PPRC manifold fabrication — custom-built from aquatherm pipe in Ankara
aquatherm piping systems supplier and manifold fabricator in Ankara since 1998. PPRC is the common Turkish name for PP-R (polypropylene random copolymer) pipe. In our own workshop we fabricate PPRC manifolds to your drawing: body diameter, number of outlets and end type are set by the project, and every manifold is pressure tested.
We do not sell mass-produced, moulded underfloor heating manifolds with 16×2 PEX outlets. What we make: meter, boiler room, fan coil, booster and industrial manifolds with Ø32–Ø250 bodies, cut to drawing from aquatherm PP-R pipe with weld-in saddle branches. If you need a standard 8-port underfloor heating manifold, we are not the right supplier; if you need a custom manifold for large zone distribution, read on.
PP-R versus metal manifolds
Does the same job as stainless steel, galvanised steel and brass; does not corrode, needs no insulation, and is lighter and more economical.
| Criterion | Stainless steel | Galvanised steel | Brass | PP-R (aquatherm) |
|---|---|---|---|---|
| Corrosion | Risk of pitting in chlorinated water | Rusts once the coating wears; rust enters the water | Risk of dezincification | No corrosion; no chemical reaction with water |
| Service life | Long, depends on water quality | Limited; rust and scale build-up | Medium; depends on joint seals | Extrapolated 50+ years (DIN 8077 pressure-temperature curves) |
| Weight | Heavy | Heavy | Heavy (limited to small diameters) | Density 0.9 g/cm³; roughly 1/8 of steel |
| Installation time | Welding/flanges, heavy lifting | Threaded joints, sealing compound | Threaded joints, many seals | Light; joins directly to pipe by socket or saddle fusion |
| Cost | High | Medium | Medium to high | Industry sources report a 50–70% advantage over stainless and brass; varies by project |
| Insulation | Separate insulation required (condensation, heat loss) | Separate insulation required | Separate insulation required | Thermal conductivity 0.15 W/mK; inherently low heat loss, little condensation |
| Water hygiene | Good | Poor; rust, taste and odour | Lead content must be limited | Approved for drinking water (DVGW, KTW); no taste or odour |
Cost ratios are the range reported in industry sources; the exact difference appears in the quote and depends on diameter, end type and valves. Details: PPRC manifold prices (Turkish).
Size range and pressure rating
Body and branches within the aquatherm green / blue range. End type and valves to suit the project.
Fabrication range
| Property | Value |
|---|---|
| Main body diameter | Ø32 – Ø250 mm (aquatherm pipe range; larger sizes on a project basis) |
| Branch (outlet) diameter | Ø20 – Ø110 mm |
| Number of outlets | 2 – 20+ (single or double row, opposing or staggered) |
| End types | Closed cap, threaded (female/male, brass insert), flanged (loose flange + adaptor), welding socket |
| Valve options | No valves, ball valves (PP-R or brass), butterfly valves (flanged large sizes) |
| Material | aquatherm fusiolen PP-R / PP-RCT; fibre-reinforced (MF) pipe preferred for the main body |
| Branch technique | Weld-in saddle: aquatherm saddle families for main pipe Ø40–630 mm, branch Ø20–160 mm; threaded saddles 1/2"–1" (catalogue pp. 105–108) |
| Testing | Leak / pressure test in the workshop; values per project specification |
| Standards | DIN 8077 / DIN 8078, DIN EN ISO 15874, fittings DIN 16962 (aquatherm product) |
| Welding parameters | DVS 2207-11; heating element 260 °C, aquatherm AQE times below +5 °C |
Permissible operating pressure (50 years)
| SDR / series | 20 °C | 60 °C | 70 °C | Application |
|---|---|---|---|---|
| SDR 11 S (PP-R) | 12.9 bar | — | — | Cold water only (20–30 °C) |
| SDR 7.4 S (PP-R) | 20.4 bar | 10.1 bar | 6.7 bar | Hot and cold water, small sizes |
| SDR 7.4 MF (fibre-reinforced PP-R) | 24.5 bar | 12.1 bar | 8.1 bar | Ø20–32, low expansion |
| SDR 9 MF RP (fibre-reinforced PP-RCT) | 23.1 bar | 12.2 bar | 10.2 bar | Mains and manifold bodies, Ø32–315 |
Values from the aquatherm green drinking-water operating pressure table for plain pipe, 50-year service life. A factor of 0.75 applies to butt-welded segment joints; the final pressure-temperature rating of saddle joints on a manifold body is confirmed per project. Images and technical data: aquatherm GmbH (Product Catalogue 2026, aquatherm.de). Used with brand permission. Pipe series: aquatherm green, aquatherm blue.
