Polypipe Under Floor Heating Systems Technical Installation Manual

TIG1 JULY 2009
EFFECTIVE: 1ST JULY 2009
Under Floor Heating Systems
Technical Installation Guide
July 2009
Technical Installation Guide
Under Floor Heating Systems
Polypipe Building Products
Edlington
Doncaster DN12 1ES
Tel: 01709 770 000
Fax: 01709 770 001
2410 London Road
Mount Vernon
Glasgow G32 8XZ
Tel: 0141 778 8822
Fax: 0141 778 2703
Dromore Road
Lurgan, Craigavon
Co. Armagh BT66 7HL
Tel: 028 38 881270
Fax: 028 38 882344
www.polypipe.com
Under oor heating systems trade website: www.ufch.com Under oor heating systems consumer website: www.freeyourwalls.com
Polypipe oor heating products, excluding manifolds and control products, are covered by a 50 year guarantee*, which protects against defects in materials or manufacture of the heating system from date of purchase. This guarantee only applies if the system is installed in accordance with the manufacturer’s recommendations contained within the Technical Installation Guide (the latest version of which can be found at www.ufch.com), and is used in a normal domestic operation. This document should be read in conjunction with all other documentation supplied with Polypipe products.
If you have any queries please contact our Technical Department on 01709 770000.
*Full terms and conditions for Polypipe heating products 50 Year Guarantee are available at www.ufch.com
CONTENTS
How to use this guide ............................................................................................................03
INTRODUCTION
About Polypipe ......................................................................................................................04
An overview of under oor heating systems ...........................................................................06
Selecting the right Polypipe under oor heating system ..........................................................07
System selection ....................................................................................................................08
Design service ........................................................................................................................09
Guide to oor coverings for under oor heating systems ........................................................10
INSTALLING THE SYSTEM
Solid Floor ..............................................................................................................................12
Floating Floor .........................................................................................................................16
Suspended Floor ....................................................................................................................18
Modular Heating Panel ..........................................................................................................22
Overlay™ ...............................................................................................................................28
Overlay™ Lite ........................................................................................................................36
CONNECTING & CONTROLLING THE SYSTEM
Connecting to heat source .....................................................................................................38
Manifolds ..............................................................................................................................39
Water temperature controls ...................................................................................................40
Room temperature controls ...................................................................................................41
Single room applications ........................................................................................................44
System commissioning ...........................................................................................................46
TECHNICAL DATA
Heat output tables .................................................................................................................48
General system information ...................................................................................................49
FAULT FINDING CHARTS
Hydraulic fault nding chart ...................................................................................................50
Electrical fault nding chart (master connecting box) ..............................................................51
STANDARDS
Accreditations, standards and guarantees ..............................................................................52
FORMS
1-2-3 Product selection form ..................................................................................................53
Design enquiry form ..............................................................................................................54
LITERATURE
Other information and literature ............................................................................................55
02 03
HOW TO USE THIS GUIDE
Important notice: This publication is provided as a comprehensive guide on how to install Polypipe
under floor heating systems. It is an important document as we cannot accept any liability, or honour any guarantee, for products and systems that have not been installed in accordance with our published instructions.
From time to time our installation advice may be updated at which time previous printed copies will become out of date. The latest version of our installation advice, including a downloadable version of the current Technical Installation Guide, can be found at our trade website, www.ufch.com
Selecting the right system
This guide is intended for competent trained plumbing and heating installers and we assume that you will have already specied your system of choice before consulting this publication for installation advice. Basic information on selecting the right system is provided in this guide. For more detailed guidance refer to our Design & Specication Guide or visit our trade website at www.ufch.com or consumer website at
www.freeyourwalls.com
Navigating the Technical Installation Guide
Having read the general introductory sections at the front of the guide, ensure that you have selected the correct system for your oor type and project. Read the guide to oor coverings to ensure that your system is compatible with your oor type.
Next, choose your selected under oor heating system type from the section “Installing the system” and follow the step by step instructions. Everything should be straightforward but remember that the Polypipe Technical Support team is always ready to help answer any questions you may have.
Whichever Polypipe under oor heating system you are installing you will need to refer to the information provided in the section “Connecting and controlling the system”. This section provides all you need to know about manifolds and controls, connecting your system to an appropriate heat source and commissioning the system.
