Uponor magna brochure by Uponor UK

Industrial underfloor heating system

Table of contents Uponor Industrial Underfloor Heating System................................................... 4 Cooling through the base slab.......................... 5 Easy design.......................................................... 6 Adjustable system solution for different floor structures................................... 8 How to cross concrete joints............................. 12 Expansion joints ............................................... 12 Construction joints (day joints).......................... 12 Dummy joints.................................................... 12 Joint layout......................................................... 14 Wearing layer....................................................... 15 Equipment in the halls....................................... 15 Uponor industrial underfloor heating system components............................................ 16 Installation of Uponor industrial manifold...... 22 Mounting........................................................... 22 Hydraulic balancing........................................... 23 Startup and testing............................................ 24 Functional heating test...................................... 25 Case studies......................................................... 26

"The Underfloor heating system in high spaces maintains the heat in the area where it is needed, close to occupied zones" All technical and legal information contained in this catalogue has been carefully compiled according to the best of our knowledge. We cannot be held liable for any errors as these cannot be fully excluded. Technical guidelines, including all sections, are protected by copyright. All uses other than those permitted under the copyright law are not allowed without the approval of Uponor. This applies particularly to reproduction, re-prints, processing, storage and processing in electronic systems, translations and microfi lming. The contents of the technical guidelines are subject to change without notice. Copyright 2010 Uponor 2

Uponor Industrial underfloor heating system

Uponor Industrial Underfloor Heating System Advantages 1. Very few system components with only one pipe size 2. Simple planning and installation 3. Possibility to use the same system for heating and cooling

The Uponor Industrial Underfloor Heating System is based on the most commonly known and widely established system solution for industrial buildings. It consists of just a few separate components from manifold segments, installation accessories and a single size of piping with 25x2.3 mm PE-Xa. This makes planning and installing the Uponor Industrial Underfloor Heating System an easy affair. Depending on the heating load, heat source and size

of the building to be heated, the length of heating circuits will range between 200 m and 300 m. Using Uponor 90° pipe guidance arcs, each heating circuit is separately connected to the Uponor industrial manifold. Given an area of 2000 m2 and a mass flow of approx. 10000 kg/h, the effect received from Industrial Underfloor Heating system can be presented as follows:

1 Indoor temperature: Max output: Supply water / return Water: Pipe distance to surface: Pipe c/c:

16°C 80 W/m² 50/35°C 217 mm 300 mm

2 Indoor temperature: Max output: Supply water / return Water: Pipe distance to surface: Pipe c/c:

18°C 73 W/m² 50/35°C 217 mm 300 mm

3 Indoor temperature: Max output: Supply water / return Water: Pipe distance to surface: Pipe c/c:

20°C 65 W/m² 50/35°C 217 mm 300 mm

Cooling through the base slab Increasing numbers of office and management buildings, residential complexes, thermally intensive production facilities and other industrial buildings are using floor cooling. However, the large concrete thicknesses above the pipe only allow for limited cooling loads. For this reason, pipe spacings between 15 cm and 20 cm are required. Given typical design parameters (tV/tR= 16/20°C and ti=26°C), cooling loads of approx. 20 W/m² to 30 W/m² can be achieved.

Cooling example: Required heat flow density:

25 W/m²

Avg. temp. for specification:

18°C

Temperature spread, max.:

Room temperature:

26°C

Pipe covering (concrete slab):

200 mm

Abrasion layer R l,B:

0.02 m²K/W

Max. pressure loss:

350 mbar

"Possibility to use the same system for heating and cooling."

To obtain the best possible cooling loads pipes should be installed as close to the surface as possible. The best option is to use Uponor mounting support.

Floor structure 250mm with no insulation or floor covering. Ground temperature 10 degrees. Concrete lamda value 2,1 W/mK.

Uponor Industrial underfloor heating system

Easy design If using a Uponor Industrial Underfloor Heating System to heat industrial buildings the piping must be chosen in accordance with the requirements, location and basic design of the building in question. The best and optimized solution for the industrial building should

be checked with your local Uponor representative. Adjustable solution The Uponor industrial manifold is an easy and adjustable solution for different sizes of industrial building. It is a modular manifold system

created from separate manifold blocks. This makes design, purchase and installation easier and safer. Manifolds can be adjusted either by increasing or decreasing manifold blocks to the existing Underfloor heating manifold even during the construction phase.

Uponor Industrial underfloor heating system

Adjustable system solution for different floor structures. In case of different heating capacity needs, different pipe spacings allow individual optimization of heat transfer capacities. Floor surface temperatures in permissible range according to physiological aspects of heating.

