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RAUPEX PIPES: PEXa

PROVEN PERFORMANCE
www.rehau.com Construction Automotive Industry

RAUPEX PIPES
OUTLINE

- What is PEX? - What is PEXa? - RAUPEX Non-Barrier and RAUPEX O2 Barrier pipes - RAUPEX UV Shield pipes - RAUPEX capabilities and limits - Markings and certifications - PEXa extrusion process - PEXa: The Green Choice

REHAU 27-Apr-09 - Page 2

RAUPEX PIPES
REHAUs TRADENAME FOR PEXa CROSS-LINKED (X) POLYETHYLENE

- RAUPEX Non-Barrier, RAUPEX O2 Barrier, RAUPEX UV Shield - Similar pipes, same pressure ratings, special capabilities - RAUPEX O2 Barrier has special coating to block oxygen (O2) diffusion - RAUPEX UV Shield has special coating to block sunlight

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POLYETHYLENE CROSS-LINKED (X), OR P-E-X

- Poly Ethylene means many ethylene molecules - Ethylene gas is the building block for polyethylene (PE) - Polyethylene is used for thousands of engineering applications, construction products and household goods - Cold water pipes, gas pipes, milk jugs, auto parts, toys, etc. - PE is not suitable for high-temperature applications - Susceptible to creep - Pressure resistance declines over time - Polyethylene is the building block for PEX

Ethylene Hydro-carbon

PolyEthylene Molecule
REHAU 27-Apr-09 - Page 4

CROSS-LINKED POLYETHYLENE
ENHANCED POLYETHYLENE

- PEX is Poly Ethylene that has been chemically or physically modified cross-linked (X) to cause the molecules to link together, permanently - Once PE is cross-linked into PEX, it becomes a thermo-set plastic, meaning that it cannot be melted and reshaped - Compared to standard PE pipes, PEX has desirable high temperature strength, reduced sensitivity to notching, improved chemical resistance, and high flexibility - There are 3 commercial processes or methods: - PEXa: High-pressure peroxide (Engel) PEXb: Silane (moisture cure) PEXc: Radiation (electron beam or nuclear) - PEXa was pioneered by REHAU

REHAU 27-Apr-09 - Page 5

REHAU PEXa
CROSS-LINKED (X) POLYETHYLENE

History: - Dr. Thomas Engel, German Inventor - Originally known as Engel Method - REHAU licensed the patent for the special PEXa process in 1967 - Started development work in 1968 - Began series production in 1972 for PEXa radiant heating pipes - Now known as High-pressure peroxide cross-linking, or simply, PEXa

Signatures from original contract


REHAU 27-Apr-09 - Page 6

REHAU PEXa
CROSS-LINKED (X) POLYETHYLENE

REHAU process: PEXa - Cross-linking takes place in special extruders designed for high pressure - Typical result is 85% crosslinking, which is the highest available - REHAU is a worldwide leader in PEXa technology

PEXa molecule

REHAU 27-Apr-09 - Page 7

RAUPEX PIPES
NON-BARRIER: THE ORIGINAL PIPE

- RAUPEX Non-Barrier (Natural Opaque) - Solid wall of PEXa - Oxygen can pass through the pipe wall (diffuse) and be absorbed into the heating system water - This may cause corrosion of iron or steel components

- All RAUPEX pipes have the same temperature and pressure capabilities PEXa molecule
REHAU 27-Apr-09 - Page 8

RAUPEX PIPES
O2 BARRIER: THE HEATING PIPE - RAUPEX O2 Barrier (Red) - EVAL oxygen diffusion barrier is the outer layer, held on by special adhesive (red) - Prevents oxygen diffusion through the pipe wall - Meets requirements of DIN 4726, German standard for oxygen diffusion protection

RAUPEX - All RAUPEX pipes have the same temperature and pressure capabilities

Adhesive (Red)
EVAL O2 Barrier

REHAU 27-Apr-09 - Page 9

RAUPEX PIPES
O2 BARRIER: THE HEATING PIPE - RAUPEX O2 Barrier (Red) - EVAL oxygen diffusion barrier is the outer layer, held on by special adhesive (red) - Prevents oxygen diffusion through the pipe wall - Protects iron and steel (ferrous) components from corrosion caused by oxygen in the water