Technical data
Towards the back of this guide you will nd technical data such as heat output tables, pipe data and general system information as well as useful forms to use with our Product Selector and System Design Service.
Additional information
Should you have any questions at any time, or require any kind of technical support call our Technical Support team on 01709 770000.
Online assistance is available at www.ufch.com, our comprehensive website for installers, developers and merchants. As well as information on technical advice and product benets, you can nd useful case studies and details of Polypipe stockists. Video instructions on under oor heating installation are also available to view.
04 05
ABOUT POLYPIPE UNDER FLOOR HEATING
Easy installation
Polypipe under oor heating systems have been designed with ease of installation in mind. Innovative product designs ensure minimal disruption to existing heating and electrical supplies during installation. As our systems are compatible with standard central heating boilers, connectivity is also streamlined. Polypipe under oor heating systems can be installed up to 20% quicker than radiators.
Polypipe under oor heating systems are installed in one stage, eliminating the need for a time consuming second x. Under oor heating components are much easier to manoeuvre on site than large, bulky radiators; reducing handling issues and potential damage. Unlike radiators, there is also very little theft value during installation.
Details of each type of Polypipe under oor heating system can be found on page 6.
Maintenance free
Once installed, a Polypipe under oor heating system is virtually maintenance free. There are no joints in the pipe work within the ooring, signicantly reducing the possibility of leaks. Polypipe under oor heating products are subjected to rigorous testing and meet a number of exacting standards, full details of which can be found on page 52. All our manufacturing processes are monitored and controlled in accordance with the international quality standard BS EN ISO 9002.
Choosing under oor heating also eliminates a number of general maintenance and decoration requirements, normally associated with radiators, such as painting the radiator or removing it to paint the wall.
Demonstrating the utmost condence in product performance, and providing our customers with peace of mind, Polypipe under oor heating systems are covered by the Polypipe 50 year
guarantee (full details can be found at www.ufch.com).
Easy to control
Polypipe manufactures a range of water and room temperature control solutions, allowing you to source a complete, integrated system from a single supplier. The range includes a number of control products, with options to suit a variety of lifestyle patterns, and the abilities to control different rooms independently.
Full details of Polypipe control products can be found on pages 40 to 43.
Flexible approach
Polypipe under oor heating systems use the exibility of polybutylene pipe to provide a solution for all house and room types. We also have a range of unique and innovative products, including the Zonal Regulation Unit (ZRU) which is an excellent enabler allowing under oor heating systems to be incorporated into single rooms or refurbishment projects with minimal disruption to existing heating and electrical supplies.
For more information on our single room applications see pages 44 and 45.
Excellent service
At Polypipe we understand that selecting the right solution for each application involves detailed consideration. This is why we offer extensive customer service support, including free system design and full technical support if any problems arise. We want to ensure that your installation runs smoothly from the beginning and our technical support staff can assist you with any questions you might have.
During installation we offer:
• Pre-project training at one of our training centres
• Pre-project training by distance learning
• On-site assistance
We also provide an extensive back up service:
• Technical representation available to discuss systems in general and particular projects
www.ufch.com
• Technical Installation CD
• Specialist Technical Hotline on 01709 770000
Energy efficient
Under oor heating systems can be more economical to run than radiator based systems. As they demand a low temperature rise output from the boiler, they are ideally suited to achieving maximum economy from a condensing boiler or heat pump. However, they are just as efcient with higher temperature heat sources, for example solar and solid fuel, where the correct water temperature can be set at the point of distribution.
Polypipe is one of Europe’s largest manufacturers of specialist plastic plumbing, heating, waste and drainage products.
Our market leading under floor heating product range has been continuously developed and improved with frequent innovative additions, the latest of which are Modular Heating Panels (MHP) - a revolutionary solution for suspended floor applications - and Overlay™ Lite, a lightweight floor panel to complement our innovative over floor heating range.
Polypipe is a member of the Underfloor Heating Manufacturers’ Association (UHMA), who set and enforce standards for materials, design and installation of under floor heating systems - standards that we embrace within every aspect of our range.
Polypipe under oor heating systems have been designed with speciers, installers and users in mind.