Option 1: Heating lines fastened to reinforcement mesh using Uponor industrial pipe ties.

Components: Uponor PE-Xa pipe Uponor PE-Xa pipe clip

Option 2: Heating lines fastened using Uponor industrial clamp track type 25. To prevent the Uponor Industrial Underfloor Heating System from buoying upwards, the industrial pipe fastening rails must be tightly anchored to the ground/insulation using appropriate ground pegs.

Components: Uponor PE-Xa pipe Uponor PE-Xa Clamp track Uponor Clamp track nail

The brief guides describe only some aspects of the process of installing Uponor industrial underfloor heating. Please read and follow the additional installation instructions supplied with the product.

Uponor Industrial underfloor heating system

Adjustable system solution for different floor structures.

Important note about designing: Insulation has to be calculated according to actual valid country standards. When using Industrial Underfloor Heating system and the floor structure is designed without insulation we recommend to use a humidity barrier underneath the floor structure to prevent soil moisture from raising up from the ground to the floor structure.

Option 4:

Option 3: Heating lines fastened to reinforcement mesh using Uponor industrial cable ties.

Components: Uponor PE-Xa pipe Uponor Pipe tie

Heating lines fastened to reinforcement mesh using Uponor industrial pipe ties. Reinforcement mesh where the pipes are installed is adjusted to the precise height using Uponor mounting support.

Components: Uponor PE-Xa pipe Uponor Pipe tie Uponor Mounting support

Uponor Industrial underfloor heating system

How to cross concrete joints Expansion joints

Joints that allow movement are generally known in the concrete construction trade as expansion joints. These provide continuous separation of the concrete slabs to a distance of approx. 15-20 mm and are filled with a soft jointing material (e.g. foam sheet or fibreboard), which is fixed in place before the concrete is poured. Expansion joints are not designed to break up the floor, but rather to provide separation from other objects like ducts, conduits, supports and walls.

pipes that cross over expansion joints must be protected against the anticipated mechanical stresses in the area around the joint using protective pipe sleeves of 1 m in length. This can be insulation material or a protective pipe for instance. Important information for planning: Expansion joints are not designed to break up the floor, but rather to provide separation from other objects like ducts, conduits, supports and walls.

1 2

Illustration of an expansion joint 1

Concrete Expansion joint 3 Protective pipe sleeve 4 Uponor PE-Xa pipe 5 Insulation 6 Ground/gravel 7 Wearing layer 8 Joint sealing compound 9 Foam rubber 2

The underfloor heating system does not affect the planning of the expansion joints but the connecting

Construction joints (day joints) 7

Neighbouring areas of the concrete slabs are connected to each other by construction joints. These are not movement joints, but rather occur simply as a result of adjoining bays being poured at different times. In order to ensure proper transmission of force from one slab to the next, these sections are combined by using tongue and groove joints or creating a positive connection with dowelled joints. Heating pipes that cross a construction joint must be sheathed for a distance of 1 m using protective pipe

sleeves or protective pipes in cases where the heating pipe is subject to mechanical stress before pouring the concrete, for example due to the positioning of formwork over the heating pipe. It is advisable to design and install the underfloor heating system in such a way that crossing these joints is avoided.

1 4

Illustration of a construction joint

Important information for planning: Heating pipes that are subject to mechanical stress during installation where they cross construction joints must be sheathed with protective pipe sleeves or protective pipes.

Concrete Protective pipe sleeve 3 Uponor PE-Xa pipe 4 Dummy joints 5 Insulation 6 Ground/gravel 7 Wearing layer 2

Dummy joints

Dummy joints are cut into the concrete slab after it is formed and serve as predetermined breaking points. These cuts are approximately 3â&#x20AC;&#x201C;4 mm wide and cut to a depth of around 25â&#x20AC;&#x201C;30% of the slab thickness. The intentional crack that occurs below the cut has a certain amount of denticulation that allows transverse forces to be transferred from one concrete slab to the next. Dummy joints do not require the use of protective pipe

sleeves or protective pipes. Dummy joints can also be of a "closed" type, created by cutting a post-casting groove approximately 25 mm deep, then using a special sealing compound and partially filling with foam rubber.

Important information for planning: Find out the joint layout from the structural engineer before preparing designs for an industrial underfloor heating system. Agree the maximum possible depth of cut with the building engineer.

