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Flexalen 600

Flexible double and single pipe solutions
Flexalen 600 pre-insulated pipes
Flexalen 600 pre-insulated pipes
Flexalen 600 pre-insulated pipes
Flexalen 600 pre-insulated pipes
Flexalen 600 pre-insulated pipes
Flexalen 600 pre-insulated pipes

The Flexalen 600 flexible pre-insulated pipe range is specifically designed to beat today’s most pressing network lifecycle performance and installation challenges. Its unique design and material properties make it a highly versatile network solution for reliable heating, cooling, and potable water supply.

Select a product range

Flexalen 600 pre-insulated pipes – first-rate material quality 

The Flexalen 600 pre-insulated pipe system consists of a  polybutene (PB-1) medium pipe: a flexible polyolefin material that assures quick and reliable assembly, over 50 year lifetime, while being the best in class for pressure and temperature rating, and energy efficiency.


Enclosing the pipe is a polyolefin-based polyethylene insulation that, thanks to its hydrophobic and closed cell structure, minimizes the risk of water absorption. This ensures the insulation properties of Flexalen 600 are safeguarded over its entire product lifecycle.


The protective HDPE outer casing with UV stabilizers ensures optimal protection against any risk of damage throughout the networks’ entire lifetime, while ensuring flexibility.

Proven sustainability 

Flexalen 600, now the world’s only Cradle to Cradle Certified™ Silver pre-insulated pipe, was developed with the aim of offering an ideal district heating and cooling solution for both engineers, installers and end-users looking for a durable, maintenance-free and quick to install system. The first Flexalen 600 pre-insulated pipe system was already installed in 1983 in Heiligenkreuz (Austria), and has been running smoothly ever since with zero leaks or maintenance issues.


Check out this recent project in Roosendaal, the Netherlands (English subtitles available)

Assortment 

Flexalen 600 is available as a single pipe system (OD25 to 225mm) or a double pipe system (OD25 to 63mm). The polybutene pipe is also available with an oxygen barrier. Flexalen pre-insulated pipes are delivered in coil up to 300m (depending on diameter). Lengths can be customized upon request.


We also offer services to optimize network design and dimensioning, calculation, training, and technical assistance on site.

  • Sustainability

    Cradle 2 Cradle certified – for a circular economy

    Download the certificate in the knowledge center!

  • Health

    Produced without (H)CFC
    Complies to REACH
    Complies to VOC (Volatile organic components)

  • Specificities

    High flexibility

    Usable for both heating and cooling applications

    Safe and secure operation

    Long lifetime expectancy

  • Installation

    Easy quick and safe to weld

  • Service temperature

    Wide temperature range

    Minimum -15°C

    Maximum 95°C

  • Availabilities

    Available in long lengths

    Full range of accessories

    Available with oxygen barrier

    Available in twin or single carrier pipes

    Several insulation thicknesses available for diverse applications

Polybutene-1, ideal for district heating, cooling and potable water networks

Flexalen 600 pre-insulated pipes consist of a flexible polybutene (PB-1) medium pipe, ensuring durable performance in large-scale district heating and cooling networks as well as domestic applications:

  • High flexibility
  • Minimal creep
  • High tensile strength
  • Minimal heat loss
  • Minimal expansion forces
  • Long lifetime (up to 100 years depending on use)
  • Size range from 20 to 125mm in SDR class 11
  • Available with oxygen barrier
  • Smooth internal walls (7 x 10-6 m over lifetime)
  • Less pressure loss, no biofilm or incrustation
  • Allows electrofusion, poly-fusion and butt-fusion welding
  • Cradle to Cradle Certified™ Silver
  • 100% recyclable

Thermaflex insulation foam – high and durable energy performance

Direct extruded polyethylene insulation encloses the pipe, keeping the water absorption coefficient to a minimum thanks to its integrated water vapor barrier and closed cell structure. It is available in 3 thicknesses: compact, standard and large-scale DHC.

HDPE jacket for superior protection

A protective corrugated HDPE outer casing with UV stabilizers ensures high mechanical strength and flexibility throughout the networks’ entire lifetime.

Complex networks mastered by design

Thanks to the unique features of the Flexalen 600 pre-insulated pipe system, many aspects of the network can be optimized to reduce the initial investment and operating costs:

  • Easy welding allows narrow trenches
  • Flexibility eliminates the need for work-arounds, reducing quantity of materials and fittings
  • Low pressure drop allows smaller pipe diameters, faster flow with less pump capacity
  • No network segmentation needed, limiting the number of on-site connections


Our team of network engineers is at your disposal for any technical questions or assistance in dimensioning or route optimization.


Find all the technical details in our product guide in the download section

Flexalen 600 – Optimal installation efficiency

The flexibility, weldability and low weight of Flexalen 600 pre-insulated pipes greatly simplifies and accelerates installation. Electrofusion, poly-fusion and butt-fusion welding techniques ensure durable and record-breaking system welding in respect to ease and speed of installation.

Prefabrication smooths the way

For even faster installation, Thermaflex can deliver fully prefabricated and factory-tested connections. This reduces the amount of on-site welded connections to just 30% of traditional designs. This comes with multiple benefits.

