Heavy Series according to DIN 3015, Part 2

 

Most economical solution available for quick, easy

and secure pipe, tube, hose and cable installation

 

Original STAUFF Block Clamps according to German

Industry Standard DIN 3015 (Part 2), designed as a

construction kit for the installation of pipes, tubes,

hoses, cables and other flexible or rigid components

with the most common metric and imperial

outside diameters from 6 mm to 450 mm / .24 inch

to 17.71 inch.

 

Clamp bodies manufactured from various thermoplastics, thermoplastic elastomers or aluminium – also with shock-absorbing and noise-reducing elastomer inserts. Excellent UV, weathering and chemical resistance –

even under extreme conditions. Tested and approved by several independent certification organisations.

 

Twin Series according to DIN 3015, Part 3

 

Most economical solution available for quick, easy

and secure pipe, tube, hose and cable installation

 

Original STAUFF Block Clamps according to German

Industry Standard DIN 3015 (Part 3), designed as a

construction kit for the installation of pipes, tubes,

hoses, cables and other flexible or rigid components

with the most common metric and imperial outside

diameters from 6 mm to 42 mm / .24 inch to 1.65 inch.

 

 

Clamp bodies manufactured from various thermoplastics. Excellent UV, weathering and chemical resistance –

even under extreme conditions. Tested and approved by several independent certification organisations.

 

Heavy Twin Series

 

Most economical solution available for quick, easy

and secure pipe, tube, hose and cable installation

 

Original STAUFF Block Clamps in addition to clamps in the

Heavy Series and the Twin Series according to German

Industry Standard DIN 3015 (Parts 2 and 3), designed as

a construction kit for the installation of pipes, tubes, hoses,

cables and other flexible or rigid components with the most

common metric and imperial outside diameters from

6 mm to 42 mm / .24 inch to 1.65 inch.

 

Clamp bodies manufactured from various thermoplastics – also with shock-absorbing and noise-reducing elastomer inserts.

Excellent UV, weathering and chemical resistance – even under extreme conditions.

 

Main Characteristics

Efficient Prevention of Crevice Corrosion under Pipe Clamps on Stainless Steel Pipework

Middle- and Long-Term Cost Savings due to Extended Service and Maintenance Intervals

 

 

 

 

 

 

 

 

 

 

 

Innovative Design and Materials

▪ Material and design in compliance with section 7.3 (Tubing Installation) of the Norwegian offshore standard

  Norsok Z-010 (Revision 3, published in October 2000 ), API RP 552 and NACE SP 0108-2008 (section 13)

 

- Clamp body made of flame-retardant PPV0 plastic material (tested and V0 classified according to UL 94)

- Integrated anti-corrosion elastomer strips avoid the accumulation of seawater between clamp body and pipe

- Drainage channels aid the dispersal of seawater (self-draining)

- ACT Mounting Hardware is made of Stainless Steel V4A (Material Code: W55) with enhanced corrosion resistance

 by practically excluding metallic and non-metallic impurities during production, processing and handling

 

▪ Suitable for continuous exposure to temperatures from -25 °C to +90 °C (from -13 °F to +194 °F)

▪ High UV stability of the clamp body material; resistant against seawater, rain and oil

▪ To be used in sub-sea and top-side environments; alleviating the requirement for two different products

 

Independent Testing and Approval

▪ Subject to stringent testing at the STAUFF in-house laboratories located in Werdohl (Germany)

▪ Salt spray tests according to ASTM B117 applied in controlled laboratory environments

▪ Long-term field tested on a rig in the Dutch sector of the North Sea

▪ Tests results independently assessed by Centre for Corrosion Technolog at Sheffield  Hallam University

▪ Fully detailed, independent test reports available on request

 

Construction based on STAUFF Clamps

▪ Constructed according to DIN 3015, Parts 1 and 3  (Standard Series and Twin Series)

▪ Tried and tested industry standard for several decades

▪ Covering the most commonly used metric and imperial pipe diameters from 6 mm to 42 mm (from 1/4 inch to 1 1/2 inch)

▪ Can be used in combination with existing mounting hardware; available ex stock from STAUFF in several stainless steel qualities

▪ Alternative configurations and pipe diameters available on request

▪ Installation time reduction (compared to alternative clamp designs)

 

In many areas, stud welding is considered to be the most

economic fastening method for components and is some

times even the only technically feasible solution. Because

the stud is joined with the substructure over the entire

surface of the stud without any hollow areas, a high

strength can be achieved.

 

STAUFF is now using this proven principle for the instal-

lation of pipe, tube, hose and cable clamps in the Standard

 and Twin Series (according to DIN 3015, parts 1 and 3)

with M6 mounting thread, where female threaded weld

studs replace the regular weld plates; distance plates

made from plastic provide the necessary spacing between

the clamp bodies and the substructure. If required, the system can also be adopted for alternative fastening methods, e.g. for clamping belts, cable ties or corrugated cable protection hoses.

