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Valid from February 2011 300055 EN - Subject to technical modifications www.rehau.com

ConstructionAutomotive

Industry

REHAU TELECOMMUNICATIONMAKING CONNECTIONS

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CONTENTSREHAU TELECOMMUNICATION

Page

Making connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REHAU PVC cable ducts and cable conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

REHAU PP cable ducts and cable conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

REHAU PE-HD cable ducts and cable conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

REHAU multiple sub-duct pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

REHAU PE composite cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

REHAU micro cable duct system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Static calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

REHAU service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

REHAU sales offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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1 MAKING CONNECTIONS CABLE PROTECTION PRODUCT RANGE

Telecommunications technology is mainly thanks to the fact that the modern world is becoming a smaller place. With modern transmission methods, sounds, images, data, energy and signals can be transported from one side of the globe to the other in a split second. And now almost everyone has global access via the internet and telephone.

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Installation of the PE RAUDUCT multiple sub-duct pipe

REHAU has continuously followed this development over the past 40 years and has helped shape the area of telecommunications considerably . In the 1960s REHAU PVC cable conduits were already increasingly replacing the conventional cable duct blocks which had been used until then to protect the voluminous copper cables .

With the introduction of the glass fibre networks REHAU developed RAUDUCT multiple sub-duct pipes to insert into cable duct blocks and cable ducts to protect the delicate glass fibre cables which were now being laid instead of the thick copper cores. Existing cable duct passages can therefore be given multiple ducts and the duct cross-sections used optimally thanks to RAUDUCT

With RAUDUCT EVMR REHAU reached another milestone in the development. Because with this multiple sub-duct pipes can be laid directly into the ground - without an additional cable conduit. With modern installation methods such as ploughing-in, with RAUDUCT EVMR large distances are covered in a short time and new lines created cost-effectively.

However, the introduction of glass fibre technology brought with it yet another REHAU development: The REHAU trapezoidal grooving RTR®. The injection technology developed for glass fibre technology requires the interior surfaces of the duct to be spe-cially designed, in order to reduce frictional forces to a minimum. The REHAU trapezoidal grooving RTR® with wide ribs and narrow channels in an asymmetrical shape combines extremely low abra-sion in the duct casing with a minimal coefficient of sliding friction, which makes long injection lengths possible.

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REHAU customers include both major national and international telecommunication companies such as e.g. Deutsche Telekom, Swisscom, France Télé-com, Telekom Austria, Royal KPN NV (Netherlands), Telia and Tele2 (Sweden), Globacom (Nigeria), as well as regional companies such as NetCologne and EWE. The protection of the power cables of cross-regional and communal energy providers is also included in the spectrum of applications. The signal lines of the German national railway rail network are also protected by REHAU cable ducts as are the signal lines of the airports at Frankfurt Main, Munich or Berlin Brandenburg International to name only a few.

But the developments are continuing. One of the biggest challenges of our time, now that the back-bones are designed in glass fibre technology, is represented by the last mile to the end customer. In many cases, even in leading industrial nations, this is still made from copper. Here the work assignment of the network operators for the next few years, which also applies for REHAU, is „Fibre To The Home“. Micro cable ducts take the glass fibre cable direct to the end customer. This makes broadband access to the internet possible for everyone. Transmission rates will be increased up to 1000 Mbit/s and above, the quality improved and new options for use created such as e.g. IPTV, video telephony and also video and web conferen-ces.

REHAU not only focuses on the product, but also on the service. Providing our customers and part-ners in the market with professional and reliable advice is a matter of course for us. In doing so we are available in all phases of your project with help and advice. Whether it’s intensive planning sup-port, support with drawing up specifications and invitations to tender, conducting static calculations or technical support at the duct line, or even wor-king out the most economical solution, e.g. with special delivery formats. We are available for you at any time. Take advantage of our extensive range of consultation services!

TOP CONNECTIONSBEST SERVICE

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PRODUCT RANGE OVERVIEWTHE RIGHT SOLUTION FOR EVERY APPLICATION

PVC/PP/PE cable duct

RAUDUCT PE multiple sub-duct pipe

For the construction of cable ducts in

Airport construction -

Tunnel construction -

Road construction -

Traffic route construction -

For installation direct into the ground

or installation in the cable conduit

Separating different networks -

Increasing capacity by replacing cables -

retrospectively

Sheathing is welded firmly to the -

individual ducts

9

PE composite duct

PE micro cable duct

For installation direct into the ground

or installation in the cable conduit

Individual duct and bundle variants -

possible

Use with mini cables, micro cables and -

blown-fi bre

Extensive accessory product range -

Cut lengths or coils

Use in road construction -

Not a heavy duty duct system -

Easy to handle due to its high fl exibility -

and low weight

Extensive range of accessories for all product ranges: Flexible bends, repair systems, rigid bends, push-fi t sockets and much more.

REHAU PVC CABLE DUCTS AND CABLE CONDUITS

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2 CONTENTS REHAU PVC CABLE DUCTS AND CABLE CONDUITS

2.1. . . . . Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.2. . . . . Area of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.3. . . . . Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.4. . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.5. . . . . Delivery format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.6. . . . . Product range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.6.1 . . . Ductswithintegralpush-fitsocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.6.2 . . . Ductswithintegralsolventweldingsocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.6.3 . . . Fittings/accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.7 . . . . Planning and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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2.1 ApplicabilityThisdocumentappliesforthematerialproperties,dimensions,deliveryformats,planning,installationandconnectionofREHAUPVC-Ucableductsandcableconduits.

2.2 Area of applicationREHAUcableductsandcableconduitsaresuitableforinstallationintothegroundasunpressurisedlinesinconjunctionwiththefittingsfortheprotectionofhighvoltageandtelecommunicationscablesagainstmechanicaldamageorascablemanagementductsandalsoretainingRAUDUCTductsystems(multiplesub-ductpipe)seeRAUDUCTsec-tioninthecatalogue.REHAUcableductsandcableconduitsarenotsuitableforuseaspressurelinesforthetransportofgas,drinkingwaterandotherfluids.REHAUoffersspeciallydevelopedductsystemsfortheseareasofapplication.

2.3 MaterialCable ductsRAU-PVC1109isaplasticiser-freePVC-U.Thetestedcableductsfulfil:- DIN8061/62andDIN16873- GuidelineHR3.31oftheSKZ- Technicalspecificationno.0053/96,ofDeutschenTelekomAG

Density»1.4g/cm3

Coefficientoflinearexpansioninthetemperaturerange0°Cto70°C»0.8x10-4K-1

Modulusofelasticity(toDIN53457)

- Short-term3600N/mm2

- Long-term1750N/mm2

Dielectric strength(toDIN53481)approx.20kV/mmSurfaceresistance(toDINIEC93;VDE0303/Part30)>1012Ohm

ChemicalresistancetoDIN8061,Supplementarysheet1

ThecolouroftheREHAUcableductsisblack.Othercoloursonrequest.

CableductsmadefromRAU-PVC1109andcableconduitsmadefromRAU-PVC1506areflame-resistant(buildingmaterialsclassB1)toDIN4102,Part1.

Cable conduitsREHAUcableconduitsfulfiltherequirementsofDIN8061,Section2andDIN8062aswellasDIN16875andGuidelineHR3.31oftheSKZ.

ThecolouroftheREHAUcableconduitsisanthracite.Otherexteriorcoloursonrequest.

Fittings and accessoriesRAU-PE330=Highdensitypolyethylene(PE-HD)

Materialproperties(at20°C)Averagedensity 0.95g/cm3

Coefficientoflinearexpansion 2x10-4K-1

Modulusofelasticity(toDIN53457) 800-900N/mm2

Surfaceresistance >1012OhmChemicalresistancetoDIN16934

Sealing ringsInthecaseofductswithintegratedpush-fitsocketsthesealingringsaremadefromelastomerstoDINEN681-1.Stick-onsealingringswillpreventthembeingpushedoutduringthepush-fitconnection.

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2.4IdentificationTheREHAUcableductsaremarkedpermanentlyatintervalsof1masfollows:REHAUcableductMaterialdesignationDIN 16873DIN8061/62SKZtestmarkDimensionDateMachinenumber

Exampleofidentification:REHAUPVC-UcableductDIN16873DIN8061/62SKZ-A447110x5.319.04.10M1

TheREHAUcableconduitsaremarkedpermanentlyatintervalsof1masfollows:REHAUcableconduitMaterialdesignationDIN 16875SKZtestmarkDimensionDateMachinenumber

Exampleofidentification:REHAUPVC-UcableconduitDIN16875SKZ-A477110x5.319.04.10M1

Theinsertiondepthmarksonthespigotendsofthecableducts,cableconduitsandcableductbendswithpush-fitsocketaremadewithcolouredadhesivetapewhichgoesallthewayaround.

REHAUcableductsandcableconduitsaredeliveredwithatanoveralllengthof6mintimberframecrates(HRVs).Otherlengthsareavaila-bleonrequest.

DN/OD Units/HRV approx. height/HRV approx. width/HRV(mm) (mm)

50 332 840 1050 63 263 940 1170 75 189 960 117090 127 960 1130110 86 950 1160125 68 960 1190140 53 980 1170160 39 930 1180

Theillustrations,dimensional,colourandweightinformationcontainedinthisdocumentprovideanon-bindingoverviewoftheproductrangeaccordingtotheplantstandard.Exactinformationcanbefoundinthestandardslisted.OurTechnicaldepartmentwillbepleasedtoansweranyfurtherquestions:

91058ErlangenYtterbiumTel.:+4991319250

2.5 Delivery format

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Duct range 3DN/OD d1) s1) tst kg/m2) approx. kg/unit Article no.

mm mm mm50* 50 1.8 80 0.43 2.60 101019110 110 3.2 170 1.67 10.05 101029125 125 3.7 185 2.16 13.12 101039160 160 4.7 190 3.50 21.00 101049


mm mm mm50* 50 1.8 80 0.43 2.60 103501110 110 3.2 170 1.67 10.05 103601125 125 3.7 185 2.16 13.12 103791160 160 4.7 190 3.50 21.00 103642


mm mm mm110 110 5.3 170 2.67 16.00 101059160 160 7.7 190 5.52 33.30 101069


mm mm mm110 110 5.3 170 2.67 16.00 103401160 160 7.7 190 5.52 33.30 103047

2.6.1Ductswithintegralpush-fitsocket

2.6 Product range

Cable ducts

Cable conduits

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2.6.2 Ducts with integral solvent welding socket Cable ducts

Cable conduits

Duct range 3DN/OD d1) s1) tkl kg/m2) approx. kg/unit Article no.

mm mm mm50 50 1.8 50 0.43 2.58 101369 63 63 1.9 63 0.57 3.43 101379 75 75 2.2 70 0.80 4.77 10138990 90 2.7 79 1.15 6.89 101399110 110 3.2 91 1.67 10.00 101409125 125 3.7 100 2.16 12.99 101419140 140 4.1 109 2.70 16.20 101429160 160 4.7 121 3.50 21.01 101439

Duct range 3 SchutzrohrDN/OD d1) s1) tkl kg/m2) approx. kg/unit Article no.

mm mm mm50 50 1.8 50 0.43 2.58 103491 63 63 1.9 63 0.57 3.43 103052 75 75 2.2 70 0.80 4.77 10353190 90 2.7 79 1.15 6.89 103551110 110 3.2 91 1.67 10.00 103591125 125 3.7 100 2.16 12.99 103621140 140 4.1 109 2.70 16.20 103691160 160 4.7 121 3.50 21.01 103651

Duct range 4DN/OD d1) s1) tkl kg/m2) approx. kg/unit Article no.

mm mm mm50 50 2.4 50 0.56 3.37 101449 63 63 3.0 63 0.87 5.22 101459 75 75 3.6 70 1.24 7.44 10146990 90 4.3 79 1.77 10.65 101479110 110 5.3 91 2.66 15.96 101489125 125 6.0 100 3.39 20.38 101499140 140 6.7 109 4.18 25.08 -160 160 7.7 121 5.52 33.41 101509

Duct range 4 SchutzrohrDN/OD d1) s1) tkl kg/m2) approx. kg/unit Article no.

mm mm mm50 50 2.4 50 0.56 3.37 - 63 63 3.0 63 0.87 5.22 1030323)

75 75 3.6 70 1.24 7.44 -90 90 4.3 79 1.77 10.65 -110 110 5.3 91 2.66 15.96 103391125 125 6.0 100 3.39 20.38 103681140 140 6.7 109 4.18 25.08 103062160 160 7.7 121 5.52 33.41 1030373)

1)DimensionsandtolerancestoDIN8062andDIN16873/2)Calculatedwithaspecificweightof1.4g/cm3 / *)Sealingringinserted/3)onrequest

1)DimensionsandtolerancestoDIN8062andDIN16873/2)Calculatedwithaspecificweightof1.4g/cm3 / *)Sealingringinserted/3)onrequest

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Duct range 3Art. no. DN/OD a3) d x s1) Rm Opermitted

4) Weight Bend lengthmm mm m mm (kg/unit)2) approx. mm

101607 50* 30° 50x1.8 1.0 5 0.32 609

101617 50* 45° 50x1.8 1.0 5 0.44 856

101816 50* 90° 50x1.8 1.0 5 0.77 1750101508 110 15° 110x3.2 1.0 6 1.02** 455101627** 110 30° 110x3.2 1.0 6 1.54 715101736** 110 45° 110x3.2 1.0 6 2.00 980101796** 110 90° 110x3.2 1.0 6 3.30 1790101528** 110 30° 110x3.2 2.7 6 3.06 15201018061 110 45° 110x3.2 2.7 6 4.32 2350101274 125 30° 125x3.7 1.5 10 3.15 1220101284 125 45° 125x3.7 1.5 10 4.00 1610101294 125 90° 125x3.7 1.5 10 6.54 2790101444 160 30° 160x4.7 2.0 10 6.20 1540101454 160 45° 160x4.7 2.0 10 8.01 2060

Duct range 4Art. no. DN/OD a d x s Rm Opermitted.

4) Weight Bend lengthmm mm m mm (kg/unit) approx. mm

103014** 110 15° 110x5.3 1.0 6 1.61 545

101637** 110 30° 110x5.3 1.0 8 2.43 715

101647** 110 45° 110x5.3 1.0 8 3.14 975101657** 110 90° 110x5.3 1.0 8 5.16 1760101548** 110 45° 110x5.3 2.7 8 6.73 2350101464 160 30° 160x7.7 2.0 10 9.84 1555101474 160 45° 160x7.7 2.0 10 12.71 2075

Bendwithintegralpush-fitsocketandstick-onsealingringforcableductsandcableconduitsMaterial:RAU-PVC1109Colour:black

ds

R m

α

L=d

2.6.3 Fittings/accessories

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Bend with integral solvent welding socket for cable ducts and cable conduits Material:RAU-PVC1109Colour:black

1) DimensionsandtolerancestoDIN8062andDIN168732) Calculatedwithaspecificweightof1.4g/cm3

3) Angletolerancefora=±3°4) Opermitted=permittedovalityoftheductcross-sectioninthebendingrange (shorteningofthebendinthebendingrangenotpermitted)*) Sealingringinserted**) ThestraightintermediatelengthL(=d)isn/aforthesearticles

ds

mR

L=d

α

Duct range 3Art no. DN/OD a3) d x s1) Rm Opermitted


101623 50 30°2) 50x1.8 1.0 5 0.30 600

101633 50 45° 50x1.8 1.0 5 0.41 855

101643 50 90° 50x1.8 1.0 5 0.75 1720101863 63 30° 63x1.9 1.0 5 0.44 707101873 63 45° 63x1.9 1.0 5 0.59 967101883 63 90° 63x1.9 1.0 5 1.04 1757102003 75 30° 75x2.2 1.0 6 0.64 730101514 75 45° 75x2.2 1.0 6 0.83 980101524 75 90° 75x2.2 1.0 6 1.47 1780101644 90 30° 90x2.7 1.0 7 0.94 736101654 90 45° 90x2.7 1.0 7 1.25 1011101664 90 90° 90x2.7 1.0 7 2.15 1796101673** 110 30° 110x3.2 1.0 8 1.23 649101683** 110 45° 110x3.2 1.0 8 1.65 899101693** 110 90° 110x3.2 1.0 8 2.96 1669101784 125 30° 125x3.7 1.5 10 2.36 990101794 125 45° 125x3.7 1.5 10 3.21 1385101804 125 90° 125x3.7 1.5 10 5.75 2560101708 140 30° 140x4.1 1.5 10 3.00 1001101718 140 45° 140x4.1 1.5 10 4.04 1391101728 140 90° 140x4.1 1.5 10 7.22 2571101924 160 30° 160x4.7 2.0 10 5.73 1519101934 160 45° 160x4.7 2.0 10 7.18 1939

Duct range 4Art. no. DN/OD a3) d x s1) Rm Opermitted


101933 63 30° 63x3.0 1.0 5 0.67 707

101943 63 45° 63x3.0 1.0 5 0.89 943

101953 63 90° 63x3.0 1.0 5 1.58 1757101584 75 45° 75x3.6 1.0 6 1.30 980101723** 110 30° 110x5.3 1.0 8 1.97 649101733** 110 45° 110x5.3 1.0 8 2.63 899101743** 110 90° 110x5.3 1.0 8 4.73 1669101854 125 30° 125x6.0 1.5 10 3.70 990101864 125 45° 125x6.0 1.5 10 5.03 899101874 125 90° 125x6.0 1.5 10 9.02 2560102004 160 45° 160x7.7 2.0 10 10.34 1385

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Duct range 3DN/OD d1) s L Weight Article no.

mm mm approx. mm approx. kg2)

50*) 50 1.8 170 0.10 101667

110 110 3.2 350 0.74 101746

125 125 3.7 430 1.04 101414

Push-ondoublepush-fitsocketswithstick-onsealingringMaterial:RAU-PVC1109Colour:black



110 110 5.3 360 1.18 101677

160 160 7.7 340 2.68 101135

Duct range 3DN/OD d1) L Weight Article no.

mm approx. mm approx. kg2)

50 50 30 0.06 101603

63 63 40 0.11 101853

75 75 50 0.17 10199390 90 60 0.28 101634110 110 60 0.42 101653125 125 70 0.64 101774140 140 75 0.84 101698160 160 80 1.21 101914

Double solvent welding sockets with duct stop Material:RAU-PVC1109Colour:black



63 63 40 0.16 101923

75 75 50 0.26 101564110 110 60 0.68 101703125 125 70 1.00 101844160 160 80 1.92 101984

L

d

L

d



110 110 3.2 400 0.77 101494

125 125 3.7 470 1.10 101264

160 160 4.7 550 2.57 101424

Doublepush-fitsocketswithductstopandstick-onsealingringMaterial:RAU-PVC1109Colour:black



110 110 5.3 400 1.20 101504

L

d

20



50 50 100 0.05 101908

110 110 180 0.33 101787

Push-on double solvent welding sockets Material:RAU-PVC1109Colour:black



110 110 180 0.55 101918

L

d

Duct range 3Design A (without duct stop)3)

DN/OD d1) L approx. mm Weight approx. kg2) Article no.110 110 200 0.55 101977

250 0.70 101074

300 0.90 101969

125 125 200 1.00 101244**

Wallbridgingpush-fitsockets(chambersockets)withstick-onsealing ring-Surfacesanded-Material:RAU-PVC1109

Design B (with duct stop)3)

DN/OD d1) L approx. mm Weight approx. kg2) Article no.50*) 50 200 0.20 101987

110 110 200 0.60 101706

300 0.70 101334

400 0.90 101344

500 1.15 101354

700 1.55 101085

125 125 300 1.15 101214**

160 160 300 1.45 101304

400 1.85 101314

1) DimensionsandtolerancestoDIN8062andDIN168732) Calculatedwithaspecificweightof1,4g/cm3

3) Otherlengthsonrequest*) Sealingringinserted**) Flaring n/a

L

d

L

d

21

Flex bendswithpush-fitsocketsand-tightandsmooth-endedsealMaterial:PEHDColour:Black(roughlyRAL9005)- Toavoidtheductlineinthecaseofobstructionsorexternalinstal-lations

-Inthecaseofheightorlateraloffsetoftheductline

DN/OD/α Length Bending radius Weight Package contents Article no.L [m] R min [m] [kg] [units]

50/90° 1.295 0.30 0.68 15 20314563/90° 1.295 0.30 0.84 5 20314675/90° 1.295 0.30 0.89 5 20314790/90° 1.430 0.30 1.43 5 203148110/90° 1.750 0.60 2.46 5 203149125/90° 2.275 0.80 3.78 5 203151160/90° 2.510 1.00 5.90 5 203153

DN/OD d L kg/unit Units/packaging Article no.mm m unit

50 50 2.0 1.24 3 101148110* 110 2.0 2.83 3 101083110* 110 6.0 10.96 3 101093

Cable duct half-duct(completefrom2supportchannels)madefromPVC-Uwithropesealpressure-tightupto0.5barColour:black(similartoRAL9005)

* AboveDN110assemblytoolart.101063required L d

- Toovercomeobstructionswithinabendarea- Bendscanbetrimmed/extendedasrequiredPressure-tightdesignonrequest.Alternativeformatsonrequest.

22

DN/OD d kg/unit Article no.mm m

50 50 0.47 101168110 110 2.60 101063

Half-duct assembly tool madefromgalvanisedsteel

d

Stop endforductspigotendforductrange3and4Material:PE-HD

DN/OD Weight L d1 d2 d1 Article no.approx. kg mm mm mm mm

50 0.01 65 44 48 60 101888110 0.07 110 97 107 119 101785160 0.09 115 140 155 166 101646

Stop end forductspigotendandsocket,forallductrangesMaterial:PP

DN/OD Weight Article no.approx. g

50 24 101588 63 28 101598 75 32 10160890 43 101618110 78 101628125 81 101638140 83 101648160 113 101658

Catch pan for junction boxes Material:RAU-PE350=PE-HDColour:blackCapacity:15.1l

Weight approx. kg Article no.1.04 645934

d 3 d 2

6

d 1

L

60510

100 18

383 mm breit

70106

wide

23

Dirt trap for access chambers Material:RAU-PE350=PE-HDColour:blackCapacity:22.6l

Weight approx. kg Article no.1.23 645924

Ø 420

24

66

188

Lubricant(canbespreadandappliedfrom-10°Cto50°C)

Delivery format Bucket BucketWeight kg 1 10Article no. 178750 119930

Lubricant requirementfor100connections(guidevalues)

DN/OD 50 110 125 160Weight kg 0.15 0.35 0.45 0.65

PVC cleaner

„Tangit“ Contents Article no.1litrefunnelbottle 251410

(Requestspecialcleanerforhotclimatezones)

PVC adhesive

„Tangit“ Contents Article no.1.0kg(funnelbottle) 251390

Adhesive requirementfor100connections(guidevalues)

DN/OD 50 63 75 90 110 125 140 160Cleaner (kg) 1.5 1.9 2.2 2.4 2.8 3.5 4.3 5.5Adhesive (kg) 1.5 2.5 3.5 4.5 6.3 7.8 9.6 12.2

24

Spacer (4, 5, 6 and 8-way) Material:RAU-PE330(doublewallblowmouldedpart)Colour:black

DN/OD/ways d d1 B H A Weight Article no.approx. mm approx. mm approx. mm approx. kg

110/2+50/3 110 50 300 150 30 0.12 157270

110/4 110 - 300 190 30 0.13 157260

110/6 110 - 440 190 30 0.19 157280

110/8 110 - 580 190 30 0.22 157290

125/4 125 - 340 220 40 0.21 156001

125/6 125 - 500 220 40 0.32 156011

125/8 125 - 680 220 40 0.42 155931

Spacer separable (4, 5, 6 and 8-way)Material:RAU-PP/PE(injectionmouldedpart)Colour:black

DN/OD/ways d d1 B H A Weight Article no.approx. mm approx. mm approx. mm approx. kg

110/4 110 284 190 30 0.11 156042

110/6 110 426 190 30 0.16 156032

110/8 110 568 190 30 0.22 156002

125/6 125 497 210 38 0.32 156012

125/8 125 658 210 38 0.33 156022

160/4 160 450 270 60 0.42 156031

160/6 160 665 270 60 0.59 156041

160/8 160 885 270 60 0.84 156051

B

Ad

AH

B

A

Ad1

H

d

B

A

Ad

H

25

2.7 Planning and installation

Notes for planning standards, regulations, guidelines, DIN1054subsoil:Permittedloadingofthesubsoil.DIN1055,Part2:Loadassumptionsforbuildings.DIN1072:Roadsandfootbridges,loadassumptions.DINENISO14688/14689:Geotechnicalexplorationandinvestigation.DINEN1610:Installationandtestingofsewerpipesandsewers.DIN4124:Excavationpitsandtrenches.DIN18300:VOBcontractingrulesforawardofpublicwork-PartC:Generaltechni-calregulations,groundworks.DIN18305:VOBcontractingrulesforawardofpublicwork-PartC:Generaltechnicalcontractingrulesforawardofpublicwork(ATV);Dewateringworks.DIN18306:VOBcontractingrulesforawardofpublicwork-PartC:Generaltechni-calcontractconditionsforbuildingservices(ATV);Sewerworks.

Datasheetforthebackfillingofbuildings,issuedbytheFor-schungsgesellschaftfürStraßenwesene.V.[ResearchInstituteforHighways]Data sheet for settlement in road construction, issued by the ForschungsgesellschaftfürStraßenwesene.V. Datasheetfortheback-fillingofducttrenches,issuedbytheForschungsgesellschaftfürStraßenwesene.V.ZTVE-StB76:Guidelinesforgroundworksinroadconstruction,publishedbytheBundesministeriumfürVerkehr[FederalMinistryofTransportalsosupplementtoZTVE-StB76.TW74:Technicalregulationsandguidelinesforcarryingoutgroundstabilisationandgroundimprovementsinroadconstruction,issuedbytheBundes-ministeriumfürVerkehr.Thetechnicalregulationsofthepublicutilitiescompaniesandclientaretobeobserved.

Structural designREHAUcableductscanbestaticallycalculatedaccordingtotheATVworksheetA127.Theload-bearingstrengthoftheductsintheinstalledconditionisdependentfirstandforemostontheinstallationandsoilconditions.Onrequestwewillissueastaticcalculationforthespecificinstallationcase.TherequiredinputvaluesforthecalculationcanbefoundintheprojectquestionnaireintheattachmentofthisTI.

Leak testCableductductunitsmustbewatertighttofacilitatetheshooting-inofdrawropesandtopreventtheingressionofgasandwater.Followingback-fillingwithsandinlayers,perhapsalsoinsections,butpriortorestorationoftheroadsurface,thecableductpassagesareleaktested(0.5bar;15min.;seeDINEN1610).