Our systems combine ease of installation with reliable long-term performance, and we hold a range of stock ready for prompt dispatch. Unique to the Polypipe service proposition is our room and house packs concept. Recognising that under oor heating systems are difcult to specify using individual components, we created a range of over 300 pre-set combinations that can be ordered as complete kits. By simply specifying key variables such as oor type, room size, control and circuit data the right pack can be specied in minutes. It’s as easy as . We have even created a unique online product selection tool.
Following recent innovative product introductions, we have categorised our range into 3 groups in order to make selecting even more instinctive:
With a long established reputation for product quality and value, backed by our strict trade-only distribution policy, Polypipe has become the clear leader in the under oor heating category. Recent innovations ensure the Polypipe range is the widest available from a single manufacturer, including traditional under oor heating systems for every oor type as well as the innovative MHP and Overlay™ products.
Polypipe under oor heating systems are ideal for every application, including new build, self build, renovation and home improvement projects. Whole house, single oor and single room projects are equally catered for in our extensive product offering. Whatever job you are undertaking, Polypipe has the product to suit.
Polypipe is a recognised and respected brand, and is well established as the system of choice for domestic homes by many installers. All Polypipe under oor heating systems are supplied as a complete system, and require no additional components for installation. Polypipe under oor heating systems are rigorously tested, and comply with (or exceed) all relevant UK standards. We use an integrated exible plumbing system, incorporating polybutylene pipes and a range of push­t ttings. The systems are also designed for use with copper pipes, allowing the integration of rigid pipes when necessary.
OVERLAY™
LITE
OVERLAY™
SOLID
FLOOR
FLOATING
FLOOR
06 07
AN OVERVIEW OF UNDER FLOOR HEATING SYSTEMS
SELECTING THE RIGHT POLYPIPE UNDER FLOOR HEATING SYSTEM
Polypipe has the widest available range of under floor heating systems, with a product available for every conceivable floor type or residential heating project. With Polypipe, under floor heating is not restricted to new build developments or self build projects. Our unique Overlay™ product is particularly well suited to single room projects such as kitchens, bathrooms, conservatories, extensions and loft conversions. Polypipe Modular Heating Panels (MHP) were developed to provide an innovative and practical solution to installing under floor heating into upper floors.
The notes below provide a brief overview of the methodologies employed to install under oor heating systems for various oor types. Refer to the overview on the page opposite. Full installation instructions for each oor type can be found in the section titled ‘Installing the system’ on pages 12 to 36.
Solid Floor
Polypipe under oor heating can be permanently built into solid concrete or screeded oors. As required by current Building Regulations, insulation is built into the oor directly beneath the unique Polypipe lightweight plastic oor panel. The heating pipe is simply slotted into the panel and then permanently covered by the screed. Suitable for all oor coverings, solid oor systems can incorporate 15mm or 18mm pipe.
The oor panels form a simple grid for the quickest possible pipe laying and provide a precise guide to achieve the minimum bending radius. Panel
castellations are set at exact centres and
hold the pipe against movement when screeding. The oor panel holds the pipe above the insulation allowing full screed surround. Optimum screed depth is 65mm from the panel base, i.e. 40mm from the pipe top. Insulation below and at the edges of the oor screed is required by Building Regulations. Edge insulation also acts as an expansion joint.
Floating Floor
When installed in oating oors, Polyplumb pipe is simply pressed in to the pre-formed heat spreader plate, which sits in grooves within the oating oor insulation panel. The oating oor system is then covered with 18mm chipboard sheeting. Suitable for all oor covering, oating oor systems can incorporate 15mm or 18mm pipe.
Suspended Floor
For installations in suspended oors, Polypipe under oor heating uses double heat spreader plates. Alternatively, pipes can be laid on top of insulation between joists. Standard tongue and groove oorboards are laid on top of the system. Suspended double heat spreader plate systems use 15mm pipe.
MHP (Modular Heating Panels)
Modular Heating Panels offer a revolutionary new way to solve the issue of installing under oor heating into upper oors. MHP is available in two widths and two lengths to t all standard joist spacings. All components and circuitry is pre-congured into the panels which are simply installed between the joists, linked together and connected to the manifold.
Overlay™
Overlay™ allows under oor heating to be installed into existing spaces quickly, easily and practically. The unique system is supplied with a choice of patented low prole panels to suit all types of oor coverings. The Overlay™ system is laid over existing solid or timber oors.