 

In addition to the individual components – weld studs, distance plates, clamp bodies and metal hardware required – the company also provides the correspondingly designed assembly tools such as the weld inverter and the weld gun with tripod, weld stud retainer and distance adaptor. The lightweight and compact weld inverter works without high-voltage current.

 

Thanks to increased productivity and flexibility for the installation of clamps, the system offers considerable savings potentials for users with significant processing volumes, especially when working in horizontal or overhead position. The amount of rework on welding locations can be significantly decreased, and material distortion is reduced to a minimum through low thermal stress.

 

The joint of the weld stud with the substructure impresses in particular with a high degree of strength and safety, which is at least at the same level as for regular weld plates.

 

Main Benefits of the STAUFF Stud Welding System

 

• High productivity due to fast and easy handling

• More flexibility when working in horizontal or overhead position
• Material distortion reduced to a minimum through low thermal stress
• High degree of safety due to a welded joint free of hollow areas
• Reducing of rework on welding locations
• One-sided accessibility of the component is sufficient
• No leaking caused by drilled holes
• Works without high-voltage current

STAUFF NRC type clamps were designed for the noise and vibration reducing installation of pipes and tubes with the most common outside diameters between 6 and 42 mm and ¼ to 1 ½ inch respectively.

 

The working principle is based on clamp bodies made from Polypropylene (colour: black) following the Standard Series according to DIN 3015 (part 1) with a specially shaped, two-part elastomer insert, which mechanically absorbs vibrations in the pipe and as a result reduces noises arising to a minimum.

 

The insert is in particular distinguished by how little of its surface is in contact with the pipe and clamp body, and as a result is far more effective than the previously known solutions.

 

The tongue-groove contour of the insert and body, which is reversed and thus diverges from DIN 3015, enables the system to be used for the widest possible range of pipe diameters per clamp size, which contributes to flexibility and versatility.

 

STAUFF NRC Clamps are completely compatible with the commonly used steel and stainless steel mounting hardware, and if necessary can simply be replaced or retrofitted.

 

STAUFF also provides an alternative version especially for use in safety-critical areas, which is made completely out of flame resistant materials according to international standards and directives, and meets the demanding requirements with regards to preventive fire protection.

 

Main Benefits of Noise and Vibration Reducing NRC Clamps

 

Mobile and stationary machines in harbour and loading areas as well as municipal and commercial vehicles

 

• Reducing the overall level of noise emissions,
• especially in urban areasƒ
• Improving occupational health and safety
• Contributing to build machinery that conforms to the
• Machinery Directive 2006/42/EC and the Outdoor Directive
• 2000/14/EC of the European Parliament and of the Council

 

Civil shipping, i.e. on cruise ships as well as yachts and sport boats

 

• Maximising flexibility with the design, layout and positioning of noise-intensive pipes and tubes (e.g. in close proximity to cabins or crew quarters)

• Making a great contribution to comfort and facilitating communication on board(e.g. for engine and control rooms)

• Reducing of underwater noise in order to protect the maritime environment

 

The benefits of using aluminium in machine and plant con-

struction are abundant: although aluminium is considered

to be a light metal with a density of 2.6 to 2.8 g per cm³,

which offers potential weight savings of up to 66% compa-

red to steel and stainless steel, it still has exceptional

strength considering these properties. However, the design

and concept of steel constructions can often not be trans-

ferred one-to-one, due to the higher malleability and lower

residual stress of aluminium components.

 

An additional benefit is the aluminium's inherent resistance

 to corrosion: When exposed to oxygen, the light metal forms an oxide coating, which is immediately regenerated upon permeation. Standard processing methods, such as MIG, TIG and CMT welding can easily be used on aluminium without hesitation – particularly on substrates that are also made of aluminium. In some instances, they can be carried out more easily, more quickly and using simpler equipment, which results in further financial benefits for the user. The magnetic neutrality is also a beneficial side effect of using aluminium in many instances.

 

Aluminium in the ship construction industry

 

There is an increasing trend towards using special seawater-resistant, high-strength aluminium alloys for components and assemblies on sailboats and yachts. The reason: these materials, which contain small portions of magnesium, manganese and silicon in addition to aluminium as the main component, are popular due to their high-quality and attractive appearance. In contrast to wood, they do not require continuous treatment or sealing.

 

Even on ferries and cruise ships, a significant proportion of the assemblies and floors of the upper decks are made from aluminium profiles and plates. The lighter weight facilitates a higher loading capacity, greater distances and lower energy costs. At the same time, the ship's centre of gravity can be placed as low as possible. Approximately 750 tons of aluminium plates and profiles were used in this way to construct the "Voyager of the Seas" – with a gross tonnage of more than 137,000 still one of the largest passenger ships even 15 years after its construction at Aker Yards in Finland (Aker Kvaerner at that time).