Transporting and storing the ducts- Impactstressonductsandfittingsistobeavoided,inparticularattemperaturesaroundfreezingpointandbelowistobeprevented

- Loadingandunloadingistobecarriedoutcarefully(tippingtheductsfromtheloadingsurfaceisnotpermitted)

- Ductsorductendsmustnotdragacrossthegroundduringtransport- Storeductsandfittingssothattheinsidecannotbesoiled- Nopermanentdeformationordamagemustoccurasaresultofstorage

- Themaximumstackingheightis3timberframecratesontopofoneanother.Whendoingthisitistobeensuredthatthetimbercratesarelyingontopofeachother

- Whenstackingwithwoodensupportsthethicknessoftheboardistobedimensionedinsuchawaythatthesocketsarenottouchingthem

- Thecouplersaretobearrangedsothattheyareoffsetduringsto-rage,inordertoavoidpoint-shapedloadsinthesocketarea

- ProtectductsandmouldingsbeforetheycomeintocontactwithsubstanceswhicharedamagingtoPVC(solvents,e.g.Tangitcleaner,etc.,seeDIN8061supplementarysheet1)

- Contactofrubbersealingringswithoilandgreaseisnotpermitted- Durationofoutdoorstorage(CentralEurope),notprotectedagainstsunlight:maximum2years

- Forprolongedperiodsofoutdoorstorageorinareaswithintensesolarradiation,e.g.insoutherncountries,orataltitudesabove

1,500m,storageoutofdirectsunlightisrequired.Coverwithalight,opaquecoverinordertoavoidabuild-upofheatandpossibledefor-mationasaresult,ensuresgoodventilationoftheductsandfittings

Possiblebleachingtothecolourofductsurfaceswhichoccursasare-sultofoutdoorstorageofupto2yearsinCentralEuropewillnotimpairthefunction.Inthecaseofsolventweldingsocketductstheadhesivesurfacesaretoberoughedupbeforecleaningwithemerypaper80grain.

26

Connecting the ducts Push-fitsocketToolsandworkequipment- REHAUlubricant(canbespreadandappliedfrom-10°Cto50°C), 1kgand10kgbucketcontainer,lubricantrequirement:seepage13.- Meteringrule,measuringtape- Ductcuttingandchamferingunit(see3.4.8)- Markerpenorcolouredadhesivetapeformarkingtheinsertiondepthfortrimmedducts

- Brushesandclothsforpotentialcleaningofdirtysockets/sealingrings- Ductstopendforinterruptionstothebuildingwork

Preparingthepush-fitsocketconnectionBeforeinstallingtheductitistobecheckedwhether1. Theendsoftheduct(spigotends)arecutatrightanglestotheductaxisandhavebeenchamferedaspertheregulations(see3.4.8)

2. Asealingringisfittedtoeachsocketgroove3. Thesealingringliesinthesocketsgroovewithouttwisting(ductsocketswiththesealingringmissingmustnotbeinstalled)

Connectingthepush-fitsocketducts- Removeanydirtfromtheinteriorsurfaceofthesocketandspigotend

- Coatthespigotend(includingchamfering)atalengthofapproxi-mately3cm-andsealingring-withlubricant.(Note:Donotuseoilorgrease!Rubbersealingringsexpandanddisintegrate!)

- Pushtheductspigotend1-2cmintothesocketandpushituptothestopwithforce(notinsertiondepth)

Solvent welding socketToolsandworkequipment- Meteringrule,measuringtape- Ductcuttingandchamferingunit(see3.4.8)- Markerpenorcolouredadhesivetapeformarkingtheinsertiondepths-Flatbrush,unpainted(resistanttocleanerandadhesive)-Crepepaper,absorbent,forcleaningthesocketconnectionandremovingthesurplusadhesivewhichleaksout

- Emerypaper,80grain- TangitcleanerandTangitadhesive(Requirementseeplantstandard,page13)

Preparing the solvent welding socket connection1. Trimandchamfertheendsoftheduct(see3.4.8)2. Marktheinsertionlengthontheendoftheduct(=socketdepth)(Mark=controlforcompletecoatingandinsertion).

3. AlignductsandfittingsIftheductspigotendandsocketarepushedtogetheratananglethiscanleadtoleakyconnectionsFollowingadhesionsubsequentalignment,e.g.ofductbends,isnotpermitted!

Safety informationTheadhesiveisafirehazard.Adhesiveandcleanercontainhighlyvolatile solvents. The mixtures of solvent/air are heavier than air and explosive. In duct trenches or in closed workrooms extinguish open firesandsparks.Donotsmoke,weld,etc.,turnoffelectricfiresetc.Fill cable duct lines with water prior to carrying out welding works and rinse or blow out with air.Ensure good ventilation in closed workrooms. Solvents which are inhaled in large quantities are harmful to health!

Moisture on the adhesion surfaces impairs the adhesion of the adhesive. Dust, strong wind and intensive sunlight also have an adverse affect on the quality of the adhesion. In these cases a tarpaulin is to be erected over the adhesion point. The ice/conden-sation water which forms during unfavourable weather conditions when using the cleaner must be removed. The minutest amount of silicone (hand protection cream) on the adhesive surfaces impairs the adhesive adhesion.

Inthecaseoftemperaturesataroundandbelowfreezingpointadhe-sionmustnolongerbecarriedout!Ductswhichhavebeenlyinginthesuncontractoncetheyarein-sertedintotheshadyducttrench.Foradhesionthetemperatureoftheductwallshouldhavereachedtheambienttemperaturetopreventtheconnectionbeingpulledapart.

Connecting the solvent welding socket ducts- Notetheinformationonthetin!- Removedirtfromadhesionsurfaceswithcleanclothsorcrepepaper,drydampsurfaces

Attemperaturesofbelow+10°Cwarmthesurfacestobegluedsothattheyarelukewarmoutsideoftheducttrench(rickofexplo-sioninthetrench!)

- Caution:Ifthesurfaceoftheductistoowarmtheadhesivestickstooquicklyandthesocketcanshrink

- Removegreaseandthewax-typesurfacecoatingfromtheadhesivesurfaceswithcleanerandcrepepaper.Todothis,soakahand-sizewodgeofcrepepapergenerouslywithTangitcleaner.Donotpourthecleanerontheadhesivesurfaces.Renewthecrepepaperfrequently

- Inthecaseofstronglycoloured,bleachedductstheadhesivesur-facesaretoberoughedupbeforecleaningwithemerypaper,

80grain- Storeadhesiveatroomtemperaturepriortoprocessing.Adhesiveissuppliedreadyforuseanddoesnotneedtobethinned.Discardadhesivewhichhasthickened

- Requirementsonconsistency:Theadhesiveshouldrunslowlyfromastickheldatanangleandformasortoffan

- Thesurfacescleanedwithcleanermustbedriedbeforetheadhe-siveisapplied

- Stiradhesivewell- Soakbrushgenerouslywithadhesive- Coattheinsideofthesocketfromtheinsideoutlengthways(axial)

27

Toavoidcontractionsoftheductcross-sectionduetoadhesivebeingpushedoutfromtheinside,theadhesivemustonlybeapplieduptoapprox.2cmbeforethebottomofthesocket.

- CoatthechamferedductwithTangitadhesiveaxiallyuptotheductendusingheavybrushforce

- Pushtheductandsockettogetherimmediatelyuptothestopwithouttwisting/tiltingortothefullsocketdepthandholdinthispositionforafewsecondsuntiltheadhesivehasset

- AboveDN/OD160aguideforpushingthecomponentstogetheristobeusedand2installersshouldapplytheadhesivetothesocketandtotheendoftheductatthesametime

- Attemperaturesofuptoapprox.25°Ctheadhesivemustbeappliedaftermax.3minutes.Increasingwiththesunlightontheductandtheairtemperaturethetimecanreduceto1minuteandless.Thereisriskofleakingiftheadhesivelayerdriesout

- Removesurplusadhesivewithcrepepaper,otherwisetheductwillbemarkedtoheavily

- Sealtinswellafteruse.Cleanerevaporatesquickly,adhesivethickens

- Usedbrushescanbecleanedwithcleanerandcrepepaper.Thebrushmustbedrywhenusedagain.

-Theconnectionisnotload-bearingimmediatelyafteradhesion!After15minutescarefulback-fillingandcompactingbyhandwithoutchangingthepositionoftheductispermitted.Refrainfromthrowingfillermaterialfromtheedgeofthetrenchdirectlyontotheconnection.After2hoursback-fillingandcompactingwithamachineispermitted.Theloweringofagluedductrunandalsobendsoftheductlinecantakeplace12hoursafteradhesionattheearliest.Settingtimebeforepressuretest:Per1bartestingpressure,atleast1hourwaitingtime.

Duct installationGeneralCablechannelsaregenerallyconstructedfromductswhichhavebeenconnectedtoeachothersothattheyarewatertight.Thefillermaterialcompactedinthelinezoneareaistobeincorporatedasanessentialload-bearingelementinthewholeconstruction.Thefillermaterial(sandorgravel-sandmix)canonlybemadeeffectiveasaload-bearingelementiftheductshavetherequiredspacingforevencompactingatallpoints.Therequiredspacingbetweentheductsisensuredbyintroducingspacers.

Duct trenchesThedimensionsoftheducttrenchinfluencethesizeanddistributionofgroundandtrafficloads.Duringthedesignthedimensionsspecifiedbythedescriptionofservicesorstaticcalculationaretobeobserved.Thedepthoftheducttrenchismadeupoftheheightoftheductbundle(thegapsbetweentheductsaredeterminedbythespacerdependingontheductdiameter)andtheintendedducttop-fill.Inthecaseofrockyorstonygroundanadditionaldepthof10cmforalayerofsand(stone-freelayer)istobetakenintoaccount.Inthecaseofanon-loadbearingandheavilywater-saturatedtrenchbaseandalsotheriskofthefillermaterialtobeappliedbeingwashedoutduetoachanginggroundwaterlevelsstabilisationistobeensuredthroughsuitablemeasures.

Install,back-fill,compact;spacerWhenconstructingmulti-waycablechannelsfromcableductsductinstallationandback-fillingworkscrossoverintotheareaofthelinezones.Thesequenceofworkcanbefoundinthefollowingillustration.Qualifiedpersonsmustbeusedforthedesignandsupervisionofthebuildingproject.Theload-bearingpropertiesofthermoformedplasticductsinadditiontotheductrigidityarealsodeterminedtoalargeextentbythepossi-bilitytoleanagainstthenearbybeddingmaterial,particularlythesidefillermaterial.Thismakesparticularlyproperandcarefulcompactingoftheareasbetweentheductsnecessary.Spacersareusedtoensuresufficientcompactingandalsostabilisationoftheductbundle.

DependingontheductdiameterinmindREHAUspacersprovidethefollowinggaps:

DN/OD Gap (A)110 30mm125 40mm160 60mm

Inthecaseofductinstallationsinsandoragravel-sandmix(largestgrain8mm,withthepredominantproportionbeingsand)orconcrete,thespacersaretobesetatintervalsofmax.1.5m,inthecaseofinstallationinacement-sandmixofmax.3m.Whencreatingcambers,dependingonthelocalconditionsthisgapmustbereducedaccor-dingly,whereitistobeensuredthattheprescribeddistancebetweentheductsisgenerallyobserved.Ductsonthelowestlayerofductsarelaidoutonthepreparedtrenchbaseandfixedtoeachotherintheirpositionusingspacers.Thenextlayerofductsisonlylaidoutoncethelayerunderneathhasbeenfilledandcompactedinlinewithregulations.Ifmorelayersbeyondthe2ndlayerofductsareintended,thespacersforretainingthe3rdlayerofductsaretobeinsertedbeforethe2ndlayerofductsisback-filledwithsand.Proceedinthesamewayforadditionallayersofducts.Inordertoavoiddamagetotheducts,thefillermaterialisalwaystobecompactedbyhandintheareaaroundthelinezone.Compactingistobecarriedoutwithwoodenmanualcompactors.Thecompactedfillermateriallayeroverthetoplayerofductsshouldbeatleast10cm.Intheareaofupto1mabovetheductapexonlylightweightcompac-tingequipmentshouldbeused.Theuseofmediumandheavycom-pactingandvibratingequipmentinthecaseofapexto-fill,measuredinthecompactedcondition,isnotpermittedbelow1m!Ifductshavetobelaidinconcrete,itistobeensuredthateachductiscompletelycovered.Inthecaseofseverallayersofductslyingontopofeachotheritistobeensuredthattheductsarenottooheavilydeformedthroughthenecessaryactionsoflifting-stabilising.Priortoconcretingthesocketgapistobesealedwithsuitableadhesivetapeinordertopreventthepenetrationofcementmortarintothesealingareaofthesocketconnection.Ifthecablechannelscomeneartoorcrosswithexternalinstallationsofotherproviders,theprescribedgapsmustnotbeundercut.

28

Connecting the ducts to chambersConcreteormortarwithPVCdoesnotformapermanentandleak-proofconnection.ConcretingthePVCductdirectlyintothechamberwallisthereforetobeadvisedagainst.Sandedwallbridgingso-cketswitharubbersealhavebeentriedandtestedasatechnicallybettersolution(plantstandardpage20).Inordertofacilitaterelativemovementbetweenthebuildingandductrun,gluedduct-chamberconnectionsshouldbeavoided.

Inthecaseofchambersmadefromin-situconcretewallbridgingsocketsandductendsarealwaystobeassembledintheshutteringpriortoconcretingthein-situconcretewall.Whendoingthistheductsaretobebroughtintothecorrectpositionusingspacers,wheretheductsorthewallbridgingsocketspushedontotheendsoftheductsmustsitflushwiththeinsideofthechamber.

Catch pan and dirt trapCatchpansareintendedforinstallationinjunctionboxes.Dirttrapsareinstalledbelowtheventilationslitsoftheaccesschambercover.

Cold bending the ductsDependingontheductdimensionsandtheoutsidetemperaturethefollowingbendingradiiarepossible.Minimumbendingradiiattemperaturesabove+10°C:DN/OD110(110x3.2/110x5.3)withRadiusR≥5mDN/OD125(125x3.7/125x6)withRadiusR≥8mDN/OD160(160x4.7/160x7.7)withRadiusR≥12mSmallercamberradiicanonlybecreatedwithductbendswhichhavebeenpre-castintheplant.Inthecoldconditionpre-castductswillbedeformedduringtheben-dingaction,wheretheinternaldiameteroftheductlyingatthebendlevelwillbeslightlyreduced.

Abstandhalter

Rohrgraben

PVC-KabelschutzrohrDN 100

d A

Breite Rohrverband

Grabensohle steinfrei

Höhe

Lei

tung

szon

e

10 c

m

A

Über

deck

ung

Höhe

Roh

rver

band

Step 1Laythebottomlayerofductsandinsertspacers.

Step 2Back-fillthespacebetweenandaroundthebottomlayerofductsandcompact.

Step 3Laythe2ndlayerofducts,pushintotheexistingspacersandinsertnew spacers.

Step 4Back-fillthespacebetweenandaroundtheducts2ndlayerofductsandcompact.

Step 5Laythe3rdlayerofducts,pushintotheexistingspacersandinsertnew spacers.

Step 6Back-fillthespacebetweenandaroundthe3rdlayerofductsandcompact.

Step 7Laythe4thlayerofducts,pushintotheexistingspacers.Back-fillthespacebetweenandaroundthelastlayerofductsandcompact.

Step 8Back-fillthespacebetween,aroundandabovetheductsandcom-pact.

DN/OD110

Duct trenches

Spacers

Wideductjoint

Stone-freetrenchbase

Heightofthepipezone

Heightoftheductjoint

TopfillPVCcableduct

29

Example:AtabendradiusR=5theinternaldiameteroftheductisstill:50x1.8=46.3mm110x3.2=99.9mm110x5.3=89mmThefewerjointingsocketsaductrunhas,theeasieritistobend.Incamberareastheductrunstobecoldbentshouldalwaysconsistsof12mlongductsandthejointingsocketsshouldbelocatedoutsideofthebendingrangeifpossible.Theductsmustonnoaccountbebentatasinglefixedpoint.Ductstobecoldbentaretobestabilisedusingstakes(pointed)tobehammeredintotheground.Thethicknessofthestakeistobedimensionedaccordingtothegapbetweenthespacers(seepage25).Thefirststakeistobehammeredintothegroundontheinsideofthecamberatthestartofthebend.Bendtheductrunanddrivethenextstakeintothegroundontheoutsideoftheductcomingawayfromthebend.Continuethebendingprocessandstabilisationoftheductrunusingfurtherstakesuntiltheductrunhasachievedtheintendedcamber.Astakeistobeinsertedbehindeveryjointingsocketinaductcamberontheoutsideofthecamber.

Pushthesecondadjacentductrunonthesamelayerofductsintothestakeusedandstabiliseusingfurtherstakesontheoutsideofthecamber.Bendothercamberedductrunsinthesamewayandthenconnectwithspacers.Everylayerofductslaidistobefullysupporteduptotheoutertrenchwallusingcompactedfillermaterial.Onlyremo-vethewoodenstakesoncethefullwidthofthetrenchhasbeenfilledandcompacted.Pushtheductstrandsonthe2ndlayerofductsintothespacersused.Layfurtherlayersofductsinthesameway.Solventweldingsocketductsshouldalreadybestucktogether1daybeforebendingoutsideofthetrenchinto24m(4x6m)longductstrands.Whencreatingcamberedpassagesofductonthebuildingsiteusingcoldbendingorwiththehelpofpre-fabricatedductbendsitistobeensuredthattheductconnectionsarecreatedusingstraightspigotendsandsocketends.

Change to the length of the ducts as a consequence of temperaturefluctuationsAlengthchangecausedbytemperaturefluctuationsinthecaseofPVC-Uductsissignificantlylargerthanforsteelducts(coefficientofexpansionPVC-U=0.08mm/mK).ThisistobetakenintoaccountinparticularinthecaseofinstallingtheductsduringtimesofhightemperaturefluctuationsbetweendayandnightandalsoinSouthernclimatezones.Ductlinesinstalledbetween2chambers,orwhichinitiallyarenotfilledorareleftopen

totemperaturechangewithglued,rigidsocketconnectionscansepa-rate.Ductpassageswithpush-fitsocketconnectionscannotseparate.InthecaseofREHAUductswithintegralpush-fitsocketstheinsertiondepthmarkedontheductspigotendsisanadditionalcontrolagainsttheconnectionpotentiallybeingpulledapart.Toavoiduncontrolledlengthchangestheductinstallationistobeback-filledpurposefully,butgradually.Ductswhichhavebeenoutsideofthetrenchinthesuncontractafterbeinglaidintheshadytrenchorduetothefillingofthetrench.

Rohrgraben

Holzpflöcke

Kabelschutzrohr

Abstandhalter

Duct trench

Stakes

Cableduct

Spacers

30

ExampleforthelengthreductionStretchofductleftopen,notyetfilled=30m

Temperaturedifferenceductwall=35K(Δl=LxΔTx0.08mm/mK)Δliscalculatedat84mm

Thelengthreductionof84mmcalculatedintheexamplecan,incertaincircumstances,affectasinglesocketandisthereforealwaystoolarge.Theopenstretchofductbetween2chamberswhicharethentobebridgedshouldbeamaximumof18m.Tomakeassemblyeasierthelastductconnectionistobemadewithinthecamberedstretchesofductifpossible.Inthecaseofthestretchesofductwhichareleftopenduringthetemperaturechange(e.g.bridgeconstruction)uncontrolledlengthchangescanbeavoidedbytakingintoaccountfixedpoints.

Creatinginfillsections(Trimandchamfertheductspigotends)Duringthepracticeofinstallationitisgenerallynecessarytoshortenductstocertainlengths.Whendoingthisductinfillsectionsmustbecutatrightanglesandhavethestandard15°chamferingonthespigotends.Creatingtheductinfillsectionsshouldbecarriedoutproperlyandbecost-effective.Trimmingtheductsbyhandistime-consumingandtechnicallyproble-maticinthecaseofretrospectivebevellingwithafile.Chamferingunitswhichjustmakeitpossibletochamfertheendsoftheductrequirearightangledcutandcanonlybeusedforoneductdiameterineachcase.Equipmentwhichseparateandchamferinoneactionarerecommended.Suchequipmentcanbeusedfordiffe-rentductdiametersandwallthicknessesthankstointerchangeableclampingjaws.(PlasticcroppingandchamferingunittypeROCUT,supplier:Rothenberger,D-65779Kelkheim).

DN/OD Duct range 3 bmin Duct range 4 bmin

Wall thickness s Wall thickness smm mm mm mm

50 1.8 3 2.4 5 63 1.9 3 3.0 6 75 2.2 4 3.6 790 2.7 5 4.3 8110 3.2 6 5.3 10125 3.7 7 6.0 11140 4.1 8160 4.7 9 7.7 14

Connectingtheductswithpush-ondoublepush-fitsocketsAreaofapplication:Adjustingductlengthswithoutsocketsinductstrandsbetweenacesschambers.Connectductinfillsectionstobeinstalledindamagedductstrands,inwhichcablehasnotyetbeenlaid.Donoinstallwithincamberedstretchesofductifpossible(makeassemblyeasier).- Ductswhicharetobeconnectedusingpush-ondoublepush-fitsocketsaretobepreparedinsuchawaythatthereisagapofmax.10mmbetweentheendsoftheduct

Shortlengths/infillsectionswhichareinstalledinthecaseofrepairinthedamagedductrunmustbecuttotheexactlengthaccor-dingly

- Thepush-ondoublepush-fitsocketistobepushedoncompletelytoanendoftheductwhichhasbeenbenttothesideortobothsidesoftheductinfillsectiontobebuilt

To do this coat both ends of the duct including chamfering, and also sealing rings with lubricant- Bringtheductendstobeconnectedtoeachotherintherightposi-tion,pushthepush-ondoublepush-fitsocketovertheendsoftheduct

Connectingtheductswithpush-ondoublesolventweldingsocketsAreaofapplicationandpreparationasdescribedonpage27.- Thepush-ondoublesolventweldingsleevesocketsistobepushedoncompletelytoanendoftheductwhichhasbeenbenttothesideortobothsidesoftheductinfillsectiontobebuilt.Todothis,applyadhesivethicklytobothendsoftheductthinlyinthesocket

- Bringtheductendstobeconnectedtoeachotherintherightposi-tion,pushthepush-ondoublesolventweldingsleevesocketovertheendsoftheduct

Removesurplusadhesivewithcrepepaper.

Doublepush-fitsocketsanddoublesolventweldingsocketsforthe installation of remaining lengthsDoublepush-fitsocketsanddoublesolventweldingsocketsallowyoutoworkeconomicallyonthebuildingsitewithleftoverductcutlengths.Thesocketinsertiondepthistobeclearlymarkedontheendsofductofthecutlengths.

Stop endStopendspreventtheingressionofdirtorfillermaterialintothestrandsofductwhichhavealreadybeenlaidduringbuildinginterrup-tions.Dependingontheproblemstopendsareonlyavailablefortheductspigotend,orfortheductspigotendandsocket.Withthemostrecentdesignitisevenpossibletosealchamberorwallbridgingsocketswhicharenotoccupiedbyaduct.Thestopendsare,withouttheapplicationoflubricants,tobepushedwithanopenhandintotheductorsocket.

b

15°

s

REHAU PP CABLE DUCTS AND CABLE CONDUITS

32

3 CONTENTS REHAU PP CABLE DUCTS AND CABLE CONDUITS

3.1 . . . Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.2 . . . Area of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.3 . . . Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.4 . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.5 . . . Delivery format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.6 . . . Product range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.6.1 . Ducts with ring stiffness SN4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.6.2 . Ducts with ring stiffness SN8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383.6.3 . Fittings/accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.7 . . . Planning and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

33

3.1 ApplicabilityThis document applies for the material properties, dimensions, delive-ry formats, planning, installation and connection of REHAU polypropy-lene cable ducts and cable conduits.

3.2 Area of applicationREHAU PP cable ducts and cable conduits are suitable for installation into the ground, as unpressurised lines in conjunction with the fittings listed in this TI for the protection of power and telecommunications cables mechanical damage and chemical attacks or as cable ma-nagement ducts, as well as for holding RAUDUCT multiple sub-duct pipes (see section 5 RAUDUCT).

Note:The PP cable ducts, cable conduits and fittings in this document are not suitable for the construction of lines for the transport of gases and fluids. REHAU offers specially developed duct systems for these areas of application.

3.3 Materials

PP cable ductsThe PP cable ducts are manufactured as standard using RAU-PP 2300 taking into account the requirements of prEN 14282 „Plastic ducting systems for underground cable ducting, polypropylene (PP), requirements on ducts, fittings and the ducting system“:

Duct properties to prEN 14282

Property Testing method Values

Ring stiffness EN ISO 9969 SN 4 or SN 8

Impact strength EN 744 TIR ≤ 10 % at 0 °C

Longitudinal shrinkage EN 743 < 2 % 150 °C / 1 h

Material propertiesPolypropylene stands out with its very good resistance to many chemicals. More detailed information can be found in DIN 8078, supplementary sheet 1. Protective measures for external and internal protection against water, soil and gas in the surrounding area are not necessary.

REHAU PP cable ducts conform to building materials class B 2 (normal flammability) to DIN 4102; use of flame proofing agent on request.

Material properties Testing method Values

Density ISO 1183 > 0.9 g/cm3

Modulus of elasticity DIN 53457- Short-term min. 1250 N/mm2

- Long-term min. 310 N/mm2

Coefficient of linear expansion DIN 53752 max. 1.4 * 10-4K-1

coefficient in the temperaturerange (0 to 110) °C

Thermal conductivity DIN 52612 min. 0.2 WK-1m-1

Part 1Specific surface DIN 53482/ > 1012 Ωresistance VDE 0303-3

The colour of the REHAU PP cable ducts is black. Other exterior colours and also marking with coloured stripes on request.

34

PP cable conduits The PP cable conduits are manufactured as standard using RAU-PP 2311 taking into account the requirements of prEN 14285 „Plastic ducting systems for underground cable duct lines, polypropylene (PP), requirements on the ducts, fittings and the ducting system“:

Properties Testing method Values

Ring stiffness EN ISO 9969 SN 4 or SN 8

Impact strength EN 744 TIR ≤ 10 %at 23 °C

Longitudinal shrinkage EN 743 < 2 %150 °C / 1 h

The colour of the REHAU PP cable conduits is black. Other exterior colours and also marking with coloured stripes on request.

Sealing ringsThe sockets for the REHAU PP cable ducts are fitted with special lip sealing rings made from permanently elastic elastomers (SBR) to DIN EN 681-1.In the case of ducts with an integral push-fit socket the sealing rings are fitted into the socket on this basis with a special retaining ring and secured against being pushed out. In the case of double push-fit sockets DN/OD 110 SN 8 and DN/OD 160 these are secured using the special Safety-Lock safety system with a clamp-type compression SL lip sealing ring clamped on.Due to the defined pre-tensioning and compression of both sealing element systems a leaktightness in the push-fit socket connection of at least 0.5 bar is achieved.

Safety-Lock safety system

The illustrations, dimensional, colour and weight information contained in this document provide a non-binding overview of the product range according to the plant standard. Exact information can be found in the standards, guidelines and worksheets listed. If you require additional information, e.g. dimensional tolerances for plan-ning, construction and carrying out building work, we recommend that you contact our technical department in:

91058 ErlangenYtterbium 4Tel.: 09131 92-50

Sealing ring system

Duct properties to prEN 14285

35

3.4 IdentificationREHAU PP cable ducts are indentified as standard using Ink-Jet printing at intervals of 1 m as follows:

Manufacturer and Area of application: REHAU cable ductMaterial: PPStandard: EN 14282Dimensions in mm: e. g. 110 x 3.4Ring stiffness: e. g. SN 4Production date (DD.MM.YY): e. g. 19.04.2010Machine no.: e. g. M7

and also with permanent printing on the socket:: Manufacturer, dimensions, production month and year.

REHAU PP cable conduits are indentified as standard using Ink-Jet printing at intervals of 1 m as follows:

Manufacturer and Area of application: REHAU cable conduitsMaterial: PPStandard: EN 14285Dimensions in mm: e. g. 110 x 3.4Ring stiffness: e. g. SN 4Production date (DD.MM.YY): e. g. 19.04.2010Machine no.: e. g. M7

and also with permanent printing on the socket:: Manufacturer, dimen-sions, production month and year.

Insertion depth marking Insertion depth marks on the spigot ends of the PP cable ducts are made using coloured adhesive tape which runs all the way around.

