For 16 to 110mm Pipe & Fittings

Polybutylene (PB) Socket Fusion Jointing
Pipe outside
diameter
o.d. (mm)

8.82
16
20
25
32
40
50
63
75
90
110
Wall thickness
minimum
mm
2.0
2.0
2.3
3.0
3.7
4.6
5.8
6.8
8.2
10.0
Welding Heating
length
time
L (mm) t (sec)
15
15
18
20
22
25
28
31
36
42
6
7
7
10
14
18
22
26
30
35
Holding
time
t1 (sec)
Cooling
time
t2 (min)
15
15
15
20
20
30
30
60
75
90
4
4
4
4
4
4
6
6
6
6
GEORGE FISCHER
Notes
GEORGE FISCHER
8.83
Notes
8.84
GEORGE FISCHER
Approvals in Europe
Keuringsinstituut
voor waterleidingartikelen
Kiwa nv
2

DVGW
Deutscher Verein des Gasund Wasserfaches e. V.

sterreichische Vereinigung
fr das Gas- und Wasserfach

SVGW
Schweiz. Verein des Gasund Wasserfaches
SSIGE
Socit Suisse de lindustrie
du Gaz et des Eaux
SOCOTEC
DIRECTION TECHNIQUE
Dpartement des
Equipements Techniques
The comprehensive INSTAFLEX

approvals in the respective countries
include:
compression joints from 16 to 63mm
o.d. inclusive,
socket fusion joints from 16 to 63mm
o.d. inclusive,
as well as system accessories.
GEORGE FISCHER
Sddeutsches
Kunststoffzentrum
Officially recognized test
institute
for plastics
AGREMENT
TECHNIQUE
AVEC
CERTIFICATION
TECHNISCHE
GOEDKEURING
MET
CERTIFIKAAT
11
2.011
GF Piping Systems > Worldwide at home

Our sales companies and
representatives ensure local
customer support in over 100
countries.
Numerous renowned international companies have years

of good experience with GF Piping Systems. We would
be pleased to demonstrate our competence in providing
reference data on the basis of these real applications.
Please find more information concerning Instaflex:
www.georgefischer.co.uk
The technical data is not binding and not an expressly warranted characteristic of the goods.
It is subject to change. Please consult our General Conditions of Supply.
Australia
George Fischer Pty Ltd
Kingsgrove NSW 2008
Tel. +61(0)2/95 54 39 77
sales@georgefischer.com.au
www.georgefischer.com.au
Denmark / Iceland
Georg Fischer A/S
2630 Taastrup
Tel. +45 (0)70 22 19 75
info@dk.piping.georgfischer.com
www.georgfischer.dk
India
George Fischer Piping Systems Ltd
400 093 Mumbai
Tel. +91(0)22/820 2362
branchoffice@georgefischer.net
Poland
Georg Fischer Sp. z o.o.
02-226 Warszawa
Tel. +48(0)22/313 10 50
www.georgfischer.pl
Switzerland
Georg Fischer Rohrleitungssysteme (Schweiz) AG
8201 Schaffhausen
Tel. +41(0)52 631 30 26
info@rohrleitungssysteme.georgfischer.ch
www.piping.georgfischer.ch
Austria
Georg Fischer
Rohrleitungssysteme GmbH
3130 Herzogenburg
Tel. +43(0)2782/856 43-0
office@georgfischer.at
www.georgfischer.at
France
George Fischer S.A.S.
93208 Saint-Denis Cedex 1
Tl. +33(0)1/492 21 34 1
info@georgefischer.fr
www.georgefischer.fr
Italy
Georg Fischer S.p.A.
20063 Cernusco S/N (MI)
Tel. +3902/921 861
office@piping.georgfischer.it
www.georgfischer.it
Romania
Georg Fischer
Rohrleitungssysteme AG
70000 Bucharest - Sector 1
Tel. +40(0)1/222 91 36
office@georgfischer.ro
United Kingdom / Ireland

