EN 253 Pre-Insulated

SPECIFICATIONS FOR EN 253 PRE-INSULATED
PART 1 - PRODUCTS
1.1 MANUFACTURERS
A. Pre-insulated piping system:

1. Brugg distributed by Rovanco
2. Approved equal.
1.2 PRE-INSULATED PIPING SYSTEM
A. General:
1. District heating pre-insulated piping system shall comply to EN 253 standard, and consist
of steel carrier pipes, polyurethane foam insulation with integral copper alarm wires and a
polyethylene outer casing. The materials shall be bonded together to form a solid unit
with shear and axial strength values as specified in the insulation section.
2. The pipe ends shall be free of insulation; insulation cut-back: 220 ± 10 mm
3. The pipe shall be supplied in straight lengths of 12 m.
4. The piping system shall be manufactured for a service life of 30 years under continuous
operation at 140 deg C.
5. The piping system shall withstand pressure testing with cold water (20 deg C) at a
maximum of 1.5 x operating pressure.
B. Steel Pipe:
1. Steel pipes shall be supplied longitudinally or spirally welded, P235TR1, P235TR2
according to EN 10217-1 or P235GH according to EN 10217-2 or EN 10217-5. Steel pipe
quality according to EN 253:
a. DN300 (12 inch NPS) and smaller: P235GH or P235TR1 or 2
b. Larger than DN300 (12 inch NPS): P235GH
2. Melt analysis (max. %): Cmax0,16; Pmax 0,025; Smax 0,020; Mnmax 1,20; Simax 0,35
3. Dimensions and tolerances shall comply with ISO 4200.
4. Mechanical properties:
a. Tensile strength > 350 N/mm2
b. Yield stress min. 235 N/mm2
c. Young's modulus 2.1 x 105 N/mm2
d. Elongation at break: Min. 23%
e. Weld factor: V = 1.0
f. Inspection certificate: EN 10204 - 3.1
g. Beveling: EN ISO 9692-1
5. The outer surface of the pipe shall comply to EN ISO 8501-1:2007 without pitting. Prior
to insulation, the outer surface of the pipe shall be cleaned so that it is free from rust, mil
scale, oil, grease, dust, paint, moisture, and other contaminants.
C. Casing:
1. The polyethylene casing shall be black colored PE-HD, bimodal classified at least PE 80
in accordance with EN ISO 12162. The casing may be a separately manufactured pipe or
be applied directly onto the insulation by extrusion.
2. Material properties and casing properties minimum as required in EN 253.
a. Thermal stability: Calculated continuous surface temperature ≥ 50°C for 30 years.
b. Melt from rate (MFR): Parts are fully weldable within the melt flow index: MFR
variation ≤ 0.5 g/10 min.
c. Oxidation induction time (OIT): > 30 min. at 210°C.
d. Resistance against crack formation: Slow crack formation (notch sensitivity) >
2000 h (notch, 4 MPa, 80°, EN 253). Rapid crack propagation, RCP (cold
sensitivity) > 5 bar (0°C, ISO 13477).
3. To ensure optimum adhesion between outer casing and insulation, the internal surface of
traditionally produced polyethylene casing shall be corona-treated. For the extruded
polyethylene, the adhesion takes place automatically during the production process.
D. Polyurethane Rigid Foam Insulation (PUR):

1. Polyurethane foam shall be made from polyol and isocyanate with cyclopentane as
blowing agent. Hard polyurethane foam (PUR) in accordance to EN 253.
2. The foam shall be homogenous with the following properties (Minimum as required by EN
253):
a. Average foam cell size ≤ 0.5 mm.
b. Density ≥ 60 kg/m3
c. Closed cells > 88%
d. Water absorption if boiled < 10% (Vol)
e. Compressive strength, At 10 % deformation > 0.3 N/mm2
f. Axial shear strength > 0.12 N/mm2
g. Tangential shear strength > 0.20 N/mm2
h. Calculated continuous operating temperature (CCOT) : >140° C for 30 years.
i. Max. short-term operating temperature: 150°C.
3. Thermal conductivity: - Traditionally manufactured pipes (50°C): 0.027 W/m K.
Table 1: Pre-insulated pipes of insulation series 1 - Pipe and casing dimensions

