RADIANT FLOOR HEATING INSTALLATION TECHNIQUES

Transcription

RADIANT FLOOR HEATING INSTALLATION TECHNIQUES
TIME-SAVING TECHNIQUES FOR LASTING RESULTS
www.rehau.com
Construction
Automotive
Industry
RAUPEX PIPE AND MANIFOLD INSTALLATION
OUTLINE
-
“Wet” installation methods
Pipe placement patterns
“Dry” installation methods
Manifold locations
Sleeving of pipes
Step-by-step installation process
Avoiding difficulties
© REHAU 17-Mar-10- Page 2
POURED OR “WET” CONSTRUCTION
TYPES
- Slab or overpour applications
- Thermal mass is poured into
place around RAUPEX pipe
- Structural concrete mix
(fibers may be used)
- “Lightweight” concrete: sand
mix, dry pack (not aerated)
- Gyp-Crete, Hacker floor
systems
GENERAL RULES
- Pipes to be fastened every 2 feet (typical) or as needed to prevent “floating”
- For medium thick slabs (4”) pipes may be installed at the bottom or in the middle
- For thick slabs (6” and above), pipes are normally installed in mid-point, unless there is a
risk of cutting/drilling the pipes
- Then move them lower in the slab to avoid damage
- Coverage over pipe must be minimum 3/4” for concrete strength and to avoid striping
- Entrained air in concrete is bad for heat transfer
- Avoid concrete with entrained air
- Wet thermal mass has lots of moisture which needs to evaporate
- Must let it dry before hardwood flooring is installed
- Floor loading of poured thermal mass is critical (13-18 lb/ft2 dead load for 1 1/2” overpour)
- Depending on the mix; 2,000 ft2 = 30,000 lbs
- Floor must be designed to carry this load
- Coordination of trades is important
- Insulation, wire mesh, double baseplates, “dams” around holes, etc. all must be done
in the proper order
SLAB CUTAWAY, TYPICAL
-
Normal slab design
Pipe located within slab (midway) or at bottom
Various fasteners available
Typical layers:
1
2
3
4
1
Slab with RAUPEX
Rigid insulation
Vapor barrier
Crushed stone
2
3
4
SLAB-ON-GRADE “WET”
IMPORTANCE OF INSULATION
Why so important?
- For even heat transfer towards space, floor temperatures
- To minimize heat loss to earth (below, backfill) and air (at edges)
- To decrease response time and increase efficiency
General Rule*:
- R-value below the slab should be at least 5 times R-value above the slab
Example: Commercial carpet with pad installed above slab, total R value = 1.5
Use minimum R-7.5 insulation below (1 1/2” of extruded polystryene) and 2” at
cold edges
*Note: 2” insulation (R-10) is recommended at slab edges and below slabs on earth
Suspended slabs (over cold air) will require even more insulation
SLAB-ON-GRADE “WET”
Edge*
Insulation
TYPICAL CONSTRUCTION LAYERS FOR HEATED SLAB FLOORS
Heated Space
Thermal Mass
with pipes
Bottom* Insulation
Vapor Barrier
Sub-Grade
*Note: 2” insulation (R-10 for EPS) is recommended at slab edges and below slabs
Suspended slabs (over unconditioned cold air) will require even more insulation
SLAB-ON-GRADE “WET” WITH RAILFIX
THESE GO DIRECTLY ONTO EPS INSULATION
EXAMPLE: STYROFOAM® SM BOARDS
SLAB-ON-GRADE “WET” WITH SCREW CLIPS AND RAILFIX
Screw Clip
RAILFIX
SLAB-ON-GRADE “WET” WITH FIXING RAIL OR RAUTACKER
RAUTACKER staple
RAUTACKER
SLAB-ON-GRADE “WET” WITH NYLON TIES
REHAU NYLON PIPE TIES TIED TO WIRE MESH
- REHAU nylon pipe ties - 50 lb. capacity, installed every 2 – 3 feet maximum
- Ensure wire mesh has no sharp edges
SLAB-ON-GRADE “WET” WITH NYLON TIES
REHAU NYLON PIPE TIES TIED TO WIRE MESH
- REHAU nylon pipe ties - 50 lb. capacity, installed every 2 – 3 feet maximum
- Ensure wire mesh has no sharp edges
SUSPENDED WOOD FLOOR “OVERPOUR”
ALSO A “WET” INSTALLATION
- Pipe is fastened to subfloor
- 1 1/2” total height (typical)
- Minimum coverage must be 3/4”
above pipes
- To avoid heat striping and
weak concrete
- Thin thermal mass overpour may
be gypsum cement concrete or
portland cement concrete with
small aggregate (3/8” or smaller)
- Ensure that subfloor is designed for
the “dead weight” of 13-18 lb/ft2
- Clarify definition of “lightweight”
- Concrete is never light!