36

3.5 Delivery format REHAU PP cable ducts and conduits are delivered in timber frame crates (HRV) at an overall length of 6 m with sealing rings inserted in the plant and with a double push-fit socket fitted if necessary. Other lengths are available on request.

DN/OD Duct external diameter Contents Height Width

[mm] [Unit] [mm] [mm]

110 110 86 1020 117

125 125 68 1010 1190

160 160 / DSM 35 920 1170

160 160 / ASM 39 980 1170

37

3.6 Product range

3.6.1 Duct with ring stiffness SN4

Ducts with integral push-fit socket (ASM) Integral cable duct long push-fit socket (ASM) on the basis of prEN 14282 or prEN 14285; lip sealing ring fixed with retaining ring; chamfered spigot end and, in the case of cable ducts, with coloured insertion depth marking applied all the way around.

Cable duct duct range SN 4 / SDR 33

DN/OD d* s* tst e kg/m Weight Article no.[mm] [mm] [mm] [mm] [approx. kg/Unit]

110 110 3.4 106 32 1.22 7.3 103259**125 125 3.9 83 30 1.58 9.5 -160 160 4.9 95 23 2.53 15.2 -

* Dimensions and tolerances to prEN 14282** Delivery time on request

Cable conduit duct range SN 4 / SDR 33


110 110 3.4 106 32 1.22 7.3 103016125 125 3.9 83 30 1.58 9.5 103046160 160 4.9 95 23 2.53 15.2 103056

* Dimensions and tolerances to prEN 14282** Delivery time on request

38

3.6.2 Duct with ring stiffness SN8

Ducts with push-on PP double push-fit socket (DSM) Long cable duct double push-fit socket (DSM) to prEN 14282 or prEN 14285 with integrated Safety-Lock safety sealing system, chamfered spigot end, in the case of cable ducts, witha stick on coloured insertion depth marking all the way around

Cable duct duct range SN 8 / SDR 23.8


110 110 4.7 110 50 1.5 9.5 103095**

160 160 6.9 135 50 3.1 19.70 ***

* Dimensions and tolerances to prEN 14282 ** Delivery time on request *** on request

Schutzrohr Rohrreihe SN 8 / SDR 23,8


110 110 4.7 110 50 1.5 9.5 103106**

160 160 6.9 135 50 3.1 19.70 103036**

* Dimensions and tolerances to prEN 14282 ** Delivery time on request *** on request

39


Bends Bends with integral push-fit socket or push-on double push-fit socketand sealing ring inserted Material: RAU-PP 2300

Flexible bendsWith sand-tight push-fit socket and smooth-ended seal Material: PEHDColour: Black (roughly RAL 9005)- To avoid the duct line in the case of obstacles or external installa-

tions- In the case of height or lateral offset of the duct line- To overcome obstacles within a bend area- Bend can be trimmed or extended as required

DN/a Length Bend radius Weight Packaging Article no.L [m] Rmin [m] [kg] contents [Units]

110/90° 1.750 0.60 2.46 5 203149125/90° 2.275 0.80 3.78 5 203151160/90° 2.510 1.00 5.90 5 203153

ds

R m

α

L=d

Duct range SN 4 / SDR 33 ca.Art. no. DN/OD a d x s* Rm Muffe Gewicht (kg/Stck.)

mm m mm m248729 110 15° 110 x 3.4 1.0 ASM 0.78247628 110 30° 110 x 3.4 1.0 ASM 1.04

247638 110 45° 110 x 3.4 1.0 ASM 1.34

248739 110 15° 110 x 3.4 2.0 ASM 1.28247648 110 30° 110 x 3.4 2.0 ASM 1.87247658 110 45° 110 x 3.4 2.0 ASM 2.52*** 110 90° 110 x 3.4 2.0 ASM283194** 125 30° 125 x 3.9 1.0 ASM 1.81283196** 125 45° 125 x 3.9 1.0 ASM 2.20*** 125 90° 125 x 3.9 1.0 ASM238566 160 30° 160 x 4.9 2.0 DSM 3.54238576 160 45° 160 x 4.9 2.0 DSM 4.81*** 160 90° 160 x 4.9 2.0 DSM283199** 160 30° 160 x 4.9 2.0 ASM 3.97283202** 160 45° 160 x 4.9 2.0 ASM 5.34*** 160 90° 160 x 4.9 2.0 KSM* Dimensions and tolerances to prEN 14282** Duct to prEN 14285; Socket on the basis of prEN 14285*** on request

Duct range SN 8 / SDR 23.8 ca.Art. no. DN/OD a d x s Rm Muffe Gewicht (kg/Stck.)

mm m mm m*** 110 30° 110 x 4.7 1.0 DSM

*** 110 45° 110 x 4.7 1.0 DSM

*** 110 90° 110 x 4.7 1.0 DSM*** 160 30° 160 x 6.9 2.0 DSM*** 160 45° 160 x 6.9 2.0 DSM*** 160 90° 160 x 6.9 2.0 DSM* Dimensions and tolerances to prEN 14282** Duct to prEN 14285; Socket on the basis of prEN 14285*** on request

Pressure-tight design on request, other formats on request

40

Double push-fit sockets with sealing ring inserted Material: RAU-PP Colour: black

DN/OD d* L Socket approx. weight Article no.[mm] [mm] [kg]

110 110 650 ASM 0.7 103129110 110 225 DSM - **125 125 - ASM - **160 160 275 DSM 0.94 103329* Dimensions and tolerances to prEN 14282 ** Delivery time on request

Push-on sockets with sealing ring inserted Material: PE-HD Colour: black

DN/OD d* L Socket approx. weight Article no.[mm] [mm] [kg]

110 110 320 - 0.53 103002110 110 225 DSM** *** ***125 125 - - 0.89 103012160 160 275 DSM** 0.93 103339* Dimensions and tolerances to prEN 14282 ** made from RAU-PP*** on request

Wall bridging sockets/chamber lining sleeve with sealing ring inserted Material: Polystyrene (PS) Colour: natural

DN/OD d* L approx. weight Article no.[mm] [mm] [kg]

110 110 110 0.29 172450110 110 240 0.57 172260125 125 110 0.34 172460125 125 240 0.69 172270160 160 110 0.46 172470160 160 240 0.90 172280* Dimensions and tolerances to prEN 14282

41

Stop ends for spigot ends for duct spigot end; with fastening eyelets for traction cableMaterial: PE-HD Colour: black

DN/OD approx. weight L d1 d2 d3 Article no.[kg] [mm] [mm] [mm] [mm]

110 0.07 110 97 107 119 101785160 0.09 115 140 155 166 101646

Universal stop endfor duct spigot end and socketMaterial: PPColour: black

DN/OD approx. weight Article no.[kg]

110 0.03 101628125 0.03 101638160 0.05 101658

Spacers Spacers (double wall, robust design) Material: RAU-PE 330Colour: black

DN/OD-/ways d1 d2 A B H Weight Article no.

approx. [mm] approx. [mm] approx. [mm] approx. [kg]110/2 + 50/3 110 50 30 300 150 0.12 157270110/4 110 - 30 300 190 0.13 157260110/6 110 - 30 440 190 0.19 157280110/8 110 - 30 580 190 0.22 157290125/4 125 - 40 340 220 0.21 156001125/6 125 - 40 500 220 0.32 156011125/8 125 - 40 680 220 0.42 155931

B

Ad

AH

B

AAd

1

H

d

d 3 d 2

6

d 1

L

8-way spacer (robust) 2/3-way spacer (robust)

42

Spacer separableMaterial: RAU-PPColour: black

DN/OD-/ways d1 d2 A B H Weight Article no.

approx. [mm] approx. [mm] approx. [mm] approx. [kg]110/4 110 50 30 284 190 0.11 156042110/6 110 - 30 426 190 0.16 156032110/8 110 - 30 568 190 0.22 156002110/6 125 - 38 497 210 0.32 156012125/8 125 - 38 658 210 0.33 156022160/4 160 - 60 450 270 0.42 156031160/6 160 - 60 665 270 0.59 156041160/8 160 - 60 885 270 0.84 156051

Branch swept-TBranch for a subsequent pipe connection suitable for all REHAU-cable-ducts (PE/PP/PVC)Material: RAU-PE 238Incl.: Seal (EPDM) and tightening straps (stainless steel) Colour: black (roughly RAL9005)

DN/OD Branch-Ø Length Angle Article no.[mm] [mm]

110 32 240 30° 242051110 50 240 30° 242041

Tapping tool for swept-TComprising:- Milling tool Ø 6 mm; milling depth can be adjusted for the thickness of the duct wall - Depth gauge for wall thicknesses 2.2 - 5.3 mm - Socket wrench 2 mm - Template as a milling guide for cutting the corresponding opening for swept-T branches for smooth-walled cable ducts

Article Article no.

Tool swept-T 245953

B

A

Ad

H

Abstandhalter 6-zügig (teilbar)

43

Catch pan for junction boxesMaterial: RAU-PE 350 = PE-HDColour: BlackCapacity: 15.1 l

Article no. approx. weight [kg]645934 1.04

Dirt trap for access chambersMaterial: RAU-PE 350 = PE-HDColour: BlackCapacity: 22.6

Article no. approx. weight [kg]645924 1.23

LubricantCan be spread and applied from -10 °C to 50 °C

Delivery format approx. weight Article no.

[kg]

Bucket 1 251510

Bucket 10 119930

Lubricant requirement for 100 connections

(Guide values)

DN/OD 110 125 160

Weight [kg] 0.35 0.45 0.65

Ø 420

24

66

188

60510

100 18

350 mm breit

70106

44


Standards, regulations, guidelinesDIN 1054: Subsoil: Permitted loading of the subsoil.DIN 1055, Part 2: Load assumptions for buildings.DIN 1072: Roads and footbridges, load assumptions.DIN EN 1610: Installation and testing of sewer pipes and sewersDIN 4022: Subsoil and groundwater.DIN 4033: Sewers and sewer pipes made from pre-fabricated ducts and also the applicable standards for this DIN.DIN 4124: Excavation pits and trenches.DIN 18300: VOB contracting rules for award of public work. Part C: General technical regulations, groundworks.DIN 18305: VOB contracting rules for award of public work: General technical regulations, dewatering works.DIN 18306: Contracting rules for award of public work. General technical regulations, sewer works. Data sheet for the backfilling of buildings, issued by the For-schungsgesellschaft für Straßenwesen e.V. [Research Institute for Highways] Data sheet for settlement in road construction, issued by the For-schungsgesellschaft für Straßenwesen e.V. Data sheet for the back-filling of duct trenches, issued by the Forschungsgesellschaft für Straßenwesen e.V.ZTVE-StB 76: Guidelines for groundworks in road construction, issued by the Bundesministerium für Verkehr [Federal Ministry of Transport] also supplement to ZTVE-StB 76.ZTV-TKNetz 12: Additional technical contracting rules of Deutschen Telekom AG for building services on the telecommunicationsnetwork; Part 12: Construction, maintenance and dismantling of cable channels. TW 74: Technical regulations and guidelines for carrying out ground stabilisation and ground improvements in road construction, issued by the Bundesministerium für Verkehr.

The technical regulations of the public utilities companies and client are to be observed.

General informationThe installation works are to be managed and overseen by suitable, experienced supervisors. During the installation works the accident prevention guidelines of the trade associations or inspectorate for health and safety at work, the road traffic act, the general technical regulations of the VOB, Part C as well as all regional applicable laws and regulations are to be upheld without fail.

Structural designREHAU PP cable ducts can be statically calculated according to the ATV worksheet A 127. The load-bearing strength of the ducts in the installed condition is dependent on the installation (bedding, filling) and soil conditions. On request we will issue a static calculation for the specific installation case. The required input values for the calculation can be found in the project questionnaire in this catalogue.

Calculation basis PPShort-term modulus of elasticity: 1250 N/mm²Long-term modulus of elasticity: 310 N/mm²Short-term flexural strength: 39 N/mm²Long-term flexural strength: 17 N/mm²

45

Transport- Deflection and impact stresses are to be avoided in particular at

temperatures around freezing point and below - Loose PP cable ducts should rest across their whole length during

transport and are to be secured against movement- The maximum stacking height is 3 timber frame crates (HRV) on

top of one another. When doing this it is to be ensured that the timber crates are lying on top of each other

- Loading and unloading is to be carried out carefully using suitable equipment (tipping ducts from the loading surface is not permitted)

- Ducts or duct ends must not rub on the ground during transport

Storage- Store ducts and fittings so that the inside cannot be contaminated- Ducts are to be stacked on an even surface. It is to be ensured that

no sharp and pointy objects damage the bottom layer of ducts or fittings

- Longitudinal deflections are to be avoided. During storage no permanent deformation or damage must occur

- The maximum stacking height is 3 timber frame crates (HRV) on top of one another. When doing this it is to be ensured that the timber crates are lying on top of each other

- In the case of stacking with wooden spacers (min. 10 cm wide) the thickness of the board is to be dimensioned in such a way that the sockets are not touching them. The wooden spacers and supports should be laid out as in the diagram below

- The sockets are to be arranged so that they are offset during storage, in order to avoid point-shaped loads in the socket area

- Protect ducts and mouldings before coming into contact with substances which are damaging to PP

- Contact of rubber sealing rings with oil and grease is not permitted- Duration of outdoor storage (Central Europe), not protected against

sunlight: maximum 2 years

- For prolonged periods of outdoor storage or in areas with intense solar radiation, e.g. in southern countries, or at altitudes above 1,500 m, storage out of direct sunlight is required. Covering with a light, opaque tarpaulin should be carried out, in order to avoid a build-up of heat and possible deformation as a result, ensure good ventilation of the ducts and fittings. Transparent foils or tarpaulins are not suitable for covering PP cable ducts.

- Possible bleaching of the colour of the duct surfaces which occurs as a result of outdoor storage of up to 2 years in Central Europe will not impair the function

Securing the stack of ductsThe ducts stacked in layers without pallets are to be secured to ensu-re they do not roll apart. The height of such a stack of ducts should not exceed more than 1 m for all DN.

46

Connecting the ducts

Tools and work equipment - REHAU lubricant (can be spread and applied from -10 °C to 50 °C), 0.25 kg to 0.5 kg tube or 1 kg and 10 kg bucket container, Lubricant requirement- Metering rule, measuring tape - Duct cutting and chamfering unit - Marker pen or coloured adhesive tape for marking the insertion

depth for trimmed ducts- Brushes and cloths for potential cleaning of dirty sockets/sealing

rings- Duct stop end for interruptions to the building work

Preparing the push-fit socket connection Prior to installation of the ducts it is to be checked that: 1. The ducts and fittings are not damaged 2. The duct ends (spigot ends) are cut vertically to the duct axis and are chamfered in line with regulations 3. A sealing ring is fitted in each socket groove (socket grooves with missing sealing rings must not be installed) 4. The sealing ring lies in the socket groove without twisting

Connecting the push-fit socket ducts - Remove dirt from the inside surface of the socket and spigot end - Coat the spigot end (including chamfering) to a length of about 3 cm and the sealing ring with lubricant. (Note: Do not use oil or

grease! Rubber sealing rings swell and disintegrate)- Insert the duct spigot ends 1-2 cm into the socket and push it up

to the stop with force (note the insertion depth marking for cable duct)

47

Duct installation

General Cable duct channels are generally constructed from ducts which have been connected to each other so that they are watertight. The filler material compacted in the line zone area is to be incorporated as an essential load-bearing element in the whole construction. The filler material (sand or gravel-sand mix) will only carry out its function as a load-bearing element if the ducts have the required spacing for even compacting at all points. The required spacing between the ducts is ensured by introducing spacers.

Duct trenchesThe dimensions of the duct trench influence the size and distribution of ground and traffic loads. When carrying out the design, the dimen-sions specified by the description of services or static calculation are to be observed. The depth of the duct trench is made up of the height of the duct bundle (the gaps between the ducts are determined by the spacer depending on the duct diameter) and the intended duct top fill. In the case of rocky or stony ground an additional depth of 10 cm for a layer of sand (stone-free layer) is to be taken into account. In the case of a non-load-bearing and heavily water-saturated trench base, and also the risk of the filler material to be applied being eroded due to changing groundwater levels stabilisation is to be ensured through suitable measures.

Install, back-fill, compact; spacerWhen constructing multi-way cable channels from cable ducts duct installation and filling works cross over into the area of the line zones. The sequence of work can be found in the following illustration. Qua-lified persons must be used to carry out and supervise the building project.The load-bearing properties of thermoformed plastic ducts in addition to the duct rigidity are also determined to a large extent by the possibility of leaning against the nearby bedding material, particularly the side filler material. This makes particularly proper and careful compacting of the areas between the ducts necessary.

Step 1Lay the bottom layer of ducts and insert spacers.Step 2Fill the space between and around the bottom layer of ducts and compact.Step 3Lay the 2nd layer of ducts, push into the existing spacers and insert new spacers.Step 4Back-fill the space between and around the ducts 2nd layer of ducts and compact.Step 5Lay the 3rd layer of ducts, push into the existing spacers and insert new spacers.Step 6Back-fill the space between and around the 3rd layer of ducts and compact.Step 7Lay the 4th layer of ducts, push into the existing spacers. Back-fill the space between and around the last layer of ducts and compact.Step 8Back-fill the space between, around and above the ducts and compact.

48

Spacers are used to ensure sufficient compacting and also to stabilise the duct bundle.

Depending on the duct diameter in mind REHAU spacers provide the following gaps:

DN/OD Clearance(A)

110 30 mm125 40 (38) mm160 60 mm

In the case of duct installations in sand or a gravel-sand mix (largest grain 8 mm, with the predominant proportion being sand) or concrete, the spacers are to be set at intervals of max. 1.5 m, in the case of in-stallation in a cement-sand mix of max. 3 m. When creating cambers, depending on the local conditions this gap must be reduced accor-dingly, where it is to be ensured that the prescribed distance between the ducts is generally observed. Ducts on the lowest layer of ducts are laid out on the prepared trench base and fixed to each other in their position using spacers. The next layer of ducts is only laid out once the layer underneath has been filled and compacted in line with regulations. If more layers beyond the 2nd layer of ducts is intended, the spacers for retaining the 3rd layer of ducts are to be inserted before the 2nd layer of ducts is back-filled with sand. Proceed in the same way for additional layers of ducts.In order to avoid damage to the ducts, the filler material is generally to be compacted by hand in the area around the line zone. Compacting is to be carried out with wooden manual compactors.The compacted filler material layer over the top layer of ducts should be at least 10 cm.In the area of up to 1 m above the duct apex only lightweight compac-ting equipment should be used. The use of medium and heavy com-pacting and vibrating equipment in the case of apex top fill, measured in the compacted condition, is not permitted below 1 m!If ducts have to be laid in concrete, it is to be ensured that each duct is completely covered. In the case of several layers of ducts lying on top of each other it is to be ensured that the ducts are not too heavily deformed through the necessary actions of buoyancy support. If the cable channels come near to, or cross with external installations of other providers, the prescribed gaps must not be undercut.

Special types of constructionConcrete sheathingThe load bearing capacity of the duct line can be increased by a con-crete sheathing. Important in its design is whether to concrete against the undisturbed ground or, for example, against sheet piling.Pulling the sheet piling will reduce the load releasing effect of the horizontal earth pressure. With concrete sheathing it is to be borne in mind that the sheathing has to be designed as the sole supporting structure without any involvement of the duct and therefore only a complete casing can be considered. The minimum wall thickness of the concrete casing is to be determined based on the static require-

ments. Prior to concreting the socket gap should be sealed with a PP compatible adhesive tape to prevent the ingression of cement mortar. A concrete of at least Bn 10 is to be used as a concrete sheathing. The duct line is to be secured, where necessary, from buoying up in the fresh concrete. The duct should be filled with water to better absorb the setting temperature of the concrete. Working joints can be secured by means of short reinforcing rods. It may be advisable to divide the concrete sheathing at suitable intervals along the duct connections by means of transverse joints. Reinforcement can be provided where necessary. However, a concrete of at least Bn 15 is to be used then.A pressure test is to be carried out prior to concreting!

Installation in groundwaterWhere there is insufficient extra load, ducts laid in the groundwater should be secured against buoyancy by anchoring or extra loading (e.g. concrete, sand sacks, etc.).Due to the increased buckling pressure that occurs during installation in groundwater, we recommend that a static calculation is always carried out for this application case.

Duct bridges, installation on bridgesDuct bridges can be the most economic solution for road junctions with obstacles. Even fewer costs are incurred if the cable duct channels can be installed on an existing bridge. In special cases the PP cable ducts which are suitable for installation in the ground can be installed - over duct bridges, bridges - above the ground. Such duct lines require case-specific planning and design. The cable duct channels should be protected against all damaging environmental influences (increased UV radiation...). Through the de-sign of the duct channels additional influences (vibrations as a result of traffic, changes in length due to temperature fluctuations...) must be absorbed.Corresponding assembly guidelines are set out in the ZTV-TKNetz 12 of the Deutschen Telekom for example:In order to absorb the temperature-related stresses in the cableducts, the following is to be noted during design:- Special, long push-on sockets are to be fitted to each duct run on

all bridge bearings and expansion joints as fixed points, in the case of all bearings a push-on socket is to be fitted to the bridge support and ground in each case as a fixed point

- At least every 20 m an expansion socket is to be fitted in each duct run and to a duct as a fixed point

.

Design example of full sheathing with concrete

49

The cable duct channels are installed/fitted in bridge tubes or as a suspension construction in and under bridges using frames or suppor-ting grids. When doing this, it is to be ensured that deformation of the duct as a result of point-shaped loads is avoided. The following is to be aimed for:- Consistent contact surface or- Support of the ducts at intervals of max. 1.5 m and - At least 60 mm wide contact surfacesIn normal cases the ducts are not normally subjected to direct UV radiation under a bridge and are sufficiently protected against damage by the bridge construction. Possible bleaching to the colour of duct surfaces will not impair the function of the PP cable ducts.If the ducts are subjected to direct UV radiation, special protective measures (covers...) must be implemented.

Connecting the ducts to chambersConcrete or mortar with PP does not form a permanent and leakproof connection. Concreting of the PP ducts directly into the chamber wall is therefore to be advised against. Special wall bridging sockets with a rubber seal, which make a jointed connection to chambers possible, have proven to be a technically better solution.

Minimum cold-bending radii at temperatures above +10 °C:DN/OD 110 (110 x 3.4 mm) - with radius R ≥ 5 m DN/OD 125 (125 x 3.9 mm)- with radius R ≥ 8 mDN/OD 160 (160 x 4.9 / 160 x 6.9 mm) - with radius R ≥ 10 m

In the case of chambers made from in-situ concrete wall bridging sockets and duct ends are always to be assembled in the shuttering prior to concreting the in-situ concrete wall. When doing this, the ducts are to be brought into the correct position using spacers, where the ducts or the wall bridging sockets pushed onto the ends of the ducts must sit flush with the inside of the chamber.

Catch pan and dirt trapCatch pans are intended for installation in junction boxes. Dirt traps are installed below the ventilation slits of the access chamber cover.

Cold bending the ductsDepending on the duct dimensions and the outside temperature the following bending radii are possible.

Rohrgraben

Holzpflöcke

Kabelschutzrohr

Abstandhalter

Cold-bending of the PP cable ducts

Smaller camber radii can only be created with duct bends which have been pre-formed in the plant.In the cold condition pre-cast ducts will be deformed during the ben-ding action, where the internal diameter of the duct lying at the bend level will be slightly reduced.In order to make cold-bending easier, the cambered areas of the duct strand to be bent should always consist of 6 m length ducts and the jointing sockets should be located outside of the bending range if possible.Ducts must on no account be bent at a single fixed point. Ducts to be cold-bent are to be stabilised using stakes (pointed) to be hammered into the ground. The width of the stakes is to be dimensioned accor-ding to the gap between the spacers.The first stake is to be hammered into the ground on the inside of the camber at the start of the bend. Bend the duct run and drive the next stake into the ground on the outside of the duct coming away from the bend. Continue the bending process and stabilisation of the duct run using further stakes until the duct run has achieved the intended camber. A stake is to be inserted behind every jointing socket in a camber on the outside of the camber.Bending in the socket is to be avoided.Push the second adjacent duct run on the same layer of ducts into the stake used and stabilise using further stakes on the outside of the camber. Bend other cambered duct runs in the same way and then connect with spacers. Every layer of ducts laid is to be fully supported up to the outer trench wall using compacted filler material. Only remove wooden stakes once the full width of the trench has been filled and compacted. Push the ducts on the 2nd layer of ducts into the spacers used. Lay further layers of ducts in the same way.When creating cambered duct passages on the building site using cold-bending or with the help of pre-fabricated duct bends it is to be en-sured that the duct connections are created using straight spigot ends and socket ends

.

Duct trench

Spacers

Stakes

Cable duct

50

Length changes in the ducts due to temperature fluctuationsA length change caused by temperature fluctuations in the case of PP ducts is significantly larger than for steel ducts (coefficient of expansion PP-B = 0.14 mm/m K). This is to be taken into account in particular in the case of installing the ducts during times of high temperature fluctuations between day and night and also in Southern climate zones.In the case of REHAU PP cable ducts the insertion depth marked on the duct spigot ends is an additional control to prevent the connection from possibly being pulled apart. To avoid uncontrolled length changes the duct installation is to be back-filled purposefully, but gradually.Ducts which have been outside of the trench in the sun contract after being laid in the shady trench or due to the filling of the trench.

Example for the reduction in length:Stretch of duct left open, not yet filled = 30 m

Temperature difference duct wall = 30 K (∆I = L x ∆T x 0.14 mm/m K) ∆I equates to 126 mm. The length reduction of 126 mm calculated in the example can in certain circumstances affect a single socket and is therefore generally too high.In the case of the stretches of duct which are left open during the temperature change (e.g. bridge installation), uncontrolled temperatu-re changes can be avoided by taking into account fixed points.

Creating infill sections(Trimming and chamfering the duct spigot ends) In installation practice it is often necessary to trim ducts to certain lengths. When doing this duct infill sections must be cut at right angles and have the standard 15° chamfer on the spigot ends. Creating the duct infill sections should be carried out properly and in a cost-effective way.Trimming the ducts hand is time-consuming and technically proble-matic in the case of subsequent bevelling with a file. Chamfering units which just make it possible to chamfer the ends of the duct requires a right angled cut and can only be used for one duct diameter. Equip-ment which separates and chamfers in one action is recommended. Such equipment can be used for different duct diameters and wall thicknesses thanks to interchangeable clamping jaws.(Plastic cropping and chamfering units type ROCUT, supplier: Rothen-berger, D-65779 Kelkheim).

DN/OD SN 4/SDR 33Wall thickness s bmin

[mm] [mm]110 3.4 6125 3.9 6160 4.9 7

DN/OD SN 8/SDR 23,8Wanddicke s bmin

[mm] [mm]110 4.7 6160 6.9 7

Connecting the ducts with push-on double push-fit sockets Area of application: - Adjusting duct lengths without sockets in duct strands between cable chambers- Connection duct infill sections to be installed in damaged duct

strands which have not yet been fitted with cable

Make assembly easier: Do not install within cambered stretches of duct if possible.

- Ducts which are to be connected using push-on double push-fit sockets are to be prepared in such a way that there is a gap of max. 10 mm between the duct ends

- Short lengths/infill sections which are to be installed in the case of repair in the damaged duct run must be cut to the exact length accordingly

- The push-on double push-fit socket is to be pushed on completely to an end of the duct which has been bent to the side or to both sides of the duct infill section to be built. To do this coat both ends of the duct, including chamfering and also sealing rings, with lubricant

- Bring the duct ends to be connected to each other in the right position, push the push-on double push-fit socket over the ends of the duct

Double push-fit sockets for the installation of remaining lengthsDouble push-fit sockets allow you to work economically on the buil-ding site with leftover duct cut lengths.The socket insertion depth is to be clearly marked on the ends of duct of the cut lengths.