Nominal pipe Pipe outside Pipe wall Jacket Min. Jacket
diameter diameter (OD) thickness OD thickness
mm mm mm mm mm
50 (2") 60.3 2.9 125 3
65 (2½") 76.1 2.9 140 3
80 (3") 88.9 3.2 160 3
100 (4") 114.3 3.6 200 3.2
125 (5") 139.7 3.6 225 3.4
150 (6") 168.3 4 250 3.6
200 (8") 219.1 4.5 315 4.1
250 (10") 273 5 400 4.8
300 (12") 323.9 5.6 450 5.2
350 (14") 355.6 5.6 500 5.6
E. Surveillance System (Leak Detection):

1. The pipes shall be supplied with two (2) copper wires, embedded in the insulation. The
piping system will be monitored by an alarm wire circuit with a documented, proven
technique. Mapping and field service to be done by pre-insulated pipe manufacture.
F. Fittings:
1. Pre-insulated fittings shall comply with EN 448, all fittings (elbows, anchors, tees, etc)
shall be pre-insulated and have embedded copper wires for surveillance.
G. Double Joint Kits:

1. Joint kit shall comply with EN 489. The joint kit installed shall be power transmitting,
double water sealed system with 100% cross linked PE thermally shrinkable material.
Joint kits to be of EW type.
2. Joints to be installed using piping system manufacturer approved equipment and method.
3. Joints to be Rhino-Joint by Rovanco or approved equal
4. Installation contractor shall be trained by the manufacturer on the proper use of the joint
system.
H. Fill and Bedding Materials:

1. Type 1 Fill (Granular ‘A’ Base Material) and Type 2 Fill (Granular ‘B’ Sub-base Material):
Properties to MTO Special Provision No. 110F13
a. Crushed, screened stone, gravel or sand consisting of hard durable particles free
from clay lumps, cementation, organic material and other deleterious materials. Pit
run granular material will not be considered as acceptable.
b. Gradations to be within limits specified when tested to ASTM C136 and ASTM
C117, as shown in Table 2. Sieve sizes to CAN/CGSB-8.1.
c. Table 2: Type 1 / Type 2 Fill
Sieve % Passing
Designation
[mm] Type 1 Type 2
75 - 100
50 - 0
37.5 0 0
25 100 0
19 75 – 100 -
12.5 - -
9.5 50 – 100 -
4.75 30 – 70 22 – 85
2.00 20 – 45 -
0.425 10 – 25 5 – 30
0.180 - -
0.075 3–8 0 - 10
2. Type 3 Fill: selected backfill material from excavation or other sources, approved for use
intended, unfrozen and free from rocks larger than 75 mm, cinders, ashes, sods, refuse,
ice, vegetable matter or other deleterious materials.
3. Type 4 Fill (Sand bedding):
a. Sand consisting of hard durable particles free from lumps, cementation, organic
material and other deleterious material.
b. Gradations to be within limits specified in Table 3.
c. Table 3: Sieve Sizes Summary for Sand Backfill Material
Sieve Size % Passing

Number (mm) (by weight)
#4 4.75 100%
#10 2.0 90-96%
#20 0.85 75-94%
#40 0.425 45-82%
#60 0.25 18-40%
#100 0.15 10-17%
#200 0.075 5%
4. Unshrinkable fill: proportioned and mixed to provide:

a. Maximum Portland cement content of 25 kg/m3.
b. Minimum strength of 0.07MPa at 24 hours.
c. Concrete aggregates: to CAN/CSA-A23.1.
d. Maximum compressive strength of 0.4MPa at 28 days.
e. Portland cement: Type 10.
f. Slump: 160mm to 200mm.
5. Shear mat: honeycomb type biodegradeable cardboard 100mm thick, treated to provide
sufficient structural support for poured concrete until concrete cured.
6. Cast-in-place concrete. Refer to Structural division specifications.

EN 253 Pre-Insulated

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SPECIFICATIONS FOR EN 253 PRE-INSULATED

A. Pre-insulated piping system:

1.2 PRE-INSULATED PIPING SYSTEM

D. Polyurethane Rigid Foam Insulation (PUR):

Table 1: Pre-insulated pipes of insulation series 1 - Pipe and casing dimensions

E. Surveillance System (Leak Detection):

G. Double Joint Kits:

H. Fill and Bedding Materials:

Sieve Size % Passing

4. Unshrinkable fill: proportioned and mixed to provide:

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