PLUMBING SOLUTIONS TECHNICAL GUIDELINES
Pkjijm O\k R\o`m \i_ M\_d\ojm >jii`^odji K@(S\ Ntno`h
Pkjijm ( k\moi`mdib rdoc kmja`nndji\gn Uponor keeps its promises People care more and more about the environment in which they live and work: whether it is commercial buildings, private residences or open and public spaces. Apart from that, standards and styles change and so do peopleÕs expectations. In order to Þnd the right systems and services to meet those demands, it becomes increasingly important to know where to go and whom to trust! With Uponor, you partner with professionals who know how to satisfy your demands. Because we Õve always been working closely together with our partners and customers, we know about their needs. We want to give you more and we have to offer something special � everything to help you enjoy more success. In an increasingly complex world, we shall always be the smarter choice.
The Uponor PE-Xa pipe system – sophisticated technology for the long run Our customers proÞt from convenient and reliable solutions for a wide range of installations. All Uponor products are available in the long-term. Top quality, outstanding services and environmental friendliness are key objectives in the development process. The system consists of in-house produced PE-Xa pipes and Þttings that Þt perfectly together. The system is complimented by the necessary accessories and a sophisticated tools program � everything out of one hand. Competence from the pioneers of plastic – the results of more than 3 decades of experience Our expertise in the Þeld of PE-Xa is the result of decades of experience. We have been producing PE-Xa pipes for more than 35 years now. From the beginnings until today, our output has topped the mark of 2.5 billion meters of PE-Xa pipes. This is a record that tells its own tale. The assembly of the whole portfolio of our PE-Xa pipes is spread over four production plants in Sweden, Spain, Canada and the USA.
>jio`ion Description of basic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Dimensions of Uponor PE-Xa tap water and radiator connection pipes . . 6 Fixation distances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Expansion compensating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Expansion compensating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 PE-Xa pipe pressure-loss graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Uponor PE-Xa clamp connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Pressure test with water for tap water pipes . . . . . . . . . . . . . . . . . . . . .16 Pressure test report for radiator connection . . . . . . . . . . . . . . . . . . . . .17 List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 How to contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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?`n^mdkodji ja ]\nd^ ntno`h The Uponor PE-Xa Tap Water and Radiator connection system For years, selecting a tap water system was done in a routine fashion. Choice of material was limited, and attention was paid only to basic re-
As in other aspects of modern life, development and improvement are continuous. Uponor PE-Xa piping systems are by no means new on the market. These have been developed and improved on since 1972.
Molecule chain for a cross-linked polyethylene pipe
quirements. Today, selecting a tap water system involves taking into consideration a wider range of aspects. Although the purpose is the same, a modern tap water system has a number of additional features, features which have a direct impact on the overall performance of a system.
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Uponor offers a complete system for domestic hot and cold water as well as radiator connection. The system consists of a wide range of pipes, Ăžttings and accessories. It is clean, easy to install and Ă&#x;exible. Being Ă&#x;exible means for example, that longer lengths of pipe can be installed, resulting in fewer joints and less associated installation work. The Uponor PE-Xa Tap Water System includes components for installation in new buildings as well as in renovation projects, and is suitable for concealed runs in building structures of wood, concrete and brick, and for exposed runs in basements or ceilings.
Uponor PE-Xa pipe Uponor PE-Xa is a pipe for hot and cold water applications. The pipes are made from cross-linked highdensity polyethylene (PE-X). Crosslinking is a process which changes the chemical structure of the plastic material in such a way that the polymer chains are connected with each other to form a strong threedimensional net of chemical bonds. The chemical structure makes it impossible to melt or dissolve the polymer, without Ăžrst destroying its structure. Uponor PE-Xa pipes are therefore suitable for use at pressures and temperatures for which previously only metal pipes were appropriate. In addition, Uponor PE-Xa pipes have a unique elasticity. Thus, when expanded, a pipe will always strive to resume its original dimension (unless it is expanded beyond the breakpoint which is over 300 %). Using this feature for example means that pipes can be simply and securely connected to each other (see joining methods below). Uponor PE-Xa pipes have excellent long-term properties and are proof against corrosion. The internal diameter will not be reduced due to corrosion or to sediment build-up that can often occur in metal pipes. The pipe material also boasts the advantage of not being affected by high Ă&#x;ow velocities or by low pHvalued water (aggressive water). Nor is it affected by building materials such as concrete, lime mortar, gypsum. Uponor PE-Xa does not give off taste and smell, or add any harmful substances to the drinking water.
