Velta case studies

Part of the Uponor Group

Industrial Flooring Solutions

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

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www.velta-uk.com

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www.uponor.co.uk

Part of the Uponor Group

Heating and cooling applications for Industrial projects velta one – floor heating and cooling system The velta one system is an embedded pipe system within the structural ground floor slab, which can be activated with warm water or cool water to provide both heating and cooling in a building.

Installed in the same construction sequence as the floor slab the system provides programme benefits compared to alternative systems, which have to have a separate programme period. The standard velta systems can be incorporated into traditional flood pour construction of the floor, but the velta one system has been specifically designed for installation in floors utilising modern laser screed floor laying techniques. This allows fast and accurate installation of the concrete floor with the embedded velta system in one operation.

Benefits of the velta one system The velta system provides many benefits

• Low maintenance costs – minimal moving parts and all maintenance at floor level.

• Long life expectancy – the system is designed to last the life of the building. No replacement costs throughout the life of the building.

• Environmental - No disposal issues of used equipment.

• Health and Safety – No high level maintenance required • Links with renewable energy sources – velta system can utilise most forms of renewable energy sources due to the low temperature heating water and high temperature cooling water requirement • Low running costs for energy • Heating/Cooling provided at the occupied floor level • High radiant component with the system reducing energy requirements for the building by 6 – 12% • Freedom of space – invisible system • Future flexibility of heating/cooling source to supply the built in velta system • velta service – design, supply, installation and commissioning with directly employed velta staff

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

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www.uponor.co.uk

Part of the Uponor Group

Design Philosophy

The Design philosophy for the building should be undertaken utilising the high radiant effect associated with floor heating. This philosophy usually leads to a reduction in the internal design temperature, as operative temperature should be utilised and not air temperature. It is common for operative to be up to 2 ยบC lower than air temperature and this can lead to energy savings of approximately 12%.

With the floor surface acting as the emitter the heat load demand can be based on the occupied zone which is usually the first 2.5m of space rather than the total height or volume of the building which is often the case for other heating systems.

This leads to a reduction in the heat loss for the building and can lead to a reduction in the plant required for the heating and cooling load.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

B&Q Superstore New Malden - London // Project Team Client Architect Main Contractor M&E Consultant M&E Contractor Structural Engineers

B&Q Retail Black Architecture Simons Construction.

McBains Cooper L J Monks Bradbrook Consulting

// velta Design Considerations

// Floor Design Considerations

Area of project Heating Flow Temperature Heating Return Temperature Cooling Flow Temperature Cooling Return Temperature Required heating output

Slab Thickness Slab loading capabilities

9000m² 36°c 28°c 14°c 19°c 60W/m²

125mm UDL of 35kN/m² Racking Leg Load 50kN

Total number of pour days 9 Specialist Info Flood poured structural topping to

pre-cast concrete beams

The award winning designed, flagship B&Q store in New Malden, London which will benefit from having 10% of its energy needs catered for by renewable energy sources on site.

The concept for this store was to demonstrate the store design and construction of the future, utilising renewable energy sources though energy piles and solar panels.

The systems used within the building and the construction methods also had to adopt this philosophy and demonstrate environmental benefits.

A velta classic heating and cooling system was incorporated into the retail floor area extending to 9,000 m².

The system was installed in the composite structural floor consisting of precast concrete units and structural concrete topping. The installation was undertaken with the concrete flooring programme, causing no delays and the system set to allow a bolt drilling zone for floor fixings.

Single warranty for both floor heating and concrete slab – offering total piece of mind for the client.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

Capital Print Beckton Waterfront // Project Team Client Architect Main Contractor M&E Consultant M&E Contractor Structural Engineers

Capital Print McLaren Const.

Simons Construction.

BSD Walter Miles T. R. Collier

// velta Design Considerations

// Floor Design Considerations

Area of project Heating Flow Temperature Heating Return Temperature Required heating output

Slab Thickness Slab loading capabilities

275mm UDL of 50kN/m² Racking Leg Load 50kN

Total number of pour days Specialist Info

9 Piled, steel fibre reinforced floor Slab placed using a laser screed with a coloured dry-shake finish.

12500m² 45°c 32°c 44W/m²

The integration of a velta one industrial heating and cooling system cast directly into the floor slabs and fed from a closed loop ground source heat pump to provide low temperature heating and cooling was an attraction.

The site received a BREEAM assessment rating of ‘very good’ for its carbon friendly initiatives.

The project was a world first to incorporate a floor heating system directly into a structural high tolerance concrete floor slab laid with laser screed techniques.

