The flexible solution for round tube constructions of all kinds
High-quality Zamak (zinc die-cast) tube inserts for round tubes are the universal connection solution for circular steel tubes and round tube frames. As a versatile connecting element with an integrated metal thread, they enable secure threaded connections in furniture making, shopfitting, and mechanical engineering – ideal for demanding industrial applications in machine and plant construction as well as metal processing.
Your advantages with Zamak pipe inserts for round pipes
✓ Universally applicable Suitable for various round tube diameters – versatile and flexible
✓ 360° locking mechanism Circumferential longitudinal ribs for permanent, form-fitting hold
✓ High-strength zinc alloy DIN EN 1774 – Tensile strength 280 MPa for maximum load capacity
✓ Corrosion-resistant The natural oxide layer provides lasting protection against rust.
✓ Quick assembly Simple press-fit installation without additional fasteners
✓ Made in Germany Precision manufacturing according to DIN ISO 9001:2015
Manufactured using zinc die casting, suitable for round tubes, thread M10, collar height 5 mm, total height 23 mm.
| Article | Dimensions | For pipe wall thickness | thread | VPE |
| B-709 | 60/2 | 2.0 mm | M10 | 150 |
Why Zamak? The technical advantages
High-strength zinc alloy for universal load-bearing capacity
Zamak tube inserts for round tubes offer outstanding mechanical properties for circular tube constructions due to their optimized material composition and special geometry.
Mechanical performance data:
- Tensile strength: 280 MPa (approx. 50 % higher than aluminum)
- Compressive strength: 415 MPa – withstands extreme loads
- Brinell hardness: 82-100 HB for wear-resistant threaded connections
- E-modulus: 85,000 MPa (high stiffness)
- Density: 6.7 g/cm³ – good strength-to-weight ratio
Practical advantage: The 360° locking mechanism The circumferential longitudinal ribs (typically 6-8 ribs) ensure even force distribution across the entire pipe circumference. This guarantees a permanent, force-fit connection without adhesives or additional securing devices.
Why round-shaped locking mechanisms are important:
- Even load distribution over 360° prevents voltage spikes
- Secure hold even with thin-walled pipes
- No point load on the pipe wall
- Constant pull-out force of 150-300 N over the entire service life
Superior wear resistance
Zamak protects itself through excellent tribological properties self and offers additional benefits:
Wear protection mechanisms:
- Natural passivation: Spontaneous oxide layer formation on the surface (µ < 0.15-0.35)
- Self-lubricating: Coefficient of friction against steel only 0.21 (dry)
- Long lifespan: At least 100 years indoors
- Suitable for electroplating: Optionally available with zinc, nickel or chrome plating
Practical wear comparison:
- Ideal for: Frequently adjusted constructions (furniture, displays)
- Suitable for: Applications subject to vibration (machines)
- Permanently: 10+ years even under high mechanical stress
- Low maintenance: No relubrication required
In comparison: 30 % lower wear rate in vibration-intensive applications compared to untreated steel components.
Precise fit for various pipe diameters
The hot chamber die casting process enables flexible adaptation to different pipe geometries with consistent quality:
Manufacturing advantages:
- Tool life: >750,000 shots (10 times higher than aluminum die-casting)
- Surface finish: Ra 1.6 µm directly from the mold
- Cycle time: 20 seconds per cycle
- Dimensional tolerance: ±0.1 mm for precise fit
Geometric flexibility:
- Customizable by setting up a new manufacturing process
- Pipe wall thicknesses of 1.5 mm to 3.0 mm covered
- Different rib heights depending on the pipe geometry
- Custom orders for different dimensions are possible.
Temperature resistance:
- Continuous operating temperature: -40°C to +95°C
- Short-term load capacity: Up to +120°C (15 minutes)
- No plastic deformation at normal temperature
Cold applications:
At -40°C, Zamak loses less than 10 % of its room temperature impact strength – ideal for outdoor and cold room applications.
