A BRUGG GROUP COMPANY
Local and district heating systems are efficient and space-saving alternatives to oil or gas-fired heating – and, most importantly, they are far more environmentally friendly. With this heating model, consumers obtain district heating from central generation facilities, such as biogas plants. Additionally, combined heat and power (CHP) plants provide an opportunity to harness district heating while reducing the loss of valuable thermal energy. When electricity is generated, a significant amount of heat is always produced at the same time. Typically, this “byproduct” goes unused; however, a much better solution is to distribute this generated heat via district heating pipes and use it to warm buildings. The distinction between local and district heating depends on the distance between the heat source and the point of consumption. If the building and the heat generation facility are only a few kilometres apart, the term “local heating” is generally used. However, the supply principle remains the same.
Both private homes and multi-storey commercial buildings can be heated sustainably and efficiently via district heating. Similar to conventional heating systems, district heating pipes are installed underground and connect directly to heat transfer stations within buildings. Whether you need to manage these supply points, expand the district heating network or establish individual building connections, BRUGG Pipes is your reliable partner. Our innovative CASAFLEX pipe system is already delivering district heating to many homes – maybe yours will be next?
CASAFLEX is a thermally insulated, self-compensating and continuous pipe system designed to handle exceptionally high temperatures and operating pressures. This monitorable district heating pipe is used for connecting buildings to district heating networks, typically running directly through the foundation wall to the transfer station, where the heat is distributed throughout the building. CASAFLEX is also an ideal choice as a primary supply line for district and local heating systems, as this helically corrugated pipe system is designed to meet the most stringent requirements. The plastic pipes with a stainless steel core are typically installed underground, often spanning long and uneven routes. This complexity is further compounded by the diversity of ecosystems they traverse – from densely populated urban areas to untouched natural landscapes. In such scenarios, pipe solutions must provide exceptional flexibility, genuine efficiency and above all, absolute reliability. Fortunately, CASAFLEX has proven time and again that it delivers on all fronts.
The CASAFLEX district heating pipe can easily withstand operating temperatures up to 150 °C and short-term peak temperatures reaching 180°C, as well as a maximum operating pressure of 16/25 bar. To ensure long-term durability and high stress resistance, this pipe solution is manufactured exclusively from premium materials. For instance, CASAFLEX features premium PIR foam thermal insulation and a corrugated stainless steel pipe at its core, offering a triple benefit: the robust pipeline is self-compensating, self-venting and self-cleaning. CASAFLEX is also available as a variant with a stainless steel double pipe.
*During the guaranteed service life of 30 years, the maximum continuous operating temperature of 150 °C up to the peak temperature of 180 °C may be exceeded twice a year for a period of one hour. After this, the maximum continuous operating temperature of 150 °C must be adjusted again.
Matched to requirements and flexible in use. Flexible when it comes to laying – obstacles can be avoided with ease. Implement narrow bending and winding radii without wrinkling or detaching the PE casing from the insulating foam thanks to corrugated outer casing.
Keep to ambitious schedules cost-effectively. The planning and construction management work required is minimal. Smaller trenches together with longer delivery lengths keep the costs in check.
Planned simply and proficiently, implemented swiftly. Statics under control thanks to the self-compensating pipe. Fewer underground connections. Simple connection system cuts installation time.
The original – used successfully for many years. The very best quality delivered. Simple, reliable and long-lasting product solutions.
Advice and innovation based on long-standing experience, needs-based, individual advice, patented connection and monitoring system. This all increases your security of supply.
District heating is always transported via a medium – most commonly hot water, which flows efficiently through the thermally conductive stainless steel pipe. At the transfer station, the heat is converted into energy for heating and distributed throughout the building via a dedicated system. District heating thus not only warms radiators but also provides hot water and heated drinking water. Gone are the days of boilers or furnaces that guzzle fuel, empty themselves in no time and constantly require refilling. With district heating, there’s no additional effort needed – simply switch the heating on. Literally!
Why buy from BRUGG Pipes? Our flexible stainless steel pipe system comes factory pre-assembled and thoroughly tested, making it ready for immediate installation. Drawing on decades of experience in both pipe development and manufacturing, we ensure that our factory-insulated district heating pipes, pipe assemblies and associated components are all rigorously certified. Our product meets all verified requirements in accordance with EN 15632-1:2009 and EN 15632-4:2009. The corresponding certifications can be found below.
At the core of CASAFLEX lies the previously mentioned corrugated stainless steel pipe. Its insulation consists of CFC-free, flexible polyisocyanurate (PIR) foam – a high-performance and temperature-resistant composite material. This thick layer of rigid PIR foam provides optimal thermal insulation for the district heating pipe. Twisted monitoring wires are embedded within this foam insulation. If an overload or localised micro-damage occurs anywhere along the pipeline, these monitoring wires – also known as leak detection wires – will issue a warning of potential damage.