?`n^mdkodji ja ]\nd^ ntno`h The material used for Uponor PE-Xa pipes is elastic and has a shock-absorbing effect in case e.g. a mixing tap is suddenly shut off. Water hammer in fact is reduced to one third compared with traditional metal pipes. Note Prevent tape, paint and sealing compounds containing plasticisers and other products containing solvents from coming into contact with the pipe as the compositions in these products affect the long-term properties of the pipe negatively Since UV radiation affects the pipe, a Uponor PE-Xa pipe should not be stored or installed in such a way as to be exposed to sunlight (UV radiation)
Uponor PE-Xa pipe
Easy to install
Security against water damage
Uponor PE-Xa pipes have many features that simplify the installation work. They are light and Ă&#x;exible and there is no need for high-temperature operations such as soldering or welding. Connecting a Uponor PE-Xa pipe is made simple by using Uponor Quick & Easy couplings and the pipe can be easily cut and bent by hand. Furthermore the pipes are delivered in coils for easy transportation and handling.
Uponor PE-Xa tap water pipes can be safely placed in concealed locations within building structures because they offer security against water damage. This is because the pipes are channelled through a conduit, a protective outer pipe, which can be installed in a single seamless length around the water-bearing pipe from the manifold all the way to the draw-off point (a Ópipe in pipeÓ system). Thus any water leakage, due for example to a pipe being damaged by a misplaced nail, will be carried and discharged beyond the building structure and will be detected at an early stage. In addition as a further guarantee against damage, the various cabinets in the Uponor range, such as the manifold cabinets, could also be Þtted with leakage indicators.
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?dh`indjin ja Pkjijm K@(S\ o\k r\o`m \i_ m\_d\ojm ^jii`^odji kdk`n Uponor tap water connection PE-Xa system 3.2, PN10 Pipe ÂŻ OD and wall thickness mm
ID
Weight
Volume
Delivery lengths
mm
kg/100 m
l/100 m
m
16 x 2.2
11.6
9.8
9.8
100
20 x 2.8
14.4
15.4
15.5
50
25 x 3.5
18.0
23.6
24.5
50
32 x 4.4
23.2
38.0
40.6
6, 50
40 x 5.5
29.0
59.2
63.8
6
50 x 6.9
36.2
92.3
99.8
6
63 x 8.7
45.6
145.9
159.0
6
75 x 10.3
54.4
207.7
227.2
6
90 x 12.3
65.4
296.5
326.1
5.7
110 x 15.1
79.8
444.2
485.0
5.7
Pipe in Pipe system of the corrugated pipe 16 x 2.2
25/20
17.3
9.8
50
20 x 2.8
28/23
24.4
15.5
50
25 x 3.5
34/28
35.4
24.5
50
OD = outer diameter; ID = inner diameter
Uponor radiator connection PE-Xa system 5.0, PN6 Pipe ÂŻ OD and wall thickness mm
ID
Weight
Volume
3 layers coating Delivery lengths
mm
kg/100 m
l/100 m
m
16 x 2.0
12.0
9.7
10.9
100, 200
20 x 2.0
16.0
13.0
19.3
120, 240
25 x 2.3
20.4
18.7
31.6
50, 100
32 x 2.9
26.2
26.8
52.9
50
40 x 3.7
32.6
43.0
81.4
50
50 x 4.6
40.8
66.5
127.8
50
63 x 5.8
51.4
104.8
203.4
50
75 x 6.8
61.2
146.1
290.7
50
90 x 8.2
73.6
211.3
417.8
50
110 x 10
90.0
314.1
624.6
50
Pipe in Pipe system of the corrugated pipe 16 x 2.0
25/20
17.2
10.9
50
20 x 2.0
34/28
26.1
16.06
50
OD = outer diameter; ID = inner diameter
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Ads\odji _dno\i^`n Distance (mm) Cold water Hot water
Uponor PEX pipe, OD (mm)
500
200
16, 20
500
300
25
750
400
32
750
600
40
750
750
50, 63, 75
1000
1000
90, 110
@sk\indji ^jhk`in\odib _`qd^`n No special expansion compensators are needed if: the water pipe is supported and anchored at a maximum spacing of 6 m the water pipe is run in a conduit where the necessary space for expansion is provided in the gap between water pipe and conduit the pipe is run in long lengths on a rack.