  • Minimize installation risk
  • Reduce handling and trench time
  • Stay on planning and budget
  • Control installation and overhead costs

Comprehensive installation support

  • Installation training
  • Pre-check of design and parts during order
  • On-site installation support
  • Welding training for complex projects
  • Installation manuals


Find all the technical details in the Flexalen product guide in the download section

Reports

  Pressure drop PB-pipes PDF 44 KB Preview Download Mail

Pressure drop PB-pipes

Brochures Catalogues

  Flexalen Product Guide PDF 4736 KB Preview Download Mail

The Flexalen Product Guide offers all system, application & technical specifications for all Flexalen product ranges.

  FAQs Polybutene PDF 2492 KB Preview Download Mail

Here you will find answers according the frequently asked quastions about Polybutene.

  Successful in the past - prepared for the future (PBPSA) PDF 1619 KB Preview Download Mail

This brochure is giving an introduction to Polybutene including a review of the performance of Polybutene pressure piping systems in meeting the needs of sustainable building regulations.

  Flexalen - No1 choice for specifiers around the world PDF 438 KB Preview Download Mail

Why is Flexalen the No1 choice for specifiers around the world?

Installation Manuals

  Flexalen instruction: Laying instruction PDF 1936 KB Preview Download Mail

Laying instruction for Flexalen 600, Flexalen 1000+, Straight lenghts and Flexalen Solar.

  Flexalen instruction: Pressure testing PDF 1599 KB Preview Download Mail

Pressure testing and pressure test protocol.

Technical Datasheets

  Drukverliezen PB-leidingen PDF 44 KB Preview Download Mail

Drukverliezen PB-leidingen

Safety Data Sheets

  Flexalen: Corrugated tubes PDF 133 KB Preview Download Mail

Safety data sheet: Flexalen corrugated tubes (outer casing).

  Flexalen: Foam PDF 136 KB Preview Download Mail

Material safety data sheet: Flexalen foam

  Flexalen: Polybutene PDF 45 KB Preview Download Mail

Material safety data sheet: Polybutene-1 (PB grey)

Whitepapers

  Verification of heat loss measurements PDF 328 KB Preview Download Mail

Heat loss tests are performed on different samples of the Thermaflex Flexalen 600 series and one ST-PUR-PE sample with the Thermaflex heat loss equipment and at two recognized test facilities, both using different test methods. The results of the institute using the same, guarded end method comply with the Thermaflex heat loss equipment’s results. The results of the institute using the calculated end method differ considerably from the Thermaflex results. In this paper a comparison of these methods and results and a verification of the Thermaflex heat loss equipment is given.

  Flexalen: Acoustic properties PDF 29 KB Preview Download Mail

Acoustic properties Polybutene.

  Flexalen: Creep resistance PDF 23 KB Preview Download Mail

Creep resistance Polybutene.

  Flexalen: Dimensions Plumbing Pipes PDF 25 KB Preview Download Mail

Dimensions plumbing pipes

  Flexalen: Expansion compensation PDF 420 KB Preview Download Mail

Expansion compensation.

  Flexalen: Fire behaviour PDF 18 KB Preview Download Mail

Fire behaviour of Polybutene.

  Flexalen: Flexural Elastic Modulus PDF 28 KB Preview Download Mail

Flexural Elastic Modulus of Polybutene.

  Flexalen: Heat conductivity PDF 40 KB Preview Download Mail

Insulation value - heat conductivity of Polybutene.

  Flexalen: Heat conductivity plastics PDF 28 KB Preview Download Mail

Heat conductivity comparision Polybutene to other plastics.

  Flexalen: Oxygen permeation resistance PDF 32 KB Preview Download Mail

Oxygen permeation resistance

  Flexalen: Temperature pressure PDF 48 KB Preview Download Mail

Temperature - pressure - resistance of Polybutene.

  Flexalen: Thermal expansion PDF 29 KB Preview Download Mail

Thermal expansion.

  Flexalen: Water hammer resistance PDF 65 KB Preview Download Mail

Water hammer resistance.

  Flexalen: Wet abrasion resistance PDF 80 KB Preview Download Mail

Wet abrasion resistance.

Environmental Certifications

  Flexalen 600 - Cradle to Cradle Silver PDF 636 KB Preview Download Mail

The Cradle to Cradle Certified Product Standard guides designers and manufacturers through a continual improvement process that looks at a product through five quality categories - material health, material reutilization, renewable energy and carbon management, water stewardship, and social fairness. A product receives an achievement level in each category - Basic, Bronze, silver, Gold or Platinum - With the lowest achievement level representing the products overall mark

  Cradle to Cradle - Carbon offsetting 2015-2019 PDF 195 KB Preview Download Mail

Thermaflex Isolatie B.V. has offset 290 tonnes of CO2 tooffset 50% of the emissions caused by the production of C2C products (Flexalen 600).

Thermaflex directly invests in emission reduction projects which combine energy, environment and developmental solutions into sustainable business opportunities in developing countries, with the help of the Climate Neutral Group.