Minimum 3/4”
above pipes
1 1/2” total
GENERAL NOTES
- Very common installation technique
- Freedom to lay pipe according to room design
- Use proper stapler tools to avoid crimping or
dimpling pipe
- REHAU Pneumatic Stapler by SENCO
GENERAL NOTES
- Can also use pipe talons
IMPORTANCE OF INSULATION
- Heat goes to cold and will go down
without proper direction
- Insulation in the joist cavity is crucial
to comfort, performance and
response
Heated space below:
- R-value in the joist cavity below a heated
overpour should be at least 5 times R-value
above (flooring + floor)
Examples:
- Tile above, Minimum R-5 in joist cavity
- Carpet above, Minimum R-11 in joist cavity
Unheated space below:
- R-value in the joist cavity below a heated
overpour should be at least 10 times R-value
above (flooring + floor)
Examples:
- Tile above, Minimum R-13 in joist cavity
- Carpet above, Minimum R-19 in joist cavity
TIPS
- Install all baseplates to mark
walls before laying pipe
- Assists routing pipes
- May have to install
loadbearing walls at the same
time
- Use double baseplates:
- Extra-wide baseplates on the
bottom, standard size on top
- 2” x 8” bottom plate at
outside walls
- 2” x 6” bottom plate at inside
walls
- For leveling screed
- For carpet tack strips
TIPS
- Double baseplates, extra wide
(that was not done here)
- Recommend:
- 8” wide under 2” x 6” wall
- 6” wide under 2” x 4” wall
- Install baseplates to mark walls
before laying pipe
- May use pressure-treated
lumber, but not necessary
“SLEEPERS” FOR HARDWOOD INSTALLATIONS
- Common with solid hardwood
- Benefits of thermal mass
- Freedom to lay pipe according to
room design
- Install sleepers opposite to
orientation of hardwood
- Use caution due to moisture!
- Thermal mass must cure and
moisture must be correct
before hardwood is installed
- May take 28+ days for curing
- Work with flooring contractors
and GC for proper scheduling
BE SURE TO SEAL OR COVER THE SUBFLOOR FIRST WHEN USING A PORTLAND CEMENT
CONCRETE OVERPOUR TO PREVENT BONDING AND SHRINKAGE OF THE CONCRETE
GYPSUM CEMENT POURS DIRECTLY ONTO WOOD SUBFLOOR (PUMPED)
FLOOR IS USUALLY SEALED FIRST
GYPSUM CEMENT POURS DIRECTLY ONTO WOOD SUBFLOOR (PUMPED)
FLOOR IS USUALLY SEALED FIRST
SUMMARY
-
Poured thermal mass is a good conductor of heat
Pipes to be fastened every 2 feet (typical) or as needed to prevent “floating”
For medium thick slabs (4”) pipes may be installed at the bottom or in the middle
For thick slabs (6” and above), pipes are normally installed in mid-point, unless there is a
risk of cutting/drilling the pipes
Coverage over pipe must be minimum 3/4” for concrete strength and to avoid striping
Entrained air in concrete is bad for heat transfer
Insulation is crucial to direct the flow of the heat
Wet thermal mass has lots of moisture which needs to evaporate
- Must let it dry before hardwood flooring is installed
Floor loading of poured thermal mass is critical (13-18 lb/ft2 dead load for 1 1/2” overpour)
- Depending on the mix; 2,000 ft2 = 30,000 lbs
Coordination of trades is important
- Insulation, wire mesh, double baseplates, “dams” around holes, etc. all must be done
in the proper order
PIPE PLACEMENT PATTERNS
THREE TYPES OF PIPE LAYOUTS
1. Serpentine (overpour, slab, joist, sleepers)
2. Counterflow Spiral (overpour, slab)
- Helps with bends
- Faster installation in the right situation
- More even temperature distribution
3. Combinations (overpour, slab)
4. Other shapes
1. SERPENTINE
- Install pipe the “long
way” to minimize
bends, for faster
installation
- Great for rectangular
rooms
- Great if there is one
outside “cold” wall
- Run hottest water
to outside wall
- Floor covering
(hardwood) way also
dictate the direction
4 x 180-degree bends
13 x 180-degree bends
SERPENTINE
SIMPLE LAYOUT, EASY INSTALLATION
Straight or in L-shape
SERPENTINE
DOUBLE 180- BEND REDUCES SHARP BENDS
SERPENTINE
DOUBLE 180- BEND REDUCES SHARP BENDS
SERPENTINE
‘U’–SHAPE IN SOME AREAS
SERPENTINE
L-SHAPED SERPENTINE
2. COUNTERFLOW SPIRAL
EVEN FLOOR TEMPERATURE, REDUCES NUMBER OF TIGHT BENDS, FASTER INSTALLATION
BEST PATTERN IF THERE IS NO OUTSIDE WALL, OR ALL OUTSIDE WALLS
COUNTERFLOW SPIRAL
EVEN FLOOR TEMPERATURE, REDUCES NUMBER OF TIGHT BENDS, FASTER INSTALLATION
BEST PATTERN IN LARGE OPEN AREAS
COUNTERFLOW SPIRAL
USE STAPLES OR TALONS
3. COMBINATION
CORNER ROOMS
Supply
Outside
Wall
Return
Perimeter
Area (3 ft.)