Stop endStop ends prevent the infiltration of dirt or filler material into the strands of duct which have already been laid during building interrup-tions. Depending on the problem, stop ends are only available for the duct spigot end, or for the duct spigot end and socket.With the most recent design it is even possible to seal chamber or wall bridging sockets which are not occupied by ducts. The stop ends are, without the application of lubricants, to be pushed with an open hand into the duct or socket.

b

15°

s

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Branch swept-TThe assembly of the swept-T branch is possible for both new cable ducts to be laid and also cabled ducts which already exist or have been installed. The assembly set facilitates a cost-effective,quick and safe creation of a leakproof house connection with cable / glass fibre cable by fitting a swept-T branch to cable ducts DN/OD 110 with nominal wall thicknesses2.2 - 3.5 mm and also 5.3 mm.

ToolsDrilling machine / cordless screwdriver with drill bit min. 10 mm Assembly set.

Branch swept-T

AssemblyThe duct section on which the assembly is to take place, must be cleaned all the way around to a length of approx. 0.5 m with a clean cloth or similar and is to be checked for any damage.- Tie down the template at the point of the planned duct branch

(Picture 1). It is important that the tightening straps are pulled tight in order to prevent the template moving during milling

- The depth stop on the drill milling tool is set to the required routing depth (Picture 2) using the depth gauge contained in the assembly set according to the existing duct wall thickness and the router is clamped into the bit

- Drill through the duct wall within the template and route the branch opening along the template - in a clockwise direction (Picture 3)

- Take the piece of duct out from the duct opening and remove sharp edges, burr etc. in the duct opening (Picture 4) with the burr remover. If necessary dirt and swarf are to be removed from this area

- Place the swept-T branch on the duct opening in such a way that the runner lies on the edge of the duct opening (Picture 7). Note the direction of the branch! In this position mark the location of the swept-T branch with the marker pen (Picture 5)

- Once the protective foil has been removed the swept-T seal (Pic-ture 6), starting with the side, is positioned on the runner to stick the opening to the duct. Clean the corresponding duct surface to remove dirt, moisture and also oil and grease!

- Fit the swept-T branch to the duct as previously marked - Position the runner on one end of the oval duct section and fix to the cable duct with the tightening straps at two points immediately to the left and right of the branch (Picture 7 and 8)

Bild 1: Anbringen der Schablone

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Picture 2: Setting the routing depth

Picture 3: Routing the duct opening

Picture 4: Deburring the duct opening

Picture 5: Marking the assembly positions

Figure 6: Application of the seal

Figure 7: Assembly position of the branch

Figure 8: Assembled swept-T branc

?????????

?????????

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Final inspection / test

Leak test Cable duct duct units must be watertight to facilitate the shooting-in of auxiliaryropes and to prevent the ingression of gas and water. Following back-filling with sand, perhaps also in sections, but before the trench is filled and prior to restoration of the road surface, the cable duct passages are leak tested (0.5 bar; 15 min.; see DIN EN 1610).

Line zone and main filling The required completion of the line zone can be analysed by checking the level of compaction (bedding, side filling, covering and main filling) and / or duct deformation; that of the main filling by checking the compaction.

REHAU PE-HD CABLE DUCTS AND CABLE CONDUITS

56

4 CONTENTS REHAU PE-HD CABLE DUCTS AND CABLE CONDUITS

I. . . . . . . PE-HD cable ducts and cable conduits with internal grooving d = 32 - 63 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.1 . . . . Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.2 . . . . Area of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.3 . . . . Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.4 . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.5 . . . . Delivery format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.6 . . . . Product range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584.6.1 . . . Cable ducts to DIN 8074/75 and DIN 16874 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584.6.2 . . . Cable conduits to DIN 8074 and DIN 16876 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584.6.3 . . . Fittings/accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.7 . . . . Planning and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

II.. . . . . . PE-HDcableconduitsd≥75mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.1 . . . . Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.2 . . . . Area of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.3 . . . . Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.4 . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.5 . . . . Delivery format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.6 . . . . Product range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68


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The illustrations, dimensional, colour and weight information contained in this document provide a non-binding overview of the product range according to the plant standard. Exact information can be found in the standards, guidelines and worksheets listed. If additional information is required, e.g. dimensional tolerances for planning, construction and carrying out building work, we recommend that you contact our technical department in:

91058 ErlangenYtterbium 4Tel.: 0 91 31/92-50

4.1 ApplicabilityPart I of this document applies for flexible PE-HD cable conduits (high density polyethylene), and also the associated fittings for manufactu-ring stretches of cable duct for energy and data cables.

4.2 Area of applicationThe cable ducts and mouldings used in the stretches of cable duct are used to protect cables (glass fibre, copper, power and data cables) against mechanical damage, chemical attacks and rodents.The pressure-tight design of the stretches of cable duct and the fitting of the inner surface of the cable ducts with the special REHAU RTR grooving facilitates, in addition to the low-abrasion insertion of the cable using cablewinches, the particularly economical installation of cables throughinjection with compressed air.

Note:The cable ducts and fittings in this document are not suitable for the construction of compressed air, gas and water lines with specified pressure levels!

4.3 MaterialsCable ducts to DIN 8074/75 and DIN 16874The cable ducts are manufacture as standard using RAU-PE 2381.The cable ducts made from RAU-PE 2381 are monitored by a third party and fulfil DIN 8074/75 and DIN 16874.

REHAU PE-HD CABLE DUCTS AND CABLE CONDUITSI. PE-HD CABLE DUCTS AND CABLE CONDUITS WITH INTERNAL GROOVING D = 32-63 MM

Material properties at 23 °C:RAU-PE 2381:Density: 0.935 g/cm³ - 0.965 g/cm³Long-term hydrostatic pressure test: 80 °C, 170 h, 4.0 N/mm²Average density: > 0.94 g/cm3

Coefficient of linear expansion: 2 0 x 10-4 K-1

Thermal conductivity: 0 41 WK-1 m-1

Modulus of elasticity: 600 - 900 N/mm2

Surface resistance: > 1012 ΩFire behaviour of PE-HD:RAU-PE 2381 has normal flammability to DIN 4102, Building materials class B 2

Cable conduits to DIN 8074 and DIN 16876Cable conduits are produced using RAU-PE 2385.

Werkstoffeigenschaften bei 23 °C:RAU-PE 2385:Average density: > 0.94 g/cm3

Coefficient of linear expansion: 2.0 x 10-4 K-1

Thermal conductivity: 0.41 WK-1 m-1

Modulus of elasticity: 600 - 900 N/mm2

Surface resistance: > 1012 ΩFire behaviour of PE-HD:RAU-PE 2385 has normal flammability to DIN 4102, Building materials class B 2.

Fittings/accessoriesThe REHAU push-type fittings and REHAU end fittings are manufac-tured from RAU-POM (Polyacetal).The REHAU end caps are made from PE-HD.

4.4IdentificationThe identification of the cable ducts made from PE-HD is carried out with permanent printing or hot stamping at intervals of 1 m with the following information:Manufacturer and area of application: REHAU cable ductMaterial: PE-HDDimensions in mm: e. g. 50 x 4.6Standard: DIN 8074Machine no.: e. g. M 14Production date (6-digit day, month, year): e. g. 190410Number of metres: e. g. 1254

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4.5 Delivery format and make-up for deliveryDuctsPE-HD cable ducts and cable conduits d = 32 -63 mmare delivered as standard as coils or on drums. Due to their flexibility REHAU cable ducts and cable conduits d = 32 - 63 mm with internal grooving are ideally suited for transport in maximum lengths on cable drums and as large coils. The maximum possible external diameter of bundled coils is set at 2.4 m.The transport of bundled coils takes place as multiple stacks on wooden disposable pallets. If requested by the customer, the packaging units can be secured using shrink wrap.Large bundled coils can, depending on the order, be bundled in layers in the plant on request. This will make it possible to unwind only the outside layer once the relevant bindings have been undone. The inner layers will remain tightly bound to each other. This will prevent the whole length of duct in a bundled coming out in an uncontrolled way once the bindings have been undone.

Standard bundled coilDN/OD Internal Ø External Ø Width Duct length[mm] [mm] [mm] [mm] [m]32 800 1400 300 250

40 800 1500 360 250

50 1500 1900 280 10063 1500 2050 280 100

Make-up for delivery

Special packaging on request For the maximum delivery lengths on steel reusable drums or wooden disposable drums the drum dimensions are set out as:

External diameter: 2.8 mTotal width: 1.6 mCore diameter: 1.2 m

Maximum delivery length in m:DN/OD Bundled coil Drum[mm]32 1300 6000

40 1000 4000

50 600 250063 1000 1500

In the case of delivery on drums and in bundled coils > 600 m, if not otherwise agreed in the order, max. 10 % of the packaging units can consist of max. 2 part lengths. Here the part lengths in each case are > 300 m.The corresponding packaging units are clearly marked with the lengths of the part pieces and a push-type fitting is included accor-dingly.

The delivery lengths in the case of alternative drum and bundled coil dimensions can be obtained on request.

4.6 Product range

4.6.1 Cable ducts to DIN 8074/75 and DIN 16874Werkstoff: RAU-PE 2381Cable ducts are produced with 5-coloured stripes.Basic colour cable duct: black, roughly RAL 9005 Standard colour stripes: white, roughly RAL 9003. (Alternative colours on request)

*: Delivery time on request1) Dimensions and tolerances to DIN 8074; in the case of ducts with internal grooving the wall thickness is measured incl. grooving2) Calculated with a specific weight of 0,95 g/cm3

d1) s1) Duct weight Duct weight approx. Art. no.[mm] [mm] [kg/m]2) [kg/coil]32 * 2.9 0.27 68 (250 m) 13051140 * 3.7 0.43 108 (250 m) 135315

50 * 4.6 0.66 66 (100 m) 134761

63 * 5.8 1.05 105 (100 m) 135711

Ducts SDR 11 to DIN 8074/75 and DIN 16874

4.6.2 Cable conduits to DIN 8074 and DIN 16876Material: RAU-PE 2385Colour: black, roughly RAL 9005

Ducts SDR 11 to DIN 8074/DIN 16876

d1) s1) Duct weight Duct weight approx. Art. no.[mm] [mm] [kg/m]2) [kg/coil]32 * 2.9 0.27 68 (250 m) 10384140 * 3.7 0.43 108 (250 m) 103065

50 * 4.6 0.66 66 (100 m) 134007

63 * 5.8 1.05 105 (100 m) 134711

1) Dimensions and tolerances to DIN 8074; in the case of ducts with internal grooving measure incl. grooving2) Calculated with a specific weight of 0,95 g/cm3

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MaterialvariantstocustomerspecificationTo fulfil the special requirements/specifications of telecoms companies and international network operators the duct dimensions mentioned SDR 11 can also be supplied on request in the corresponding material variants.

Labelling variantsFor clear differentiation of the individual PE-HD cable duct in the stretches of cable duct which are assembled from a variety of ducts, a variety of labelling variants is available for the delivery of SDR 11 ducts on request.The labelling can be a complete coloured sheathing or different numbers of coloured stripes in various colours.

4.6.3 Fittings/accessoriesFittings are delivered packed in boxes or loose. Accessories are deli-vered loose. The delivery of the REHAU Vario insertion garniture is as a set in a stable case which is suitable for the construction site.

Push-typefittingmadefromRAU-POMMaterial: RAU-POMColour: grey

Following assembly the push-type fittings create a longitudinally stable connection with extraction forces which fully meet the permitted pull values of the cable ducts.Can be used up to an injection pressure of 12 bar.Notes about use: see section on planning and installation

Duct diameter Insertion depth Weight Article €/unitDN/OD [mm] [g/unit]32 53 90 23663440 60 220 242038

50 67 270 242048

63 84 580 133062

EndfittingmadefromRAU-POMMaterial: RAU-POMColour: grey

Duct diameter Cable Weight Article €/unitDN/OD diameter [mm] [g/Stück]32 10-18 120 26590540 10-18 160 265915

50 10-18 200 265925

Duct diameter Weight Article €/unitDN/OD [g/unit]32 42 26548940 63 265499

50 84 265509

63 121 265519

Sealing capMaterial: PE-HD Colour: grey


50 220 133472

63 620 133482

Milling tool for bevelling PE ducts

60


50 120 134213

63 168 134223

Dismantlinghalf-shells(pair)forpush-typefittings

Cable insertion garnitureREHAUVarioinsertiongarnitureArticle: 132 392Delivery format Set in sturdy case for duct dimensions d = 25, 32, 40, 50 mm and cable diameter d = 10 - 19 mm.Function description see section I.4

Duct dimension Weight Articled x s [mm] [g/unit]32 x 2 61 25707632 x 3 61 24121140 x 2 76 25709640 x 3 76 26403340 x 3.5 76 26402340 x 3.7 76 26554250 x 2.5 96 25710650 x 3.5 97 26401350 x 4.6 97 265552

Dolly


General informationThe installation of PE-HD cable ducts is to be managed and overseen by suitable, experienced supervisors. During the installation works the accident prevention regulations of the trade associations or inspectorate for health and safety at work, the road traffic act, the general technical regulations for building services of the VOB, Part C as well as all regional applicable laws and regulations are to be considered.

UnwindingcoilsanddrumsWhen unwinding the cable ducts from bundled coils or special drumsit is vital to ensure that the ends of the duct cannot spring out when the bindings are removed. To prevent buckling of the ducts, the ducts must not be unwound spirally. The use of mechanical unwinding devices is recommended for unwin-ding cable ducts. In the simplest design, the bundled coils can then, for example, be positioned horizontally on the turnstile and unwound by hand or with a slow moving vehicle.

TransportThe PE-HD cable ducts with internal grooving d = 32-63 mm are generally transported on drums or in bundled coils. For bundled coils horizontal transport in multiple stacks on disposable pallets is recommended. The packaging units are to be secured against slipping and rolling on the loading surface. In the case of direct storage of the bundled coils on the loading surface of the HGV, this is to be cleaned, and all nails, screws and other pointed objects on the loading surface removed. In the case of loading or unloading, the bundled coils must not be dragged over sharp edges. The direct contact of the loadinggear with the ducts is to be avoided.

Due to the high bundled coil and drum weight, smooth removal of the packaging units is to be ensured. In the case of transport of drums only the drums, but not the ducts wound on to them, must be loaded.

61

StoragePE-HD cable ducts can only be stored for a limited time in the effects of sunlight. In Central Europe the ducts can be stored outside for up to 2 years without this affecting the physical properties.For prolonged periods of outdoor storage, or in areas with intense solarradiation, e.g. on the coast, in southern countries, or at altitudes above 1,500 m, storage out of direct sunlight is required. In the case of covering with tarpaulins, good ventilation of the cable ducts must be ensured in order to avoid an accumulation of heat and therefore defor-mations. Transparent foils or tarpaulins are not suitable for covering PE-HD cable ducts!The ducts are to be stored in such a way that no damage or perma-nent deformation occurs. This is to be ensured in particular if drums are stored on uneven ground. Contact with potentially damaging substances (see e.g. DIN 8075-Supplementary sheet 1) is to be avoided.In the case of storing bundled coils, it is critical that this takes place on a stone-free surface. If necessary, a suitable surface is to be crea-ted through additional measures (e.g. wooden boards).If the bundled coils are stored upright, they must be secured at the side to prevent them falling.The upright storage of bundled coils of duct range SDR 17.6 is not permitted!

Temperature rangeNo temperature limitations apply for the transport of PE-HD cable ducts. However, it is to be ensured that at temperatures > 50 °C even slight mechanical loads can lead to deformation and that at tempera-tures < -15 °C the duct material cannot be subjected to any impact stress. The installation of PE-HD cable ducts and the cable injection or extrac-tion can take place at temperatures between -15 °C and 50 °C. When doing this the large bending radii which occur at lower temperatures are to be taken into account. At ambient temperatures below -20 °C protected storage for at least approx. 12 hours prior to installation of the ducts, e.g. in a clo-sed storage hall or at least behind wind protection, is recommended.

The use of cable lubricating greases when inserting the PE-HD cable ducts SDR 17.6. into existing cable channels is problematic in areas with low relative humidity and to be avoided if possible due to possible clumping of the cable lubricating grease.

Pressure rangeIn its function as a cable duct for copper and glass fibre cable, the PE-HD cable ducts are not subjected to constant internal pressure.However, for the shooting-in of draw ropes, and primarily the direct shooting-in of glass fibre cables, sufficient pneumatic leak tightness and pressure tightness is required.

Themaximumpermittedpressurewhenshooting-inglassfibrecables is 12 bar at a temperature of max. 35 °C.In order to guarantee this function of the PE-HD cable ducts d = 32 - 63 mm, the cable ducts are randomly subjected to pressure tests during each production:

Test temperature: 35 °CTest pressure: 12 barTest duration: > 2 h

Tensile forcesThe tensile forces on the PE-HD cable ducts SDR 17.6 which occur in the existing cable conduit units during insertion, the PE-HD cable ducts SDR 11 in the duct trenches and also ploughing-in or routing should not exceed the values mentioned in the table below for the corresponding temperatures.

Maximum permitted tensile forces on PE cable ducts for duct ranges SDR 17.6 and SDR 11:

External dia- Wall thick- Force at 0 °C Force at 20 °C Force at 40 °Cmeter [mm] ness [mm] [kN] [kN] [kN]32 2.0 1.6 1.5 1.132 2.9 2.3 2.1 1.5

40 2.3 2.4 2.1 1.6

40 3.7 3.7 3.3 2.550 2.9 3.8 3.4 2.550 4.6 5.9 5.2 3.963 3.6 6.0 5.3 4.063 5.8 9.3 8.3 6.2

Length changesFollowing the insertion of PE-HD cable ducts into existing cable duct units the ends of the duct must extend past the cable duct passage on both sides by at least 50 cm. As a result of this, the shrinkage of the elastic PE-HD cable ducts which occurs once the draw rope is released is equalised.In order to equalise the length changes which occur during trench installation as a result of temperature fluctuations, the duct connection should not take place if possible until after a storage duration of at least 12 h following introduction of the ducts into the duct line.In the case of installation of PE-HD cable ducts using ploughing-in and routing the influence of the length changes due to temperature fluctuations is extremely low, because the friction of the ground across the large surfaces of the ducts prevents the movement of the ducts in the ground. In order to equalise the shrinkage of the ploughed-in or routed in ducts it is recommended to pull out both ends of the ducts to be connected by at least 1.0 m above the edge of the trench, and that the duct fittings are not assembled if possible until 12 h after installation of the ducts. This also applies if a new cable conduit to be installed is to be connected to a cable conduit which has already been installed at a later date.The immediate connection and installation of REHAU duct connections is possible without a problem during the replacement of bundled coils or drums!

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In-situ (ground) waterPE-HD cable ducts from the SDR 17.6 duct range are suitable for an in-situ external pressure of up to max. 0.47 bar, which equates to an in-situ water column of max. 4.7 m.PE-HD cable ducts from the SDR 11 duct range are suitable for an in-situ external pressure of up to max. 2.16 bar, which equates to an in-situ water column of max. 21.6 m.

Duct installation

GeneralDuring installation the bundled coils and also the cable ducts to be installed must not be pulled over sharp edges. The cable ducts must not be kinked. Impact loads on the cable ducts are to be avoided.

Duct trenchesFor direct installation into the ground PE-HD cable ducts of duct range SDR 11 are recommended exclusively. The filler material introduced into the trench and compacted in the area of the line zone is to be viewed as an essential supporting element in the overall construction of a trench installation. The filler material of sand or gravel-sand mix should be at least 10 cm above the duct apex in the compacted condition. In the case of rocky or sto-ny ground an additional depth of 10 cm for a layer of sand (stone-free layer) below the duct is to be taken into account.In the area of up to 1 m above the duct apex only lightweight compac-ting equipment should be used.The erection of duct line barrier tapes generally takes place at a height of 0.3 - 0.5 m above the duct apex.In the case of insertion of PE-HD cable ducts into the duct trenches, insertion from the lower diameter of the cable drum horizontally into the duct line is recommended. The use of a cable duct bend at the inlet to the line and of cable rolls in the case of longer lines is absolutely necessary. The PE-HD cable ducts must not be dragged over sharp edges or kinked under any circumstances. The bending radius of the PE-HD cable ducts at installation should not be below a radius of 1.0 m.

Ploughing-in and routingDue to their flexibility and the option of delivering them on drums or as bundled coils with very large duct lengths PE-HD cable ducts are par-ticularly suitable for direct ploughing-in/routing into the ground. Based on experience, traffic loads of up to SLW 60 are not a problem above a coverage height > 0.9 m.A static calculation according to the ATV worksheet A 127 can be carried out on request. The required input values for the calculation can be found in the project questionnaire in the attachment of this Technical Information.

Push-fitconnectionThe specially developed REHAU push-type fitting made from RAU-POM (Polyacetal) is recommended for the longitudinally stable connection of REHAU cable ducts.

The high longitudinal stability is achieved using a multi-toothed, conical clamping ring which slotted on one side and is in contact with the duct. The sealing ring made from RAU-SR which is inserted gu-arantees use up to 12 bar. In the case of tensile force being exerted on the duct the clamping ring is pulled into the internal cone of the fitting body where the clamping force of the clamping ring is reliably increased up to the max. value of the longitudinal stability. The longitudinal stability of the REHAU push-type fittings equates to the max. permitted tensile force for the corresponding duct dimension (see tensile forces).

Assemblingthepush-typefittingsBevelling the ductBy rotating the milling tool (see accessories) in a clockwise direction the ends of the duct are bevelled precisely, cleanly and without burring.

Mark insertion depthMark the insertion depth of the fittings (see table) with a marker pen. The duct must not be scratched during marking.

Duct diameter Insertion depth

[mm] [mm]

32 53

40 60

50 67

63 84

Push-fitconnectionDo not use lubricant - perhaps sprinkle the end of the duct with water. The duct is inserted into the fitting up to the stop or marking level and without turning by overcoming the two resistances (clamping ring and sealing ring).Dismantlingthepush-typefittingsThe push-fit connections created using the push-type fittings can be removed again with the help of dismantling support channels (see accessories). If necessary, sprinkle the dismantling support channels with water or coat thinly with lubricant (inside and outside).

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Pressure testing and calibrationCable lines made from PE-HD cable ducts must be sufficiently leak proof in order to facilitate the shooting-in of draw ropes or the direction shooting-in of glass fibre cables and light copper cable, and to also prevent the ingression of gas and water from the ground into the cable ducts.With regard to the operational leak tightness of the overall system, a pressure test can be carried out according to the KRV installation instruction A 535. The test is carried out with air according to EN 1610 (excess pressure 0.5 bar, test duration 15 minutes).It is often necessary following the installation and insertion of the cable ducts to carry out a pressure test to prove the injection suitability. The prerequisite for the pressure test described below is that a maximum number of 5 fittings on a 100 m stretch of duct is not exceeded.The test is carried out at a pressure of 4 bar. Prior to the test, conditio-ning at 4.5 bar for 15 minutes is to be carried out. The pressure is then reduced to the testing pressure of 4 bar and the measuring started.The test is passed if the drop in pressure is less than 0.1 bar every 5 minutes, or maximum 0.8 bar over 30 minutes. A useful extension of the pressure test is the calibration of the cable duct with a calibration diameter for the individual dimensions according to the following table. When doing this, a calibration plate of the corre-sponding diameter, fitted with a sender, with a max. pressure of 3 bar is used to blow through every cable duct installed across the length of the line installed. Any duct contractions are located with a search device located in the sender fitted to the caliber and the cable duct restored at this point.

Duct dimension Caliber dimension

[mm] [mm]

32 x 2 24

32 x 2.9 22

40 x 2.3 31

40 x 3.7 28

50 x 2.9 40

50 x 4.6 35

63 x 3.6 49

63 x 5.8 45

End capReusable end caps made from PE-HD are used to seal unoccupied PE-HD cable ducts. A corresponding end cap is available for every cable duct diameter. The end caps are not pressure tight, but just serve to protect the cable duct against the ingression of dirt, moisture and vermin.If necessary, non-woven, thin draw ropes can be fixed with the end caps and therefore secured. The end caps are also used as transport seals for the cable ducts delivered as bundled coils or drums.

EndfittingEnd fittings are used for the leakproof connection of the PE cable ducts. On one side the end fittings have a pressure tight push-fit connection the same as the push-type fittings. The other side of the end fittings consist of a threaded connector with an axially applied spherical sealing surface for the insertion of an O sealing ring with

integrated sealing plug and a union nut for the pressure-tight connec-tion of the fitting opening.The assembly and dismantling of the end fittings is carried out in the same way as the push-type fittings.

Introduction of cablesREHAU has developed an installation method for the installation of long lengths of glass fibre which offers the user both technical and commercial advantages.With the REHAU Vario insertion garniture, glass fibre cable and light copper cables up to an external diameter of approx. 20 mm can be inserted directly into the PE-HD cable ducts or RAUDUCT ductswithout the help of compressed air, and without using a draw rope. This installation method prevents overstraining of the delicate cable. The REHAU Vario insertion garniture is also suitable for the shooting-in of draw ropes.

AdvantagesTechnical advantage:One main advantage of the cable insertion garniture is the fact that the tensile force on the cable is distributed elastically across the column of air which lies between the insertion garniture and dolly. As a result of this, the erratic increases in tensile force which frequently occur with cable winches can safely be avoided. The tensile force applied to the cable head simply depends on

Fixing and sealing the cableThe sealing and fixing of cables which have been inserted into the PE-HD cable duct is carried out using end fittings as described previously. When doing this, the sealing plug in the O rubber sealing ring on the sealing side of the end fitting is simply removed. The O rubber sealing ring positioned on the inserted cable is compressed with the union nut. This ensures the fixing of the cable and a pressure-tight connec-tion.

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the ring cross-section between the external diameter of the cable and internal diameter of the duct, and also the pressure applied. As this ring cross-section cannot be changed for a selected combination of duct/cable, the tensile force applied can be managed very easily using the pressure, which can be regulated on the insertion garniture. The max. possible tensile force for the REHAU Vario insertion garniture also lies at the max. permitted pressure of 12 bar in the range of max. 50 to 60 % of the permitted tensile load mentioned by glass fibre cable manufacturers.

Advantages for the user:The REHAU Vario insertion garniture insertion block is fitted with replaceableclamp shells, so that the cable installation is possible in all PE-HD cable ducts or RAUDUCT ducts with the external diameters 25, 32, 40 and 50 mm. The insertion block is fitted with two air connections in order to ensure a sufficient supply of compressed air from the compressor. Fitting a regulating armature with pressure measuring device facilitates the precise setting and monitoring of the injection pressure.Using the hinged insertion block, cables can be fitted in sections over very large distances in the cable conduit. When introducing the inserti-on block the slotted sealing set is removed and can be used again. In order to be able to shoot in the whole fabrication length of glass fibre cables in sections, it is simply necessary to retighten the sections which have already been installed by hand. This action can be sup-ported through the use of a second insertion garniture.

Through the cost-effective installation of complete fabrication lengths from 2000 m to 4000 m, the number of glass fibre cable sockets required reduced and therefore significantly lower absorption of the signal to be transmitted is achieved.

Allocation of ducts/cablesThe possible max. cable diameter which can be inserted into the existing internal duct depends decisively on the construction of the tension elements on the cable head. The following allocation of inter-nal ducts/cable is based on the difference of 10 mm tested in practice between the external diameter of the cable and the internal diameter of the duct to be occupied. In some cases deviations to practical experience both upwards and downwards can occur.

