A new era of hydraulic innovation at San Siro: Aquatechnik’s contribution with pre-insulated pipes

Close to the heart of Milan, San Siro is more than just a dynamic neighborhood and home to major events; it is now also a symbol of innovative hydraulic solutions thanks to Aquatechnik’s advanced systems. At the forefront of this transformation is the ISO FIBER-COND pre-insulated pipe, used in a 250 mm diameter for a district heating project that redefines the concept of sustainable energy efficiency.

Project objectives: maximizing efficiency and comfort

For San Siro, the goal was clear from the very beginning: to create a system that combined operational excellence with sustainability. Energy efficiency and environmental awareness are fundamental: for this reason, the project aimed to implement a solution that would ensure the efficient and circular use of resources in the area, minimizing energy losses and improving overall comfort. In particular, the system involved recovering heat from the Silla 2 waste-to-energy plant and distributing it to Milanese homes through the district heating network.

The ISO FIBER-COND system proved to be perfectly in line with these objectives: designed to withstand pressure in demanding environments and ensure flawless operation in variable conditions, its ability to function in both aerial and underground installations provided additional flexibility.

The systems used: the advantages of Iso-technik pre-insulated pipes

ISO FIBER-COND is the Aquatechnik solution that caught the attention of Mattia Panza and his company Termoidraulica Panza for the installation of systems in the San Siro district.

A system specifically designed for heating and air conditioning, suitable for transporting water at the top of the range of pre-insulated solutions, combining state-of-the-art materials and precision engineering to offer unparalleled performance. Among its most interesting advantages:

• Superior thermal insulation. Rigid polyurethane foam (PUR) insulation between the service pipe and the casing minimizes heat and thermal energy loss, improving energy efficiency. This feature is particularly advantageous for high-performance heating and cooling systems that can operate optimally throughout the year. The very low thermal conductivity of the service pipe also makes a difference.
• Resistance to oxidation and temperatures. The PP-RCT WOR (White Oxidation Resistance) combination guarantees greater resistance to oxidation and high temperatures, extending the life and reliability of the system. WOR technology increases resistance to oxidizing agents up to 40 times compared to normal PP-R, with a performance increase from 20% (with cold water) to 50% (with hot water). The strength and durability of the system translate into lower maintenance costs and a significantly longer service life.
• Versatility in applications. Available in diameters ranging from 32 mm to 315 mm for the service pipe (with external casing from 90 to 450 mm), ISO FIBER-COND is suitable for various installations including mechanical, heating, air conditioning, irrigation, compressed air and drinking water transport systems
• Eco-friendly composition. Manufactured with recyclable materials that allow the transport of drinking water and free of harmful substances, the system is in line with global sustainability objectives.

The innovation behind ISO FIBER-COND

The advanced technology of ISO FIBER-COND starts with the service pipe Fusio-technik faser FIBER-COND, and extends to the casing, making it an indispensable ally for designers and installers who aim for the best in their plumbing and heating projects.

• Three-layer design. The service pipe is made with an inner layer of PP-RCT with the addition of antioxidant additives (WOR) to increase its chemical and thermal resistance; a fiber-reinforced intermediate layer (PP-RF) to reduce thermal expansion by up to 70% compared to a single-layer PP-R pipe; an outer layer of PP-R 80 Super that guarantees ductility and resilience.
• PUR insulation. High-quality PUR foam improves thermal insulation, ensuring the compactness of the system thanks to a bonded configuration that guarantees uniform insulation along the entire length of the pipe.
• External casing in PE-HD. The high-density polyethylene (PE-HD) casing protects the system from mechanical and environmental damage, ensuring durability even in underground installations. The casing is corona treated to improve adhesion with the PUR foam.

The data speaks for itself: Iso-technik compared to metal pipes

The Iso-technik system is the benchmark for many installers and designers who have chosen it for remote energy distribution as a winning alternative to traditional metal pipes. Why? If the advantages analyzed so far are not enough for you, here are the comparison data.

• Thermal performance. ISO FIBER-COND offers thermal conductivity at 20°C of 0.190 W/mK, significantly outperforming standard steel pipes, which have higher heat loss (52 W/mK).
• Lightweight and durable. Unlike metal systems, ISO FIBER-COND pipes are lightweight and easier to install without the use of heavy machinery, reducing costs and labor time.
• Noise and maintenance reduction. With an internal roughness of only 0.007 mm (0.20 mm steel), the pipes minimize friction, reducing pressure losses and operating noise, as well as preventing limescale buildup and corrosion.

Additional benefits: easier installation and energy savings

The technical characteristics of ISO FIBER-COND are reflected in the applications of the system, from the installer to the end user who utilizes the installed systems.

• Easy installation thanks to heat-welded flaring joints for smaller diameters (from 32 to 125 mm), butt joints for larger diameters (from 160 to 315 mm), and electrofusion welding, which guarantees greater safety and efficiency. To further simplify the process, we provide advanced welding equipment capable of mechanically self-aligning pipes from 50 to 315 mm in diameter. This precision reduces installation errors and ensures a more secure joint.
• Improved maneuverability on site because the pipes are lighter than traditional metal pipes, eliminating the need for heavy machinery. In addition, the system does not require transverse welding trenches, making installation faster and less labor-intensive. Furthermore, single or double seals can be quickly created using PUR foaming technology on site.
• The ease with which the pipe can be shelled is another key advantage that allows for customized installations based on specific project requirements. The system has also been designed for use in all conditions, allowing pipes to be pre-assembled outside the trenches and then repositioned. This feature proves invaluable in adverse weather conditions, preventing work from being interrupted.
• Self-compensating characteristics. The viscoelastic properties of Iso Fiber-COND naturally absorb residual thermal stresses, eliminating the need for mechanical compensators in underground installations.
• Energy savings. By reducing pump loads and fluid resistance, as seen, Iso FIBER-COND significantly reduces energy consumption, ensuring long-term operating cost savings.

Setting new standards with Aquatechnik

The Iso-technik system is the starting point for the future of eco-friendly and more efficient solutions in heating and air conditioning installations. From aerial installations to underground networks, ISO FIBER-COND has proven its ability to adapt to different operating requirements, while also ensuring minimal environmental impact.

The project not only highlights the transformative potential of innovative engineering, but also reinforces our commitment to providing sustainable, forward-thinking solutions. San Siro is now a model for all urban neighborhoods, where advanced hydraulic systems meet the demands of modern life without compromising efficiency or reliability.

Aquatechnik means future-proof plant engineering solutions: contact us for more information and discover the future of the industry today.