Typical operating temperatures:
- Cold storage rooms and deep-freeze facilities (-30°C to -40°C)
- Outdoor installations (alternating load down to -40°C)
- Temperature cycling (-30°C to +80°C continuous)
High-temperature applications:
At a constant temperature of +80-95°C, Zamak retains its full mechanical strength – no tendency to creep.
- Mechanical engineering: Areas with elevated temperatures ≈ +80-95°C (engine, gearbox)
- Shopfitting: Illuminated displays with heat generation
Zamak is NOT a problem with:
Controlled indoor environments (10-30°C, normal humidity):
- Normal production areas, workshops
- Air-conditioned production areas
- Standard industrial environments
Mechanically stressed structures:
- Vibrating machines and equipment
- Frequently adjusted connections
- Mobile and transportable systems
When high strength is more important than lightweight construction:
- Tensile strength 280 MPa (significantly higher than plastics)
- E-modulus 85,000 MPa (no creep deformation)
Practical tip: Most industrial applications (production environments ranging from -40°C to +95°C, normal humidity) are completely unproblematic for Zamak. Its mechanical properties remain consistently excellent.
Application areas: Where Zamak round tube inserts are the best choice
Furniture industry & contract furnishing
Typical applications:
- Steel tube frames for chairs, tables and seating furniture
- Round tube frame constructions for shelving systems
- Coat racks and clothes stands
- Bistro and catering furniture with round tube frames
- Seating systems for event spaces
Why Zamak is ideal here:
- Stable mounting of leveling feet and glides
- Corrosion protection for permanent use in public areas
- Precise height adjustment thanks to an exact thread
- Various surface finishes to meet design requirements
- Quiet operation thanks to vibration damping
Advantage:
- Higher load-bearing capacity than plastic inserts
- More durable than pure steel constructions without corrosion protection
- Aesthetically pleasing (chrome-plated or painted)
- Cost-efficient for medium to large production runs
Shopfitting & Retail Equipment
Typical applications:
- Clothes racks and presentation systems made of round tubing
- Display systems and product presenters
- Window displays with pipe constructions
- Modular shop fittings
- Sales counters with round tube legs
Why Zamak is ideal here:
- Flexible reconfiguration through detachable connections
- High-quality appearance (chrome-plated, nickel-plated, powder-coated)
- Durable and resilient under daily use
- No corrosion even in humid shop windows.
- Easy assembly saves setup/conversion time.
Advantage used:
- Quick setup/dismantling during seasonal or promotional changes
- Chrome-plated finishes for a premium look
- Reusable for various shop concepts
- Matching feet and glides are also available.
Exhibition stand construction & exhibition systems
Typical applications:
- Mobile exhibition stands with round tube frames
- Exhibition systems and information counters
- Presentation walls and partitions
- Event furniture for temporary events
- Portable presentation systems
Why Zamak is ideal here:
- Can be mounted multiple times without loss of quality
- Easy disassembly for transport and storage
- Robust connection despite frequent assembly/disassembly
- Weatherproof for indoor and outdoor events
- Cost-efficient due to long service life
Mechanical and plant engineering
Typical applications:
- Machine frames with round tube frames
- Transport trolleys and trolleys
- Handling systems and conveyor systems
- Workplace systems with pipe structures
- Protective enclosures for machines
Why Zamak is ideal here:
- High vibration damping minimizes vibration transmission
- Self-lubricating properties reduce wear.
- Temperature resistant for machine areas
- Precise tolerances for accurate assembly
- Durable enough for 24/7 operation
Why Zamak instead of plastic or steel:
- Higher strength than PA/PP with similar corrosion resistance
- More cost-effective than complex welded steel structures
- No follow-up treatment required
- Long service life without maintenance
Craftsmanship & Special Constructions
Typical applications:
- Custom steel structures with round tubes
- Workshop equipment and workbenches
- Transport and storage systems
- Frame construction for special applications
- Prototypes and custom-made products
Why Zamak is ideal here:
- Flexible use for various pipe diameters
- Subsequent modifications are possible
- Removable for maintenance and adjustments
- Cost-effective alternative to welded joints
Assembly and application instructions
Professional installation in 4 steps
1. Preparation
Check the pipe's inner diameter and ensure it is clean, burr-free, and dry. If necessary, slightly chamfer the pipe edge (0.5 mm x 45°).