Single warranty for both floor heating and concrete slab – offering total piece of mind for the client.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

Royal Opera House Production Workshops // Project Team Client Manoukian Brothers Architect McLaren Construction.

M&E Consultant Arup M&E Contractor Swiftline Engineering Structural Engineers WSP

// velta Design Considerations

// Floor Design Considerations

Area of project Heating Flow Temperature Heating Return Temperature Cooling Flow Temperature Cooling Return Temperature Required heating output

Slab Thickness Slab loading capabilities

3300m² 47°c 39°c 16°c 19.8°c 60-80W/m²

175mm UDL of 50kN/m² Racking Leg Load 50kN

Total number of pour days 3 Specialist Info Laser screed finish.

The integration of a velta one industrial heating and cooling system cast directly into the floor slabs and fed from a closed loop ground source heat pump to provide low temperature heating and cooling was an attraction.

The building had varying room heights that benefited from a heating/cooling system that worked specifically in the occupied zone.

The floor was pour using the laser screed machine meaning high levels of tolerance were achieved for the slab Single warranty for both floor heating and concrete slab – offering total piece of mind for the client.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

Brendon Powerwashers Industrial Unit // Project Team Client Architect Main Contractor Structural Engineers

Brendon Powerwashers Stone and Partners C. S.Williams Andrew Waring

// velta Design Considerations

// Floor Design Considerations

Area of project 1250m² Heating Source Used Standard Gas Boiler Heating Flow Temperature 45°c Heating Return Temperature 36°c Required heating output 63W/m² Total length of pipework installed into the floor 5000m+

Slab Thickness Slab loading capabilities

150mm UDL of 35kN/m² 50kN Point Load

Total number of pour days Specialist Info

2 Standard flood pour with a drilling zone of 75mm maintained throughout the slab

The integration of a velta one industrial heating and cooling system cast directly into the floor slabs and fed from a closed loop ground source heat pump to provide low temperature heating and cooling was an attraction.

The building had varying room heights that benefited from a heating/cooling system that worked specifically in the occupied zone.

The floor was pour using the laser screed machine meaning high levels of tolerance were achieved for the slab Single warranty for both floor heating and concrete slab – offering total piece of mind for the client.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

Chatterley Valley Blue Planet, Stoke-on-Trent // Project Team Client Main Contractor M&E Consultant M&E Contractor Structural Engineers

Gazeley UK Ltd McLaren Construction KTA C A Sothers Capita Symonds

// velta Design Considerations

// Floor Design Considerations

Area of project Heating Flow Temperature Heating Return Temperature Required heating output

Slab Thickness Slab loading capabilities

33000m² 39°c 31°c 39W/m²

225mm UDL of 50kN/m² Racking Load 100kN

Total number of pour days 18 Specialist Info Laser screed finish

Boarder zone in front of dock levellers 68W/m²

The scheme was 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 ultra-green sustainability credentials for the 385,000sq ft warehousing facility.

Built by Main Contractor McLaren Construction, the velta one 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 velta one system was achieved.

Single warranty for both floor heating and concrete slab – offering total piece of mind for the client.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

Chessington Garden Centre Extension to Retail Area // Project Team Client Architect Main Contractor Structural Engineers

Chessington Garden Centre A.J.Younger Architects Segment Engineering Segment Engineering

// velta Design Considerations

// Floor Design Considerations

Area of project Heating source used Heating Flow Temperature Heating Return Temperature Required heating output

Slab Thickness Slab loading capabilities

150mm UDL of 5kN/m² Racking Load 100kN

Total number of pour days Specialist Info

3 Traditional flood poured slab with the inclusion of the Installation of floor finishes on top of completed heated slab

1200m² Ground Source Heat Pump 45°c 35°c 50W/m²

Total length of pipework installed into the floor 4500m+

The offering of slab insulation, underfloor heating, concrete slab and floor finishes was an attractive offer to the main contractor and one that he could not refuse.

A combined warranty covering all aspects from slab design, underfloor heating installation and floor finishes with one point of contact made the main contractor’s life much easier. The co-ordination of the works was seamless as one company had the responsibility of giving a full heated floor back to the main contractor from start to finish.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

Cricklewood Bus Depot Edgware Road - London // Project Team Client Architect Main Contractor M&E Consultant Structural Engineers

London Transport Cornish Architects Fitzpatrick Construction Silcock Dawson & Partners SDP Consulting

// velta Design Considerations

// Floor Design Considerations

Area of project Heating Flow Temperature Heating Return Temperature Required heating output

Slab Thickness Slab loading capabilities

1000m² 45°c 35°c 70W/m²

Total length of pipework installed into the floor 3200m+

200mm UDL of 5kN/m² 3t Fork Lift Truck Load

Total number of pour days 2 Specialist Info Laser screed pour in warehouse,

traditional flood pour to offices

The velta one system was used in this application to maintain a high level of comfort to the warehouse area.The heat was in the occupied zone which helped achieve the comfort levels required.