Illustration of a dummy joint 5 1

Uponor Industrial underfloor heating system

Wearing layer Joint sealing compound 3 Foam rubber 4 Concrete 5 Uponor PE-Xa pipe 6 Ground/gravel 7 Insulation 8 Fine crack 9 Dummy joint 2

Uponor Industrial underfloor heating system

Joint layout

Wearing layer

Joint planning is the responsibility of the structural engineer and, due to the low temperature of the heating surface, is unaffected by industrial underfloor heating. The specialist heating engineer must request a joint plan, which will be used to agree the layout of the heating circuits and connecting pipes. The type and positioning of a joint depends on numerous factors, for example:

The bay size is dependent on various factors, for example the quality and load capacity of the substructure, and can therefore only be determined by a structural engineer. Edge joints around the concrete slab or fixtures in the concrete slab must be implemented as expansion joints and also shown on the joint plan. Below are some examples of possible joint arrangements for different methods of concrete placement.

Slab thickness Other objects in vicinity (supports, walls, ducts) Long-term loadings Type of concrete placement

Examples of possible joint arrangements for different methods of concrete placement.

Placing of concrete in one workstep placement.

Placing of concrete in lanes.

Floors that are subject to heavy wear due to, for example, being driven on by forklifts and heavy industrial trucks, are exposed to a lot of abrasion and therefore need a stable surface layer, a wearing layer, as otherwise the surface of the concrete slab may suffer excessive wear. Which type of wear layer is best suited to a specific situation must be decided by the responsible building engineer. For example, the following may be applied to the surface of the concrete: mastic asphalt screed, magnesite screed, and cementitious hard-aggregate screed. The plasticity of the wearing layer and the concrete slab must be matched to each other. Joints in the concrete slab must

therefore also be considered in the surface layer. Floors that are subject to less heavy wear do not necessarily require a separate surface layer. In many cases the concrete surface will be roughened by brushing or, in the case of floors that need to be extremely level, sanded down. Important information for planning: Take into account the possible thermal resistance of the wearing layer.

Placing of concrete in fields.

Equipment in the halls

Expansion joint

Dummy joint

Construction joint

Important information for planning: Give consideration to the structural engineer's joint plan. Agree placement of heating loops and connecting pipes on the joint plan.

Commercial buildings often have footings for various equipment, for example high rack storage and machine foundations, anchored into the concrete floor. The specialist heating engineer must be fully informed about how deeply these foundations and anchor points penetrate into the concrete slab. Occasionally there may be a risk that they penetrate far enough into the concrete slab to reach the level of the heating pipes. Should this be the case due to the concrete slab being insufficiently thick, then the heating pipes must be left out of this area, creating a so-called blind area.

5 6

Important information for planning: Determine the maximum depth of penetration into the concrete slab of all anchor points and foundations for all equipment to be installed in the building.

Base slabs with either low-shrinkage rolled concrete or continous steel reinforcement can generally be designed without joints as far as possible.

A minimum safety distance of 50 mm from the pipe should be observed.

Uponor Industrial underfloor heating system

Penetration depth of equipment 1

Rails for industrial trucks 2 Equalisation base 3 Wearing layer 4 Anchors

Uponor PE-Xa pipe Reinforcement 7 Spacer 8 Insulation 9 Ground/gravel 6

Uponor industrial underfloor heating system components Uponor PE-Xa pipe

Uponor PE-Xa pipe, 25 x 2,3 mm pressure loss diagram The pressure gradient in Uponor PE-Xa pipes can be determined using this diagram.

Uponor PE-Xa pipe, 25 x 2.3 mm Pipe dimensions

25 x 2.3 mm

Material

PE-Xa

Manufacture

As per EN ISO 15875

Oxygen impermeability

As per DIN 4726

Density

0.938 g/cm3

Thermal conductivity

0.35 W/mK

Lin. expansion coefficient

At 20 °C, 1.4 x 10-4 1/K At 100 °C, 2.05 x 10-4 1/K

Crystalline melting temperature

133 °C

Materials class

Min. bending radius

125 mm

Surface roughness of pipe

0.007 mm

Water content

0.33 l/m

Range of heating application

70 °C/7.2 bar

Max. cont. operating pressure (water at 20 °C)

15.4 bar (safety factor ≥ 1.25)

Max. cont. operating pressure (water at 70 °C)

7.2 bar (safety factor ≥ 1.5)

DIN-CERTCO registration no.

3V209 PE-X

Pipe connections

Connector couplings and clamp ring screw connections, Q&E joints, type Uponor 25 x 2.3

Preferred installation temperature

≥ 0 °C

Approved water additive

Uponor GNF antifreeze

UV protection

Optically opaque cardboard (unused portion must be stored in the box)

Uponor - Nr.

d [mm]

s [mm]

L [m]

1005278

2,3

220

1005282

2,3

240

1005277

2,3

270

1005281

2,3

300

1045072

2,3

340

Uponor Industrial underfloor heating system

Uponor Industrial Clamp track for 25mm pipe

Uponor Cable Tie For fastening Uponor pipes on reinforcement steel mesh. Made of polyamide.