2. Positioning
Position the pipe insert at the end of the pipe with the thread facing outwards. The collar must be flush with the pipe edge.
3. Press in
Press the insert into the center of the tube with controlled force (approx. 50-100 N for manual installation) until the collar acts as a stop. For serial installation: the use of pneumatic cylinders or hand presses is recommended.
4. Check
Check that the insert is securely in place by gently twisting it – it should not rotate or be able to be pulled out. A pull-out force of 150-300 N is required when correctly installed.
Important tips for optimal results
- Pipe preparation: The inner diameter should be clean and free of chips.
- Press tools: Use suitable mandrels with centering aids for round tubes.
- Do not hit: Hammer blows can damage the threads or the longitudinal ribs.
- Coated pipes: For powder-coated pipes, remove any coating in the injection area.
- Tightening torque: Note the permissible torques for M10 (approx. 40-50 Nm) and M8 (approx. 20-25 Nm)
- Centering: Pay particular attention to central positioning when using round tubes.
Frequently Asked Questions (FAQ)
Which pipe diameters are supported?
Our Standard pipe insert B-709 is designed for round tubes with a Ø 60 mm and a wall thickness of 2.0 mm.
Other diameters available upon request:
- Ø 20-40 mm: For lightweight constructions (furniture, displays)
- Ø 40-60 mm: For medium loads (standard applications)
- Ø 60-100 mm: For heavy constructions (mechanical engineering)
Important: The pipe wall thickness must be at least 1.5 mm for secure anchoring of the longitudinal ribs.
How do I calculate the required wall thickness?
Rule of thumb for pipe wall thickness:
For loads up to 1,000 N: Minimum wall thickness of 1.5 mm
For loads up to 2,500 N: Minimum wall thickness of 2.0 mm
For loads exceeding 2,500 N: Minimum wall thickness of 2.5 mm.
Tip: For dynamic loads (vibrations, impacts), include a safety factor of 1.5-2.0.
Can I combine different thread sizes?
Yes, You can use different thread sizes on one construction:
- M10 at heavily stressed points (main bearings)
- M8 in less stressed areas (stabilization)
Important: Use appropriate leveling feet/screws with a matching thread.
How do round and rectangular tube inserts differ?
Pipe inserts for round pipes: ✓ 360° locking mechanism thanks to circumferential ribs
✓ Even force distribution
✓ Better suited for thin-walled pipes
✓ More flexible with different diameters
Pipe inserts for rectangular tubes: ✓ Positive locking anti-rotation device through corner geometry
✓ Higher pull-out forces possible
✓ More options for different cross-sections
✓ Ideal for frame constructions
Are the pipe inserts suitable for outdoor applications?
Yes, Zamak pipe inserts are generally suitable for outdoor use:
✓ Natural corrosion resistance through oxide layer formation
✓ Optional electroplating (galvanized/chrome-plated) for increased protection
✓ Temperature range covered -40°C to +95°C
✓ UV-resistant (no aging like with plastics)
Recommendation:
- Protected outdoor areas: Natural finish sufficient
- Unprotected areas: Choose between galvanized or chrome-plated finish
- Saltwater pollution: Chrome-plated version recommended
Are you looking for the right pipe inserts for round pipes?
Whether threaded pipe inserts for circular steel pipes in furniture construction, shopfitting, exhibition stand construction or mechanical engineering – we are happy to advise you personally and find the optimal solution for your pipe diameter and your application.
Contact our sales department: