A BRUGG GROUP COMPANY
Our innovative FLEXSTAR low-temperature system is a pre-insulated pipe system that is both highly flexible and extremely robust thanks to our patented manufacturing process. FLEXSTAR is ideally suited for connections to heat pumps, integration into local heating networks, and for house-to-house energy distribution. By choosing our efficient pipe system, you also benefit from BRUGG Pipes' full-service offering. We support your project planning and tailor pipe lengths or complete sets with accessories for easy connection to heat pumps.
We manufacture in accordance with EN 15632-2; our entire product range meets the quality standards of ISO 9001, ISO 45001 and ISO 14001. But that’s not enough for us: as a leading manufacturer, we don’t just meet standards—we set new ones. That’s why BRUGG Pipes products are known for their outstanding Swiss Quality.
We are happy to explain all the advantages of our components and system parts in our product training sessions.
We offer FLEXSTAR UNO (single medium pipe) and FLEXSTAR DUO (twin medium pipes) in standard coil lengths or as ready-to-install heat pump sets including accessories. In Germany, we supply the coil only. The heat pump set includes screw fittings, shrink end caps, a sealing ring and a warning tape.
The FLEXSTAR low-temperature system is pre-insulated with PUR foam, delivering excellent insulation performance: with high-quality CP-blown PUR foam, it achieves a lambda value of 0.024 W/m·K—around 40% lower than traditional PE insulation. The medium pipe made of PE-Xa is highly flexible, corrosion-resistant, and chemically robust, allowing for very tight bending radii. Yet even in such tight installations, whether in heat pump connections, local heating networks, or house-to-house links, FLEXSTAR remains highly durable and resilient.
Simple connection of your heat pump: Laying pipes with FLEXSTAR
It’s actually very simple: if you’re installing a heat pump, you should install FLEXSTAR. These pipes are easy to store, transport, and install. Obstacles can be easily bypassed thanks to the pipe’s flexibility. That makes the task of “laying heat pump pipes” convenient, fast, and efficient.
FLEXSTAR is temperature-resistant, suitable for fluctuating operating temperatures up to 95 °C, and can handle operating pressures up to PN 6. The UV-resistant outer casing is made of flexible LLD-PE, while the medium pipe is manufactured from PEXa—a specially processed polyethylene. The system complies with DIN 16892/93 and features an EVOH oxygen diffusion barrier in accordance with DIN 4726. This barrier prevents corrosion on metal parts and fittings, improves system efficiency, and minimizes thermal loss.
The pre-insulated pipe system is available as a single or twin pipe in various sizes: FLEXSTAR UNO from DN 20–50, FLEXSTAR DUO from DN 20–40. Its physical properties combined with FCKW-free, cyclopentane-blown PUR insulation allow for installation without compensating for thermal expansion. No additional expansion joints or compensators are needed.
FLEXSTAR is a bonded system, meaning the carrier pipe and insulation foam form a single, air-tight unit that prevents CO₂ from escaping. Unlike non-bonded systems, where multiple insulation layers can allow moisture or gases to infiltrate, FLEXSTAR eliminates these risks—ensuring longevity and reliability.
Thanks to its bonded construction, FLEXSTAR is optimally protected from moisture ingress. Even if the outer casing is damaged, FLEXSTAR’s longitudinal water tightness prevents moisture from penetrating the insulation and reaching the medium pipe. This significantly increases the lifespan of the pipe system and ensures dry basements and indoor spaces.
Do you heat your home with an air/water heat pump? Or are you planning a renovation or energy upgrade for a residential or commercial building? FLEXSTAR is ideal for a wide range of applications—from heat pump connections and local heating networks to house-to-house energy transfers. FLEXSTAR is especially advantageous for building entries, as tight bending radii enable installation in confined spaces without entry bends.
Another benefit: our innovative connection system eliminates the need for welding, making installation fast and simple. Long delivery lengths allow for fewer joints and narrow trench widths—reducing excavation work and overall installation costs.
Heat pump pipes are a key component in modern, energy-efficient heating systems that prioritize sustainability and environmental responsibility. Heat pumps extract 100% of their thermal energy from the environment—eliminating the need for fossil fuels or other energy sources.
Heat pumps operate most efficiently when temperature differences between the source and the target medium are minimized. This makes choosing the right heat pump pipe critical, as it must transport heat with minimal losses.
Based on a real-world project, we calculated the specific performance values of FLEXSTAR in heat pump applications. With a typical usage of 8,600 hours/year over a 30-year lifespan, FLEXSTAR can save up to 45,150 kWh and reduce CO₂ emissions by more than 7 metric tons—just by switching to an energy-efficient pipe system.
The energy savings are a direct result of reduced thermal losses compared to conventional PE pipe systems, thanks to FLEXSTAR’s superior lambda value of 0.024 W/m·K. Additional cost savings are possible due to shorter installation times and reduced earthworks.
More information and the data from our case study is available in the compact training course in the Downloads section.
The swift and remarkably uncomplicated installation process is also due to our sophisticated connection technology, which ensures minimal labour costs and an extended system lifespan. Instead of complex welding, only the pipelines themselves, the fittings, a wall sealing ring (only for building penetrations) and end caps are required for installation.
FLEXSTAR offers a choice between screw fittings and press fittings: screw connections can be effortlessly attached to the pipes without tools, making them ideal for building entries, while press fittings provide a permanent and secure connection and are particularly suitable for underground installations. The fittings are typically made of steel or brass. The patented labelling method employed for our FLEXSTAR pipe systems greatly simplifies the process of identifying them at the construction site. Supplementary insulation can be easily added to fully insulated heating pipes using clip shells and distribution boxes.
• Pipe lengths or sets including accessories, precisely matched to your requirements
• Planning assistance
• Global distribution network
• Product training and support worldwide
• Production standards in accordance with EN 15632-2
• Quality standards in accordance with ISO 9001, ISO 45001 and ISO 14001
FLEXSTAR has been audited by the independent institute IMA Dresden and certified by the German Accreditation Body.