Uponor clamp track for 25 mm pipes.

Uponor - Nr.

b [mm]

h [mm]

d [mm]

ra [mm]

l [mm]

1005290

3000

Uponor Fastening Nails for Clamp Track

b [mm]

h [mm]

1005291

b [mm]

h [mm]

1005287

200

1005372

300

Uponor Mounting support for 5mm steel mesh For lifting, precise height adjustment and stabilising the pipe level relative to the upper reinforcement. Variable height depending on slab construction.

For fastening the Uponor clamp track 25.

Uponor - Nr.

No. required : 4 per m2

Uponor Pipe Clip

Uponor - Nr.

H [mm]

1005384

1005386

100

1042300

120

1005383

140

For fastening Uponor pipes on reinforcement steel mesh.

Uponor - Nr.

h [mm]

h1 [mm]

b [mm]

d [mm]

d1 [mm]

1005289

3-8

Uponor Pipe Bend Support Made of impact resistant plastic to provide 90Â° bend.

Uponor Industrial Pipe Uncoiler

Uponor - Nr.

d [mm]

1001230

For pipe dimension of 25 and coil length of 300 m.

Uponor - Nr.

l [mm]

h [mm]

1006256

740

1300

Uponor Industrial underfloor heating system

Uponor Industrial Manifold 25-G 11/2

Uponor Industrial Manifold Bracket Kit

Uponor Industrial Manifold 25-G 11/2 as supply and return for Industrial heating.

Uponor Industrial Manifold Bracket Kit for mounting the Industrial manifold. Includes mounting materials.

Consists of: - supply-segment with control valves for pre adjustment, heating loop connection for PE-Xa Pipe 25x2,3 with compression adapter. -

Uponor - Nr.

1045816

return-segment with thermostat upper section incl. cap for locking. Uponor actuator can be mounted directly on the return manifold, heating loop connection for PE-Xa Pipe 25x2,3 with compression adapter.

Uponor Industrial Flowmeter

Spacing of outlet: 100 mm

Uponor Industrial Flowmeter for adjusting the water quantity in the individual heating loops in a range of 4-20 l/min. Water quantity is indicated in the inspection window with shut-off function.

Uponor - Nr.

1045813

Uponor - Nr.

Uponor Industrial Manifold Basic Kit

1030134

Uponor Industrial Manifold Basic Kit for assembly and mounting the Industrial manifold, consists of:

Uponor Industrial Ball Valve G11/2

- 2 brackets short - 2 brackets long - 2 filling valves brass - 2 thermometers 0 - 60Â°C - 1 manometer - 2 endcaps - 2 flat sealing screw connection pieces with swivel nut - 1 mounting material: - 8x screws 6x60mm - 8x plastic anchors 8x40mm - 2x flat sealings 44x32x2

Uponor Industrial Ball Valve G 11/2 for use with the Uponor Industrial manifold G 11/2 connection: - G 11/2 FT - G 11/2 MT

Uponor - Nr.

1030135

Uponor - Nr.

1045815

Uponor Industrial underfloor heating system

Installation of Uponor industrial manifold Mounting

Hydraulic balancing Technical data:

Circuits L [mm] Required clamps

Connection dimensions

G 1½

Max. operating temperature

70°C

Max. operating pressure

6 bar

Max. test pressure (24 h, ≤ 30°C)

10 bar

kvs value inlet/outlet valves

2,35 m3/h

Max. flow rate per manifold

10 m3/h

Maximum number of loops

310

410

510

610

710

810

910

1010

1110

1210

1310

1410

1510

1610

1710

1810

1910

2010

2110

1. Determine the setting valve.

4. Open the supply valves

2. Close the supply valves.

3. Set the setting value (1) on the ring.

1. Open the supply valve until the calculated water

2. Turn the ring to the stop of the supply valve

quantity (1) is displayed on the flow meter

Uponor Industrial underfloor heating system

Startup and testing

Functional heating test

Fill pipes 1

Open the return valve of the first heating circuit a. Open the supply valve of the first heating circuit b. Close all other valves c.

Fill the system to max. 5 bar and rinse it.

Close the supply and return valves of the filled heating circuit

Repeat the filling and rinsing procedure (steps 1 and 2) for all further heating circuits

Connect the hose to the boiler fill and drain valve and open the boiler fill and drain valve.