Under floor heating systems
Product selection: Typical applications and features
New build Existing floor
SUSPENDED
FLOOR
Under floor
All floor coverings
High mass system
Typical ground floor or beam and block construction
All floor covering except natural wood/thick laminates
Lightweight construction
No wet trades required
Lightweight floor coverings
Larger areas
Multiple rooms
Tiles or natural wood
Wet areas
Over floor
MODULAR
HEATING
PANEL
All floor covering
Fit from above
Traditional joists
Traditional heat source
All floor coverings
Fit from above/below
Traditional or engineered joists
Traditional or renewable heat sources
SUSPENDED
FLOOR
08 09
SYSTEM SELECTION
Our comprehensive system design service includes:
• System design, including heat loss calculations for residential applications
• Circuit lengths
• Circuit pressure losses and velocities
• Flow rate settings per circuit
• Full product material specication
Installation service
• Pre-project training at training centre
• Pre-project training by distance learning
• On-site assistance if required during project installation
Backup service
• Technical representation available to discuss systems in general and particular projects
• Web-site and information on CD
• Specialist Technical Hotline on 01709 770000
Polypipe has removed the mystique from specifying the correct under floor heating solution for a given project and the need to calculate all of the individual components required. Our unique Product Selector, which is available on page 53 or online at www.ufch.com, uses a simple 3 step process to calculate your requirements using basic project data that you provide. The system includes details of over 300 pre-configured system kits that contain all of the parts and components you need. Once you have determined the correct pack for your project it can be ordered under a single item code via your merchant.
DESIGN SERVICE
For projects that fall outside the scope of the room packs or house packs, Polypipe offers a fully bespoke system design service. To utilise this facility, simply complete the enquiry form on page 54, or at www.ufch.com, and submit your drawings to Polypipe. You will then receive a complete design and component list for the project.
To use the Polypipe Product Selector you rst decide whether the project is a single room, a whole house solution, or requires a bespoke design. You then simply input data for each room, providing oor type, room size, and control zones to calculate the required pack.
All packs have a single order code and include all the necessary ooring materials, pipe, distribution (manifolds, ZRU, etc.), water temperature and room temperature controls.
To select the appropriate solution, choose from the following options:
Room Packs
Room packs are designed for single room applications: i.e. kitchens, bathrooms, conservatories, loft conversions and extensions. This range of under oor heating packs contain all the ooring and control equipment required for a single project, in solid oor, our traditional Overlay™ and our NEW Overlay™ Lite systems. All room packs have a maximum heat output of 100W/m
2
.
House Packs
House packs provide you with a quick and easy way to select and order from our range of under oor heating products, without the need to submit a design. The packs are designed for solid, oating or suspended (double heat spreader plate) projects.
Packs can be applied to all new build or renovation properties that fall into the following criteria:
• Rooms requiring up to 70W/m
2
• Properties built to current Building Regulations
• Projects where the manifold can be positioned within 6m of the room entrance
Design services
For projects that fall outside the scope of the room packs or house packs, Polypipe offers a fully bespoke system design service. To utilise this facility, simply complete the enquiry form on page 54, or at www.ufch.com, and submit your drawings to Polypipe. You will then receive a complete design and component list for the project.
Modular Heating Panels
Our revolutionary new MHP panels, designed to make under oor heating easier to install between ceiling joists for upper oor suspended oor applications, have their own product selector, which is also available online at www.ufch.com
10 11
GUIDE TO FLOOR COVERINGS FOR UNDER FLOOR HEATING SYSTEMS
Under floor heating systems will work efficiently with any floor covering, as long as it is well insulated underneath. However, each covering has different thermal conduction properties, and harder surfaces offer better conductivity and, therefore, better heat output rates. The following notes provide some guidance on each type of covering.
Vinyl
Suitable for all Polypipe under oor heating systems:
Sheet vinyl is sensitive to long term exposure to heat. There are two categories of vinyl; one is limited to constant temperatures of around 26°C and the other to 30°C. Check the oor surface temperature indicated by your vinyl supplier for compatibility with under oor heating. If unsure contact the Polypipe hotline or the vinyl oor manufacturer.
Laminate
Suitable for all Polypipe under oor heating systems:
Laminate ooring should be laid on roll type oor leveller, rather than the rigid panel type. Movement that occurs must be accommodated by an expansion gap around the oor deck.