However, in installations allowing for thermal expansion, where the pipes are expected to stay straight, expansion compensators should be used.
Calculation of a exible arm and expansion loop
The Ă&#x;exible arm should be long enough to prevent damage, and support clamps should be placed sufĂžciently far from the wall to allow for longitudinal thermal expansion.
Use the formula below to calculate the minimum length of the Ă&#x;exible arm. When designing an expansion loop it is preferable to design it so that l2 = 0.5 l1. In this case the Ă&#x;exible arm is calculated according to the equation below:
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@sk\indji ^jhk`in\odib _`qd^`n Example: An Uponor PE-Xa pipe with an outside diameter (OD) of 50 mm is installed with 30 m between anchor points. The hot water it carries is 70ยกC and the ambient temperature is 20ยกC. Calculate the length (LB) of the ร exible arm. Calculate the thermal length variation by using the diagram.
From the graph, the thermal expansion at 20ยกC is 2.5 mm/m, while the expansion at 70ยกC is 12.5 mm/m. The expansion of the pipe will be 12.5-2.5 = 10 mm/m when carrying water at 70ยกC. The total thermal length variation in this case is: ร L = 10 mm/m x 30 m = 300 mm.
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K@(S\ kdk` km`nnpm`(gjnn bm\kc kPa/m
100,00
Watertemp: 10ÂşC
16x2.2 20x2.8
Pressure loss graph for Uponor PE-Xa PN10 (series 3.2) pipes
25x3.5 32x4.4 12,0 10,0
40x5.5 50x6.9 63x8.7 75x10.3
7,0 6,0
10,00
90x12.3 110x15.1
5,0 4,0
3,0
Presuredrop
2,5
The pressure loss graph due to the pipe friction shows the pipe characteristics, along with the various dimensions and Ă&#x;ow-rate limits. It is simple to ascertain the pipe friction resistance per metre - for a given volume or Ă&#x;ow using the graph in relation to the dimensions of the pipe and the Ă&#x;ow rate.
2,0 1,75 1,5
1,00
1,25 1,0
m/s 0,50 0,40
0,10
0,30
0,25
0,20 0,15
= Recommended max. Ă&#x;ow speed
0,10
0,01 0,01
0,10
1,00
10,00
Flow
100,00 l/s
Correction factors for other temperatures Temperature ÂĄC: 90 80 70 60 50 40 30 20 10 Factor: 0.76 0.78 0.80 0.82 0.84 0.87 0.91 0.96 1.00
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K@(S\ kdk` km`nnpm`(gjnn bm\kc kPa/m
100,00
Watertemp: 70ÂşC
16x2.0
Pressure loss graph for Uponor eval PE-Xa PN6 (series 5.0) pipes
20x2.0 25x2.3 32x2.9 12,0 40x3.7 10,0 50x4.6 63x5.8 75x6.8 7,0 6,0
10,00
90x8.2 110x10.0
5,0 4,0
3,0 2,5
Presuredrop
2,0 1,75
1,00
1,5 1,25 1,0
m/s 0,60 0,50
0,10
0,40
0,30 0,25 0,20 0,15 0,10
0,01 0,01
0,10
1,00 Flow
10,00
100,00 l/s Convertion of kg/h to l/s by 284¡10-6
Correction factors for other temperatures Temperature ÂĄC: 90 80 70 60 50 40 30 20 10 Factor: 0.95 0.98 1.00 1.02 1.05 1.10 1.14 1.20 1.25
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The pressure loss graph for the pipe friction shows the pipe characteristics, along with the various dimensions and Ă&#x;ow-rate limits. It is simple to ascertain the pipe friction resistance per metre - for a given volume or Ă&#x;ow using the graph in relation to the dimensions of the pipe and the Ă&#x;ow rate.