The thermal mass of the system means that the system is instantly reactive to sudden changes in temperature due to the doors opening and closing as the buses come and go. The plant to serve an air system would need to have been over 35% larger to cope with the demands on the building usage.

The system had a built in drill zone of 75mm to enable fixings into the slab.

Single warranty for both floor heating and concrete slab – offering total piece of mind for the client.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

LAPICIDA Tile showroom Harrogate (Leeds) // Project Team Client Architect Main Contractor M&E Contractor Structural Engineers

LAPICIDA SMC Gower Leeds HACS Construction Robinsons Mechanical and Electrical GHA Livigunn

// velta Design Considerations

// Floor Design Considerations

Heated Area of project Heating Flow Temperature Heating Return Temperature Required heating output

Slab Thickness Slab loading capabilities

160mm UDL of 50kN/m² 27kN FLT Wheel Load

Total number of pour days Specialist Info

2 Traditional flood pour method used for showroom Laser screed pour in warehouse area

3200m² 55°c 27.8°c/47°c 60-120W/m²

Total length of pipework installed into the floor 13200m+

This luxury tile showroom used a combination of the standard velta slab system and velta one system to deliver a dual purpose system.

In the showroom the standard velta slab system was used to showcase the comfort achieved by utilising a tile finish underfoot.

In the warehouse area the system was used to dry the stone imported in from Italy. The warehouse system was designed to achieve an output in excess of 120W/m² and due to the stable heating effect of radiant heating this helped to decrease the standard drying times of the stone significantly.

Single warranty for both floor heating and concrete slab – offering total piece of mind for the client.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

Wanis - Cash and Carry Warehouse - Leyton // Project Team Client Main Contractor M&E Contractor Structural Engineers

Wanis Foods Costain Walter Miles T. R. Collier

// velta Design Considerations

// Floor Design Considerations

Area of project Heating Flow Temperature Heating Return Temperature Cooling Flow Temperature Cooling Return Temperature Required heating output

Slab Thickness Slab loading capabilities

9500m² 39°c 32°c 16°c 20°c 45W/m²

225mm UDL of 50kN/m² Rack Leg Load 50kN

Total number of pour days 6 Specialist Info Laser Screed Pour achieving

High Tolerances

The integration of a velta one industrial heating and cooling system cast directly into the floor slabs and fed from a closed loop ground source heat pump to provide low temperature heating and cooling was an attraction.

A velta classic heating and cooling system was incorporated into the warehouse floor area extending to 9,500 m².

The system was installed in the concrete slab at a depth of 50mm above the sub-base. The installation was undertaken with the concrete flooring programme, causing no delays and the system set to allow a bolt drilling zone for floor fixings.

Single warranty for both floor heating and concrete slab – offering total piece of mind for the client.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

Olympic Velodrome Stratford - London // Project Team Client Architect Main Contractor M&E Consultant M&E Contractor Structural Engineers

ODA Hopkins Architects ISG Construction BDSP Imtech Aqua Expedition

// velta Design Considerations

// Floor Design Considerations

Heated Area of project Heating Flow Temperature Heating Return Temperature Required heating output

Slab Thickness Slab loading capabilities

Total number of pour days Specialist Info

5000m² 44-50°c Varies 45W/m²

Total length of pipework installed into the floor – 12000m+

100/125mm UDL of 20kN/m² 18 Traditional flood pour method used.

Infield slab installed using steel fibre reinforcement, concourse areas using macro-synthetic fibres.

The 6,000 seat Velodrome will host the Olympic and Paralympic track cycling events in 2012. After the Games, the legacy Velodrome will be used by elite athletes and the local community and will include a café, bike hire and cycle workshop facilities.

The heating was incorporated within the main in-field areas as well as transient spaces on the upper and first floor levels. Heating was also incorporated into the competitors changing areas and officials changing areas to give maximum comfort prior to any competition.

Single warranty for both floor heating and concrete slab – offering total piece of mind for the client.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

Cooling and heating design data Typical data associated with a system of this nature would be as follows:

Internal temperature Heating/ Cooling Output: Flow water temperature: Return Water temperature: Av. temp. of the concrete surface

Winter mode 18°C 60 W/m2 37°C 31°C 24.5°C

Summer mode 26°C up to 40 W/m2 14 °C 18 °C 20.5 °C

Control and zoning The building can be split into a series of zones and each individual zone controlled to different conditions, allowing for future flexibility for re-design of the building function and layout.