Timber
Suitable for Polypipe solid oor and suspended oor systems:
Concerns regarding the effect of heat on a timber oor are misplaced. The more important issue is the oor moisture content. Timber oors should be laid at a moisture content of 10-11%, which when heated will reduce to 8-9%, and cause only a very small amount of shrinkage. The oor will re-absorb some moisture when the heating is not operating and the moisture content will increase to 12-13%. Further details on installing timber oors over Polypipe under oor heating systems can be found on page 15.
Carpet and underlay
Suitable for all Polypipe under oor heating systems:
The nature and thickness of the carpet underlay is fundamental in determining good heat transfer. The most popular underlay type is sponge with a wafe pattern moulded into the underside. These allow good heat transfer. Felt and rubber crumb underlay should be avoided. These products can seriously reduce the effectiveness of an under oor heating system, as they insulate the oor surface and prevent heat transfer.
The TOG value of carpet and underlay should be available from the respective manufacturer. For optimal system performance choose an underlay with a maximum TOG value of approximately
0.5. The maximum TOG value of carpet should be approximately
1.0 to 1.5.
Stone and ceramic tiles, marble or flagstones
Suitable for all Polypipe under oor heating systems:
These types of oor nishes are usually cold underfoot. However, with oor heating they are transformed into warm comfortable surfaces. Each of these nishes is essentially brittle and it is imperative that the design of the supporting oor structure is stable and rigid to prevent cracking. It is recommended that exible adhesives and grout be used.
Pre-installation requirements
The sub oor must be swept clean and be free from mortar residues.
Installation
Fitting Insulation
Step 1:
In accordance with Part ‘L’ of the current Building Regulations,
a suitable layer of insulation material should be included within
the oor construction. It is the responsibility of the Architect or
Builder to ensure compliance. However, in all instances insulation
must be installed beneath the under oor heating system in order
to ensure that any downward heat loss does not exceed 10W/m
2
,
in accordance with BS EN 1264.
Fitting the edge insulation strips
Step 2:
Using edge insulation strip allows the free expansion of the oor
screed. The insulation strip should be installed around all perimeter
walls and xed constructions such as columns, steps and access doors.
Edge insulation strip is bent at 90° near to the base to form
a double sided self-adhesive strip which bonds the oor plates
to the oor insulation. Edge insulation strip should be tted in
addition to perimeter insulation required by Building Regulations.
Fitting the floor panels
Step 3:
The oor panels are laid over the pre-installed insulation and
should be overlapped at the edges.
NOTE: The ½ castellation should overlap the ¾ castellation. The rst
panel should be laid with the ½ castellation edge against the wall.
Panels can be cut by simply using a saw or snips or it can
be overlapped to the nearest castellation t.
Floor panels should not be used at the base of the manifold
as pipes need to be closer together than the oor panels allow.
Pipes around this area should be secured using pipe clips which can
also be used intermittently to secure the clip plate to the insulation.
When a pumped (liquid) screed is to be used it is essential that all of
the panel joints are made correctly and that no panels are allowed to
simply ‘butt-up’ as this may allow the screed to penetrate below the
under oor heating system and cause the panels to rise up. Similarly
the panels should be rmly secured around the perimeter of the room
using staples so as to prevent possible risk of the panels lifting.
Preparing the pipe
Step 4:
You will need to remove the coil from the bag, leaving the shrink
wrap on, uncoiling from centre of the coil.
Laying the pipe
Step 5:
Once you have completed laying the solid oor panels the pipe
can be tted starting at the manifold position in line with the
pre-designed centres. 15mm and 18mm pipe can be laid
at 100mm or 200mm centres as required, 18mm pipe can also
be laid at 300mm centres.
The minimum bend radius is achieved by encircling two
castellations for a 90° bend or three castellations for a 180° bend
(see diagrams on next page).
12 13
SOLID FLOOR
Key design and installation information
Material requirements (approx)
Maximum heat output Approx. 100W/m
2
Recommended design ow temp 50°C Maximum circuit length 100m (15mm pipe)
120m (18mm pipe) Maximum coverage per circuit 12m2 at 100mm centres
22m2 at 200mm centres 30m2 at 300mm centres* *(18mm pipe only)
Pipe 8.2m/m
2
at 100mm centres
4.5m/m2 at 200mm centres
3.3m/m2 at 300mm spacing* *(18mm pipe only)
Floor plate usage 1 plate/m2 allowing for cutting (Actual 1·2m2/plate)
Edging insulation strip 1.1m/m
2
Conduit pipe 2m/circuit
Polypipe under floor heating in solid or screeded floors incorporates the unique Polypipe screeded floor panel. The lightweight plastic floor panels nest for easy storage and carrying.
