Galliate (NO): efficient and sustainable district heating with Aquatechnik pre-insulated solutions

A 5 km pipeline system, an expanding urban network and a technical challenge overcome thanks to innovation. In Galliate, in province of Novara, a district heating project is taking shape and marking a turning point for the plant engineering sector: an efficient, sustainable infrastructure built with Aquatechnik’s ISO FIBER-COND pre-insulated polypropylene pipes.

A system designed to meet thermo-hydraulic performance and sustainability requirements, with results made possible thanks to the collaboration between Aquatechnik, the Bonavera Agency, the local representative and the installation company Denzio Service. An exceptional teamwork that has transformed the challenge into an opportunity.

A strategic project for the city supported by PNRR funds

The district heating project in the municipality of Galliate is part of a broader framework of energy transition and sustainability, with a total investment of 7 million euros, of which 3.7 million is financed by the Ministry of the Environment through PNRR funds. It is being promoted by Enerprom srl, a Trentino-based company already active in the area, which is expanding the network starting from the existing plant in Via Di Vittorio, integrating it with a new virgin wood chip plant in Via Foscolo.

The heart of the plant is fuelled by local wood biomass (approximately 6,000 tonnes per year), ensuring continuous and renewable heat production for around 30 users including public buildings, apartment blocks, healthcare facilities and commercial activities, such as the “Il Gallo” centre.

In terms of infrastructure, the network will cover over 5 km of urban routes, crossing the town from north-east to south-west with several local branches.

District heating: an ongoing technological evolution

District heating is now an increasingly strategic solution for improving energy efficiency in urban centres. The idea is simple but significant: produce heat in a single power plant and distribute it through a network of pre-insulated pipes to multiple buildings, thereby reducing consumption and emissions. However, to ensure reliability and efficiency over time, it is essential that the network is designed and built with high-performance materials.

“Until a few years ago, the idea of district heating with polypropylene was unthinkable, due to the pressures and temperatures involved,” explains Paolo Caizzi, technical promoter at Agenzia Bonavera. “Today, thanks to the evolution of Aquatechnik technologies, we can count on advanced plastic solutions even in demanding thermal contexts, with advantages in terms of installation, durability and sustainability.”

This is where ISO FIBER-COND* comes into play, the range of pre-insulated pipes in fibre-reinforced PP-RCT WOR perfect for high-temperature closed-circuit systems such as district heating.

The Bonavera Agency explains why polypropylene is the winning choice

Iso FIBER-COND: why it is the winning choice for district heating

At the heart of the Galliate project is ISO FIBER-COND SDR 11, the Aquatechnik solution developed specifically for closed high-temperature and medium-pressure heating and cooling circuits. This pipe combines multi-layer technology and advanced thermal insulation to ensure efficiency, durability and ease of installation. In this specific case, the ECO version of COND pipes was used to meet the CAM requirements of the PNRR.

1. Fibre-reinforced layered structure: dimensional and thermal stability

The core of the pipe consists of FIBER-COND piping made of PP-RCT WOR (White Oxidation Resistance), an advanced plastic material with high resistance to oxidizing agents and high temperatures. The pipe has a fiber-reinforced intermediate layer that drastically reduces linear thermal expansion (up to 0.035 mm/m·K) compared to single-layer PP-R systems.

This feature translates into greater system stability even in the presence of long underground sections and in challenging thermal conditions, such as in the 5 km section built in Galliate.

2. High-performance PUR insulation: minimum dispersion, maximum efficiency

The Faser pipe is pre-insulated with closed-cell polyurethane (PUR) foam (>90%), enclosed in a high-density polyethylene (PE-HD) outer sheath. This “bonded” system ensures perfect adhesion between the layers and prevents the formation of air gaps, improving the effectiveness of the insulation.

The thermal conductivity value of the system has been further optimized by Aquatechnik:

• Initial λ reduced from 0.0227 to 0.0142 W/mK
• Stabilised λ improved from 0.027 to 0.023 W/mK

Thanks to these values the heat loss along the network is significantly reduced, contributing to tangible energy savings. 

In addition, the polyurethane foam is also CAM certified.

3. Self-compensation of expansion: no compensation loops

One of the most significant advantages of the Iso-technik system is its ability to self-compensate for thermal expansion in underground sections thanks to cold installation and the intrinsic flexibility of the material. This means that there is no need to insert omega profiles, loops or thrust bearings, greatly simplifying design and reducing construction costs.

Alessio John Paladino, technical manager of the Bonavera Agency, explains Aquatechnik’s WOR technology

4. Ease of processing and handling

The low linear weight of the pipes facilitates handling on site without the need for hoists. The pipes can be welded outside the trench thanks to polyfusion and laid after processing.

Efficient installation and ongoing assistance: the role of Aquatechnik and Bonavera

In addition to the product itself, another key aspect of the project’s success was the technical and logistical support provided by Aquatechnik and the Bonavera Agency. The field work was accompanied by targeted training for installers, ensuring faster and safer installation of this type of piping. 

“We followed Denzio Service step by step, both in the early stages and during the welding operations,” Caizzi continues. “With Aquatechnik, our goal was to provide not only a high-performance product, but also all the tools to use it to its full potential.”

The Iso-technik system allows the use of different joining techniques – socket welding, butt welding and electrofusion welding – with dedicated equipment. It is also possible to pre-assemble the lines outside the trench, a decisive advantage on construction sites subject to variable weather conditions.

Another strength of Aquatechnik’s logistics is its flexibility in supply: ISO FIBER-COND pipes are available in different lengths (in 5.8 m and 11.6 m bars), diameters up to Ø 315 mm and external casings up to 450 mm, with a complete range of pre-insulated fittings ready for installation.

A growing urban network: Galliate looks to the future

The Galliate Council project is undoubtedly a replicable model for new-generation district heating thanks to the possibility of gradually extending the urban network. The 5 km currently under construction are just the beginning: the choice of a modular, lightweight and flexible system such as Iso FIBER-COND allows for future expansions without infrastructure constraints.

For designers, this means having a scalable solution that is also suitable for contexts that have historically been difficult for district heating thanks to the low impact of installation operations and the simplicity of technical management.

Aquatechnik: technology, support and sustainability for the plant engineering of the future

The Galliate case study clearly demonstrates how Aquatechnik is now an ideal partner, capable of offering not only innovative plant engineering solutions, but also supporting the customer through all stages of the project, from design to installation, right through to on-site training.

Our ISO FIBER-COND system is the most advanced solution for district heating, offering concrete advantages for:

• Designers, thanks to the reduction in compensation calculations and the predictability of expansion
• Installers, who find the lightness and ease of joining PP-R a great ally in speeding up construction times
• Clients, who benefit from a high-efficiency system with low heat loss and long service life
• Distributors and wholesalers, such as the Cambielli Group, a partner in the project who find Aquatechnik to be a reliable and strategic brand in terms of supply.

Behind a system of the future, the innovation of Aquatechnik’s PP-RCT fibre-reinforced pipes

The construction of the district heating system in Galliate is a concrete example of how innovation in pre-insulated plastic materials can redefine the frontiers of plant design. A construction site that has successfully combined high technology, sustainability and collaboration between various players in the sector with our Iso-technik line playing a leading role.

Behind every great system there is always great technology, the result of innovation and collaboration, and in Galliate, it is called ISO FIBER-COND.