 

Aluminium mounting hardware for STAUFF pipe clamps

 

For pipe clamps in the Standard Series as per DIN 3015 (Part 1), which are designed for easy and secure fixing of metric or inch pipelines with outer diameters from 6 mm to 102 mm, STAUFF is offering an aluminium alternative for all dimensions of mounting hardware such as cover plates and weld plates. Even in the Heavy Series as per DIN 3015 (Part 2), certain components and sizes are available in aluminium.

 

The dimensions and material thicknesses of the aluminium components correspond to the standard surface-treated designs generally made of steel or stainless steel, and therefore facilitate the use of bolts of conventional types and lengths, using the usual recommended tightening torques. Due to the low tendency to corrosion when in contact with aluminium, the use of bolts with the standard STAUFF zinc/nickel coating (material code W3) is no problem.

 

The retention forces of the tested pipe clamps in direction of the cover plates, which were tested and documented under controlled conditions at the STAUFF in-house laboratories, clearly met the requirements.

 

Light Series LB/LBG/LBU

 

▪ Compact and light-weight design for applications such as                 Pneumatics, Instrumentation and Automotive Technology,

  Machine Tool Industry, Lubrication and Mechanical Engineering

▪ Available in 4 different sizes and covering all standard metric

  and imperial diameters between

  3,2 mm and 25,4 mm / .13 inch and 1.00 inch

 

 

 

 

 

 

Light Series LN/LNGF/LNUF

 

▪ Compact and light-weight design for applications such as Pneumatics, Instrumentation and Automotive Technology,

  Machine Tool Industry, Lubrication and Mechanical Engineering

▪ Available in 4 different sizes and covering all standard metric

  and imperial diameters between

  6 mm and 22 mm / .24 inch and .87 inch

 

 

Heavy Saddles according to DIN 1592 / 1593

 

▪ Saddles according to DIN 1592: Single-ended design

▪ Saddles according to DIN 1593: Double-ended design

▪ Covering all standard metric and imperial diameters

between 5,5 mm and 115 mm / .22 inch and4.53 inch

 

 

 

 

 

 

 

Light Saddles according to DIN 1596 / 1597

 

▪ Saddles according to DIN 1596: Single-ended design

▪ Saddles according to DIN 1597: Double-ended design

▪ Covering all standard metric and imperial diameters

between 5,5 mm and 115 mm / .22 inch and4.53 inch

 

 

 

 

 

 

 

 

Flat Steel U-Bolts FB

 

▪ With plastic pipe saddle RUK (short) and u-profile

▪ To be used as fixed point clamps only

▪ Covering all standard metric and imperial diameters

between 48,3 mm and 521 mm / 1.90 inch and 20.51 inch

 

 

 

 

 

 

 

 

Round Steel U-Bolts RB

 

▪ With plastic pipe saddle RUK (short) or RUL (long)

▪ Covering all standard metric and imperial diameters

between 25 mm and 521 mm / .98 inch and 20.51 inch

 

 

 

 

 

 

 

 

 

 

 

Round Steel U-Bolts RBD according to DIN 3570

 

▪ Covering all standard metric and imperial diameters

between 25 mm and 521 mm / .98 inch and 20.51 inch

 

 

 

 

 

 

 

Plastic Saddle Clamps ZR

 

▪ Custom-designed Plastic Saddle Clamps according to customer‘s

  specifications or based on STAUFF developments

 

 

 

 

 

 

Wind Energy Clamps

 

Secure and orderly vertical installation of power cables in

wind energy turbines Modular design offers full flexibility

in terms of quantity and alignment of the cables

 

Original STAUFF Wind Energy Clamps can be found in

thousands of Wind Energy Turbines all over the world,

and have been exclusively engineered according to the

individual requirements in this particular market. They

have already become known as a solution which allows

power cables to be installed securely, simply and quickly

with minimum use of tooling, thus reducing installation

time and costs – from the main power connection in the bottom of the tower up to the nacelle itself.

 

Thanks to their modular design and the unique triangular shape of the internal contours, STAUFF Wind Energy Clamps are fully flexible with regards to quantity and alignment of individual or bundles of up to three power cables: By using additional inserts, they can also be used to fasten only two cables or lines with smaller external diameters.

 

▪ Modular design: Suitable for single-level or multi-level (stacking) installation

▪ Clamp bodies and inserts manufactured from flame-retardant PPV0 thermoplastic   material:    Tested and V0 classified according to UL 94 (Vertical Burning Test)

▪ Metal hardware (such as threaded bolts, nuts, cover plates and other substructures) made of steel or stainless steel

▪ Selection of proper hardware subject to stringent testing at the STAUFF in-house laboratories considering

  the individual requirements (e.g. the dimensions, the overall weight and the insulation material of the cables in use)