Polypipe has the perfect solution for installing under oor heating into solid or screeded oors. Utilising our unique lightweight plastic oor panels, which are quick and easy to cut to size, it is possible to t Polypipe under oor heating into any shaped room.
Polypipe solid oor panels form a simple grid to ensure the fastest possible pipe laying and also provide a precise guide for the pipe, ensuring that the minimum pipe bending radius is achieved.
The panels are laid above pre-installed insulation and the system includes edging insulation strip to ensure maximum performance and efciency.
Polypipe under oor heating systems can be used with the following solid oor constructions:
Sand & cement screed (4:1 mix)
Pumped screed systems (anhydrite, etc)
Fine or heavy concrete
Polymer modied screeds
Step 6:
Circuits being laid at 100mm or 200mm centres must be laid in a spiral conguration. The rst loop of pipe should be laid around the perimeter of the area to be covered by that circuit. The next loop of this circuit should be laid either 200mm from the rst loop of pipe for 100mm centres or 400mm from the rst loop of pipe for 200mm centres.
Step 7:
Continue to loop the pipe into the centre of the panels leaving enough space to form a double return (‘S’ shape in the centre of the loop).
Step 8:
Now work back out from the centre by lling the space between the inwardly spiralling loop of the primary circuit ensuring the pipe is laid at the correct spacing centres.
18mm pipe installation formation
Where 300mm centre spacing is require (18mm pipe systems only)
a meander pattern can be used. The pipe simply crosses the room
from one side to the other encapsulating 3 castellations at each
return bend.
Conduit pipe
A 400mm length of conduit pipe should be tted over the under oor
heating pipe in any situation where damage may be caused to the
pipe i.e. where the pipe passes through internal walls or doorways,
where the pipe emerges through the oor up to the manifold
or where the pipe passes through either an expansion or day joint.
Preformed long radius bends can also be used to provide a neater
solution if required.
A section of conduit pipe 400mm long should be tted around the
heating pipe where the pipe passes through the edge insulation strip,
e.g. room to room, or through expansion joints within the oor.
Conduit pipe should also be used where the pipe leaves the oor
adjacent to the manifold. This can be threaded down the pipe
after the pipework has been installed.
14 15
Expansion joint
BS EN 1264-4 recommends that an expansion joint is constructed
in stone and ceramic nished screeds for every 40m
2
of oor area
at a maximum length of 8m and an aspect ratio of 2:1.
An expansion joint is also required in long narrow areas such
as corridors, etc.
The image below shows a typical arrangement where the pipes
pass through either an expansion or a day joint. A strip of edge
insulation is used to provide the expansion capacity.
For further information regarding oor screeding requirements
for under oor heating systems please refer to BS8204-1 or the
BISRIA Guide: Screeds with Under Floor Heating.
Testing
Step 9:
Once the pipes circuits have been installed and pressure tested the
screed cover can be applied. Care should be taken to ensure that
the screed is tightly compacted around the pipe to ensure that no
voids are present. The system should remain under pressure (6 bar)
in order to prevent the risk of any damage being caused to the
walls of the pipe whilst the screed is being applied.
Laying the screed
Step 10:
The overall quality and thickness of a sand and cement screed
should meet the requirements of BS8204-1 which stipulates that
in domestic or light commercial applications a minimum thickness
of 65mm should be used. The thickness of alternative coverings,
such as anhydrite or polymer modied screeds, may differ depending
on construction requirements. This information should therefore
be provided by the specialist screed manufacturer/supplier.
After the screed has been laid the oor should be covered with
a membrane to retard the drying out process, particularly in warm
weather. The oor should be allowed to cure and dry naturally until
full strength is reached in accordance with relevant British Standards
and manufacturers’ instructions (approx 30 days for sand and
cement and concrete oors). Under no circumstances should the
under oor heating system be used to articially dry/cure the screed
as this could cause the screed to crack and seriously undermine
the integrity of the oor construction. Once the screed has fully
cured the under oor heating system can be switched on and the
manifold ow temperature slowly increased up to the calculated
design temperature.