B`i`m\g dinomp^odjin Minor repairs
Pipe bending
Minimum bend radius
Because cross-linked polyethylene cannot be welded or repaired with adhesives, if a pipe is accidentally sliced or punctured, the safest and simplest repairing method is to cut away the damaged area and replace it with a Uponor Q&E joint.
Uponor PE-Xa pipes are normally bent without the need for any special tool. If bends with small radii are necessary, a bending support should be used.
The Ăžgures below give the minimum bending radius for pipe dimensions used in the Uponor PE-Xa water system. OD = outer diameter.
However if a pipe has been buckled, after for example being bent too far, an alternative repair method, which actually reforms the pipe and takes advantage of Uponor PE-Xa cross-linked polyethyleneĂ•s unique thermal memory, can be applied as shown below. Reforming method: 1. Straighten the damaged section by hand. 2. Carefully heat the damaged area with a hot-air gun, rotating the gun around the pipe throughout the process for an even application. Heat until the pipe has returned to its original shape or until the material begins to become transparent round its whole circumference. This will happen at around 130 ÂĄC. However no open Ă&#x;ame must be used. 3. Allow the pipe to cool to room temperature before use. Using cold water or blowing cold air on the repaired section will accelerate cooling. Once cooled it will return to its original appearance and regain all of its strength.
Alternatively, the pipes can be bent after being heated up in accordance with the procedure described below. 1. Heat the pipe carefully with a hot-air gun. Move the gun around the pipe throughout the process for an even application. 2. Heat the pipe until the material begins to become transparent where the pipe is to be bent, which will occur at around 130 ÂĄC (no open Ă&#x;ame must be used). 3. Bend the pipe at once to the required angle. 4. Hold the pipe at the required angle and cool it with water or air. The pipe will maintain the new shape. If it is heated once more it will resume its original shape. Useful tips: Where a sharp bend with a narrow radius is required, a Ă&#x;exible support should be placed in the pipe at the bending point prior to bending (step 3), in order to prevent the pipe from folding. Note: An open Ă&#x;ame must not be used for heating the pipe. Do not heat more than necessary. If heating has discoloured the pipe (brown), this indicates that the material has been damaged and the pipe must be replaced. Note any change in the surface of the pipe during the heating operation. Do not heat Uponor pePE-Xa or Uponor evalPE-Xa pipes. They have an outer oxygen diffusion barrier which, if heated, will be damaged.
Cold bending 8 x OD Cold Ăžxture bending 5 x OD Hot bending 5 x OD Note: It is not practical to manually bend dimensions larger than 32 mm to the minimum bending radius. The radius with which Uponor PE-Xa pipes can be bent, depends on the installation temperature, pipe wall thickness and type of pipe.
Filling the system All pipe systems should be Ăžlled slowly in order to expel as much air as possible. In order to remove any remaining air pockets, venting the system afterwards is recommended. Examine the coupling points and pipe runs whilst Ăžlling the system. Note: In extremely cold areas the system should be protected at all times from freezing.
Pressure test Uponor PE-Xa systems can be pressure tested in accordance with the local standards and regulations which apply to metal pipes. However there is a more appropriate method of testing, which takes into account the fact that a Uponor PEXa systems expands and contracts radially when pressure is applied.
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Dino\gg\odji Diajmh\odji Before the pipe system is installed, it is vital that the Ăžtter reads, understands and takes note of this instruction. On using the Uponor Q&E battery tool and Uponor Q&E manual tool, it is vital that the Ăžtter reads, understands and takes note
of the operating and maintenance instruction attached to this tool. The pipes are not to be unpacked before installation to stop any pipe damage or imperfections arising from UV radiation. The pipes must not be fouled at all (free of dust,
mortar and grease). Pressure-seal caps are to be Ăžtted onto the pipe ends to stop dirt getting inside. The pressure-seal caps are to remain on the pipe ends for as long as possible.