All values are confirmed per project. If you have a specification, send it with the enquiry and we will select the pressure class and SDR accordingly.
Five types, one fabrication method
All from the same aquatherm pipe, all with the same weld-in saddle technique. The difference is body diameter, outlet layout and end type.
Water meter manifold
Apartment distribution in multi-storey buildings. Single or double row of outlets by number of flats, each with a threaded end and valve for the meter connection.
Meter manifold details (Turkish)Boiler room supply and return manifold
Large-diameter supply and return bodies collecting boiler, calorifier and zone lines. Flanged ends, butterfly valves, drain and air-vent outlets.
End type and valve guide (Turkish)Heating-cooling / fan coil manifold
Supply and return distribution for air handling units and fan coil lines. Low thermal conductivity means little condensation and heat loss; matches aquatherm blue.
aquatherm blue pipePump group / booster manifold
Header on the suction and discharge side of booster and circulation pump groups. Body diameter and ends chosen for vibration and pressure fluctuation.
What drives the price (Turkish)Industrial / treatment manifold
Treatment, UF membrane, process and seawater lines. Material is verified against the aquatherm chemical resistance list.
Send project detailsNot on the list?
Seawater, compressed air, chemical process: we check the aquatherm compatibility list and get back to you.
Write on WhatsAppFive steps from drawing to dispatch
Using aquatherm's weld-in saddle technique: a single weld instead of a tee, a homogeneous body, and the option to add outlets later.
- 01
Drawing and dimensions
A project drawing, hand sketch or photo is enough. Together we settle body diameter, number of outlets, branch spacing and end types.
- 02
Drawing approval
We send a dimensioned fabrication drawing; once overall length, outlet positions and connection dimensions are approved, fabrication starts.
- 03
Weld-in saddle branches
Outlets are opened on the aquatherm pipe with the weld-in saddle technique and fused. Pipe and saddle become one homogeneous body; no seals, no threads.
- 04
Pressure and leak test
Every manifold is tested in the workshop. Test pressure and duration follow the project specification; a test record is supplied on request.
- 05
Labelling and dispatch
Outlets are labelled to the project numbering and ends are shipped with protective caps. Delivery within Ankara and freight to other provinces.
Images and technical data: aquatherm GmbH (Product Catalogue 2026, aquatherm.de). Used with brand permission.
How the weld-in saddle works
- 01A hole is drilled in the main pipe with the aquatherm drill bit or hole saw matching the branch diameter (Ø50 and Ø63 bits are used only on a stationary drill stand).
- 02On OT or UV layered pipe the area around the hole is peeled with the saddle peeling tool (separate tool series for Ø50–125 and 160–250 mm).
- 03The saddle welding tool for the main × branch diameter combination is fitted to the heating element; the hole edge and the saddle's welding surface are heated together.
- 04The saddle is pressed into the hole: the outer welding surface fuses to the pipe outside, the inner socket to the inner pipe wall (catalogue wording: 'weld-on surface and additional weld-in socket for the fusion with the inner pipe wall').
- 05The branch pipe is socket-welded into the saddle (threaded saddles take a direct threaded connection).
In manifold fabrication several saddles are welded onto the main body pipe this way; each needs the welding tool for its main × branch diameter (catalogue pp. 178–179 list tools from 40×20/25 up to 630×125).
For a branch on an existing pressurised line, the weld-on saddle with ball valve plus the hot tapping tool (Art. 9800050890) is used; main pipe Ø75–630 mm; not for blue OT.
