EXPANSION CALCULATIONS AND LOOP SIZING

In a bonded system, the carrier pipe, foam insulation, and

EXPANSION COMPENSATION
outer protective jacket are joined together forming one co-
hesive unit that expands and contracts together. Thermal
expansion of the carrier pipe during operation is therefore
Elbow
transfered to the polyurethane foam and outer jacket. These
movements are naturally restricted to a certain extent by
the friciton between the soil and jacket. In extreme cases,
the force of friction can become so great that free expansion Z-Bend
can not occur and the unit becomes “fixed” into place. In
such a case, the opposing force from thermal expansion
can place impermissibly high stresses in the carrier pipe. Loop
Therefore, free expansion must be allowed to occur, but
expansion must ultimately be compensated for through sys-
tem design. The most common method is the inclusion of
expansion elbows, loops, or z-bends.
NATURAL FIXED POINT
Thermal expansion will occur between all fixed points in the
piping system. If the system has the same covering height,
natural fixed points will occur in the center of a line section
between two expasion elbows. Unequal covering will cause
the fixed point to be displaced due to varying frictional forces
and if there is any doubt, the fixed point should be set with
an anchor. In all cases, this fixed point should be consid-
ered when calculating expansion.

GUIDELINES FOR LOOP SIZING

1. The expansion loop is usually located on the side of the EXPANSION LOOP
hottest line.
2. The expansion loop as a rule should be located in the
center of the distance between two anchors.
3. The height of the expansion loop is normally twice the
width. The exception to this rule occurs when more
than one line runs parallel in a common trench. The
dimensions of the loops for the additional line must be
increased to allow nesting of the loops.

CALCULATIONS EXAMPLE
1. The formula for calculating thermal expansion: Find the loop size for a 6” diameter steel pipe carrying
ÄL = C x L x (Tf - Tg) x 12in./ft. 200°F heating water with 200 ft. between anchors and
Coefficient of thermal expansion (C): an average annual ground temperature of 50°F.
Steel (C) = 6.5 x 10-6 in./in.°F Given:
Copper (C) = 9.2 x 10-6 in./in.°F Steel (C) = 6.5 x 10-6 in./in.°F
Distance between fixed points (L) in feet. Distance (L) = 200 ft.
Temperature of fluid (Tf) Temp. Diff. (ÄT) = (200°F - 50°F) = 150°F
Temperature of ground (Tg) Pipe Diam. (D) = 6”
2. After calculating the expansion, find the expansion loop Calculations:
size from the charts for the applicable pipe or tube. Loop ÄL = C x L x (Tf - Tg) x 12in./ft.
sizes are taken to the nearest half foot on the height ÄL = 6.5 x 10-6 x 200 x (200 - 50) x 12
and witdth. ÄL = 2.34 in. (expansion)
From the expansion loop chart for steel:
Requires 5’x10’ expansion loop.
 EXPANSION LOOP SIZES FOR STEEL PIPE EXPANSION LOOP SIZES FOR COPPER TUBING
Expansion loops are sized for A53 Grade B ERW steel pipe allowable stresses. Expansion loop dimensions are for ASTM B-88 seamless cop-
per tubing based on an allowable stress of 6,000 psi. as
stated in the copper development association handbook for
copper tubing. Pressure shall not exceed 150 psig.