Uponor Q&E Fitting 1. Cutting to length Use Uponor pipe cutter to cut pipe to length in a correctly angled manner. The cutting edges must be straight and burr-free. Any conduit can be cut to length Ă? independently to the Q&E pipe Ă? using the combi-Uponor pipe cutter. In doing so no damage is done to the actual pipe.
1 2
max. 1 mm
max. 45°
max. 45°
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2. Fitting Q&E Ring/eval Ring Slip the Q&E ring matching the pipe dimension and type onto the pipe. Have it project slightly over the pipe end (max. 1 mm).
3a. Expanding operation using the Uponor Q&E manual tool The Uponor expander head matching the pipe dimension and type must be mounted on the tool. Open the Uponor manual expander tool fully and insert the Uponor expander head straight and as far as possible into the pipe end. Slowly completely close the expander tool and hold for 2-3 seconds. Then open the tool and retract to the extent that the jaws detach themselves from the pipe wall. Radially turn the tool (maximum 45ÂĄ). Then immediately push in as far as possible into the pipe and again Ă&#x;are. Keep on repeating until the pipe end rests on the limit stop of the expander jaws. Then Ă&#x;are one Ăžnal time. Detach expander tool and immediately go on with point 4. 3b. Expanding operation using Uponor Q&E battery tool The Uponor expander head matching the pipe dimension and type must be mounted on the tool. Insert the Uponor expander head straight and as far as possible into the pipe end and press the machine against the pipe. Switch on machine (keep switched pressed). As soon as the Uponor expander head is fully opened (recognisable from the cracking sound), the machine automatically switches to return travel and the head is again closed. Let go the switch again, pull the head a little out of the pipe so that the jaws detach themselves from the pipe wall. Turn the machine radially a little (maximum 45ÂĄ) and press in the Uponor expander head as far as possible. Switch on the machine. Repeat the expanding operation for as long as it takes the expander jaws to be inserted up to the limit stop in the pipe. Then expand for the Ăžnal time. Immediately go on with point 4.
Dino\gg\odji Diajmh\odji 4. Fitting Swiftly push the pipe up to the limit stop onto the Ăžtting stub. Hold in this position for a few seconds until the pipe has shrunk onto the Ăžtting stub. Please note No gap is to arise between pipe and Ăžtting stop.
Mounting operation If the Q&E ring is not tight enough on the pipe, then push back the Q&E ring. Slightly Ă&#x;are the pipe and then return it to the right position. The Q&E ring will then Ăžt Ăžrmly on the pipe. Place the Q&E ring on the pipe
Widen the pipe end with the expander tool
It is vital before each expanding operation that the tool is turned somewhat (max. 45ÂĄ) before being inserted. Only in this way it can be ensured that the pipe inner wall is striation-free Ă&#x;ared and as a result a permanent seal-tight connection is provided. Considerable play on putting together Ăžtting and pipe or the need to hold the pipe for over 3 seconds before it grips round a Ăžtting point to the fact that the pipe has been Ă&#x;ared too often and/ or kept too long in the expanded position. It thus takes longer until the joint is seal-tight.
Push the pipe onto the Ăžtting Ă? done! Uponor PPSU Ăžtting with Q&E
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Pkjijm K@(S\ ^g\hk ^jii`^odji Assembling a PE-Xa clamp coupling The PE-Xa clamp coupling is an excellent pipe Ăžtting, intended mainly for use with Uponor PE-Xa pipe dimensions greater than 32 mm. Assembling procedure: 1. Chamfer the square cut pipe end with a deburring tool or knife. Ensure that the pipe end is clean and that any external burrs are removed. 2. Unbolt the clamping sleeve, prise it apart as shown with pliers and remove it from the coupling. 3. Mount the sleeve on to the end of the pipe. Note that the clamping sleeve is strong and will resist being prised apart. Therefore, once the bolt has been removed and the sleeve forced open, place the head of the bolt into the gap before removing the pliers, in order to keep the lugs apart. 4. Connect the pipe to the coupling pressing it as far as the locking groove. 5. Reunite the clamping sleeve with the coupling ensuring that the locking groove on the support sleeve of the coupling engages with the clamping sleeve. 6. Lubricate the threads on the bolt and the washer with a suitable lubricant and insert the bolt into position. Tighten until the outer sleeve are drawn together.