Duct dimension Cable diameter

[mm] [mm]

50 x 2.5 by 35

50 x 3.5 by 33

50 x 4.6 by 30

40 x 2.0 by 26

40 x 3.0 by 24

40 x 3.5/3.7 by 23

32 x 2.0 by 18

32 x 2.9 by 16

25 x 2.0 by 11

FunctiondescriptionREHAUVarioinsertiongarniture

A building compressor with re-cooling and 10 bar operating pressure (10 bar, 10 m3/min)isrequiredtooperatetheREHAUVarioinsertiongarniture.

The matching dolly for the cable duct intended for installationis fastened to the cable to be inserted with the help of an anti-twist device and a cable draw cord.The dolly is pushed into the cable duct up to the cable draw cord.

Cable trum

Cable

Cable

DollyTwist trap

Twist trap

Cable draw cord

To the compressor (10bar, 10 m3/min)

Dolly

PE cable duct/RAUCUT cableWith REHAU special grooving

REHAU VarioInsertion garniture

Control valve with pressure measuring device

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Once the insertion block has been fitted with the corresponding clam-ping shell for the external diameter of the cable duct, the end of the cable duct is inserted up to the stop in the front end of the insertion block and this part closed with the two clamp levers.

The cable is fitted with 4 slotted gaskets with internal drill hole which matches the cable 2 slotted plastic sponges coated with lubricant. This complete sealing set is inserted into the depressions provided for it in the rear part of the insertion block.

The rear part of the insertion blocked is clamped at the bottom and locked with crosswise tightening of the 6 hexagon socket screws.

In order to guarantee a sufficient supply of air, two 3/4“ compressed air hoses are connected to the regulating unit of the insertion block. To achieve maximum shooting in lengths, it is recommended that both air inlets are connected to the compressor via a compressed air lubrication unit so that the cable is constantly being lubricated during the injection process.When handling compressed air it is essential to note the regulations for safety at work!The maximum permitted pressure for injection of 12 bar should not be exceeded!The injection pressure, starting at approx. 0.5 bar, is gradually incre-ased until the required feed speed is achieved. In practice an even speed of up to max. 45 - 50 m/min has proven to be advantageous. When shooting-in cables with the REHAU Vario insertion garniture, it is essential that the surface of the cable is well coated with liquid lubricant (cable lubricant, e.g. Softenol or Gliss F).

The application of the cable lubricant using the injected compressed air is particularly advantageous.

Conventional cable lubricant greases are not suitable for the coating of the cables to be injected!

Determining the maximum shooting in lengthsThe possible shooting in lengths can easily be determined using the two tables below and the diagram. Note:Diagram 1 has been created on the basis of a coefficientof friction µ = 0.2. This coefficient of friction is easily achieved for cables with a PE sheath and when coating the surface of the cable with liquid cable lubricants. Diagram 1 applies for extensive, straight stretches with a total angle of up to 180°.Workingconditionswhichdeviatetothiscancauseasignificantdeviation in the shooting in lengths which can be achieved!

This is determined in 3 steps:Step 1:Determine the effective dolly surface in mm2 from Table 1 depending on the internal diameter of the PE-HD cable duct or RAUDUCT duct to be occupied, and the external diameter of the cable to be inserted.Step 2:Using Diagram 1, the max. shooting in length at 10 bar is determined depending on the effective dolly surface and the effective dolly surface and the weight of the cable. This max. shooting in length applies if the max. compressor pressure of 10 bar is available.Step 3:At an effective compressor pressure below 10 bar the result from Step 2 must be multiplied by the corresponding reduction factor from Table 2.

Example:Situation given:Cable Ø: 12 mmCable weight: 0.20 kg/mDuct Ø: 40 x 3.7Actual pressure: 8 barRequired:Maximum achievable shooting in lengthStep 1:Effective dolly surface from Table 1:A = 721 mm2

Step 2:Maximum shooting in length at 10 bar from Diagram 1: approx. 1,837 mStep 3:Reduction factor for 8 bar from Table 2 = 0.8:1837 m x 0,8 = 1470 m maximum achievable shooting in length

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Effective dolly surface A in mm2

Duct dimension 32 x 2.0) 32 x 2.9 40 x 2.3 40 x 3.7 50 x 2.9 50 x 4.6 63 x 3.6 63 x 5.8Duct ID (mm) 28 26.2 35.4 32.6 44.2 40.8 55.8 51.4Cable AD (mm) 8 565 489 933 784 1483 1257 2394 2024 9 552 475 920 771 1470 1243 2381 201010 537 460 905 756 1455 1228 2366 199511 520 444 889 739 1439 1212 2349 197912 502 426 871 721 1420 1194 2331 196113 483 406 851 702 1401 1174 2312 194114 462 385 830 680 1380 1153 2290 192015 439 362 807 658 1357 1130 2268 189716 414 338 783 633 1333 1106 2243 187317 389 757 607 1307 1080 2217 184718 361 729 580 1279 1052 2190 182019 700 551 1250 1023 2161 179120 670 520 1220 993 2130 1760Table 1

Actual pressure (bar) 10 9 8 7 6 5 4 3 2Factor 1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2Table 2

Maximum shooting in length at 10 bar; µ = 0.2Cable weight 0.10 kg/m up to 0.45 kg/m

Diagram 1

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4.1 ApplicabilityPart II of this document applies for flexible cable conduit made from PE-HD (high density polyethylene), and also accessories for installingmulti-way cable channel lines and one or multi-way cable ductlines.

4.2 Area of applicationThe PE-HD cable conduit d ≥ 75 mm is used to protect high voltage and telecommunications cables against mechanical damage, chemical attacks and rodents and also to retain several PE-HD cable ducts or cable conduits d = 32-63 mm or RAUDUCT duct systems (multiple sub-duct pipes).

Note:The cable ducts and fittings in this document are not suitable for the construction of compressed air, gas and water lines with specified pressure levels!

4.3 Materials

DuctsThe cable ducts d ≥ 75 mm are made from RAU-PE 2386 (PE-HD).

Material properties at 23 °C:RAU-PE 2386:Average density: > 0.94 g/cm3

Coefficient of linear expansion: 2.0 x 10 -4 K-1

Thermal conductivity: 0.41 WK-1 m-1Modulus of elasticity: 600 - 900 N/mm2

Surface resistance: > 1012 Ω

Fire behaviour of PE-HD:RAU-PE 2386 has normal flammability to DIN 4102, Building materials class B 2.

AccessoriesThe spacer (blow moulded part made from RAU-PE for ducts d = 110 and 125 or injection moulded parts made from RAU-PP for ducts d = 110, 125 and 160) from the section „PVC cable ducts and cable conduit“ can be used to construct multi-way cable duct lines.

REHAU PE-HD CABLE DUCTS AND CABLE CONDUITSII. PE-HD CABLE CONDUITS D ≥ 75 MM

4.4IdentificationThe identification of the cable ducts made from PE-HD is carried out with permanent printing or hot stamping at intervals of 1 m with the following information:

Manufacturer and area of application: REHAU cable conduitMaterial: PE-HDDimensions in mm: z. B. 160 x 14.6Standard: DIN 8074Machine no.: e. g. M 14Production date (6-digit day, month, year): e. g. 190410Number of metres: e. g. 1254(for bundled coils or drums)

4.5 Delivery format

CoilsThe PE-HD cable ducts d ≥ 75 mm can be delivered as 100m bundled coils up to dimension 180 x 16.4 mm.

DN/OD Internal Ø External Ø Width[mm] [mm] [mm] [mm] 75 * 1500 2000 420 90 1600 (2400) 2350 (2900) 440 (430)110 2400 3000 540125 2170 (2400) 2900 (3200) 660 (610)140 * 2400 3100 710160 ** 2400 3200 1200180 */** 2400 3200 1200

Bundled coil 100 m:

* Non-standard - Delivery time on request** Only duct range SDR 11( ) = different coil dimension for ducts SDR 17.6

The delivery of long production lengths in large coils or on special drums is possible on request.

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Cut lengthsThe PE-HD cable ducts d ≥ 75 mm are delivered as standard as 12 m cut lengths in timber frame crates (HRV) (also as 6 m cut lengths on request).

DN/OD Height Width Contents[mm] [mm] [mm] [unit] 75 * 550 1185 102 90 580 1140 69110 590 1120 48125 550 1185 34140 * 575 1180 30160 540 1180 20180 * 580 1140 17200 700 1060 15250 * 610 1060 8280 * 670 1180 8315 * 740 1005 6* Non-standard - Delivery time on request

Timber frame crates for PE cut length ducts 12 m:

d1) s1) Duct weight Duct weight approx. Article[mm] [mm] [kg/m]2) [kg/100 m coil] 75 * 4.3 0.97 97 134501 90 5.1 1.39 139 134371

110 6.3 2.08 208 134381

125 7.1 2.66 266 134521140 8.0 3.34 334 135025160 9.1 4.35 -- 102322180 * 10.2 5.48 -- 135035200 11.4 6.79 -- 102652250 14.2 10.6 -- 100002280 * 15.9 13.2 -- 100011315 * 17.9 16.7 -- 100005

Ducts SDR 17.6 to DIN 8074 and DIN 16876

4.6 Product range

Material: RAU-PE 2386Colour: black, roughly RAL 9005

d1) s1) Duct weight Duct weight approx. Article[mm] [mm] [kg/m]2) [kg/100 m coil] 75 * 6.8 1.47 147 102732 90 8.2 2.21 221 102722

110 10.0 3.14 314 134391

125 11.4 4.08 408 134209140 * 12.7 5.08 508 135522160 14.6 6.67 667 131001180 * 16.4 8.42 -- 134419200 18.2 10.4 -- 102642250 22.7 16.2 -- 100003280 * 25.4 20.3 -- 100021315 * 28.6 25.6 -- 100004

Rohre SDR 11 nach DIN 8074 und DIN 16876

1) Dimensions and tolerances to DIN 80742) Calculated with a specific weight of 0.95 g/cm3

* Non-standard - Delivery time on request

d

s

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General informationThe installation works are to be managed and overseen by suitable, experienced supervisors. During the installation works the accident prevention regulations of the trade associations or inspectorate for health and safety at work, the road traffic act, the general technical regulations of the VOB, Part C as well as all regional applicable laws and regulations are to be taken into account.

UnwindingcoilsAs in particular when unwinding dimensions d ≥ 75 mm enormous forces are released, care is to be taken here accordingly. When un-winding cable ducts from bundled coils or special drums it is critical to ensure that the ends of the duct cannot spring out when the bindings are undone.To prevent buckling of the ducts, the ducts must not be unwound spirally.The use of a mechanical unwinding device is recommended when unwinding cable ducts from bundled coils. In the simplest design, the bundled coils can then, for example, be positioned horizontally on the turnstile and unwound by hand or with a slow-moving vehicle.The pictures show examples of a horizontal or vertical unwinding device:

Particular safety is provided by the relevant unwinding devices in basket design offered by the industry. Here the bundled coils are inserted vertically into the unwinding devices.If required, the bundled coils are bound together in layers in the plant. By doing this it is possible to unwind the outside layer of the bundled coil only. Due to the firm connection of the inside layers with each other this prevent this complete length of coil springing out when the outside connection is removed.

TransportThe transport of cut lengths should always take place if possible in the timber frame crates (HRV) provided by the plant. If this is not possible, before the cable ducts are loaded on a HGV the loading surface must be cleaned and all items such as nails, screws removed from the loading surface. During transport the cable ducts must be secured against sliding, should lie across the whole loading surface and not protrude past the loading surface. In the case of loading or unloading, the bundled coils must not be dragged over sharp edges.Particular attention is to be paid to the loading and unloading of-bundled coils, as due to their external diameter in general they cannot be transported vertically or horizontally, but at an angle on the HGV. The relevant securing of the bundled coils against movement during is unavoidable.During loading and unloading, and also transport to the construction site or warehouse, only lifting equipment is to be used which prevents load concentrations (e.g. ropes, not steel bars under any circum-stances). Furthermore, impact stresses and deep scratches are to be prevented by placing the ducts carefully and not dragging them across uneven ground.

StoragePE-HD cable ducts can only be stored for a limited time in the effects of sunlight. In Central Europe the ducts can be stored outside for up to 2 years without this affecting the physical properties. For prolonged periods of outdoor storage, or in areas with intense solarradiation, e.g. on the coast in southern countries, or at high altitudes above1,500 m, storage out of direct sunlight is required. In the case of covering with tarpaulins, good ventilation of the cable ducts must be ensured in order to avoid an accumulation of heat and there-fore deformations. Transparent foils or tarpaulins are not suitable for covering PE-HD cable ducts!The ducts are to be stored in such a way that no damage or permanent deformation occurs. Contact with potentially damaging substances (see e.g. DIN 8075- Supplementary sheet 1) is to be avoided.The storage of cut lengths is to be carried out if possible on HRVs supplied by the plant. The max. stacking height is 3 HRV on top of one another. When doing this it is to be ensured that the timber crates are lying on top of each other.

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If storage of cut lengths without HRV should become necessary an even storage surface is to be ensured which makes it possible for the whole length of duct to rest on it. Storage on stony or sharp-edged items is not permitted. The cable ducts in cut lengths are to be secured to stop them rolling sideways. The max. stacking height is 1 m

The storage of cable ducts and duct line parts should always take place at a sufficient distance from the duct trench so that the trenchwalls are not loaded in a way which is not permitted.In the case of storing bundled coils, it is critical that this takes place on a stone-free surface. If necessary, a suitable surface is to be crea-ted through additional measures (e.g. wooden boards). In the case of upright storage of the bundled coils, they must be secured at the side to prevent them falling.

The upright storage of bundled coils of PE-HD cable duct from duct range SDR 17.6 is not permitted!

Temperature rangeNo temperature restrictions apply for the transport of PE-HD cable ducts. However, it is to be ensured that at temperatures > 50 °C even slight mechanical loads can lead to deformation, and that at tempe-ratures < -15 °C the duct material cannot be subjected to any impact stress. The installation of PE-HD ducts can take place in principle at temperatures down to -15 °C.However, in practice this is only possible without any additional work with cut lengths. The unwinding of coils from the bundled coil at tempera-tures below 0 °C becomes more difficult with increasing temperature, where the risk of accident increases significantly. The dangers and difficulties can be avoided by pre-warming the bundled coils, e.g. by storing them temporarily in a heated hall or heated tent for a period of at least 12 hours. Warming devices are also used which are based on hot air or releasing vapour (max 80 °C).

Tensile forcesWhen installing PE-HD cable ducts 17.6 and SDR 11, tensile forces which occur must not exceed the values mentioned in the table below.Maximum permitted tensile forces on PE-HD cable ducts for duct ranges SDR 17.6 and SDR 11:

External diam. Wall thickn. --------------- Duct temperatures ----------------[mm] [mm] 0 °C 20 °C 40 °C 75 4.3 8.5 7.6 5.7 75 6.8 13.1 11.6 8.7

90 5.1 12.2 10.8 8.1

90 8.2 18.9 16.8 12.6110 6.3 18.4 16.4 12.3110 10.0 28.2 25.1 18.8125 7.1 23.6 21.0 15.7125 11.4 36.6 32.5 24.4140 8.0 29.8 26.5 19.9140 12.7 45.7 40.6 30.4160 9.1 38.8 34.5 25.8160 14.6 60.0 53.3 40.0180 10.2 48.9 43.5 32.6180 16.4 75.8 67.4 50.5200 11.4 60.7 54.0 40.5200 18.2 93.5 83.1 62.3225 12.8 76.7 68.2 51.1225 20.5 119 105 79.0250 14.2 94.6 84.1 63.1250 22.7 146 130 97.2280 15.9 119 106 79.1280 25.4 183 163 122315 17.9 150 134 100315 28.6 232 206 154355 20.1 190 169 127355 32.2 294 261 196400 22.7 242 215 161400 36.3 373 332 249These tensile forces also apply for welding seams which are created correctly

Tensile force in kN

ChangesinlengthinthecaseoftemperaturefluctuationsThe length change in PE-HD cable ducts caused by temperature fluc-tuations is considerably greater than for metallic ducts. The following is to be taken into account when calculating the length change:1. The prevalent temperature during installation. 2. The expected lowest and highest duct wall temperature following assembly.Length change (mm) = Duct length (m) x temperature difference (K) x coefficient of expansion (0.2 mm/mK)

Example:Production temperature: 25 °CInstallation temperature: -5 °CLength change: Per 10 K temperature difference = 2 mm/mTemperature difference: 30 KThis results in a length change: -6 mm/m

A 100 m long duct made from PE-HD shortens at -5 °C by 100 m x 6 mm/m = 0.6 m!

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Cold bending the ductsThe high flexibility of the cable ducts as cut lengths or bundled coils facilitates easy and quick installation. As a result of this, small obsta-cles can be overcome and changes in direction carried out without the use of fittings.However, based on the duct temperature, the minimum bending radii specified in the following table must be observed:

Duct range SDR 17.6 / SDR 11:

Installation temperature Minimum bending radius [°C] R [mm] 20 20 x d 10 35 x d 0 50 x d

ManufacturinginfilllengthsIf the manufacture of infill lengths is required it is necessary to shorten the PE-HD cable ducts to the specified lengths. Here the ducts should be cut to length with either a pipe cutter or with a fine-toothed saw. When doing this, it is to be ensured that the cuts run parallel to the duct axis.

Note 1:WhencuttingPE-HDcableductsd≥75mmtolengthitiscritical to bear in mind the strong bond between the two duct parts to be separated. Warning! Risk of injury from duct ends springing out!

Note 2:In practice it is impossible to avoid bending stress occurring at the point of separation during trimming. When using saws the intermittent loading from the saw teeth in the case of thick-walled ducts (in particular in the case of ducts above 10 mm wall thickness) can lead to a brittle break. This is not a defect, but is material-related. If necessary, the tension-free duct end is to be cut parallel to the duct axis again.

When creating infill lengths, the temperature-related length change of the ducts is to be taken into account. In the case of installation of ducts above ground (e.g. below bridges) high tensile forces are exerted on the fixed points of the duct lines due to the temperature-related shortening or extension of the ducts. The overall length of duct line in these cases is therefore to be planned taking temperature into account.

Structural designREHAU cable ducts can be statically calculated according to the ATV worksheet A 127. The load-bearing strength of the ducts in the installed condition is dependent first and foremost on the installation and soil conditions. On request we will issue a static calculation for the specific installation case. The required input values for the calculation can be found in the project questionnaire in the attachment of this Technical Information.

In the case of trenchless installation methods, e.g. such as horizontal drilling, the information regarding the expansion head diameter is critical for the static calculation according to the ATV Worksheet A 127!

In-situ (ground) waterPE-HD cable ducts from the SDR 17.6 duct range are suitable for an in-situ external pressure of up to max. 0.47 bar, which equates to an in-situ water column of max. 4.7 m.PE-HD cable ducts from the SDR 11 duct range are suitable for an in-situ external pressure of up to max. 2.16 bar, which equates to an in-situ water column of max. 21.6 m.

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Duct installation

GeneralDuring installation the bundled coils and also the cable ducts to be installed must not be dragged across sharp edges. The cable ducts must not be kinked. Impact loads on the cable ducts are to be avo-ided.PE-HD cable ducts d ≥ 75 mm are generally installed using ploughing-in, routing or insertion through horizontal boreholes. When doing this, the back-filling and compacting in the area of the line zone or in the borehole is sufficiently fulfilled statically by washing in the soil in the surrounding area, e.g. bentonite washing in used in the case of sewer duct ducts or compression in the case of horizontal boreholes. In the case of ploughed-in or routed ducts the necessary sand back-filling of the ducts installed into the ground takes place in the tunnel-shaped installation position using the sand or other fine particles of soil which have been washed in with rainwater. For the alternative installation of the cable ducts in open duct trenches it is necessary to take into account the conventional assembly technique (sand back-filling or plain concrete) used for the old duct systems made from polymer materials (cut lengths with push-fit socket).

Duct trenchesThe dimensions of the duct trench influence the size and distribu-tion of ground and traffic loads. During the design the dimensions specified by the description of services or static calculation are to be observed.In the case of rocky or stony ground, an additional depth of 10 cm for a layer of sand (stone-free layer) is to be taken into account.

Install,back-fill,compact;spacerThe load-bearing properties of thermoformed ducts made from polymer materials in addition to the duct rigidity are also determined to a large extent by the possibility to lean against the nearby bedding material, particularly the side filler material. In the case of multi-way duct installations, particularly proper and careful compaction of the spaces between the ducts is required. Spacers are used to ensure sufficient possibility for compaction and also to stabilise multi-way ducts which are installed. In the case of duct installations in sand or a gravel-sand mix (largest grain 8 mm, with the predominant proportion being sand) or concrete, the spacers are to be set at intervals of max. 1.5 m, in the case of installation in a cement-sand mix of max. 3 m.The compaction in the area of the line zone is generally to be carried out by hand. The compacted layer of filler material above the top layer of ducts should be at least 10 cm.In the area of up to 1 m above the duct apex only lightweight compac-ting equipment should be used.If installing the ducts in concrete, buoyancy support is to be provided for and it is to be ensured that the ducts installed are completely covered.

Horizontal boreholesA particularly frequent use for the PE-HD cable ducts d ≥ 75 mm is the application of these ducts for insertion into horizontal boreholes mostly for road underpasses, overcoming obstacles or foundation underpasses, small river courses, canals or dams.For the use of bundled coils, it is to be borne in mind that the ducts could have become oval during unwinding. For SDR 11 ducts a max. ovality in the wound condition of 10 % of the external diameter and for SDR 17.6 ducts up to 20 % distortion is to be anticipated.Due to the memory-effect of the PE-HD material used, reshaping in the unwound condition to ovality values of approx. 6 % of the external diameter is to be expected. For optimum reshaping sufficient storage time in the unwound condition prior to assembly of the ducts of at least 1 day at 20 °C is to be scheduled. At lower temperatures the storage time required increases up to 72 hours at 0 °C.If sufficient storage time for reshaping the duct ovality is not possible for construction reasons, this reshaping takes place anyway, but a lot more slowly, in the assembled condition.It is critical to take into account the unavoidable ovality of the duct due to transport in bundled coils when making the connection between the insertion head and the ends of the duct to be inserted. In problem cases a flange piece (with the known dimensions and qualities) of approx. 1.5 m should be welded on to the stub of the length of duct to be inserted and the insertion head (e.g. parison stretching mandrel) fastened to this flange piece.

Duct connection using butt-weldingFor the connection of coils and primarily when creating long installati-on lengths from cut lengths heated tool butt-welding is usual above a duct diameter d = 110 mm. During this process the ends of the duct are heated on a heating element and butt welded by pushing them together.

Heating elementDuctDuct

73

PrecautionsThe welded area is to be protected from wind and in order to prevent the welding seam cooling too quickly. At low outside temperatures suitable measures (e.g. pre-warming, heating or working under a tent) are to be taken to ensure that a duct temperature sufficient for welding is maintained. The ends of the duct to be welded should in any case be the same temperature. If the duct is warmed unevenly by sun radiation, temperature equalisation is to be achieved by quickly covering the welded area. PE-HD cable ducts from coils are oval immediately after being un-rolled. The ends of the duct are therefore to be made round again prior to welding with the help of a hot air device (50-80 °C) or clamping in a round pressure clamp (clamping tool).The connecting surfaces must not be damaged. In order to ensure that the welding area is free from contamination (dirt, grease, chippings), cleaning of the connecting surfaces has to take place immediately prior to welding.During welding, and until it has cooled completely, the welding area is not to be subjected to any mechanical loading by using clamping devices.Continuous monitoring is required throughout the entire welding period. The connections must satisfy the testing requirements accor-ding to the DVS data sheet 2207 Part 1. It is recommended that the welding values for each connection are recorded in a welding report (example see DVS 2207).

Welding seam preparationThe devices used for welding must meet the requirements of DVS data sheet 2207-Part 1. The ends of the ducts to be welded are inserted, aligned and clamped into the clamping device.

Once the plane has been lifted out the chips are removed.

WeldingThe heating blade is positioned between the ends of the duct. Once the connecting surfaces have been aligned with high contact pressure the welding surfaces are warmed to the welding temperature at a reduced pressure.

Once the heating time has elapsed, the heating plate is removed and the duct ends joined together under increasing pressure. During this process, the typical weld beads for this process occur inside and outside.

More information about heated tool butt-welding and also the necessary welding parameters can be found in the DVS data sheet 2207-Part 1.

A plane consisting of two rotating blades is positioned between the ends of the duct. The front of both duct ends is planed so that it is flat and parallel.

REHAU MULTIPLE SUB-DUCT PIPESRAUDUCT/RAUDUCT PE-HD EVMR

76

5 CONTENTS PE-HD RAUDUCT/RAUDUCT EVMR MULTIPLE SUB-DUCT PIPES

5.1 . . . Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77


5.3 . . . Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5.4 . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5.5 . . . Delivery format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5.6 . . . Product range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805.6.1 . RAUDUCT multiple sub-duct pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805.6.2 . RAUDUCT EVMR - multiple sub-duct pipes for underground installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825.6.3 . Fittings/accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84


77

5.1 Applicability

This document applies for flexible RAUDUCT PE-HD duct systems and associated multiple sub-ducting of cable channels DN 100-110 and DN 100-125 and also RAUDUCT EVMR PE-HD duct systems for direct installation into the ground.The cross-section of the RAUDUCT duct systems and RAUDUCT EVMRduct systems consist of 2 to 5 internal ducts which are connected to each other tightly using a jointless, water and gas-tight sheathing which follows the contour of the internal ducts.

5.2 Area of application

RAUDUCTThe RAUDUCT systems are duct bundles for the protection of coaxial and glass fibre cables, primarily in communications engineering. The basic idea of the systems is the multiple sub-ducting, and therefore multiple utilisation of cable channels, which are constructed from either individual Polymer ducts (PVC, PE und PP) and also ducts made from user-defined materials or cable channel moulded bricks (con-crete) and have been installed over the last decades at considerable financial expense. The RAUDUCT system represents a solution for all cable network ope-rators. The installation of coaxial and glass fibre cables required as a result of the technical advancement (e.g. digitalisation of information) of cable-based communication and the development of multimedia applications based on this is simplified in a cost-effective way through the multiple utilisation of existing channels by the RAUDUCT system and, in many cases, is made possible for the first time.RAUDUCT systems consist essentially of 2 to 5 PE-HD internal ductswhich are connected to each other using a shared, jointless sheathing, also PE-HD, which follows the contour. The duct sheathing is gas and water tight and, in addition to the fixing of the required contour and additional protection of the internal ducts, also has the task of trans-ferring the longitudinal forces which occur in the RAUDUCT system, e.g. during insertion of the RAUDUCT system into the cable channel. Due to the use of PE-HD for both the internal duct and also the shea-thing, a flexible system developed based on a cable reel is available, which without a connecting piece can be pulled through from one access chamber to the next access chamber.

Note:REHAU RAUDUCT and RAUDUCT EVMR systems are not suitable for use as pressure lines for the transport of gas, drinking water and other fluids.REHAU offers specially developed duct systems for these areas of application.

RAUDUCT 5-way,RAUDUCT 4-way,RAUDUCT 3-way 40,These RAUDUCT systems have a max. external diameter of approx. 89 mm.They are suitable for the multiple sub-ducting of cable channel sections made from PVC or other materials and also cable duct blocks with an internal diameter of 95 mm or bigger.