PIPE LOOP SIZE PIPE LOOP SIZE PIPE LOOP SIZE

SIZE ÄL (FT) SIZE ÄL (FT) SIZE ÄL (FT)
(IN) (IN) H W (IN) (IN) H W (IN) (IN) H W

3/4 0.00 - 1.50 4 2 10 0.00 - 0.42 4 2 3/4 0.00 - 2.09 4 2

1.50 - 6.00 6 3 0.42 - 0.91 6 3 2.09 - 4.69 6 3
1 0.00 - 1.00 4 2 0.91 - 1.44 8 4 4.69 - 8.35 8 4
1.00 - 4.14 6 3 1.44 - 2.00 10 5 1 0.00 - 1.62 4 2
2.00 - 2.57 12 6 1.62 - 3.65 6 3
1-1/4 0.00 - 0.93 4 2 2.57 - 3.16 14 7
0.93 - 3.33 6 3 3.65 - 6.49 8 4
3.16 - 3.80 16 8 6.49 - 10.14 10 5
3.33 - 5.56 8 4 3.80 - 4.14 18 9
1-1/2 0.00 - 0.88 4 2 1-1/4 0.00 - 1.32 4 2
12 0.00 - 0.39 4 2 1.32 - 2.98 6 3
0.88 - 2.75 6 3 & 0.39 - 0.87 6 3
2.75 - 4.75 8 4 2.98 - 5.31 8 4
14 0.87 - 1.34 8 4 5.31 - 8.30 10 5
2 0.00 - 0.85 4 2 1.34 - 1.88 10 5
0.85 - 2.38 6 3 1.88 - 2.43 12 6 1-1/2 0.00 - 1.12 4 2
2.38 - 4.00 8 4 2.43 - 3.00 14 7 1.12 - 2.53 6 3
3.00 - 3.57 16 8 2.53 - 7.02 8 4
2-1/2 0.00 - 0.78 4 2 7.02 - 10.11 10 5
3.57 - 4.14 18 9
0.78 - 2.14 6 3
2.14 - 3.71 8 4 16 0.00 - 0.41 4 2 2 0.00 - 0.89 4 2
3.71 - 5.31 10 5 0.41 - 0.85 6 3 0.89 - 1.93 6 3
0.85 - 1.32 8 4 1.93 - 3.44 8 4
3 0.00 - 0.72 4 2 3.44 - 5.37 10 5
0.72 - 1.78 6 3 1.32 - 1.83 10 5
1.83 - 2.34 12 6 5.37 - 7.73 12 6
1.78 - 3.00 8 4
3.00 - 4.35 10 5 2.34 - 2.86 14 7 2-1/2 0.00 - 0.69 4 2
2.86 - 3.43 16 8 0.69 - 1.56 6 3
3-1/2 0.00 - 0.68 4 2 3.43 - 4.00 18 9 1.56 - 2.78 8 4
0.68 - 1.35 6 3 2.78 - 4.35 10 5
1.35 - 2.70 8 4 4.35 - 6.26 12 6
2.70 - 3.84 10 5 6.26 - 8.52 14 7
3.84 - 5.00 12 6
3 0.00 - 0.58 4 2
4 0.00 - 0.63 4 2 0.58 - 1.31 6 3
0.63 - 1.45 6 3 1.31 - 2.33 8 4
1.45 -2.41 8 4 2.33 - 3.65 10 5
2.41 - 3.45 10 5 3.65 - 5.26 12 6
3.45 - 4.52 12 6 5.26 - 7.16 14 7
5 0.00 - 0.42 4 2 7.16 - 9.34 16 8
0.42 - 1.27 6 3 4 0.00 - 0.99 4 2
1.27 - 2.12 8 4 0.99 - 1.77 6 3
2.12 - 3.00 10 5 1.77 - 2.76 8 4
3.00 - 3.96 12 6 2.76 - 3.98 10 5
3.96 - 4.13 14 7 3.98 - 5.42 12 6
6 0.00 - 0.46 4 2 5.42 - 7.08 14 7
0.46 - 1.16 6 3 7.08 - 8.96 16 8
1.16 - 1.87 8 4 5 0.00 - 0.80 6 3
1.87 - 2.35 10 5 0.80 - 1.42 8 4
2.35 - 3.51 12 6 1.42 - 2.22 10 5
3.51 - 4.26 14 7 2.22 - 3.20 12 6
8 0.00 - 0.54 4 2 3.20 - 4.36 14 7
0.54 - 1.00 6 3 4.36 - 5.70 16 8
1.00 - 1.64 8 4 5.70 - 7.21 18 9
1.64 - 2.30 10 5 6 0.00 - 1.19 8 4
2.30 - 2.95 12 6 1.19 - 1.86 10 5
2.95 - 3.64 14 7 1.86 - 2.68 12 6
3.64 - 4.35 16 8 2.68 - 3.65 14 7
3.65 - 4.77 16 8
4.77 - 6.03 18 9
6.03 - 7.45 20 10