- All RAUPEX pipes have the same temperature and pressure capabilities

REHAU 27-Apr-09 - Page 10

RAUPEX PIPES
UV SHIELD: SUPERIOR UV PROTECTION

- RAUPEX UV Shield - (Red, White, Blue) - Colored HDPE shield is the outer layer - Superior UV protection - Plumbing and non-ferrous heating applications - 1/2, 3/4 and 1, coils, straight lengths - No oxygen barrier

- All RAUPEX pipes have the same temperature and pressure capabilities

REHAU 27-Apr-09 - Page 11

RAUPEX PIPE LABELS


1/2 RAUPEX NON-BARRIER 1/2 RAUPEX O2 BARRIER

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RAUPEX PIPE LABELS


1/2 RAUPEX UV SHIELD BLUE 1/2 RAUPEX UV SHIELD RED

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RAUPEX PIPE CAPABILITIES


CAPABILITIES AND LIMITS FLEXIBILITY, FREEZE RESISTANCE, KINK RESISTANCE Flexibility - Bending radius of 5 times the pipe OD; the tightest of all PEX pipes - Pipes are less likely to kink when bending quickly or too tightly - Flexible to below -100F; will not become brittle or break at cold temperatures Freeze resistance - With room to expand evenly along its length, RAUPEX pipe will expand when frozen and not break; pipe will return when thawed - This helps a pipe installed in a wall, but Not when inside a floor - Pipes inside a concrete floor are likely to break if allowed to freeze Kink Resistance - PEXa resists kinking, even well below freezing temperatures - If kinked, PEXa can be field-repaired without cutting - See instructions - Be sure to let pipe cool before moving it or applying any stress
REHAU 27-Apr-09 - Page 14

RAUPEX PIPE CAPABILITIES


CAPABILITIES AND LIMITS THERMAL MEMORY: ONLY PEXa ALLOWS THIS! If RAUPEX pipe becomes kinked it may be heated to 265F (130C) with hot air to remove the kink.

Non-Barrier pipe turns clear when fully heated; coated pipes simply re-round
REHAU 27-Apr-09 - Page 15

Stop when the kink is gone! Do not overheat the pipe!

RAUPEX PIPE CAPABILITIES THERMAL MEMORY


CAPABILITIES AND LIMITS NEVER USE A TORCH

Do not use a torch and do not overheat the pipe!


REHAU 27-Apr-09 - Page 16

RAUPEX PIPE CAPABILITIES


CAPABILITIES AND LIMITS TEMPERATURE / PRESSURE CAPABILITY RAUGEO PEXa pipes are made according to national standards which establish the capabilities and application limits: Pipes are CTS (copper tube size), SDR9, with tight tolerances on dimensions Pipes have long-term pressure ratings* of: - 160 psi @ 73.4F, 130 psi @ 120F, 100 psi @ 180F, 80 psi @ 200F - These certifications are based on a 50-year extrapolation according to D 2837 - Temperature/pressure ratings are marked on the pipes - Pipes will withstand short-term exposure over 230F Pipes have minimum quick-burst capability (short-term) per ASTM F 876: - 475 psi @ at 73.4F, 210 psi @ 180F, 180 psi @ 200F

*Temperature/Pressure ratings are based on an extrapolated time-to-failure prediction as defined in ASTM D 2837,with 2:1 Safety Factor on pressure
REHAU 27-Apr-09 - Page 17

RAUPEX PIPE CAPABILITIES


CAPABILITIES AND LIMITS THERMAL EXPANSION - RAUPEX Coefficient of longitudinal thermal expansion: 9.3 x 10-4 in/ft x F (0.14 mm/m x C) - Rule of thumb: 1 inch of expansion/contraction per 10F temperature change per 100 ft. length

Example: - 100 foot length of pipe heated from 70F to 100F - Thermal expansion = almost 3 inches for an unrestrained pipe