RAUDUCT 3-way largeThis RAUDUCT system has a max. external diameter of approx. 92 mm.It is suitable for the multiple sub-ducting of cable duct sections made from PVC or other materials and also cable duct blocks with an inter-nal diameter of 98 mm or bigger.

RAUDUCT 4-way 32RAUDUCT 2-way 40These RAUDUCT systems have a max. external diameter of approx. 80 mm.They are suitable for the multiple sub-ducting of cable channel sections made from PVC or other materials and also cable duct blocks with an internal diameter of 90 mm or bigger.

RAUDUCT 3-way small,RAUDUCT 3-way 32These RAUDUCT systems have a max. external diameter of approx. 76 mm.They are suitable for the multiple sub-ducting of cable duct sections made from PVC ducts or other materials and also cable duct blocks with an internal diameter of 80 mm or bigger.

78

RAUDUCT EVMR

The RAUDUCT EVMR systems are made from reinforced wall ducts for the protection of coaxial and glass fibre cables in the case of direct installation into the ground in trenches or by ploughing-in.The composition of the RAUDUCT EVMR is the same as the RAUDUCT system. Due to the reinforced wall design of the internal ducts, with RAUDUCT EVMR, the construction of multi-way, underground and statically stable duct systems for communications technology between chambers or in continuous installation is possible.In the case of the simultaneous installation of up to four RAUDUCT EVMR systems through ploughing-in, in one operation up to 16-way cable duct can be created without the use of additional cable ducts.Through the shared, jointless sheathing which follows the contour of the internal ducts, the turning and undesirable changing of position of the internal ducts, particularly in the curved areas of the duct line, is largely avoided.

If the RAUDUCT EVMR systems have to be installed in cable conduits, so the internal diameter of these cable conduits should not generally fall below the following internal diameters. Depending on the linedesign and type of cable conduit, larger cable conduit dimensions may also be required.

Duct dimension conduit Internal Ø cable

min. [mm]

RAUDUCT EVMR 4-way 95

RAUDUCT EVMR 4-way 40 107



RAUDUCT EVMR 3-way comp. 98




RAUDUCT EVMR 2-way 50/40 98

5.3 Material

RAU-PE 2387 = PE-HD to DIN 8075

Colour basic ducts: RAL 9005 blackColour of the sheathing: RAL 9005 blackor as per RAL colour register.

Material properties at 23 °C:RAU-PE 2387:average density: > 0.94 g/cm3

Coefficient of linear expansion: 2.0 x 10-4 K-1

Thermal conductivity: 0.41 WK-1 m-1

Modulus of elasticity: 600 - 800 MPaSurface resistance: > 1012 Ω

Fire behaviour of PE-HD:RAU-PE 2387 has normal flammability to DIN 4102, Building materials class B 2.

5.4 Identification

The identification of the RAUDUCT and RAUDUCT EVMR systems is carried out with printing on the sheathing in the welded contact area with the internal ducts.The additional application of a property mark is possible on request.One duct from each of the RAUDUCT and RAUDUCT EVMR systems is marked at an interval of 1 m with the specified identification text incl. production date and metre marks.The continuous metre marking of the RAUDUCT and RAUDUCT EVMR systems is marked on each reel from 0 to the delivery length or from the delivery length to 0.In the case of all RAUDUCT and RAUDUCT EVMR systems with more than two internal ducts a second duct is also to be provided in each case with continuous marking. As a result, during the fitting with ca-bles at any point of the duct lines fitted with or made from RAUDUCT systems or EVMR systems an exact allocation of the internal ducts is possible.

5.5 Delivery format

Due to their flexibility RAUDUCT and RAUDUCT EVMR systems are sui-table for transport in long lengths on cable drums. Due to the low tare weight of the RAUDUCT and RAUDUCT EVMR systems, steel drums or light wooden disposable drums are used for delivery.

Standard make-up for delivery on steel reusable drums:External diameter: 2.8 mTotal width: 1.6 mCore diameter: 1.2 m

RAUDUCT 5-way: 1000 m

RAUDUCT 4-way: 1000 m

RAUDUCT 4-way 32: 1350 m

RAUDUCT 3-way large: 800 m

RAUDUCT 3-way small: 1200 m

RAUDUCT 3-way 32: *600 m



RAUDUCT EVMR 4-way: 1000 m

RAUDUCT EVMR 4-way 40: 800 m



RAUDUCT 3-fold compakt: 800 m




RAUDUCT EVMR 2-way 50/40: 1500 m

*Alternative drum dimension

79

Other delivery lengths on the standard drums, and also other drum formats on request. Coil dimensions for RAUDUCT EVMR and also to a limited extent for RAUDUCT on request.

Information:During transport and handling of the cable drums the familiar work and safety regulations are to be observed. During handling of the cable drums on an uneven floor, it is to be ensured that the coils do not become loose and that the duct is not dragged across the ground. Resting the coiled layers of duct on uneven floors is to be avoided without fail.

Text for invitations to tender

The invitation to tender texts for the individual RAUDUCT and RAU-DUCT EVMR dimensions can be provided on request.The invitation to tender texts can also be downloaded from the internet at www.rehau.de.

Brief overview of the dimensions of RAUDUCT and RAUDUCT EVMR

RAUDUCT

Article Description 25 x 2 32 x 2 40 x 2 50 x 2.5

101027 5-way 2 2 1

101037 4-way 2 2

102134 4-way 32 4

101017 3-way large 2 1

101217 3-way small 2 1

257169 3-way 32 3

102119 3-way 40 3

102029 2-way 40 2

RAUDUCT EVMR

Artikel Bezeichnung 32 x 2.9 40 x 3.0 40 x 3.7 50 x 3.5 50 x 4.6

101208 4-way 2 2

101398 4-way 40 4

102129 4-way 32 4

102101 3-way 50 3

101488 3-way compakt 2 1

102393 3-way 40 3

101008 2-way 40 2

101007 2-way 50 2

101018 2-way 50/40 1 1

80

5.6.1 RAUDUCT multiple sub-duct pipes

RAUDUCT 5-wayInternal ducts: 1 duct 40 x 2 2 ducts 32 x 2 2 ducts 25 x 2Article: 101027Weight: 1.11 kg/mMake-up for delivery: 1000 m on a drum

5.6 Product range

RAUDUCT 4-wayInternal ducts: 2 ducts 40 x 2 2 ducts 32 x 2Article: 101037Weight: 1.07 kg/mMake-up for delivery: 1000 m on a drumNote: Can be connected directly with RAUDUCT 4-way EVMR, Art. 101208.

RAUDUCT 4-way 32Internal ducts: 4 ducts 32 x 2Article: 102134Weight: 0.88 kg/mMake-up for delivery: 1350 m on a drumDelivery time on request

RAUDUCT 3-way largeInternal ducts: 1 duct 50 x 2,5 2 ducts 40 x 2Article: 101017Weight: 1.03 kg/mMake-up for delivery: 800 m on a drum

40

25

32

2

2

2

40

32

2 2

2

32

2

40

50

2

2,5

81

RAUDUCT 3-way smallInternal ducts: 1 duct 40 x 2 2 ducts 32 x 2Article: 101217Weight: 0.76 kg/mMake-up for delivery: 1200 m on a drum

RAUDUCT 3-way 32Internal ducts: 3 ducts 32 x 2Article: 257169Weight: 0.68 kg/mMake-up for delivery: 600 m on a drumDelivery time on request

RAUDUCT 3-way 40Internal ducts: 3 ducts 40 x 2Article: 102119Weight: 0.85 kg/mMake-up for delivery: 1000 m on a drum

RAUDUCT 2-way 40Internal ducts: 2 ducts 40 x 2Article: 102029Weight: 0.55 kg/mMake-up for delivery: 2000 m on a drumSubsequent insertion into already occupied cable ducts possible.

40

32

2

2

40

2

2

40

82

RAUDUCT EVMR 4-way 40Internal ducts: 4 ducts 40 x 3.7Article: 101398Weight: 1.80 kg/mMake-up for delivery: 800 m on a drumDelivery time on request

RAUDUCT EVMR 4-way 32Internal ducts: 4 ducts 32 x 2.9Article: 102129Weight: 1.19 kg/mMake-up for delivery: 1350 m on a drum


RAUDUCT EVMR 3-way compactInternal ducts: 2 ducts 40 x 3.0 1 duct 50 x 3.5Article: 101488Weight: 1.30 kg/mMake-up for delivery: 800 m on a drum

4,650

50

3,0

3,5

40

5.6.2 RAUDUCT EVMR multiple sub-duct pipes for underground installation

RAUDUCT EVMR 4-wayInternal ducts: 2 ducts 32 x 2.9 2 ducts 40 x 3.7Article: 101208Weight: 1.61 kg/mMake-up for delivery: 1000 m on a drumNote: Can be connected directly with RAUDUCT 4-way, Art. 101037.

40

32

3,7

3

83




RAUDUCT EVMR 2-way 50/40Internal ducts: 1 duct 40 x 3.7 1 duct 50 x 4.6Article: 101018Weight: 1.14 kg/mMake-up for delivery: 1500 m on a drumDelivery time on request

40

3,7

3,7

40

4,6

505040

3,7

4,6

84


So that the RAUDUCT duct systems can be properly connected and Material: PVC-U attached to buildings and chamber, REHAU offers Colour: grey a variety of fittings which have been tested in practice.

Individual duct connector- Plug connector for the tight connection of multiple sub-duct pipes- Suitable for installation direct into the ground, for ploughing-in and

also for insertion into cable conduits- Can be used up to an injection pressure of 12 bar - Connection can be removed with dismantling support channels - Water-tight up to 10 m water column Material: RAU-POMColour: greyFor notes about use, see planning and installation

Duct diameter Weight articles

[mm] [g]

25 100 252723

32 90 236634

40 220 242038

50 270 242048

Plug connector set for RAUDUCT 4-way and RAUDUCT EVMR 4-wayFor RAUDUCT 4-way/EVMR (Art. 101037 and 101208) also available as a set.comprising:- 2x individual duct connector 32 mm and- 2x individual duct connector 40 mm Article: 101117

Plug connector RAUDUCT 3-way large- With reduced external diameterMaterial: PVC-UColour: grey

Duct diameter t Weight articles

[mm] [mm] [g]

40 35 66 266868

50 46 136 266858

t = Insertion depth

End fitting with cable seal- For the pressure-tight end sealing of multiple sub-duct pipes (up to

10 bar)- To seal the cables installed in the multiple sub-duct pipe (up to 0.5 bar)- Connection can be removed with dismantling support channels (see section 2.4.2)Material: RAU-POMColour: greyFor notes about use, see planning and installation

Duct diameter Cable diameter Weight articles

[mm] [mm] [g]

32 10 - 18 120 265905

40 10 - 18 160 265915

RAU-POM plug connector

RAU-PVC plug connector

85

Sealing plug- To seal the end of multiple ducts- Pressure-tight up to 0.5 barMaterial: RAU-POMColour: grey

Duct diameter Weight Article

[mm] [g]

25 30 285587

32 35 239244

40 40 239224

50 60 239234

End cap - To seal the ends of the duct against dirt and vermin Material: PE-HD Material: PE-HDColour: grey


[mm] [g]

25 24 265479

32 42 265489

40 63 265499

50 84 265509

Individual passage seal separable- To seal the cables installed in the multiple ducts- Separable design for subsequent assembly for cables which have

already been installed- Pressure-tight up to 0.5 barMaterial: RAU-POMColour: whiteFor notes about use, see planning and installation

Dimension Cable diameter Weight

Individual duct

9-14,5 mm 13-18 mm 18-23 mm

[mm] Article Article Article [g]

25 x 2.0 285592 35

32 x 2.0 - 2.9 239204 239084 - 55

40 x 2.0 - 2.5 239094 239104 239144 75

40 x 3., 239114 239124 239134 68

50 x 2.5 - 3.5 on request on request

50 x 4.6 239154 239164 239174 85

86

Sealing plugs for RAUDUCT 5-way for sealingin cable conduits 110 x 5.3- Separated design for sand-tight sealing Material:Material:Flange: RAU-PARubber seal: RAU-SRColour: white/black

Design Weight Article

[g]

separated 250 101146

Chamber connection systems- For attaching RAUDUCT EVMR multiple sub-duct ducts 3 x 50 and 2 x 50 to chambers and buildings- For RAUDUCT EVMR 2 x 50 an additional sealing plug for closing

the unoccupied socket is required and must be assembled prior to back-filling of the trench.

- Diameter of the attachment 110 mm for insertion into chamber sockets or wall bridging pieces

Material: PVC-UColour: black

Description Weight Article

[g]

3-way 50 620 261079

A sealing plug art. no. 101588 is required for attaching RAUDUCT EVMR 2 x 50.

Sealing plug separable for sealing in cable conduits110 x 3.2 up to 5.3- For sealing the remaining annular space between the cable conduit

and RAUDUCT multiple sub-duct pipe- For sealing the chamber connections of RAUDUCT EVMR multiple

sub-duct pipes for underground installation- Separable design for subsequent installation- Secure against the cable conduit being pushed out (for temperture- related length changes of the RAUDUCT ducts)- Pressure-tight up to 0.5 barMaterial:Flange: RAU-PARubber seal: RAU-SRColour: blackFor notes about use, see planning and installation

Dimension cable conduit Weight Article

[mm] [g]

110 x 3.2 - 3.4 420 102037

110 x 5.3 400 102097

The sealing plug is designed for the sealing of RAUDUCT 4-way.Due to the use of sealing plugs and reducing sleeves the sealing plug can be used to seal other RAUDUCT dimensions.Accessory sets are available for the following dimensions on request:

RAUDUCT-/RAUDUCT EVMR dimension 4-way 323-way 323-way small2-way 40

87

Milling tool for bevelling PE ducts

Duct diameter Weight Article

[mm] [g]

25 70 133442

32 100 133452

40 170 133462

50 220 133472

Dismantling support channels (pair) for push-type fittings


[mm] [g]

25 80 134183

32 90 134193

40 100 134203

50 120 134213

A paring blade for stripping the multiple pipes

Weight articles

[kg]

0.4 231574

88

Cable blowing-in machine

REHAU Vario cable blowing-in-machineDevice for the injection of cables into RAUDUCT AND RAUDUCT EVMR systems and also PE cable ducts.Article: 132392Delivery formatSet in a sturdy case which is suitable for the building site for:- Duct dimension 25, 32, 40 und 50 mm- Cable diameter 10 to 19 mmFunction description see planning and installation

DollyThe dolly must be checked before every injection onto fir tightened nuts.The maximum permitted tensile force of the dolly is 4500 N.

Rohrdurchmesser Gewicht Artikel

[mm] [g]

25 x 2 53 257066

32 x 2 61 257076

32 x 2.9 61 241211

40 x 2 76 257096

40 x 3 76 264033

40 x 3.7 76 265542

50 x 2.5 97 257106

50 x 3.5 97 264013

50 x 4.6 97 265552

89

General informationThe installation of RAUDUCT and RAUDUCT EVMR multiple sub-duct duct systems is to be managed and overseen by suitable, experienced supervisors. During the installation works the accident prevention regulations of the trade associations or safety inspectorate, the road traffic act, the general technical regulations of the VOB, Part C as well as all regional applicable laws and regulations are to be observed. Unwinding drums and coilsWhen unwinding the RAUDUCT and RAUDUCT EVMR systems from drums or bundled coils it is vital to ensure that the ends of the duct cannot spring out when the bindings are removed. Note: Risk of injury! To prevent buckling of the ducts, the ducts must not be unwound spirally.The use of mechanical unwinding devices is recommended for unwin-ding RAUDUCT and RAUDUCT EVMR systems from the bundled coil.

TransportThe RAUDUCT and RAUDUCT EVMR systems are generally transported on drums or in bundled coils. For bundled coils horizontal transport in multiple stacks on disposable pallets is recommended. The packaging units are to be secured against slipping and rolling on the loading surface. In the case of direct storage of the bundled coils on the loading surface of the HGV, this is to be cleaned and all nails, screws and other pointed objects on the loading surface removed. In the case of loading or unloading, the bundled coils must not be dragged over sharp edges. The direct contact of the loading gear with the ducts is to be avoided.Due to the high drum and bundled coil weight, smooth removal of the packaging units is to be ensured. During the transport drums, only the drums, but not the ducts wound onto them, must be subjected to any load.

LagerungThe RAUDUCT and RAUDUCT EVMR systems can only be stored to a limited extent under the effects of sunlight. In Central Europe the ducts can be stored outside for up to 2 years without this affecting the physical properties.For prolonged periods of outdoor storage or in areas with intense solarradiation, e.g. on the coast, in southern countries, or at altitudes above 1,500 m, storage out of direct sunlight is required. In the case of co-vering with tarpaulins, good ventilation of the ducts must be ensured in order to avoid an accumulation of heat and therefore deformations. Transparent foils or tarpaulins are not suitable for covering the ducts!


The ducts are to be stored in such a way the no damage or permanent deformation occurs. This is to be ensured in particular if drums are stored on uneven ground.Contact with damaging substances (see e.g. DIN 8075 - Supplemen-tary sheet 1) is to be avoided.In the case of storing bundled coils, it is critical that this takes place on a stone-free surface. If necessary, a suitable surface is to be crea-ted through additional measures (e.g. wooden boards).If the bundled coils are stored upright, they must be secured at the side to prevent them falling.

The upright storage of bundled coils of the RAUDUCT systems is not permitted!

Temperature rangeNo temperature restrictions apply for the transport of RAUDUCT and RAUDUCT EVMR systems. It is to be noted however that at tempera-tures > 50 °C slight mechanical loads could already lead to deforma-tions and that at temperatures < -15 °C the duct material should not be subjected to any impact stress.The installation of RAUDUCT and RAUDUCT EVMR systems and the cable injection or extraction can take place at temperatures between -15 °C and 50 °C.At low temperatures, it is to be noted that due to the then higher rigi-dity of the material bigger bending radii may be required. At ambient temperatures below -20 °C protected storage for at least approx. 12 hours prior to installation of the ducts, e.g. in a closed storage hall or at least behind wind protection, is recommended.

The use of cable lubricating greases when inserting the RAUDUCT systems into existing cable channels is problematic especially in areas with low relative humidity and is to be avoi-ded if possible due to possible clumping of the cable lubricating grease.

Pressure rangeIn its function as a cable conduit for cable RAUDUCT and RAUDUCT EVMR systems are not subjected to constantinternal pressure.However, for the insertion of draw ropes and primarily the direct injection of glass fibre cables sufficient pneumatic leak tightness and pressure tightness is required.The maximum permitted pressure when shooting in cables is 12 bar at a temperature of max. 35 °C.

90

In order to ensure the function of the RAUDUCT and RAUDUCT EVMR systems, the ducts are randomly subjected to pressure tests during each production:

Test temperature: 35 °CTest pressure: 12 barTest duration: > 2 h

Tensile forcesWhen inserting the RAUDUCT systems into cable channels and during the installation of the RAUDUCT EVMR systems, it is to be ensured that the tensile forces occur are not larger than those permitted for the relevant duct system.

The following tensile forces should generally not be exceeded:

Duct dimension permitted tensile force

RAUDUCT 5-way

RAUDUCT 4-way 8.000 N

RAUDUCT 4-way 32 (0.8 to)

RAUDUCT 3-way large

RAUDUCT 3-fold 40

RAUDUCT 3-way small 5.000 N

RAUDUCT 3-way 32 (0.5 to)

RAUDUCT 2-way 40

RAUDUCT EVMR 4-way 40 16.000 N

RAUDUCT EVMR 3-way 50 (1.6 to)

RAUDUCT EVMR 4-way

RAUDUCT EVMR 3-way comp. 12.000 N


RAUDUCT EVMR 2-way 50

RAUDUCT EVMR 4-way 32 9.000 N


RAUDUCT EVMR 2-way 50/40

When observing these values the ducts are just elastically deformed during installation.

The tensile force values listed can be exceeded in some cases for a short-time by up to 50 %.An increase in tensile forces beyond this leads to unpermitted, per-manent elongations of the ducts or even to tearing of the RAUDUCT system!The tensile force values listed in the table also apply for systemconnections with REHAU plug connectors.

Shrinkage following installationDuring insertion of the RAUDUCT systems in cable channels and duri-ng the installation of RAUDUCT EVMR systems these are elongated in their length due to the tensile load. Once the tensile force is remo-ved the duct relaxes and returns to its original length.

The ends of the RAUDUCT systems must therefore extend over the mouth of the cable channel on both sides by 0.5 - 1.0 m. If the permitted tensile force as per section 3.1.5 is exceeded, an overhang of the ducts over the mouth of the cable channel on both sides of 2 - 3 m may be necessary!These specifications also apply for the connection points of RAUDUCT EVMR systems which are installed or ploughed into trenches. The connection of 2 RAUDUCT EVMR systems installed at separate times should not take place of possible until after a storage period of at least12 hours after covering the ducts in the duct trench.

Fixed lengths/remaining lengthsWhen installing fixed lengths or remaining lengths it is already to be considered in the preliminary planning that the duct lengths contract at low temperatures due to the temperature-related length change. The duct section is then actually shorter on installation than it says on the metre mark printed on the duct.

Example:Production temperature: 25 °CInstallation temperature: 5 °CTemperature difference: 20 °CDuct length 200 mResulting reduction = 0.8 mGeneral reduction of the duct length:every 10 °C / every 100 m = 20 cm

In-situ (ground) waterRAUDUCT systems made from PE-HD are suitable for an in-situ exter-nal pressure of up to max. 0.5 bar, which equates to an in-situ water column of max. 5 m.RAUDUCT EVMR systems made from PE-HD are suitable for an in-situ external pressure of up to max. 2.2 bar, which equates to an in-situ water column of max. 22 m.

Fitting

GeneralDuring installation the RAUDUCT and RAUDUCT EVMR systems must not be dragged across sharp edges. The ducts must not be kinked. Impact loads on the ducts are to be avoided.

Connection to the draw ropeThe required longitudinal connection between the draw rope and the RAUDUCT or RAUDUCT EVMR system is achieved with a conventio-nal draw cord. In order to avoid the duct turning during insertion or ploughing in, the draw rope must be fitted with a twist trap between the rope clamp piece and the shackle of the draw cord.For optimum force application of the draw cord the transition between draw cord and RAUDUCT or RAUDUCT EVMR system is joined using self-adhesive insulating tape.

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If high tensile forces are expected, it is recommended that the draw cord is bound with self-adhesive insulating tape across the whole contact area. For extreme tensile forces the use of supports (e.g. round timbers or copper cable ends) in the internal ducts is recom-mended.

Insertion into cable conduitsThe insertion of the RAUDUCT systems from the cable drum into the cable duct passage is carried out in the same way as the usual insertion technique for cables. The cable duct passage to be occupied must be of the minimum specified diameter for the insertion of RAU-DUCT systems (see section 1.2.1) and be clean. In case of doubt, the calibration of the cable duct passage is urgently recommended!For the case that the dolly for inserting the draw rope falls considerab-ly short, calibration of the cable duct is also recommended.Cable duct blocks made from concrete must be calibrated with the appropriate devices (e.g. duct file) prior to insertion in the RAUDUCT systems.The position of the rotating stored cable drum at the chamber or at the end of the cable duct should preferably be chosen in such a way that the cable drum is located above the cable duct passage to be occupied, and the RAUDUCT system falls from the top apex of the cable drum into the cable duct. Experts know this process as „overhead insertion“.If due to the local conditions the drum has to be placed at an angle to the access chamber, the clean infeed of the RAUDUCT systems over a cable protective sheet is to be ensured. The bend radius of the RAU-DUCT systems should be R > 1.0 m on installation! When planning the line it is to be noted that the insertion of the RAUDUCT systems in the case of the repeated occurrence of small bend radii is made significantly more difficult.

Trench installationThe insertion of RAUDUCT EVMR system into duct trenches is recom-mended from the lower apex of the cable drum horizontally into the duct trench. The use of a cable duct bend at the inlet to the line and of cable rolls in the case of longer lines is absolutely necessary.

The bend radius of the RAUDUCT EVMR systems should beR > 1.5 m on installation!In the case of installation in open duct trenches it is necessary to ob-serve the conventional assembly technique used for all duct systems made from polymer materials (sand back-filling or plain concrete).If the optimum installation of the RAUDUCT EVMR systems under tensile load is not possible, the prior laying out of the ducts next to the duct line under force is recommended (storage duration min. 24 hours).

Ploughing-in and routingDue to their flexibility and the option of delivering them on drums or as bundled coils with very large duct lengths RAUDUCT EVMR systems are particularly suitable for direct ploughing-in/routing into the ground. In the case of ploughed-in RAUDUCT EVMR systems the back-filling with sand of the ducts installed into the ground takes place in the tunnel-shaped installation position using the sand or other fine parti-cles of soil which have been washed in with rainwater.Based on experience, traffic loads up to SLW 60 are not a problem above an installation depth > 0.9 m.

LubricationDue to the smooth outer sheathing made from PE-HD and the low tare weight the RAUDUCT systems can generally be inserted without any external lubrication into all cable ducts units on the basis of PVC, PP, PE ducts, concrete blocks or other materials with a smooth surface.If due to the condition of the cable duct passage (e.g. rough surface) high tensile forces are expected, lubrication with a cable lubrication grease or cable lubrication oil is recommended.Depending on the stretch of duct to be occupied, e.g. in the case of frequent, tight radii, or for insertion lengths > 300 m, and also for the insertion of RAUDUCT 3-way large it is vital to ensure that the sheathing is sufficiently lubricated.The RAUDUCT systems are resistant to all conventional cable lubrica-tion greases or oils.RAUDUCT EVMR systems are installed without lubrication. In the case of long installation lengths, the use of conventional cable transport rolls, primarily in the curved area, is recommended.

RAUDUCT from REHAU

Cable draw cord ChamberChamber

Hoist

PipeDN 100

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Jointing techniqueThe RAUDUCT systems are generally inserted into lengths of tunnel from access chamber to access chamber without a connecting piece. Connecting the internal ducts of a RAUDUCT system is therefore not normally required. Creating the connections between the RAUDUCT and RAUDUCT EVMR systems is however necessary:- In cable chambers in order to ensure optimum use of the possible insertion or shooting in lengths of cable - In the cable duct passage in order to use remaining lengths opti-

mally - During ploughing-in or routing of the RAUDUCT EVMR systems

Requirements on the system connectionAs the external diameters of the individual ducts of the RAUDUCT and RAUDUCT EVMR systems comply with DIN 8074, the connectors of the corresponding diameter suitable for the system connection of all PE cable ducts and PE pressure ducts can be used. The connector must however fulfil the following conditions: - Pressure resistance at least 10 bar:- The plug connectors must possess sufficient tensile strength in

order to be able to withstand the forces which occur during instal-lation

- Slim construction for optimum behaviour during installation. - Easy creation of the connection even under tight space conditions

in the access chamber- Plug connectors are preferred, as the space required for tightening screw connectors is often not available - Easy removal of the connection, so that it can be quickly removed

again at any time for injection or insertionThe special plug connector designed by REHAU are excellently suited to this purpose.The main body of the REHAU is made RAU-POM (Polyacetal).The inserted elastomer sealing ring ensures use up to 12 bar injection pressure.High longitudinal stability is achieved through the multi-toothed, conical clamping ring made from RAU-POM which is slotted on one side and is in contact with the duct. In the case of tensile force being exerted on the duct the clamping ring is pulled into the internal cone of the main body where the clamping force of the clamping ring is reliably increased up to the max. value of the longitudinal stability.

Creating the push-fit connection

Bevel duct endsBy rotating the milling tool in a clockwise direction the ends of the duct are bevelled precisely, cleanly and without burring.

The bevel should equate to 50 % of the thickness of the duct wall.