Concrete slabs with integrated underfloor heating must be heated up after the concrete and wearing layers have been laid. The earliest time at which heating can be started is dependent on the quality and thickness of the concrete, so the functional test must be carried out in consultation with the relevant concreting contractor/ structural engineer and take into account their specifications. The following procedure for functional heating tests is usually acceptable for standard concrete thicknesses of 10â&#x20AC;&#x201C;30 cm:

Bleed the system at the boiler fill and drain valve. 2

Pressure test 1

Pressurise the system to 6 bar for 2 hours.

After 2 hours perform a leak test (the decrease in pressure may not exceed 0.2 bar)

Fill the system with water until the operating pressure is reached

4 5

Uponor Industrial underfloor heating system

The operational status must be documented during and after the functional heating test procedure. Please request a copy of the Uponor Functional Heating Test report for Uponor Industrial Underfloor heating systems. If the first time the industrial building is heated coincides with the heating season, then the building should be enclosed before the heating season starts. This allows the energy absorbed by the concrete slab from its surroundings to be used for heating. The system must not be switched off during winter if there is a risk of frost, unless other precautionary measures have been implemented.

Start functional heating test once concrete floor has been signed off by construction management (approx. 28 days after concrete placed) Set flow temperature to 5 K above the concrete temperature and maintain for at least 1 week Increase the flow temperature by 5 K each day until the design temperature is reached Maintain design temperature for 1 day Decrease the flow temperature by 10 K each day until the operating temperature is reached Set the operating temperature

Uponor Industrial underfloor heating system

U N D E R F LO O R H E AT I N G C A S E S T U D Y

Chatterley Valley

BMW Dynamic Centre Dingolfing

The project A scheme to build one of the world’s greenest business and logistics parks in North Staffordshire. The pioneering new project called Blue Planet Chatterley Valley was developed by Gazeley UK Ltd and hosts ultragreen sustainability credentials for the 35,800m2 warehousing facility.

The solution

Built by main contractor McLaren Construction, the Uponor system was incorporated directly into the ground bearing slab in conjunction with a laser screed machine. Working alongside Stuarts Industrial Flooring the pipework was integrated into the slab without causing any time delays. Daily production of up to 1,800m² of completed floor incorporating the Uponor system was achieved. The benefits

- The heat is in the occupied working zone and provides an even temperature distribution. - The system offers the flexibility to provide high rise racking without obstruction by fans or ductwork. - No requirement to clean or maintain the system, a marked contrast to visible heating systems which require a additional maintenance expenditure.

The project This construction plan signalled the start of the most important project in parts distribution that the BMW Group had undertaken in the last 30 years. The distribution centre is intended to ensure the successful worldwide distribution of parts, on the basis of a totally new logistics structure. The solution The internal climate within the

dynamic centre provides thermal comfort through Uponor industrial underfloor heating system which was integrated into joint-free rolled concrete using the "DFT process". The floor concrete material is transported right to the facility entrance using a tipper truck and then tipped over the first section of underfloor heating. A rough distribution of the material then takes place using a wheel loader, so that the next tipper truck can

drive over this surface with a further load of concrete. In this way the heating pipes are protected by the overlaying concrete. The distribution of the concrete within the facility takes place using a laserguided leveler. The concrete is then compacted using a vibrating roller and plate vibrator. The benefits - Thermal comfort - Energy efficiency - Low lifetime maintenance costs The team Client BMW Group General planning CBP GmbH Concrete Floor DFT

- The system was installed at the same time as installing the concrete floor with a Laser Screed Machine, providing super flat floors with great programme savings.

Uponor system installed Uponor Industrial underfloor heating system – 122,000m2

- High energy efficiency The team Client Gazeley UK Ltd. Main Contractor McLaren Construction M&E Consultant Kelly Taylor Associates M&E Contractor C A Sothers Concrete Flooring Contractor Stuarts Industrial Flooring Uponor system installed Uponor industrial heating system 27,000m2

Uponor Industrial underfloor heating system

Uponor offers construction professionals uncompromising quality, industry-leading expertise and long-lasting partnerships. As a leading international company, we are known for our solutions that help create better human environments.

Uponor Industrial underfloor heating system 02/2011

Uponorâ&#x20AC;&#x2122;s Simply More philosophy includes services for all stages of the construction process â&#x20AC;&#x201C; from the first concept of a project to a building in use.

Uponor Corporation Robert Huberin tie 3 B FIN-01511 VANTAA Finland +358 20 129 211 www.uponor.com