REHAU 27-Apr-09 - Page 18

RAUPEX PIPE CAPABILITIES


CAPABILITIES AND LIMITS ENVIRONMENTAL RESISTANCE Chemical resistance (see REHAU TB120R2) - RAUPEX pipes are resistant to glycols, latex paints, silicone, urethane foam, most acids and bases - RAUPEX Non-Barrier pipes are sensitive to certain adhesives at elevated temperatures - Do not apply adhesive tape to RAUPEX Non-Barrier pipes - If in doubt, check with REHAU Chlorine and Chloramines potable water disinfectants (see REHAU TB135R2) - RAUPEX meets the strict requirements of ASTM F 876 and ASTM F 2023 for chlorine resistance; pipe is tested also in accordance with NSF P171 - RAUPEX is chlorine resistant - Tested with free chlorine (Cl2) at 4.0 ppm, pH 6.8, 80 psi, 140F - Chloramines (another water disinfectant) are not as aggressive as free chlorine

REHAU 27-Apr-09 - Page 19

RAUPEX PIPE CAPABILITIES


CAPABILITIES AND LIMITS ENVIRONMENTAL RESISTANCE UV Resistance (see REHAU TB218) - RAUPEX pipes are tested in the desert near Phoenix, AZ for natural exposure to prove the capabilities, following ASTM F 2657 test procedure - Then the pipes are subjected to the chlorine resistance test and must show retention of chlorine resistance Results: - RAUPEX Non-Barrier -15 days - RAUPEX O2 Barrier - 30 days - RAUPEX UV Shield White up to 3 months - RAUPEX UV Shield Red & Blue up to 1 year

REHAU 27-Apr-09 - Page 20

RAUPEX PIPE CAPABILITIES


CAPABILITIES AND LIMITS SEE PRODUCT SUBMITTALS FOR FURTHER DETAILS

REHAU 27-Apr-09 - Page 21

PEX PIPE EXTRUSION


HOW IS PEXa MADE?

Basic Extrusion Process: 1. Polymer compound is blended 2. Melted to temperature 3. Compressed in extrusion chamber 4. Forced through extrusion die that controls shape and dimensions PEXa: cross-linking takes place in a special extruder, right at the die

REHAU 27-Apr-09 - Page 22

PEX PIPE EXTRUSION

Hopper (materials fed in) Heating chamber (melts materials) Compression chamber Die (forms the shape)
1

REHAU PVC extruder: 1948


REHAU 27-Apr-09 - Page 23

REHAU PEXa EXTRUSION: RAUPEX NON-BARRIER (PEXa)

High Density Polyethylene (HDPE)

UV Heat AntiStabilizers Oxidants Stabilizers Liquid Peroxide

Coiler

Inspection Devices

REHAU - R....

Water Bath

Extruder

Ink Jet

REHAU 27-Apr-09 - Page 24

REHAU PEXa EXTRUSION: RAUPEX O2 BARRIER (PEXa)

High Density Polyethylene (HDPE) AntiHeat UV Stabilizers Oxidants Stabilizers Liquid Peroxide

Co-Extruder EVAL Adhesive Coiler Inspection Devices Water Bath


REHAU - R....

Extruder

Ink Jet

REHAU 27-Apr-09 - Page 25

REHAU PEXa EXTRUSION: RAUPEX UV SHIELD (PEXa)

High Density Polyethylene (HDPE)

Heat AntiUV Stabilizers Oxidants Stabilizers Liquid Peroxide

Inspection Devices Coiler Ink Jet


REHAU 27-Apr-09 - Page 26

Co-Extruder PE Shield Water Bath Extruder

PEX EXTRUSION METHODS


REHAU PEXa SUMMARY

REHAU High-pressure peroxide method (PEXa) - Compounding: HDPE and stabilizers mixed, then liquid peroxide is carefully added - Compound fed into special extruder, melted at high pressure and precise temperature - Cross-linking occurs as the pipe is extruded, consistently throughout the pipe wall - Degree of cross-linking is closely controlled - Carbon-Carbon bonds are unbreakable - QA inspection devices are in-line - No secondary process - Typical degree of cross-linking is 80 - 89% (85% target for REHAU)