Finishing
Timber floors
Many people are concerned by the effect of heat on a timber
oor, but this concern is misplaced. The important factor is the
oor moisture content.
Timber oors can be laid directly over the screed at a moisture
content of 10-11% which during the heating season will reduce
to 8-9% and may cause a small amount shrinkage.
The oor will re-absorb some moisture when the heating is not
operating and the moisture content will increase to 12-13%.
Application of timber floors over solid floor systems
Where solid oak ooring is to be laid on a solid oor, joists can
be tted at 1m centres to provide a xing point for the boards.
Insulation, solid oor panels and pipe can be laid between
the joists and screed laid level with the top of the joists
(see diagram below).
Individual circuits of pipe are then laid between each set of joists
with care being taken to ensure the screed is completely dry prior
to tting the solid oak covering (see diagram).
90° 180°
Screed Timber floor covering Solid floor plate Joist at 1m spacings
Pipe Conduit
Insulation Sub floor
Pre-installation requirements
The sub oor must be swept clean and be free from mortar residues.
Installation
Laying the floating floor panels
Step 1:
Lay the 1200 x 1200 x 50mm oating oor panels directly over the entire oor area to be heated, ensuring the panel grooves are aligned. The panels can be cut to t where necessary.
A void in the insulation is often retained around the edge of the room to allow for distribution pipes to be laid from the room to the manifold.
Laying the spreader plates
Step 2:
Single heat spreader plates that have pre-formed grooves at 300mm centres need to be laid on top of the oating oor panels. These plates ensure an even spread of heat across the oor area and hold the pipe rmly within place in the oating oor panel.
Laying the pipe
Step 3:
Once you have completed laying the oating oor panels and heat spreader plates the pipe can be tted into the pre-formed grooves of the heat spreader plate. Start at the manifold position and use the grooves in the oating oor panel to loop round the entire room.
The maximum circuit length is 80m using 15mm pipe or 100m using 18mm pipe. Pipe should be laid in the pattern shown below.
NOTE: Areas of potential high point loading, e.g. under heavy furniture kitchen units and appliances, will require additional oor support. Timber battens (50mm x 50mm) should be positioned between the oating oor panels and notched to allow the passage of pipes.
Testing
Step 4:
Once the pipe circuits have been installed and connected to the manifold the system should be pressure tested to 6 bar for a minimum of 1 hour before the timber oor covering is laid. It is recommended that the system remains under pressure whilst the ooring is laid.
Finishing
The room can then be nished by tting 18mm or 22mm tongue and groove sheets of chipboard, glued on the edge, over the oating oor system. Mark the position of the pipe where door thresholds or carpet strip are to be installed.
When laying a ceramic or stone oor covering ensure that any deection in the oor is minimised. It is recommended that a slip mat or uncoupling membrane is used rather than a second layer of wood.
The Polypipe floating floor system is designed for use in applications where a solid floor installation is not suitable due to structural weight limitations or where a ‘dry build’ floor option is required. Suitable for use in either new build or existing properties, the floating floor panels can be installed directly on top of both solid and timber floors.
The 50mm thick high density polystyrene panels have a thermal value of 0.036W/mK and can be used to enhance the thermal insulation requirement of the oor structure as required under current Building Regulations. However, care should be taken when installing oating oor panels on top of a primary insulation layer to ensure that excessive deection does not occur in the nal oor construction.
It is therefore recommended that any other insulation materials used below the oating oor panels are of a high density construction (100kN/m
2
@ 10% compression min).
16 17
FLOATING FLOOR
Key design and installation information
Pipe 3.1m/m2 at 300mm centres Floating oor panel 1 panel/1.4m
2
Single spreader plate 3 plates/m
2
Material requirements (approx)
Maximum heat output Approx. 70W/m
2
Recommended design ow temp 60°C Maximum circuit length 80m (15mm pipe)
100m (18mm pipe) Maximum coverage per circuit 25.8m2 at 300mm centres
(15mm pipe) 30m2 at 300mm centres
(18mm pipe)
Polyplumb
barrier pipe
Single heat
spreader plate
Insulated floating
floor panel
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