A multi-layer barrier film and expanded metal mesh add a high degree of stability while ensuring the pipe remains flexible and bendable – an advantage in challenging terrain. The corrugated outer casing, seamlessly extruded from low-density polyethylene (PE-LD), is extremely durable and capable of withstanding significant stress.
Our product range includes five different CASAFLEX variants characterised by different properties in four main categories: dimensions (nominal sizes DN 20–50 or ¾ to 2 inches), inner pipe measurements, outer casing thickness and bending radius range.
Installing a complete pipe system requires a sufficiently large route – the designated area where the individual pipes will be placed. The size of this route depends on the specific construction project. Typically, the pipes are installed underground in deep trenches, though in some cases, trenchless construction methods may be more suitable, depending on local conditions.
For building connections, the pipe system must be aligned with the existing concrete channels. Thanks to flexible pipe sections in the form of coils, our district heating pipe can be easily adjusted to the required lengths. Since CASAFLEX UNO is a flexible, self-compensating pipe system, expansion bends and fittings are only required for extremely sharp angles.
Once all components have been delivered, the pipes should ideally be unrolled from the drum as close to the installation site as possible. The installers will then lay the pipe sections in the trench, slide on the wall penetrations and connect the fittings. Following this initial preparation, the connection between the pipe termination point and the in-house district heating system can often be completed the very next day, enabling installation to proceed without delay.
Thanks to a wide range of accessories, including T-pieces, CASAFLEX can be flexibly used as a main supply line, branch line or return line. When used as a return line, CASAFLEX reliably transports wastewater to designated treatment facilities within the system. Once treated, the water is recirculated through the pipes as a heat transfer medium, returning to the consumer. This creates a closed-loop system that consistently heats the building, maintaining a warm and comfortable environment.
In most cases, a cost-benefit assessment will ultimately determine which district heating pipe is the best choice. However, the innovative CASAFLEX pipe solution almost always stands out as the ideal choice due to its numerous advantages and exceptional versatility. For instance, BRUGG Pipes’ optimised connection technology – perfected over many years and now patented – significantly reduces the installation effort required for excavation work. As a result, our district heating pipe can be installed quickly and easily. In addition, the encapsulated graphite seals are not only ultra-secure but also simple to handle. Short installation times are especially important in public spaces, and CASAFLEX delivers on this front, too. Yet another advantage is the routing requirements – the need for only narrow trenches significantly minimises the pipeline’s environmental impact. Additionally, as no compensatory measures are needed, district heating systems can be regarded as environmentally friendly in many ways – or at the very least, exceptionally eco-compatible.
While many heating pipes on the market achieve respectable results in energy efficiency tests, CASAFLEX consistently scores top marks, making it a standout choice among pipe systems with regard to energy efficiency. The primary goal for all such systems is to minimise heat loss over transport distances, and the CASAFLEX district heating pipe truly excels in this department – thanks in no small part to its intelligent design and high-quality materials.
From route-marking tape to measurement junction boxes, BRUGG Pipes offers a wide range of fittings, accessories and other products tailored specifically to the CASAFLEX UNO series, covering every requirement.
Various connection options for all sizes of CASAFLEX enable seamless transitions to additional pipelines within buildings or via couplings. The CASAFLEX UNO accessory range includes permanent press connections that are not only 100% secure but also quick and easy to install. Each set comprises a support ring, a durable graphite seal, the actual connection piece and a compression ring. For smaller connections, additional components like snap rings and press sleeves are included.
In addition, “Y-pipes” allow a single pipe to be easily upgraded to a double pipe. These versatile elements typically serve as the link between internal building pipelines and district heating lines. And, like the rest of the CASAFLEX range, our Y-pipes are equipped with a leak monitoring system. We also offer T-joints equipped with flexible branch lines at various angles as extension or reduction elements for pipe systems. Incidentally, our T-joints are manufactured to the same certified standards as the CASAFLEX pipes themselves, ensuring exceptional reliability. To prevent heat loss at these junctions, the pipe components are insulated with PUR foam to optimise thermal performance.
Couplings are another essential type of connector and terminal component, ensuring a secure and well-insulated connection between two pipes. Most commonly, shrink couplings with shrink sleeves are used, adapting flexibly to different pipe sizes and making them a truly universal solution. The BRUGG Pipes coupling set includes various mounting elements and small parts such as sealing plugs, foam hole closures and a PUR foam cartridge, all designed to seal underground pipelines effectively. If the installation is carried out by someone other than BRUGG Pipes, only a few extra tools are needed to assemble the system – allowing installation to begin immediately.
End caps designed specifically for CASAFLEX pipes are also available, providing additional protection. These plastic half-shells or metal caps shield the pipe ends in buildings or shafts and securely fix them within couplings.
Our sealing rings, available in various materials and sizes, are suitable for both retrofitting and the initial installation. They can be customised to fit the pipe dimensions, media and the siphons or fittings being used. Completing our extensive range of accessories for the CASAFLEX product family, we can also provide annular space seals to protect core-drilled or fibre-cement casing pipes from gas and pressurised water, along with wall sealing rings for secure wall penetrations.