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Note: Because the nut, bolt and washer are made of acid-resistant stainless steel, the threads and the washer must be lubricated. For a correctly Ăžtted, secure connection follow the instructions enclosed with the PE-Xa clamp coupling. O-rings are used for sealing all joints in the PE-Xa clamp assortment and are supplied with the Ăžttings. If a coupling is to be Ăžtted to some other component, seal the threaded joint with hemp yarn, Ă&#x;ux or a linseed oil based compound. For further product information please consult Uponor.
Uponor clamp tee
Hjpiodib dinomp^odjin Uponor PE-Xa pipes 63 – 110 mm 1. Cutting Uponor PE-Xa pipes 63 - 110 mm 5
2
6 4
1
3
2. Bevelling Uponor PE-Xa pipes 63 - 110 mm
OD
5
1
3 4 OD
2
3. Installation Uponor clamp ďŹ tting Uponor clamp Ăžtting 25 - 110 mm
3 2 1
4
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MASTER
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MASTER
Km`nnpm` o`no m`kjmo ajm m\_d\ojm ^jii`^odji A@EFDG5F;A@ BDA<75F
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(max. pressure loss 0.2 bar!) F:Q ;:K
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17
Gdno ja \]]m`qd\odjin Short cut
German description
English explanation
DIN
Deutsches Institut fÂ&#x;r Normung
German institute for standardisation
EnEV
Energieeinsparverordnung
German directive for energy saving
EN
EuropÂ&#x160;ische Norm
European Standard
DVGW
Deutscher Verein des Gas- und Wasserfaches
German Technical and ScientiĂ&#x17E;c Association on Gas and Water
ABP
Allgemeine bauaufsichtliche PrÂ&#x;fzeugnisse
General test certiĂ&#x17E;cates of the supervising authority
PPSU
Polyvenylsulfon
Polyphenylsulfone
SKZ
SÂ&#x;ddeutsches Kunststoffzentrum
South German Plastics Centre (Wuerzburg)
KTW
Kunststofferzeugnisse in der Trinkwasserinstallation
Plastic articles for food use in drinking water supply
ZSVHK
Zentralverband SanitÂ&#x160;r, Heizung und Klima
Central association of plumbing, heating and climatisation
TRWI
Technische Regeln Trinkwasserinstallation
Directives for domestic drinking water supply systems
Cjr oj ^jio\^o pn Customer service center
T +49 (0)9521-690-370 F +49 (0)9521-690-750 E export@uponor-europe.com
Technical assistance
T +49 (0)9521-690-739 or 834 F +49 (0)9521-690-750 E export@uponor-europe.com
We reserve the right to make technical amendments and carry out updates.
18
Uponor – partnering with professionals Uponor is a leading supplier of plumbing and heating systems for the residential and commercial building markets across Europe and North America, and a prominent supplier of municipal infrastructure pipe systems in Europe. UponorÕs key applications are radiant heating, tap water systems and infrastructure solutions. The Group employs 4,500 people globally. In 2007, UponorÕs net sales totalled 1.2 billion euros. Uponor Corporation is listed on the Nordic Exchange in Helsinki, Finland. Uponor International Sales takes care of all business activities in Western Asia, Far East, Africa and Latin America.
1042728 Ð 03/2008 Ð Subject to modiÞcations
Uponor. Simply more.
Uponor Europe – East and International
International Sales P.O. Box 1641 97433 Hassfurt Germany T +49-(0)9521 690 0 F +49-(0)9521 690 750 E export@uponor-europe.com W www.uponor.com/international