The velta one system can be controlled from standard BMS systems.

Manifolds The velta industrial manifold can serve up to 450m² and can be used to serve dedicated zones. These zones can be controlled individually if required or as a one for the entire building. The control philosophy can be changed at a future date as long as sufficient zoning is designated in the initial design.

Each zone can be either in cooling or in heating mode. We suggest that the decision of changeover between heating and cooling is based on the whole building and not individual zones. velta manifolds can be located vertically on walls and concealed in cabinets or they can be placed horizontal within the floor slab itself with the appropriate steel covers.

Primary pipework to the manifolds can be treated in a number of ways.

Overhead solutions can be considered or the pipework can be embedded under or within the structural slab. Alternatives have also been constructed with the primary pipework running underground external to the building.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

Ground floor slab construction The velta one system can be incorporated into most concrete floor slabs with insignificant modification to the floor slab depth and construction.

The system has been used with Lafarge Extensia concrete, which eliminates the requirement for reinforcement and minimises the use of joint profiles due to the low shrink properties of the new material. This provides environmental benefits and can also be polished to provide the permanent floor-wearing surface. The properties of Extensia also allow the floor slab depth to be reduced.

This is an alternative to the terrazzo floors currently used. A single monolithic construction producing the heating and cooling with the finished wearing surface of the floor.

Concrete joint formation Joint requirements Structural engineers are responsible for planning joints in the structural concrete floor and the velta heating system is not a critical factor due to the low temperature of the water used to heat the floor and the high temperature of the water used to cool the floor.

Standard bay sizes and pour profile proportions apply dependant upon the concrete and the reinforcement utilised.

Standard joint profiles such as Alpha type, can be used with the velta system and velta request a joint plan in order to coordinate the pipework circuits and the connecting pipework to minimise the crossing of formed joints.

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

Expansion / Movement Joints The velta system does not influence expansion joint planning.

Heating pipes that cross expansion joints should be protected using velta 1m protective pipe sheathing due to the anticipated mechanical loading in the area of the joint.

1. Wearing course / floor finish 2. Concrete 3. velta heating and cooling pipe 4. Seperation / sliding layer / Damp proof membrane 5. Foundation course 6. Expansion joint 7. Protective pipe sheathing 8. Joint sealing compound 9. Cellular rubber

Pipe design should be undertaken such that no movement joints are crossed.

Induced / Sawn Joint A velta protective pipe sheath is not required for induced or sawn joints. The joints can be sealed by making a subsequent cut of approx. 25mm depth and using a suitable special sealing compound with partial filling using cellular rubber. Other standard joint profile techniques can also be used.

1. Wearing course / floor finish 2. Concrete 3. velta heating and cooling pipe 4. Separation layer / Sliding layer / Damp proof membrane 5. Foundation course 6. Joint sealing compound 7. Cellular rubber 8. Dummy joint 9. Fine crack

Floor Fixings The foundations of racking or equipment are often anchored in the concrete floor.Velta must be informed of the depth of these foundations or anchoring in the concrete slab. There is rarely a danger that these will penetrate as far as the level of the heating pipes. However, if this occurs due to insufficient thickness of the concrete, then the heating pipe in this area should be omitted.

Part of the Uponor Group

1. Wearing course / floor finish 2. Concrete 3. velta heating and cooling pipe 4. Separation layer / Sliding layer / Damp proof membrane 5. Foundation course 6. Reinforcement support 7. Fixing rail 8. Spreader plate 9. Anchor fixings

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk

Part of the Uponor Group

velta one floor heating and cooling system to include:

• Design development and Contract management • Design – drawings and calculation • PE- Xa pipe coils • velta fixing grid and fittings • Manifold and isolation valves • Installation and pressure testing • Commissioning of system • Warranty and certification • Supply and installation of floor slab and velta one system can be undertaken as a single contract with associated single warranty

Part of the Uponor Group

Offering a complete flooring solution

Part of the Uponor Group

velta, Unit 1 Skelmanthorpe Technology Park, Station Rd, Skelmanthorpe, Huddersfield, HD8 9GA

Uponor Limited, Head Office, Gilmorton Rd Lutterworth, Leicestershire, LE17 4DU

T +44 (0) 1484 860 811

T +44 (0) 1455 550355

|

www.velta-uk.com

|

www.uponor.co.uk