George Fischer Sales Limited
Coventry, CV2 2ST
Tel. +44(0)2476 535 535
info@georgefischer.co.uk
www.georgefischer.co.uk
Belgium / Luxembourg
Georg Fischer NV/SA
1070 Bruxelles/Brssel
Tl. +32(0)2/556 40 20
info.be@be.piping.georgfischer.com
www.georgfischer.be
Germany
Georg Fischer GmbH
73095 Albershausen
Tel. +49(0)7161/302-0
info@georgfischer.de
www.rls.georgfischer.de
Japan
Georg Fischer Ltd
556-0011 Osaka,
Tel. +81(0)6/6635 2691
info@georgfischer.jp
www.georgfischer.jp
Singapore
George Fischer Pte Ltd
417 845 Singapore
Tel. +65(0)67 47 06 11
info@georgefischer.com.sg
www.georgefischer.com.sg
USA / Canada / Latin America / Caribbean

George Fischer Inc.
Tustin, CA 92780-7258
Tel. +1(714) 731 88 00
Toll Free 800/854 40 90
infoship@us.piping.georgefischer.com
www.us.piping.georgefischer.com
Brazil
George Fischer Ltda
04795-100 So Paulo
Tel. +55(0)11/5687 1311
Georg Fischer DEKA GmbH

35232 Dautphetal-Mornshausen
Tel. +49(0)6468/915-0
info@dekapipe.de
www.dekapipe.de
Netherlands
Georg Fischer N.V.
8161 PA Epe
Tel. +31(0)578/678 222
info.vgnl@nl.piping.georgfischer.com
www.georgfischer.nl
Spain / Portugal
Georg Fischer S.A.
28009 Madrid
Tel. +34(0)91/781 98 90
info@georgfischer.es
www.georgfischer.es
Export
Georg Fischer Rohrleitungssysteme (Schweiz) AG
8201 Schaffhausen
Tel. +41(0)52 631 11 11
export@piping.georgfischer.com
www.piping.georgfischer.com
Norway
Georg Fischer AS
1351 Rud
Tel. +47(0)67 18 29 00
info@no.piping.georgfischer.com
www.georgfischer.no
Sweden / Finland
Georg Fischer AB
12523 lvsj-Stockholm
Tel. +46(0)8/506 77 500
info@georgfischer.se
www.georgfischer.se
China
Georg Fischer Piping Systems Ltd Shanghai
Pudong, Shanghai 201319
Tel. +86(0)21/58 13 33 33
info@cn.piping.georgfischer.com
www.cn.piping.georgfischer.com
LITGF0472 (08.04)
George Fischer Sales Limited
Greece
Georg Fischer S.p.A.
10434 Athens
Tel. +30(0)1/882 04 91
office@piping-georgfischer.gr

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Technical Manual

Polybutylene PB The complete piping system

George Fischer Company Profile

metal processing machines; and

George Fischer Piping Systems,

George Fischer Distribution

This manual contains all the essential

The general section at the

Technical Regulations (Standards etc.)

INSTAFLEX System Technology

Expansion & Contraction

Standards and Regulations

INSTAFLEX system technology

Comparison of pipe dimensions

Allowing prefabrication and being

INSTAFLEX the plastic piping

The efficient distribution of services in buildings is a

Above figures based on 50 year lifespan and safety factor of 1 .5.

The INSTAFLEX system philosophy

It incorporates the experience

Hot & cold water services

The INSTAFLEX system has been

Long service life

Launched in 1980 into mainland

Pipe & fittings 16 -110mm

Each of which have advantages

What is Polybutylene (PB)?

Flexibility, even at low temperatures,

socket fusion 16mm - 110mm o.d.

Like PE and PP, PB belongs to the

The physical values shown in the table below

Melt flow index MFI @90/5

Bending-creep modulus (@ min.)

Crystalline fusion temperature

Coefficient of linear expansion

Normal working temperature range

At George Fischer every

Why polybutylene (PB)?

With the development of

Polybutylene's strength and versatility also make it

Hot & cold water services

Compressed air systems

High temperature drainage

Chilled water systems

Fan coil units Two pipe systems

Thermal conductivity can

The heat expansion

Expansion & contraction a

PEX PP-R PVC-C

The E-modulus is the

Expansion loop comparison

Using a typical example, with

using the formula

Creep is the extension of a

expansion loop leg

Therefore, under the same

Expansion leg LBS

As can be seen from the above the

Determining the expansion

Comparison of minimum breaking

Safety against breakage

Hoop stress in MPa

Minimum breaking strength

Hoop stress in MPa