aquatherm saddle families and size ranges
| Saddle type | Main pipe | Branch | Catalogue p. |
|---|---|---|---|
| Weld-in saddle, socket welding | Ø40, 50, 63, 75, 90, 110, 125, 160, 200, 200–250, 250, 315, 315–355 mm (blue section also 355, 400–630 mm) | Ø20, 25, 32, 40, 50, 63, 75, 90, 110, 125 mm (depends on main size) | 105–106 (green), 59–61 (blue) |
| Weld-in saddle butt welding | Ø315, 355 mm | Ø160 mm | 106 |
| Weld-in saddle with female thread, spanner flat | Ø40–250 mm | 1/2" and 3/4" (Ø25 socket), 1" (Ø32 socket) | 107 |
| Weld-in saddle with male thread, spanner flat | Ø40–160 mm | 1/2" and 3/4" | 107 |
| Weld-in saddle with female thread, stainless steel | Ø40–250 mm | 1/2", 3/4", 1" | 108 |
| Weld-on saddle with ball valve for installation under pressure | Ø75, 90, 110, 125, 160, 200, 250, 315–355, 400–630 mm | Ø40 and Ø63 mm | 108 |
Saddle welding tools
| Tool | Range | Art. no. |
|---|---|---|
| saddle welding tools | 40×20/25 … 630×125 (main × branch) · full list catalogue pp. 178–179 | 9800050614–9800050746 |
| drills for installation of weld-in saddles | Ø20/25 (main 40–160 and 63–250), 32, 40, 50*, 63* · *stationary drill stand only | 9800050940–9800050948 |
| saddle-hole saw for branch, center drill, hole saw holder | Ø75, 90, 110, 125, 160 mm | 9800050987–9800050991; 9800050973–9800050976 |
| saddle peeling tools for OT and UV pipes | Saddle Ø20/25, 32, 40, 50, 63 | 9800050921–9800050928 (Ø50–125); 9800050421–9800050428 (Ø160–250) |
| drill duss DIA303 / drill rig / welding fixture | — | 9800050978, 9800050977, 9800050979 |
Sample saddle dimensions
| Main pipe Ø | Branch Ø | Welding depth z2 | Weight |
|---|---|---|---|
| 63 mm | 32 mm | 18.0 mm | 0.028 kg |
| 110 mm | 50 mm | 23.5 mm | 0.091 kg |
| 125 mm | 63 mm | 27.5 mm | 0.149 kg |
| 160 mm | 90 mm | 33.0 mm | 0.36 kg |
| 200 mm | 125 mm | 40.0 mm | 0.862 kg |
| 315 mm | 125 mm | 40.0 mm | 0.83 kg |
The welding depth (z2) in the saddle's branch socket equals the socket welding table values; full list in catalogue pp. 105–106.
Images and technical data: aquatherm GmbH (Product Catalogue 2026, aquatherm.de). Used with brand permission. Saddle welding details and all joining methods: fittings page (Turkish).
Which dimensions do we need for a quote?
The four dimensions in the schematic plus the end types are enough; we prepare the dimensioned fabrication drawing and submit it for your approval.
- DMain body outside diameter (Ø32–Ø250)
- d1…dnOutside diameter of each branch (Ø20–Ø110); different sizes can share one body
- aBranch spacing (centre to centre); on meter manifolds set by meter + valve length
- LOverall length; state whether end flanges / caps are included
- End typesInlet and outlet ends: closed cap, threaded, flanged, welding socket; with or without valves
From the workshop
The gallery will be updated with Kaskyapı workshop and site photos; for now a manufacturer sample image.
Images: aquatherm GmbH.
Where are they used?
Multi-storey residential
Apartment meter manifolds, riser distribution, booster groups.
Hospitals and hotels
Distribution manifolds suited to hot-water circulation and thermal disinfection (70 °C+).
Shopping centres and offices
Fan coil and AHU supply/return manifolds, boiler room headers.
Industry and treatment
Process water, treatment and UF lines; selection by chemical resistance list.
Data centres and cooling
Low thermal conductivity and a corrosion-free body for chilled water distribution.
The list of completed projects and the sizes used is on the references page; technical catalogues, pressure tables and certificates are in the document centre (both Turkish).
Request a manifold quote
Choose the configuration and attach a drawing. We reply with an itemised quote and delivery date as soon as possible.
PPRC manifold FAQ
How long does a PPRC manifold last?
aquatherm PP-R pipe is rated on the DIN 8077 pressure-temperature curves for a 50-year service life. Because the manifold is fusion-welded from the same pipe, the body has the same life as the pipe; what really sets the lifetime is matching operating temperature and pressure to the right SDR.
Which sizes do you fabricate?
Main body Ø32–Ø250 mm, branches Ø20–Ø110 mm. Larger body sizes are assessed per project, depending on aquatherm pipe availability and butt-welding capacity.
What is the lead time?
Lead time starts after drawing approval and is stated as a firm date in the quote. Manifolds with many outlets, flanges and valves can take longer.
