Casaflex pipe: a flexible solution for heating systems

"Casaflex" - today the generalized name of the pipeline systems, as well as other components necessary for the trenchless laying of heat and hot water supply lines with a production transport temperature of 150 degrees and a pressure of 25 atmospheres. In practice, the Casaflex pipe can withstand a short-term increase in temperature by an order of magnitude higher.

Casaflex: the constituent elements

The Casaflex system consists of the following elements:

• Pressure pipe corrugated, steel;
• Heat-insulating layer of improved qualities, consisting of a safe polyurethane foam;
• Remote monitoring system, consisting of a signal cable (UDC);
• Polyethylene waterproofing sheath.

Many variants of the gasket allow the flexibility of Casaflex (pipes) to be applied. The description of already laid trunk pipelines makes it possible to install new systems without disrupting the integrity of the old ones and choosing the most optimal routes. In the presence of a barrier in conditions of a deficit in the area of urban development, the Casaflex pipe easily bypasses it. There is no need to use starter compensators, sliding supports. The cost and timeframe for the installation of the mains are reduced by several times, since there is no need to combine the flexible pipe and the steel in PPU insulation.

Description of Casaflex pipe

1. Technical characteristics permit the use of a carrier in the system with a pressure of 25 atmospheres and a temperature of 150 degrees.
2. In the insulation material there is a foamed polyisocyanurate foam with a high thermal protection.
3. The surface corrugated layer is covered with an LDPE-polyethylene sheath with identification marking strips.
4. Inside the heat-shield layer there are integrated wires connected to the ODK system.

Characteristics and variety of pipes

The "Casaflex" pipe is supplied in coils of length from 120 to 250 m, with a meter weight from 2.46 to 7.40 kg with a bend radius of 1 to 2 meters. Depending on the diameter of the pressure pipe, "Casaflex" is divided into the following types:

• 55/110 - with a pipe diameter of 55x0.5 / 48 mm;
• 55/125 Plus - with a pipe diameter of 55x0.5 / 48;
• 66/125 - with a pipe diameter of 66 × 0.5 / 60;
• 66/140 Plus - with a pipe diameter of 66 × 0.5 / 60;
• 86/140 - with a pipe diameter of 86 × 0.6 / 75;
• 86/160 Plus - with a pipe diameter of 86 × 0.6 / 75;
• 109/160 - with a pipe diameter of 109 × 0.8 / 98;
• 143/200 - with a pipe diameter of 143 × 0.9 / 127.

Trunking installation

According to experts' estimates , maintenance costs are reduced 3-fold in the case of the Casaflex pipe. The installation of the system allows you to reduce the volume of land works 5 times and its cost in 8. Five-fold savings on the cost of landscaping. The figures justify the popularity of the application of these systems in Russia and CIS countries.

The speed of installation in comparison with metal standard pipes allows to reduce the installation time of the system by 5-8 times. Pipes are attached to each other by means of fittings.

Step-by-step installation of the Casaflex system

• Diametrically cut the insulating layer 20 cm from the end of the tube, without damaging the signal inner cable.
• With a knife, cut the insulation layer and remove it from the polyethylene.
• Bend the wires and remove the layer of polyurethane foam, clean the surface.
• Cut the pipe depending on its diameter, handle the edge of the pipe with a file.
• Screw the flange to the end of the insulation.
• Do not use the ring included in the kit, put the main part of the fitting up to the stop.
• Screwing the flange, expose the gap between it and the fitting in half a millimeter.
• Remove fitting, wear ring.
• Put the fitting back on, hold on the retaining bolts.
• Wrap the heat-shrinkable tubing on the signal cable wires and treat with a soldering iron.
• Mastic tape to wind the fitting.
• Put on the coupling, handle with a soldering iron.

Maximum simplicity allows you to assemble the most complex systems with a laying speed of up to 600 meters per day by a team of 4 people. Consumers are disconnected for no more than 3 hours during installation of Casaflex-pipes. Power consumption is not necessary. Installation of pipes can be carried out in all weather conditions, even in winter.

Advantages and disadvantages of the Casaflex pipe

Benefits:

1. Minimal heat loss during transportation of coolant.
2. The Casaflex pipe is not subject to wear, corrosion, durable.
3. No waterproofing is required, as a result - a cheaper main system.
4. The shape of the tube in the form of a corrugation, as a result of which it is simplified to lay the system, overcome obstacles, there is no need for compensators and additional supports.
5. Possibility of non-channel laying.

With all the advantages, the Casaflex pipe has drawbacks:

• High sensitivity to ultraviolet and low fire resistance;
• High cost of the Casaflex pipe;
• Installation of pipes requires a hydraulic press, a burner and other additional equipment;
• To prevent the rupture of the shell, it is necessary to install the system on a sand pillow;
• Polyethylene outer film easily damages;
• When storing pipes for a long time, special conditions must be created to protect them from sunlight;
• The installation of the system should be handled by skilled workers.

With these shortcomings, the Casaflex pipes are successfully used in world projects of increased complexity. Laying of heating mains using these systems was implemented at railway stations, in the metro, in reservoirs and mountains. Wherever the use of a rigid pipeline is impossible and impractical.

Today, global companies use this high-tech product, paving engineering routes not only qualitatively and quickly, but also saving energy resources within the whole state.