Mark insertion depthMark the insertion depth of the connector (see table) with a marker pen. The duct must not be scratched during marking!

Duct diameter Insertion depth

[mm] [mm]

25 53

32 53

40 60

50 67

Push-fit connectionDo not use lubricant - perhaps sprinkle the end of the duct with wa-ter. The duct is inserted into the fitting up to the stop or marking level in the connector without turning by overcoming the two resistances (clamping ring and sealing ring).

Dismantling the plug connectorThe push-fit connections can be removed again with the help of dismantling support channels.Two of the steel support channels adjusted for the external contour of the individual ducts are pushed into the narrow space between the duct and connector until the support channel lifts the clamping ring from the duct. The end of the duct can then be pulled out of the plug connector.If necessary, sprinkle the dismantling support channels with water or coat thinly with lubricant (inside and outside).

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Creating the system connectionThe connection of the internal ducts of the RAUDUCT system in the accesschamber of prior to insertion into the cable duct duct passage and also the RAUDUCT EVMR system takes place in stages at a length of approx. 75 cm so that the total diameter of the system does not exceed the permitted measurement at any point.To create the connection both of the RAUDUCT systems to be connected are each separated at a length of min. 60 cm by cutting through the sheathing between the internal ducts. The individual ducts of the two RAUDUCT systems to be connected are cut according to the required level. The levels are at intervals of approx. 25 cm. On all duct ends of the RAUDUCT or RAUDUCT EVMR systems to be connected the sheathing is to be separated from the individual ducts with a blade at a length of approx. 10 cm so that it is flush.

It has been shown to be advantageous to shorten one of the individual ducts (in the case of different duct dimensions the one with the largest individual duct dimension) of the two multi-duct systems to be con-nected by approx. 30 cm and to carry out the connection of this duct immediately. The remaining individual ducts now overlap and can be cut to the right length level and then connected to each other.To connect the individual ducts, it may be necessary to bend the two duct ends parallel to the stretch of duct in order to carry out the connec-tion.It is to be considered during every system connection that a space of approx. 5 mm must be left for the duct stop in the plug connectors between the two ducts to be connected.It must be ensured that individual ducts of the duct group are not mixed up once the connection has been created, otherwise the total tensile force of the system connection will not be achieved.In order to reduce the friction resistance in the cable duct passage, it is recommended that the whole connection area is bound with self-adhesive insulating tape or at least at some points the individual ductsare again attached to the duct group with the connectors.In the case of connecting RAUDUCT EVMR systems, proceed in the same way, in order to ensure a clean introduction of the connection points into the cable plough .In the case of connection in duct trenches the stepping of the connec-tion point is not essential, but is however recommended.

Tensile strength of the system connectionWhen using REHAU plug connectors the permitted tensile forces listed should generally not be exceeded!

Pressure testing and calibrationCable lines made from RAUDUCT and RAUDUCT EVMR systems must be sufficiently leak-tight in order to facilitate the shooting in of draw ropes or the direction shooting in of glass fibre cables and light copper cables, and to also prevent the ingression of gas and water from the ground into the ducts.With regard to the operational leak tightness of the overall system a pressure test can be carried out according to the KRV installation instruction A 535. The test is carried out with air according to EN 1610 (excess pressure 0.5 bar, test duration 15 minutes).It is often necessary following the installation and insertion of the cable ducts to carry out a pressure test to prove the injection suitability. The prerequisite for the pressure test described below is that a maximum number of 5 fittings on a 1000 m stretch of duct is not exceeded.The test is carried out at a pressure of 4 bar. Prior to the test, conditio-ning with 4.5 bar for 15 minutes is to be carried out. The pressureis then reduced to the testing pressure of 4 bar and the measuring started.The test is passed if the drop in pressure is less than 0.1 bar every 5 minutes, or maximum 0.8 bar over 30 minutes. A useful extension of the pressure test is the calibration of the ducts installed with a calibration diameter for the individual dimensions ac-cording to the following table. When doing this a calibration plate of the corresponding diameter, fitted with a sender, with a max. pressure of 3 bar is used to blow through every cable duct installed across the length of the line installed. Any duct contractions are located with a search device located in the sender fitted to the caliber and the duct restored at this point.

Duct dimension Caliber dimension

[mm] [mm]

25 x 2 16

32 x 2 24

32 x 2.9 22

40 x 2 31

40 x 3 29

40 x 3.7 28

50 x 2.5 40

50 x 3.5 38

50 x 4.6 35

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End capReusable end caps made from PE-HD are used for the sealing of RAU-DUCT and RAUDUCT EVMR systems. The corresponding end caps are available for every duct dimension. The end caps are not pressure-tight, but just serve to protect the ducts against the ingression of dirt, moisture and vermin.

If necessary, non-woven, thin draw ropes can be fixed with the end caps and therefore secured. The end caps are also used as transport seals for the ducts delivered as bundled coils or on drums.

End fittingEnd fittings are use to seal RAUDUCT and RAUDUCT EVMR systems so that they are leak-tight. On one side the end fittings have a leak-tight push-fit fitting in the same way as the push-type fittings. The other side of the end fitting consists of a threaded connector with a sealing surface for holding an O rubber sealing ring. A sealing plug inserted into the O rubber sealing ring forms with the help of a union nut the pressure-tight seal on the fitting opening. With the use of an end fitting pressure-tightness of up to 12 bar is achieved.The assembly and dismantling of the end fittings is carried out in the same way as the push-type fittings.

Separable cable sealFor lesser requirements on the leak-tightness separable individual passage seals can also be used as an alternative. These parts seal the internal surface of the ducts and can alsobe used if e.g. the excess of the ducts in the access chamber is insuf-ficient for the assembly of the end fittings. In the case of subsequent assembly to cable which has already been installed, the union nut is unscrewed and split into its two halves. The body of the seal can now be clipped on and is positioned on the cable. Once the two halves of the union nut have been reattached to the cable and this has been screwed onto the thread of the seal, the indi-vidual passage seal on the cable can be pushed into the cable to be sealed. With the help of the reducing fitting enclosed in the individual passage seal, different cable diameters can be sealed. In the case of subsequent assembly of the individual passage seal, the reducing sleeves are to be cut through lengthways with shears.

The end fittings can also be used as a pressure-tight duct seal during the pressure test.For lesser requirements on the leak-tightness, sealing plugs can also be used as an alternative.These parts seal the internal surface of the ducts and can also be used if e.g. the excess of the ducts in the access chamber is insuffici-ent for the assembly of the end fittings.

Fixing and sealing the cableThe sealing and fixing of the cable inserted to the RAUDUCT and RAUDUCT EVMR system is carried out using end fittings as described above. When doing this, the sealing plug in the O rubber sealing ring on the sealing side of the end fitting is simply removed. The O rubber sealing ring positioned on the inserted cable is compressed with the union nut. This ensures the fixing of the cable and a pressure-tight connection.

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Separable sealing plugThe RAUDUCT systems inserted into cable ducts must be sealed and fixed in the cable chambers. The specially developed REHAU sealing plugs are used for this.Through the fixing of the RAUDUCT system, movement of the duct group in the cable duct passage during work in the access cham-ber during insertion of cables, and also temperature-related length changes of the RAUDUCT ducts are prevented.Through the sealing of the remaining space between the RAUDUCT system and cable duct passage the diffusion of water and gas in the cable duct system from chamber to chamber is prevented. The sealing plugs can be assembled in the delivered condition in the closed version onto the multiple sub-duct pipes which end in the access chambers and are not yet occupied.If the multiple sub-duct pipes are already occupied with cables or if the multiple duct runs through the access chamber uninterrupted, the sealing plugs can be separated and used in the split version. The assembly of the sealing plug is carried out according to the parts of the assembly instructions included in the delivery.

The sealing plugs were developed for the sealing for the most frequently occurring dimension RAUDUCT 4-way. Other RAUDUCT and RAUDUCT EVMR systems can be sealed with the sealing plug by using reducing sleeves and dummy plugs. In the case of RAUDUCT and RAUDUCT EVMR systems, for which no sealing plug exists, the sealing can be carried out by foaming the gap with assembly foam. The contact of such substances with the RAUDUCT system is not a problem.For the connection of the RAUDUCT EVMR systems 3 x 50 and 2 x 50 to cable chambers or introduction into buildings, special chamber connection systems are available which are inserted directly into the chamber sockets or wall bridging sockets.

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Advantages of the REHAU system

REHAU RTR internal groovingThe interior surfaces of the REHAU PE cable ducts and RAUDUCT and also RAUDUCT EVMR systems are produced with the REHAU RTR internal grooving (REHAU trapezoidal grooving).The internal grooving ensures that the compressed air during injection can pass along the full extent of the cable. During this process, cables are shifted in waves, as a result of which the contact surface between the cable and internal wall of the duct is scaled down and the friction of the cable during injection is reduced to a minimum. The REHAU RTR internal grooving achieves the best values in a comparison test between ducts with different grooving geometry. Even ducts with a groove-free internal layer (so-called pre-lubricated ducts) could not achieve any better results. In the case of the REHAU RTR internal grooving, contrary to other internal grooving, the circular internal surface is retained, as this is simply interrupted by the groo-ving (so-called negative grooves). This protects the cable, cable jacket during installation, as in the case of ducts with sharp-edges or round grooves which protrude into the internal cross-section (so-called positive grooves) it rules out them inevitably coming into contact.

Allocation of ducts/cablesThe possible max. cable diameter which can be inserted into the existing internal ducts depends decisively on the construction of the tension elements on the cable head.The following allocation of internal ducts/cable is based on the difference of 10 mm tested in practice between the external diameter of the cable and the internal diameter of the duct to be occupied. In some cases deviations to practical experience both upwards and downwards can occur.

Duct dimension Cable diameter

[mm] [mm]

50 x 2.5 by 35

50 x 3.5 by 33

50 x 4.6 by 30

40 x 2 by 26

40 x 3 by 24

40 x 3.5/3.7 by 23

32 x 2 by 18

32 x 2.9 by 16

25 x 2 byw 11

REHAU has developed an installation method for the installation of long lengths of glass fibre which offers the user both technical and commercial advantages. With the REHAU VARIO insertion garniture glass fibre cable and light copper cable up to an external diameter of approx. 20 mm can be injected with the help of compressed air direct into the RAUDUCT or RAUDUCT EVMR ducts without the use of a draw rope. This installation method prevents overstraining of the delicate cable.The REHAU Vario insertion garniture is also suitable for the shooting in of draw ropes.

Introduction of cables

Technical advantage:One main advantage of the cable insertion garniture is the fact that the tensile force on the cable is distributed elastically across the column of air which lies between the insertion garniture and dolly. As a result of this, the erratic increases in tensile force which frequently occur with cable winches can safely be avoided.The tensile force exerted on the cable head depends simply on the remaining ring cross-section between the external diameter of the cable and internal diameter of the duct as well as the pressure exerted. As this ring cross-section cannot be changed for a selected combination of duct/cable, the tensile force applied can be managed very easily using the pressure which can be regulated on the insertion garniture. The max. possible tensile force for the REHAU VARIO inser-tion garniture also lies at the max. permitted pressure of 12 bar in the range of max. 50 to 60 % of the permitted tensile load mentioned by glass fibre cable manufacturers.

Advantages for the user:The REHAU VARIO insertion garniture insertion block is fitted with replaceable clamp shells, so that the cable installation is possible in all RAUDUCT or RAUDUCT EVMR ducts with the external diameters 25, 32, 40 and 50 mm. The insertion block is fitted with two air connec-tions in order to ensure a sufficient supply of compressed air from the compressor. Fitting a regulating armature with pressure measuring device facilitates the precise setting and monitoring of the injection pressure.Using the hinged insertion block cables can be fitted in sections over very large distances in the cable conduit. The slotted sealing set is dismantled following the injection process and can be reused.In order to install the full fabrication length of glass fibre cables in sections a second insertion garniture can be connected in sequence in an intermediate chamber or a support excavation pit.2000 m to 4000 m the number of glass fibre cable sockets required reduce and therefore significantly lower absorption of the signal to be transmitted is achieved.

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Function description REHAU VARIO insertion garniture

The matching dolly for the duct dimension intended for installation is fastened to the cable to be inserted with the help of an anti-twist device and a cable draw cord.The dolly is pushed into the cable duct up to the cable draw cord.

Once the insertion block has been fitted with the corresponding clam-ping shell for the external diameter of the cable duct, the end of the cable duct is inserted up to the stop in the front end of the insertion block and this part closed with the two clamp levers. The cable is fitted with 4 slotted gaskets with internal drill hole which matches the cable 2 slotted plastic sponges coated with lubricant. This complete sealing set is inserted into the depressions provided for it in the rear part of the insertion block.

The rear part of the insertion blocked is clamped at the bottom and locked with crosswise tightening of the 6 hexagon socket screws. In order to guarantee a sufficient supply of air, two 3/4“ compressed air hoses are connected to the control unit of the insertion block. To achieve maximum shooting in lengths, it is recommended that both air inlets are connected to the compressor via a compressed air lubrication unit so that the cable is constantly being lubricated during the injection process.

Regelarmatur mit Druckmessgerät

REHAU Vario-Einschießgarnitur

Cable trum

Cable

Cable

DollyTwist trap

Twist trap

Cable draw cord

To the compressor (10bar, 10 m3/min)

Dolly

PE cable duct/RAUCUT cableWith REHAU special grooving

REHAU VarioInsertion garniture

Control valve with pressure measuring device

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To operate the REHAU VARIO insertion garniture a building compressor with re-cooling and 10 bar operating pressure is required (10 bar, 10 m³/min).When handling compressed air it it essential to note the provisions for safety at work! The maximum permitted pressure for injection of 12 bar should not be exceeded!The injection pressure, starting at approx. 0.5 bar, is gradually incre-ased until the required feed speed is achieved. In practice an even speed of up to max. 45 - 50 m/min has proven to be advantageous.When shooting in cables with the REHAU VARIO insertion garniture it is essential that the surface of the cable is well coated with liquid lubricant (cable lubricant, e.g. Softenol or Gliss F). The application of the cable lubricant using the injected compressed air is particularly advantageous.

Conventional cable lubricant greases are not suitable for the coating of the cables to be injected!

Determining the maximum shooting in lengthsThe possible shooting in lengths can easily be determined using the two tables below and the diagram.

Note:Diagram 1 has been created on the basis of a coefficient of friction µ = 0.2. This coefficient of friction is easily achieved for cables with a PE sheath and when coating the surface of the cable with liquid cable lubricants.Diagram 1 applies for extensive, straight stretches with a total angle of up to 180°.

Working conditions which deviate to this can cause a significant deviation in the shooting in lengths which can be achieved!

This is determined in 3 steps:Step 1:Table 1 is used to determine the effective dolly surface in mm² depending on the internal diameter of the RAUDUCT or RAUDUCT EVMR ducts to be occupied and the external diameter of the cable to be inserted.

Step 2:Using Diagram 1, the max. shooting in length at 10 bar is determined depending on the effective dolly surface and the effective dolly surface and the weight of the cable.This max. shooting in length applies if the max. compressor pressure of 10 bar is available.

Step 3:At an effective compressor pressure below 10 bar the result from Step 2 must be multiplied by the corresponding reduction factor from Table 2.

Example:Situation given:Cable Ø: 12 mmCable weight: 0.20 kg/mDuct Ø: 40 x 3.7Actual pressure: 8 bar

Required:Maximum achievable shooting in length

Step 1:Effective dolly surface from Table 1:A = 721 mm²

Step 2:Maximum shooting in length at 10 bar from Diagram 1:ca. 1837 m

Step 3:Reduction factor for 8 bar from Table 2 = 0.8: 1837 m x 0.8 = 1470 m maximum achievable shooting in length

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Duct dimension 25x2.0 32x2.0 32x2.9 40x2.0 40x3.5 40x3.7 50x2.5 50x3.5 50x4.6

Duct ID [mm] 21 28 26 36 33 32.6 45 43 40.8

Cable AD [mm] Effective dolly surface A [mm²]

8 296 565 481 967 805 784 1539 1401 1257

9 283 552 467 954 791 771 1526 1388 1243

10 268 537 452 939 776 756 1511 1373 1228

11 251 520 436 922 760 739 1495 1356 1212

12 502 418 904 742 721 1477 1338 1194

13 483 398 885 722 702 1457 1319 1174

14 462 377 864 701 680 1436 1298 1153

15 439 354 841 678 658 1413 1275 1130

16 414 330 816 654 633 1389 1251 1106

17 389 790 628 607 1363 1225 1080

18 361 763 601 580 1335 1197 1052

19 734 571 551 1306 1168 1023

20 703 541 520 1276 1137 993

Table 1

Actual pressure [bar] 10 9 8 7 6 5 4 3 2

Factor 1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2

Table 2

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Maximum shooting in length 10 bar; µ = 0.2Cable weight 0.10 kg/m up to 0.45 kg/m

Diagram 1

REHAU PE COMPOSITE CABLE DUCTS

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6 CONTENTS REHAU PE COMPOSITE CABLE DUCTS

6.1 . . . Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103


6.3 . . . Composition/Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

6.4 . . . Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

6.5 . . . Delivery format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

6.6 . . . Product range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1036.6.1 . Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1046.6.2 . Fittings/accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104


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6.1 ApplicabilityThis document applies for flexible PE composite cable ducts and associated fittings.The illustrations, dimensional, colour and weight information contained in this document should provide a non-binding overview of the product range.

6.2 Area of applicationPE composite ducts are used to protect underground lines in power, high voltage, telecommunications, control and communications technology. Installation is carried out in a single layer or with spacers in several layers above and next to each other.

6.3 Composition/Design- Corrugated outer layer- Smooth internal layer- Easy handling due to low weight- Standard colour: Black, other colours on request- The composite ducts are produced to DIN EN 50086-2-4 - Leak-tightness: sand-tight as standard, water-tight connection in

the double push-fit socket with additional sealing rings on request

6.4 MaterialThe PE material guarantees high robustness, pliability (even at low temperatures) and chemical resistance.

Coils:Flexible due to the material combination of PE-LD (interior layer) and PE-HD (outer layer)

Cut lengths:Internally and externally in PE-HD

6.5 Delivery format - The coils are delivered in 50 m or 25 m coils- A double push-fit socket is assembled per coil- Each coil is fitted with an integral pulling aid- The cut lengths are delivered as 6 m cut lengths in HRVs (timber

frame crates)- Each cut length is fitted with a push-on double push-fit socket- Other lengths on request

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DN/OD 40 50 63 75 90 110 120 125 160 175 200

Coil/Art. no. 102801 102811 102821 102831 102841 102851 102861 102871 102881 102891 -

da (mm) 40 50 63 75 90 110 120 125 160 175 -

di (mm) approx. 30 40 50 60 74 93 100 106 136 150 -

Coil contents (m) 50 40 50 50 50 50 50 50 25/50 25/50 -

Bend radius approx.

(at 20 °C; m) 0.35 0.35 0.46 0.46 0.46 0.46 0.50 0.50 0.65 0.70

Cut lengths/Art. no. - 102901 102911 102921 102931 102941 102951 102961 102971 102981 102991

da (mm) - 50 63 75 90 110 120 125 160 175 200

di (mm) approx. - 40 50 60 74 93 100 106 136 150 174

Bend radius approx.

(at 20 °C; m) - 2.5 3.0 3.0 3.5 4.0 4.0 6.0 8.0 8.0 15

45° bend

incl. socket black - 246481 246491 102531 102541 102551 102561 102571 102581 102591 102601

Bend radius (m) - 0.60 0.60 0.75 0.75 1.10 1.10 1.10 1.10 1.10 1.40

90° bend

incl. socket black - 246461 246471 102611 102621 102631 102641 102651 102661 102671 -

Bend radius (m) - 0.60 0.60 0.75 0.75 1.10 1.10 1.10 1.10 1.10 -

Double push-fit socket

made from PE-HD; black 102691 102701 102711 102721 102731 102741 102751 102761 102771 102781 102791

Sealing plug

made from PE 103001 103011 103021 103031 103041 103051 103061 103071 103081 103091 103101

Sealing ring

made from PE-HD; black 102421 102431 102441 102451 102461 102471 102481 102491 102501 102511 102521

Spacer

made from PE-HD; black

multi-way; double-sided * * * * * * * * * * *

Transition socket to

smooth-walled duct, made from PVD-U - * * * * * * * - -

* on request

6.6 Product range 6.6.1 Ducts

6.6.2 Fittings/Accessoires


- PE composite ducts are slightly pliable, i.e. altering the trench course possible without, or with only a few bends

- Obstacles can be overcome with the flexible composite ducts – taking into account the cable insertion conditions and properties of the cable used

- Due to the low weight of the plastic cable ducts no special equip-ment is required during assembly

- During installation the installation instructions A515 of the Kunst-stoffverbandes e.V. (plastics association) in Bonn, DIN EN 1610 and ATV-A 127 are to be taken into account

- Long stretches can also be laid with the coils without a socket connection

- Easy to trim- Use of remaining lengths easily possible

- Easy connection of duct lengths using the double push-fit socket- Multi-way, adjacent and stacked cable duct channels are created

with spacers- A range of accessories in line with practice expands this composite

cable duct system- Other accessory parts such as transition sockets to smooth ducts,

branches or flexible bends on request

REHAU MICRO CABLE DUCT SYSTEMAREA OF APPLICATION “FIBRE TO THE X”

106

7 CONTENTS REHAU MICRO CABLE DUCT SYSTEM

7.1 . . . . Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

7.2 . . . . Area of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

7.3 . . . . Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

7.4 . . . . Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

7.5 . . . . Delivery format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

7.6 . . . . Product range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1087.6.1 . . . Micro cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1087.6.2 . . . Duct bundles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1087.6.3 . . . Fittings/accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109


107

The flexible expandability in line with requirements is particularly important in distribution networks. This includes simple and quick branching and connection options for supplying end customers.In addition to this, the separability of the cable capacity into different connections which are often unknown during network planning is particularly significant.The micro cable and glass fibre bundles facilitate this flexible compo-sition in conjunction with the micro cable ducts.Both during the construction of new cable networks, in particular dis-tribution networks, and when using existing empty duct lines, a variety of benefits can be achieved with micro cable ducts:- Jointing technique including tools- Range of fittings and accessories- Greatest possible flexibility- Amendment to each requirement- Individual identification options

PE micro cable ducts are characterised by the REHAU trapezoidal grooving (RTR). It optimises the inner surface of the duct to reduce the friction values, facilitates large injection or insertion lengths of the fibre optic cable and ensures protection of the cable sheath against friction.

7.3 MaterialMicro cable ducts made from RAU-PE 3204Material properties: Average density: > 0.94 g/cm3

Coefficient of linear expansion: 2.0 x 10 4 K-1

Thermal conductivity: 0.41 WK/m-1

Modulus of elasticity: > 800 MPaFire behaviour: B2 to DIN 4102

7.1 ApplicabilityThis document applies for micro cable ducts and also the associated fittings for creating cable duct lines, into which glass fibres, glass fibre bundles, sheathed glass fibre bundles (EPFU) and also micro cables can be injected.

Note:The micro cable ducts and fittings are not to be used for the construc-tion of compressed air, gas and water lines and other lines which are permanently pressurised.

7.2 Area of application

7.4 IdentificationThe ink-jet marking includes at least: „REHAU micro cable duct“< External diameter x wall thickness >< running metres>“

With regard to the specific project, these micro cable ducts can be supplied with different coloured stripes and customer-specific markings.

7.5 Delivery formatThe micro cable ducts from REHAU are delivered as standard on wooden disposable drums.The corresponding delivery lengths can be found under „product range“. Other delivery formats and delivery lengths are possible on request.

108

7.6.1 Micro cable ducts

For the installation of fibre optic cablesMaterial: PE-HD, transparent with coloured stripes

7.6.2 Duct bundlesMicro Duct bundle 24 Outer layer: PP, Colour Green Micro cable ducts: PE-HD, coloured, internal slip coat

Art. no. Dimension Outer diameter (AD) Internal diameter Delivery lengths[mm] [mm] [m]

102403 5 x 0.75 5 3.5 2.000102580 7 x 0.75 7 5.5 1.250102158 7 x 1.5 7 4 1.250102560 10 x 1.0 10 8 2.500102164 10 x 2.0 10 6 2.500102148 12 x 2.0 12 8 1.750102166 14 x 2.0 14 10 1.250102165 16 x 2.0 16 12 1.000

Art. no. max. outer diameter (AD) in mm Description Delivery length in m

102156 36 x24 5 x 0.75 1.200

7.6 Product range

GeneralMicro cable ducts can be installed up to a minimum bending radius, which equates to 10x the duct diameter, in the case of uncontrolled bending.

Micro cable ducts d5 for the injection of micro cables (EPFU) and glass fibre bundles - normal flammabilityThe double-layered REHAU micro cable ducts for the injection of micro cables (EPFU) and glass fibre bundles consist of RAU-PE and also pos-sess an inner layer which is optimised for high injection speeds and large injection widths.The ring stiffness of the micro cable ducts is at least 128 kN/m2 (SN 128) to DIN EN ISO 9969.

Micro cable ducts above d7 for the injection of mini cablesThe REHAU micro cable ducts made from RAU-PE for the injection of mini cables are made as standard from transparent RAU-PE with coloured stripes. Due to the translucency, occupied micro cable ducts can be differentiated from unoccupied cable ducts, the coloured stripes guarantee that they are distinguishable. In addition to this, the micro cable ducts possess the tried and tested REHAU RTR internal grooving, which ensures high injection speeds and large injection widths. The ring stiffness of the micro cable ducts is at least 32 kN/m2 (SN 32) to DIN EN ISO 9969.

109

Plug connectorFor the tight and pressurised connection of micro cable ducts up to 10 bar


Reducing fittingsFor the tight and pressure-tight connection of micro cable ductsup to 10 bar

Locking clip

End stopperFor the pressure-tight sealing of unoccupied micro cable ducts,pressure-tight up to 10 bar

Art. No. d [mm] Packaging unit [Unit]

225512 (di) 5 10225652 (db) 7 10150187 (di) 10 10225672 (db) 10 10225682 (db) 12 10225692 (db) 14 10150186 (db) 16 10

Art. No. Reduction Packaging unit [Unit]

225742 (di) 12 mm - 10 mm 10225722 (di) 10 mm - 7 mm 100225702 (di) 7 mm - 5 mm 100

Art. No. Dimension [mm] Packaging unit [Unit]

150188 10 100150189 12 100


225792 5 10225812 7 10225832 10 10225842 12 10150195 14 10150196 16 10

110


225752 5 10225782 10 10227592 12 10150209 16 100


225862 5 100225872 7 100225892 10 100150185 12 100150193 14 100150194 16 100


150198 40-40-32 1225992 40-40-40 1150199 50-50-32 1150203 50-50-40 1226012 50-50-50 1

Sealing plug For the pressure-tight sealing of unoccupied micro cable ducts in connection with REHAU plug connectors

Individual passage sealsPressure-tight and tight connection of fibre optic cables to the micro cable duct

45° Y-branch Separable branch, tight connection of the connected cable ducts

90° T-branch Separable branch, tight connection of the connected cable ducts

Reducing fitting for 45° and 90° branchesReducing fittings for adjustment to the existing PE cable ducts


226032 40-40-40 1150204 50-50-50 1


226042 40-32 10226052 50-32 10150205 50-40 10

111


150206 40/5 x 7 mm 1150207 40/5 x 10 mm 1150208 50/7 x 10 mm 1


225952 5150197 7

Multiple sealing element

Injection socket (push-on garniture)

Tangit expansion resin M 3000 In the case of masonry and walls for which sealing from the outside with the house lead-in is insufficient, hollow spaces can also be sealed reliably using Tangit M 3000.