How does it differ from a stainless steel manifold?
A PP-R body does not corrode, carries no pitting risk in chlorinated water and gives low heat loss without separate insulation. Stainless steel may still be preferred where very high temperatures or mechanical impact are involved; for building services water up to 70 °C, PP-R is both lighter and more economical.
Can it be used for underfloor heating?
Yes, but what we fabricate is not a mass-produced underfloor heating manifold (moulded product with 16×2 PEX outlets). If you need a large-body, project-specific manifold with custom outlet spacing for underfloor zone distribution, we make it; if you are after a standard 8-port product, we are not the right supplier.
Do you deliver with valves fitted?
Yes. We deliver with ball valves (PP-R or brass) or, on flanged large sizes, butterfly valves fitted. Delivery without valves, with closed caps, is also possible; our valve and end-type guide (Turkish) explains which suits which case.
Do you ship outside Ankara?
Yes. Manifolds ship across Türkiye by freight or courier, with protective caps on the ends and the body packed. Transport appears as a separate line in the quote. Export enquiries are handled case by case.
Is every manifold pressure tested?
Every manifold passes a leak and pressure test in the workshop before dispatch. Test pressure and duration follow the project specification; a test record can be supplied with the delivery on request.
Can outlets be added to an existing manifold later?
Yes; this is the main advantage of the weld-in saddle technique. If there is enough free length on the body, a hole can be drilled on site and a new branch welded onto the installed manifold; a metal manifold would need removal and re-welding.
Can I order without a drawing?
Yes. Send the body diameter, number and size of outlets and the branch spacing on WhatsApp; a hand sketch or a photo of the existing manifold also works. We prepare the dimensioned fabrication drawing and submit it for your approval.
Two commitments, kept separate
aquatherm system warranty
aquatherm pipe and fittings are covered by the manufacturer's 10-year insured system warranty (up to 20 million € per claim), subject to a documented pressure test and trained installation. This warranty covers the aquatherm product; it does not cover manifold fabrication.
Scope published by the manufacturer: 10-year warranty, insurance of up to 20,000,000 € per claim, for piping systems and surface heating/cooling solutions under aquatherm services and for prefabricated elements that pass the factory leak and function test.
General warranty conditions (terms, exclusions, claims process) are not covered on the source pages; to be verified separately on aquatherm.de.
Kaskyapı fabrication and test commitment
Every manifold we fabricate is leak and pressure tested in the workshop, and we stand behind the weld quality and dimensional accuracy. The fabrication warranty period is stated in writing with the quote.
Standards and approvals
- DIN 8077 / DIN 8078 (PP-R pipe dimensions and strength)
- DIN EN ISO 15874
- DIN 16962 (PP fittings)
- DVGW, SKZ, KTW approvals (aquatherm green)
- aquatherm ISO 9001 / 14001 / 50001
The same logic as aquatherm's own prefabrication
aquatherm plans and produces manifolds and special parts to customer specification in its own factory and ships them ready for installation worldwide. All that is needed is planning data, 3D drawings and/or dimensioned sketches; a quote with a bill of materials and drawing follows.
- 01Review and preparation
Project data is submitted; existing documents are reviewed together. Preliminary planning support is given where needed.
- 02Enquiry and checking
Project details are entered on the aquatherm manifold enquiry forms (sanitary, heating, cooling); the planning team checks plausibility and completeness.
- 03Planning and coordination
The design department prepares a detailed CAD drawing, sent to the customer for checking and production release. CAD data can be shared for import into the customer's planning software.
- 04Production
Pipe systems, manifolds and special parts are produced by a 25-person prefabrication team on roughly 1,600 m². Finished elements pass a leak and function test before leaving the factory.
- 05Delivery
After the individual assemblies are checked, the finished systems are delivered to site through the wholesale channel.
Kaskyapı manifolds follow the same steps in our Ankara workshop: dimensioned drawing approval, weld-in saddle branches, leak and pressure test before dispatch. The warranty and insurance cover of the 1,600 m² prefabrication shop in Attendorn applies to aquatherm's own prefabricated elements; Kaskyapı fabrication carries its own separate commitment.
Images and technical data: aquatherm GmbH (Product Catalogue 2026, aquatherm.de). Used with brand permission.
Send the drawing, get the quote.
Body diameter, number of outlets and end type are enough. Fabricated, pressure tested and delivered from our Ankara workshop.