Certificates

  WRAS Approval - Polybutene pipes PDF 823 KB Preview Download Mail

Approval contact with wholesome water for domestic purposes having met the requirements of BS 6920-1:2000 'suitability of non-metallic products for use in contact with water intended for human consumption with regard to their effect on the quality of water'.

  Bureau Veritas Ship building approval Flexalen 600 PDF 793 KB Preview Download Mail

Certificate number: 21665/B0 BV. 

Type of product: Thermoplastic material pipes and fittings, Flexalen 600. 

(July 2014).

  KIWA International Conformity EN15632 Flexalen 600 PDF 524 KB Preview Download Mail

KIWA International Conformity EN15632 part1 and 3 - Flexalen 600.

(May 2011).

  KIWA - KOMO Certificate BRL 5609 - Flexalen 600 PDF 1179 KB Preview Download Mail

KIWA - KOMO technical approval-with-product certificate for Flexalen 600. 

(January 2007).

  Ecospecifier Certificate - Flexalen 600 PDF 197 KB Preview Download Mail

Reference number: 0910276AU.

Ecospecifier Product Assessment Certificate for Flexalen 600.

(November 2010).

  DIN 4102 B2 Certificate Flexalen 600 PDF 1008 KB Preview Download Mail

"Kleinbrenner"-test (Buyilding material Class B2) according to DIN 4102 B2  for Flexalen 600

  Lambda test certificate according to EN 15632-1 - Flexalen 600, 0.037 PDF 1229 KB Preview Download Mail

Lambda test certificate according to EN 15632-1 - Flexalen 600

  Determination of the resistance to internal pressure at a constant temperature - PB pipes PDF 106 KB Preview Download Mail

Determination of the resistance to internal pressure at a constant temperature according to ISO 1167- PB pipes

  Lambda test certificate according to EN 15632-1 - Flexalen 600, 0.036 PDF 1304 KB Preview Download Mail

Lambda test certificate according to EN 15632-1 - Flexalen 600, 0.036

  Determination of the resistance to internal pressure at a constant temperature - PB pipes grey PDF 112 KB Preview Download Mail

Determination of the resistance to internal pressure at a constant temperature according to BRL K17401 - PB pipes grey

  Public health certificate - Polybutene pipes PDF 191 KB Preview Download Mail

Public health certificate for polybutene pipes (IT)

  VOC Microchamber test certificate - Flexalen 600, ThermaSmart PRO PDF 151 KB Preview Download Mail

VOC Microchamber test certificate - Flexalen 600, ThermaSmart PRO. According to ISO 16000.

  Determination of influence of heating at 110 degrees - PB pipes grey PDF 104 KB Preview Download Mail

Determination of influence of heating at 110 degrees according to DVGW W544  - PB pipes

  KIWA certificate K8492801 welding process for plastic piping systems Flexalen 600 PDF 371 KB Preview Download Mail

This process certificate is issued by KIWA on the basis of BRL 5609 'pre-insulated flexible plastics piping systems for warm water distribution outside buildings'

Together with KIWA the welding process of electrofusion, polyfusion and butt welding is technical approved with product certificate stated requirements.

  Earth Quake resistance certificate PDF 735 KB Preview Download Mail

Technical report of dynamic tests performed on Flexalen pre-insulated pipe systems, simulating seismic with 7-9 intensity on the MSK-64 scale.
Flexalen is recommended for applications in the regions with seismic activity of 7-9 magnitude.

  Drinking water Health Certificate - Flexalen, PB pipes PDF 225 KB Preview Download Mail

Drinking water Health Certificate for Flexalen and PB pipes (RO)

  KTW organoleptic test certificate - Flexalen, PB pipes - Size group 1and 2 PDF 221 KB Preview Download Mail

KTW organoleptic test certificate for drinking water purposes - Flexalen, PB pipes - Size group 1 and 2

Certification nr. DW-8326CP0310 75 - 160mm

Certification nr. DW-8321CM0089 10 - 63mm

  KIWA Certificate BRL K536C - PB pipes PDF 543 KB Preview Download Mail

Product certificate for PB pipes.

(August 2005).

  KWR Biofilm cultivation test certificate - PB pipes PDF 577 KB Preview Download Mail

KWR Biofilm cultivation test certificate - PB pipes

  CE Declaration of Conformity - ThermaSmart PRO, Flexalen 600 PDF 524 KB Preview Download Mail

CE Declaration of Conformity - ThermaSmart PRO, Flexalen 600

  Temperature cycling test certificate - Flexalen PDF 1536 KB Preview Download Mail

Temperature cycling test certificate according to EN 12293 - Flexalen

  DVGW W544 approval Flexalen PB (Group 2) PDF 434 KB Preview Download Mail

DVGW type examination certificate. 

Product Category: plastic pipes for drinking water installations (group 2).

Registration number: DW-8326CP0310 (September 2014).

  Determination of influence of heating at 110 degrees - PB pipes PDF 103 KB Preview Download Mail

Determination of influence of heating at 110 degrees according to DVGW W544

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