House lead-in House lead-in for the sealing of micro cable ducts during introduction into house walls. For micro cable ducts from 7 mm to 14 mm or 2 micro cable ducts ≤ 7 mm. Borehole diameter 24 mm Standard for wall thicknesses up to 400 mm. For larger wall thicknesses on request. Gas-tight and water-tight up to a 4 m water head

Art. No. Contents/Coverage Packaging unit [Unit]

150213 150 ml/0,75 l 10150214 300 ml/1,5 l 6

Art. No. Packaging unit [Unit]

150001 individually

112


Injection of micro cables and mini cablesREHAU Mikrokabelrohre können in Kabelrohre mittels marktüblicher Einblasgeräte eingeblasen werden.

Direct installation into the groundDirect installation into the ground in sand 0/2 is generally possible. When doing this, it is to be ensured that rougher soil particles cannot migrate as far as the micro cable ducts. Furthermore, the risk of damage caused by rodents is also to be taken into account.

Injection of glass fibre and micro cables (EPFU)Glass fibre, glass fibre bundles and micro cables (EPFU) can be injected into REHAU micro cable ducts using conventional injection devices.When doing this the device manufacturer’s operating instructions are to be observed.

During this process, the following maximum tensile forces for RAU-PE micro cable ducts are permitted at 20 °C:

Micro cable duct Tensile force5 x 0.75 80 N7 x 0.75 115 N7 x 1.5 200 N10 x 1.0 220 N10 x 2.0 400 N12 x 2.0 500 N14 x 2.0 600 N16 x 2.0 700 N

Insertion of micro cable ductsREHAU micro cable ducts can be inserted into cable ducts. To do this, it recommended that the micro cable ducts are fastened using a tight clamping device to a draw rope.

Storage and transportPoint loads and also contact with sharp objects are to be avoided during storage and transport.Drums are to be stored in such a way that the load is absorbed exclu-sively by the flange of the drum.

The REHAU RAU-PE micro cable ducts are UV-stabilised and can be stored outside in Central Europe for up to a year.

Direct sun radiation and also heating above 35 °C should however be avoided, as the micro cable ducts reels can become oval due to their own weight.

STATIC CALCULATION

114

8 CONTENTS STATIC CALCULATION

8.1 . . . . Technical principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 8.1.1 . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1158.1.2 . . . Guaranteeing the load assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

8.2 . . . . Calculation basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

8.3 . . . . Permitted deformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

8.4 . . . . Soil types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

115

STATIC CALCULATION BASED ON WORKSHEET ATV-DVWK-A 127, 3RD EDITION, AUGUST 2000

8.1 Technical principlesDuct lines are technical structures, where the interaction of compo-nents, bedding and filling is the basis for the stability and operating safety. The parts supplied, such as ducts, fittings and seals, together with the services to be provided on site, such as bedding, creating the duct connection, side and main filling, are important factors for ensuring that the proper function of the building is ensured.

8.1.1 GeneralUnderground plastic ducts and fittings behave like elastic, i.e. they are more flexible than the soil material in the proximity. The ducts and fit-tings are removed by an intentional slight deformation of the load and activate the supporting forces of the sheathing. The static calculation takes into account the loads, the ground characteristic values and also the parameters of the ducts.In the case of less stable ground, it is to be ensured that the bedding and duct sheathing cannot push into the native soil, as a result of which the supporting forces would reduce considerably. In order to avoid this, we recommend in this case that the duct sheathing is covered with a tear-resistant non-woven material / geotextile and, if necessary, that the base of the excavation is stabilised.

8.1.2 Guaranteeing the load assumptionsBefore the start of the building project, the load bearing capacity of a duct line must be tested, decided or stipulated in accordance with EN 752-3 and EN 1295-1.The work should be completed in a controlled fashion in such a way that the load assumptions which arise from the planning documents are assured or adapted to the different conditions. The load assump-tions are essentially influenced by the following factors and their changes:- Difference between the actual trench width and the calculated

trench width Calculated trench width- Difference between the trench width created and the calculated

trench width- Type of trench lining and the effects of its removal - level of compac-

tion in the line zone

- Level of compaction of the main filling- Duct bedding and trench base- Site traffic and occasional loads- Types of soil and ground characteristic values (e.g. subsoil, trench

walls and filling)- Trench format (e.g. stepped trenches, trenches with sloped walls);- Condition of the subsoil and soil (e.g. during frost and dew, rain,

snow, flooding)- Groundwater level- Further duct lines in the same trench

8.2 Assumptions

PVC-U

Modulus of elasticity:

Short-term: 3000 N/mm2

Long-term: 1500 N/mm2

Short-term bending strength: 90 N/mm2

Long-term bending strength: 50 N/mm2

PP-B






PE-HD






8.3 Permitted deformation

All REHAU duct systems in the area of telecommunication are struc-tural components which bend elastically. A controlled deformation in the assembled position is required, as the duct and floor form a load bearing system.

The long-term deformation (max) 6 % at a security factor of 2.5, or 9% in well-founded individual cases with non-linear test to ATV-DVWK Worksheet A 127 (3rd edition).

116

8.4 Soil types

Group Specific gravity Inner angle Deformation modulus EB in N/mm2

Bof friction for level of compaction Dpr in %

kN/m3 Dpr = 85 90 92 95 97 100

G 1 20 35 2.0 6 9 16 23 40

G 2 20 30 1.2 3 4 8 11 20

G 3 20 25 0.8 2 3 5 8 13

G 4 20 20 0.6 1.5 2 4 6 10

Specification of soil groups G1-G4Group 1: non-cohesive soils

Gruppe 2: low-cohesive soils

Grain size Grain size

Description < = 0.06 mm

> 2 mm Identifying feature Examples

GE Tightly graded chippings

< = 5 % > 40 % Steep grain line as a consequence of the prevalence of a grain size area

Rubble, moraine gravel, volcanic scoria and ashRiver and beach gravel, patio

GW Loosely graded gravel-

< = 5 % > 40 % Grain line running continuously over seve-ral grain size areas

River and beach gravel, patio sand mixture rubble, moraine gravel, volca-nic scoria and ash

GI Intermittently stepped gravel sans mixtures

< = 5 % > 40 % Step-like grain line as a consequence of a lack of one or more grain size areas

River and beach gravel, patio rubble, moraine gravel, volcanic scoria and ash

SE Tightly graded sands < = 5 % < = 40 % Steep grain line as a consequence of the prevalence of a grain size area

Dune and drifting sand, valley sand (Berlin sand), basin sand, tertiay sand

SW Loosely graded sand gravel mixtures

< = 5 % < = 40 % Grain line running continuously over seve-ral grain size areas

moraine sand,terrace sand,Beach sand

SI Intermittently stepped sand-gravel mixtures

< = 5 % < = 40 % Step-like grain line as a consequence of a lack of one or more grain size areas

moraine sand,terrace sand,Beach sand




GU Gravel-siltmixtures

5-15 % > 40 % Widely or intermittently steppedgrain line,Fine grain content is silty

weathering gravel, talus material,limey gravel, boulder clay

GW Gravel-day mixtures 5-15 % > 40 % Widely or intermittently steppedgrain line,Fine grain content is clayey


SU Sand-silt mixtures

5-15 % < = 40 % Widely or intermittently steppedgrain line,Fine grain content is silty

floating sand

ST Sand-claymixtures

5-15 % < = 40 % Widely or intermittently steppedgrain line,Fine grain content is clayey

Limey sand, creeping sand

117

Gruppe 3: Cohesive mixed soils, silt

Gruppe 4: cohesive soils




GŪ Gravel-silt mixtures 15-40 % > 40 % Widely or intermittently stepped grain line, fine grain content is silty


GT Gravel-clay mixtures 15-40 % > 40 % Widely or intermittently stepped grain line, fine grain content is clayey


SŪ Sand-silt mixtures 15-40 % < 40 % Widely or intermittently stepped grain line, fine grain content is silty

Alluvial clay, sand loam

ST Sand-clay mixtures 15-40 % < 40 % Widely or intermittently stepped grain line, fine grain content is clayey

boulder clay, glacial drift

UL Slightly plastic silts > 40 % Low dry strenght, quick Shake test reaction, none to slightPlasticity during knead test

loam, high tide loam

UM Medium plastic silts > 40 % Low to medium dry strength,slow shake test reaction, slight tomedium plasticity during knead test

lacustrine clay, basin silt

Grain size


Identifying feature Examples

TL Slightly plastic Clays > 40 % Medium to high dry strength, no to slow shake test reaction, slight plasticity during kneading trial

glacial drift, varved day

TM medium plastic clays > 40 % High dry stability, no shake test reaction,medium plasticity during knead test

loam clay, basin clay, keuper marl

TA Distinctive plasticity clays

> 40 % Very high dry stability, no shake test reaction, pronounced plasticity during kneading trial

Tarras, septaria clay, jura clay

OU Silts with oranic constituents and organic silts

> 40 % Medium dry strength, slow to very quick shake test reaction, medium plasticity during knead

lake marl, diatomaceous earth,native soil

OT Clays with organic constituents and organic clays

> 40 % High dry stability, no shake test reaction,pronounced plasticity during knead test

mud, clay soil

OH Coarse to mixed-grained soil withconstituents

< = 40 % constituents of a vegetable type, mostly dark coloured, musty smell, loss on ignition up toabout 20 weight %

Topsoil

OK Coarse to mixed-grained soil with chalky, gravelly formations

< = 40 % constituents of a non-vegetable type, mostly light coloured, light weight, high porosity

Chalk sand, tuff sans

UA Silts with filling from foreign materials

- - Rubbish, scoria, building rubble, industrial waste

118

INFORMATION ABOUT THE STATIC CALCULATION OF GRAVITY DUCT LINES

Building project:

Client: Installer:Specifier:

Sheet: Town/post code:

Tel./fax/mail:

Contact person:

Phase: Planning Quotation Order

Cable duct duct system PE cable duct. . . . . . . . . . . . . . . . . . .

PP cable duct

PVC cable duct

Dimension: DN/OD.................. DN/OD.................. DN/OD..................

Wall thickness: ......................mm ......................mm ......................mm

Quantity (running metres): ca. ....................m ca. ....................m ca. ....................m

Coverage height above min h= .............m min h= .............m min h= .............m

duct apex (incl. road surface: max h= .............m max h= .............m max h= .............m

Groundwater: available - Height above the duct base ................m - at coverage height ................m

not existing

available - Height above the duct base ................m - at coverage height ................m

not existing

available - Height above the duct base ................m - at coverage height ................m

not existing

Soil groups according to ATV-DVWK-A 127 and DIN 18196:

G1: non-cohesive soilsG3: cohesive

G2: low-cohesive soilsG4: cohesive soils

Covering 1 Level of compactionDPr= ...............%

Level of compactionDPr= ...............%


Soil group to ATV-DVWK-A 127

G1 G2 G3 G4 G1 G2 G3 G4 G1 G2 G3 G4

Duct zone 2 Level of compactionDPr= ...............%




G1 G2 G3 G4 G1 G2 G3 G4 G1 G2 G3 G4

Available as a download from our homepage at www.rehau.de/tiefbau - Calculation to ATV-DVWK-A 127 -

Please fax to your nearest REHAU Sales Office or send by email:

119



Native soil 3 Level of compactionDPr= ...............%




G1 G2 G3 G4 G1 G2 G3 G4 G1 G2 G3 G4

Sub-soil under the duct 4 Level of compactionDPr= ...............%




G1 G2 G3 G4 G1 G2 G3 G4 G1 G2 G3 G4

Trench shape: Individual trench Individual trench Individual trench

Stepped trench Stepped trench Stepped trench

Multiple trench Multiple trench Multiple trench

Embankment Embankment Embankment

Trench width: b= ...................m b= ...................m b= ...................m

Angle of slope: ß= ...................° ß= ...................° ß= ...................°

1

2 23 3

4

bß

Cover conditions for the trench fillingTrench filling above the duct zone in accordance with ATV-DVWK-A 127

A1In layers of compacted filling against the undisturbed ground (without verification of the level of compaction)

A2Vertical construction of the duct trench with trench sheeting or light sheet profiles which are only removed following back-fillingTrench lining boards or equipment which is removed gradually during back-filling of the trench / uncompacted trench back-filling / washing-in of the back-filling (soil group G1 only)

A3 Vertical stope support of the duct trench with sheet piling, wooden beams, stope support sheets and devices which are only remo-ved after filling.

A4 Layers of compacted trench back-filling against the undisturbed ground with verification of the required Proctor density to ZTVE-StB (cannot be used for soil group G4)

B1 Layers of compacted bedding against the undisturbed ground or layers in the embankment (without verification of the level of compaction)

B2 Vertical lining of the duct trench with trench sheeting or light sheet profiles which are only removed once the trench has been back-filled/ trench lining plates or equipment, under the condition that the compacting is secured following removal of the lining / washing-in of the bedding (G1 group soil only)

Bedding conditions for trench back-fillingBedding in the line zone

120



B3 Vertical lining within the duct zone with sheet piling, wooden beams, trench lining sheets and equipment, withoutremoving them until effective re-compacting has taken place (NB: This bedding condition cannot be recorded by any verified arithmetic model. Therefore B3 cannot be used for the calculation to ATV-DVWK A 127)

B4Layers of compacted bedding against the undisturbed ground or layers in the embankment (without verification of the required Proctor density to ZTVE-StB (cannot be used for soil group G4)

Below

ram

depth:

ts= ...................m ts= ...................m ts= ...................m

Moving load: None None None

LKW 12 LKW 12 LKW 12

SLW 30 SLW 30 SLW 30

SLW 60 SLW 60 SLW 60

UIC 71 single track UIC 71 single track UIC 71 single track

UIC 71 multiple track UIC 71 multiple track UIC 71 multiple track

Aircraft load BFZ ..............



Miscellaneous Surface load ..............kN/m2



Road covering: yes no yes no yes no

Support forProof of stress (2a)

60° 60° 60°

90° 90° 90°

120° 120° 120°

Miscellaneous ............° Miscellaneous ............° Miscellaneous ............°

Sketch for special installation situations

ts

Comments/additions:

Date:

Signature:

2α

REHAU SERvicE

122

Full-service for your success

With comprehensive and forward-thinking system solutions, REHAU has long been setting new trends for energy-efficient construction, and at an increasing rate. The solutions offer signifi-cant potential savings, preserve resources and the environment and ensure the supply of energy for future generations.

In addition to user-orientated system solutions, as an architect, specialist company, specialist trade, private or public/commercial property owner you can access a wide range of practice-related REHAU services.

SERvicE WiTH SYSTEMS REHAU DiENSTLEiSTUNGEN

The focus here is always on the benefits for our customers and partners. In this respect we support you with technical applications and commercial

support, specially tailored advice with technical spe-cialists and a service concept based on partnership.

123

Our services with systems:

Consultancy- Planning support: Right from the planning phase

REHAU is available to you as a reliable partner during your technical preparation through to submitting quotations Our current invitation to tender texts can be found on the internet on the individual product sites (downloads tab) and at www.rehau.de/downloads

- Technical instruction: Questions about the first installation of our systems? We will gladly come to you at the construction site and instruct you and your colleagues professionally

- Technical telephone support: We will answer your questions across the REHAU civil enginee-ring product ranges

- Sales offices in your area: Benefit from our local presence

Software- Planning and calculation programs: We will

gladly support you with your planning or static calculation

- Software for air-ground heat exchangers, RAUSIKKO, biomass, sewer systems: Use the appropriate software for designing your building project

REHAU ACADEMY- Product and specialist training: Benefit from our extensive range of seminars on

products or current topics. Learn more in our seminar planner or at www.rehau.de/akademie

- Building site workshops: From experience emerges common practice!

- Central and decentral events: Whatever suits you! Visit the REHAU ACADEMY in Erlangen or benefit from our on-site training

Discover the world of REHAU services

and speak to us. We are happy to help.

You will find further information on the

internet at

www.rehau.de/service

REHAU E-Business- EDI: For specialist tradesmen with their own

goods management system. Organise your data exchange with us electronically.

Paperless, quick, simple- Customer portal: Orders, order tracking and

current information 24 hours a day, 365 days a year

- Internet presentation civil engineering: Around the clock and always up-to-date!

Simply have a look under www.rehau.de/tiefbau - E-Mailings and newsletters: We keep you

up-to-date by e-mail. Simply request our free newsletter at www.rehau.de/newsletter

Marketing/Advertising/Sales promotion- Sales literature: Receive detailed information

about our product ranges also via a convenient download at

www.rehau.de/downloads- Sales promotion and customer support: We support you with professional sales promotion

tools which are tailored to the target group

SERvicE WiTH SYSTEMS REHAU DiENSTLEiSTUNGEN

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iNNOvATivE SYSTEMS FOR cONSTRUcTiONFROM ENERGY-EFFiciENT cONSTRUcTiON TO RESOURcE-

SAviNG WATER MANAGEMENT

Windows and curtain walling technologySystems for:1 Windows2 French windows3 Curtain walling 4 Residential doors 5 Tambour doors and folding shutters 6 Conservatories 7 Ventilation technology 8 Interior window boards9 Fillings for residential doors

Lift-slide patio doorsPassive house certified solutions

Building technologySystems for:10 underfloor heating/cooling 11 Wall heating 12 Drinking water and heating installations13 Roof drainage 14 Heat pumps15 Solar thermal energy16 Central vacuum cleaner systems17 Sound insulating domestic waste water systems18 Facility heating

Concrete core temperingGas installationsElectrical installations

Civil engineeringSystems for:19 foul sewer and storm sewer systems20 Sewer chambers 21 Civil engineering pipes and drainage 22 Rainwater harvesting

REHAU is a leading supplier of integrated system solutions for construction with extensive services in planning, design and operation, e.g. for energy-efficient construction and sustainable water management.

23 Rainwater percolation24 Drinking water pipes25 Gas pipes26 Geothermal heat recovery with probes27 Geothermal heat recovery with colletors28 Air-ground heat exchanger systems 29 Communication lines30 Trenchless technology for installation of cables and pipelines31 Earthworks and traffic route construction32 Decentral waste water cleaning

House lead-insLocal and district heating supplySewage plantsBiogas units

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Windows and curtain walling technologySystem solutions for windows, residential doors, tambour doors, folding shutters, conservatories and curtain walling. Whether it’s a renovation project or a new build: Systems and first-class services for all building phases from project planning through to execution.

Building technology System solutions: From heat pumps via underfloor he-ating cooling and plumbing, heating and gas installati-on, solar thermal energy, electrical installation through to industrial pipe and compressed air networks

Civil engineering System solutions: From supply via communica-tions engineering and geothermal energy and also rain water management through to traffic route construction, earth and groundworks and disposal.

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REHAU sAlEs officEs

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REHAU aims to be as close to its customers as possible. Your regional REHAU sales offices are available for rapid, satisfactory and constant support on site. The expert employees there ensure professional advice and handling of enquiries and problems.

The popular REHAU products are kept for you in efficient logistics centres and large warehouses. We support you with advice and information during the preparation and planning of large projects or difficult constructions through to execution.

REHAU locations in Europe

REHAU sAlEs officEsAlwAys in yoUR AREA

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REHAU sAlEs officEs

REHAU SALES OFFICES AE: Dubai, Phone: +9714 8835677, [email protected] AR: Buenos Aires, Phone: +54 11 489860-00, [email protected] AT: Linz, Phone: +43 732 381610-0, [email protected] Vienna, Phone: +43 2236 24684, [email protected] AU: Adelaide, Phone: +61 8 82990031, [email protected] Brisbane, Phone: +61 7 38897522 [email protected] Melbourne, Phone: +61 3 95875544, [email protected] Perth, Phone: +61 8 94564311, [email protected] Sydney, Phone: +61 2 87414500, [email protected] BA: Sarajevo, Phone: +387 33 475-500, [email protected] BE: Brussels, Phone: +32 16 3999-11, [email protected] BG: So a, Phone: +359 2 89204-71, so [email protected] BR: Arapongas, Phone: +55 43 3152 2004, [email protected] Belo Horizonte, Phone:+55 31 33097737, [email protected] Caxias do Sul, Phone:+55 54 32146606, [email protected] Mirassol, Phone: +55 17 32535190, [email protected] Sao Paulo, Phone: +55 11 461339- 22, [email protected] BY: Minsk, Phone: +375 17 2450209, [email protected] CA: Moncton, Phone: +1 506 5382346, [email protected] Montreal, Phone: +1 514 9050345, [email protected] St. John‘s, Phone: +1 709 7473909, [email protected] Toronto, Phone: +1 905 3353284, [email protected] Vancouver, Phone: +1 604 6264666, [email protected] Winnipeg, Phone: +1 204 6972028, [email protected] CH: Berne, Phone: +41 31 7202-120, [email protected] Vevey, Phone: + 41 21 94826-36, [email protected] Zurich, Phone: +41 44 83979-79, [email protected] CL: Santiago, Phone: +56 2 540-1900, [email protected] CN: Guangzhou, Phone: +86 20 87760343, [email protected] Beijing, Phone: +86 10 64282956, [email protected] Shanghai, Phone: +86 21 63551155, [email protected] CO: Bogota, Phone: +57 1415 7590, [email protected] CZ: Prague, Phone: +420 2 72190-111, [email protected] DE: Berlin, Phone: +49 30 66766-0, [email protected] Bielefeld, Phone: +49 521 20840-0, [email protected] Bochum, Phone: +49 234 68903-0, [email protected] Frankfurt, Phone: +49 6074 4090-0, [email protected] Hamburg, Phone: +49 40 733402-100, [email protected] Leipzig, Phone: +49 34292 82-0, [email protected] Munich, Phone: +49 8102 86-0, [email protected] Nuremberg, Phone: +49 9131 93408-0, [email protected] Stuttgart, Phone: +49 7159 1601-0, [email protected] DK: Copenhagen, Phone: +45 46 7737-00, [email protected] EE: Tallinn, Phone: +372 6 0258-50, [email protected] ES: Barcelona, Phone: +34 93 6353-500, [email protected] Bilbao, Phone: +34 94 45386-36, [email protected] Madrid, Phone: +34 91 6839425, [email protected] FI: Helsinki, Phone: +358 9 877099-00, [email protected] FR: Agen, Phone: +33 5536958-69, [email protected] Lyon, Phone: +33 472026-300, [email protected] Metz, Phone: +33 3870585-00, [email protected] Paris, Phone: +33 1 348364-50, [email protected] Rennes, Phone: +33 2 996521-30, [email protected] GE: Ti is, Phone: +995 32 559909, [email protected] GB: Glasgow, Phone: +44 1698 50 3700, [email protected] Manchester, Phone: +44 161 7777-400, [email protected] Slough, Phone: +44 1753 5885-00, [email protected] GR: Athens, Phone: +30 210 6682-500, [email protected] HR: Zagreb, Phone: +385 1 3444-711, [email protected] HU: Budapest, Phone:+36 23 5307-00, [email protected] ID: Jakarta, Phone: +62 21 89902266, [email protected] IE: Dublin, Phone: +353 1 816502-0, [email protected] IN: New Delhi, Phone: +91 11 450 44700, [email protected] Mumbai, Phone: +91 22 67922929, [email protected] IT: Milan, Phone: +39 02 95941-1, [email protected] Pesaro, Phone: +39 0721 2006-11, [email protected] Rome, Phone: +39 06 900613-11, [email protected] Treviso, Phone: +39 0422 7265-11, [email protected] KR: Seoul, Phone: +82 2 5011656, [email protected] KZ: Almaty, Phone: +7 727 394 1304, [email protected] LT: Vilnius, Phone: +3 705 24614-00, [email protected] LV: Riga, Phone: +3 71 67 609080, [email protected] MA: Casablanca, Phone: +212 522 250593, [email protected] MK: Skopje, Phone: +3 892 2402-670, [email protected] MX: Celaya, Phone: +52 461 61880-00, [email protected] Monterrey, Phone: +52 81 81210-130, [email protected] NL: Nijkerk, Phone: +31 33 24799-11, [email protected] NO: Oslo, Phone: +47 22 5141-50, [email protected] NZ: Auckland, Phone: +64 9 2722264, [email protected] PE: Lima, Phone: +51 1 2261713, [email protected] PL: Katowice, Phone: +48 32 7755-100, [email protected] Poznań, Phone: +48 61 849-8400, [email protected] Warsaw, Phone: +48 22 2056-300, [email protected] PO: Lisbon, Phone: +3 51 21 94972-20, [email protected] TW: Taipei, Phone: +886 2 87803899, [email protected] RO: Bacau, Phone: +40 234 512066, [email protected] Bucharest, Phone: +40 21 2665180, [email protected] Cluj, Phone: +40 264 415211, [email protected] RU: Chabarowsk, Phone: +7 4212 411218, [email protected] Yekaterinburg, Phone: +7 343 2535305, [email protected] Krasnodar, Phone: +7 861 2103636, [email protected] Moscow, Phone: +7 495 6632060, [email protected] Nizhny Novgorod, Phone: +7813 786927, [email protected] Nowosibirsk, Phone: +7 383 2000353, [email protected] Rostov-on-Don, Phone: +7 8632 978444, [email protected] Samara, Phone: +7 8462 698058, [email protected] St. Petersburg, Phone: +7 812 3266207, [email protected] RS: Belgrade, Phone: +3 81 11 3770-301, [email protected] SE: Örebro, Phone: +46 19 2064-00, [email protected] SG: Singapore, Phone: +65 63926006, [email protected] SK: Bratislava, Phone: +4 21 2 682091-10, [email protected] TH: Bangkok, Phone: +66 2 7443155, [email protected] TR: Istanbul, Phone: +90 212 35547-00, [email protected] UA: Dnepropetrowsk, Phone: +380 56 3705028, [email protected] Kiev, Phone: +380 44 4677710, [email protected] Lviv, Phone: +380 32 2244810, [email protected] Odessa, Phone: +380 48 7800708, [email protected] US: Chicago, Phone: +1 630 3173500, [email protected] Detroit, Phone: +1 248 8489100, [email protected] Grand Rapids, Phone: +1 616 2856867, [email protected] Greensboro, Phone: +1 336 8522023, [email protected] Los Angeles, Phone: +1 951 5499017, [email protected] Minneapolis, Phone: +1 612 253 0576, [email protected] ZA: Durban, Phone: +27 31 657447, [email protected] Johannesburg, Phone: +27 11 201-1300, [email protected]

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Notes:

131

Notes:

Delivery and payment terms:For detailed informations please contact your local REHAU sales office.

Article identification:To ensure the clear designation of the articles, the article, material and colour number must be specified.

Other REHAU product ranges:

Sewer technologyPressure pipes

Subject to technical modifications.

Should you have any queries please contact our application engineering department.

Our verbal and written advice relating to technical applications is based on experience

and is to the best of our knowledge correct but is given without obligation. Conditions

that are beyond our control or for applications other than those specified releases us

from any obligations in regard to claims made in respect of the products.

We recommend that a check is made as to whether the REHAU product is suitable for

the envisaged purpose. Application, use and processing of the products is carried out

beyond the scope of our control and are therefore carried out exclusively at your own

responsibility. In the event that a liability is nevertheless considered, then this will be

based exclusively on our conditions of sale, which can be seen under www.rehau.de/

LZB. This also applies to any warranty claims, where the warranty assumes consistent

quality of our products in accordance with our specification.

Please note that our consultation and design planning is based on the data provided by

you and the relevant technical regulations. Please check using the attached docu-

ments whether the data and results apply to your building project. We ask you for your

understanding that REHAU cannot assume any guarantee for this service provided free

of charge.

www.rehau.com ©REHAU 300055 EN 02.2011

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