REHAU 27-Apr-09 - Page 27

PEX EXTRUSION METHODS


PEXb METHOD

Silane method (PEXb) HDPE modified with Silane (Silicone) by a custom compounder Modified compound is mixed with catalyst in the plant and fed into extruder Partially cross-linked pipe is extruded fast and wound onto large coils Coils are subjected to steam (sauna) or hot water to cause cross-linking over time Pipes may be unwound and rewound onto smaller coils for packaging Typical degree of cross-linking: 65 - 70%

REHAU 27-Apr-09 - Page 28

PEX EXTRUSION METHODS


PEXc METHOD

E-Beam method (PEXc) - Non cross-linked HDPE pipe is extruded from a normal extruder - Non-cross-linked pipe is wound onto large coils after cooling - Pipe is uncoiled and passed under an electron beam and dosed with radiation; several passes are required to get even cross-linking - Pipes are unwound and rewound onto smaller coils for packaging - Typical degree of cross-linking: 65 - 70%.

REHAU 27-Apr-09 - Page 29

SUMMARY OF PEX EXTRUSION METHODS


INDUSTRY SNAPSHOT

PEXa - Peroxide: Controlled cross-linking occurs in the extruder - 80-89% cross-linking is typical (REHAU ~ 85%) - Stronger and more flexible PEXb - Silane: uses secondary moisture-cure process - 65-70% cross-linking is typical PEXc - E-beam: uses secondary radiation process - 65-70% cross-linking is typical

REHAU 27-Apr-09 - Page 30

PEX EXTRUSION METHODS


INDUSTRY SNAPSHOT: PEX MANUFACTURERS

PEXa method

PEXb Silane method

PEXc E-Beam method

REHAU Uponor Golan (HeatLink) LK Pex (Mr. Pex) Pex-Cor

Bow CB Supplies Genova Plastics IPEX JM Eagle Viega Watts Industries/Radiant Zurn/Qest (formerly US Brass)

- Golan (HeatLink, ComfortPro) - Hewing (Burnham) - Mercury - NIBCO - Roth - Viega

REHAU 27-Apr-09 - Page 31

ALTERNATIVE METHODS - COMPOSITES


INDUSTRY SNAPSHOT

PEX-AL-PEX (PEXb) - Multi-layer pipe with aluminum - Unicore, Weil-McLain, Uponor PERT-AL-PERT (PERT = polyethylene Raised Temperature) - IPEX XPA (replaced Kitec) - Multi-layer pipe with aluminum - Not a PEX; only PERT Rubber Hose - Watts Radiant ONIX

REHAU 27-Apr-09 - Page 32

REHAU PEXa AS PART OF SUSTAINABLE DESIGN


PEXa IS GREEN

- Lower cost to the environment for production - No mining operations for the ore, PE is abundant, created by refining operations - Low energy cost to produce compared with copper - No chlorine is used in production of PEXa - Reduced heat loss and condensation through pipes - Saves energy, faster delivery of hot water - Smooth wall, excellent flow characteristics - Reduces pumping costs - Proven long life and durability - Provides value: Performance vs. environmental cost - Light weight of PEX reduces transportation costs - Light weight also reduces the necessary equipment to install pipes - Quiet operation - Dampens water hammer, reduces pressure spikes that may harm equipment - Protects health and safety - Does not add minerals to drinking water or to the public water system

REHAU 27-Apr-09 - Page 33

RAUPEX PIPES
SUMMARY: PROVEN PERFORMANCE

Higher strength Greater flexibility Proven longevity 35+ years Chlorine resistance UV resistance Widest range of sizes and colors The Green choice Backed by: - REHAU PEXa Limited Warranty - 35+ years of experience - Stringent quality control - ISO 9001 factories in Europe and USA - National and international certifications - REHAU Know-How

REHAU 27-Apr-09 - Page 34

RAUPEX PIPES: PEXa


PROVEN PERFORMANCE

www.rehau.com

Construction Automotive Industry