Occupied
Area
4. OTHER SHAPES…
IN BATHROOMS USE MORE PIPE, NOT LESS. TRY 3/8” RAUPEX FOR FLEXIBILITY
4. OTHER SHAPES…
IT IS IMPORTANT TO FILL THE HEATED SPACE WITH PIPES AND AVOID GAPS (COLD SPOTS)
CONSTRUCTION JOINTS
ARRANGE PIPES TO AVOID PASSING THROUGH JOINTS
JOIST SPACE “DRY” INSTALLATIONS
GENERAL RULES FOR JOIST SPACE INSTALLATIONS
- No poured screed is involved (“dry”)
- Aluminum plates, the air cavity (in joist space) and the subfloor are all parts of the
thermal mass
- Aluminum heat transfer plates are very important for efficiency and response
- Can increase efficiency by 20% to 40%
GENERAL RULES FOR JOIST SPACE INSTALLATIONS
Pro’s:
- Suitable for retrofit
- No structural weight issues
- No added moisture
Con’s:
- Installation can be difficult and slow
- Not the most efficient radiant technique
- Higher water temperatures will be
required, as compared with other RFH
- Slower response time compared with
pipes installed above the subfloor
- High R-value insulation is critical
underneath plates and at ends of cavities
- Below the 2” air gap:
- Minimum R-19 over heated space
- Minimum R-30 over unheated space
How does it work?
Typical 2” x 10” joist
construction with 2” air gap.
Follow the path of the heat
MAINTAIN 2” AIR GAP BELOW SUBFLOOR FOR FULL HEAT TRANSFER, REDUCED STRIPING
Light Gauge Heat Transfer Plate
Locking Clip
Talon
INSTALLATION TIPS
- Uncoiler is very useful in larger areas
- Otherwise, 2-3 workers is ideal
- With light gauge plates, install all
pipe, then plates
- With heavy gauge plates, install the
plates first, then snap in the pipes
- Use protection sleeving at joist
penetrations to prevent chafing and
possible noise of rapid thermal
expansion
- If the design allows, 3/8” RAUPEX O2
Barrier pipe is more flexible than 1/2”
pipe, faster to install
- Feel free to use EVERLOC couplings
when in a jam
PE Protection
Sleeve
Pipe must be
free to move at
ends
MAINTAIN 2” AIR GAP BELOW SUBFLOOR FOR FULL HEAT TRANSFER, REDUCED STRIPING
- Heat transfer plates enhance heat distribution
- 20 - 40% improvement
- Use 6 screws per light gauge plates
- Use 8 screws per heavy gauge plates
- Because staples may work loose over
time, and plates would fall down
- Insulation is important (foil face up for
radiation)
- Insulation should be 2” away from
subfloor (for convection heat transfer)
- Be careful of sharp edges on heat transfer
plates. Wear eye and hearing protection
when cutting heavy gauge plates. Wear
work gloves.
LIGHT GAUGE PLATES – 2 FEET LONG EACH
HEAVY GAUGE PLATES – 4 FEET LONG EACH
JOIST SPACE OUTPUT – FINITE ELEMENT ANALYSIS
SAMPLE CALCULATION WITH HEAT TRANSFER PLATES
THEORETICAL JOIST-SPACE SYSTEM WITH R-1.0 FLOOR COVERING
- FEA shows that heat is conducted by Heat Transfer Plates and is distributed more evenly
under the entire subfloor and joist cavity
- Lower water temperature, more efficiency, better response time
JOIST SPACE OUTPUT – FINITE ELEMENT ANALYSIS
SAMPLE CALCULATION WITHOUT HEAT TRANSFER PLATES
THEORETICAL JOIST-SPACE SYSTEM WITH R-1.0 FLOOR COVERING
- FEA shows that heat is concentrated in the air around the pipes
- There is less transfer to subfloor, more striping on floor surface
- Higher water temperature, less efficiency, slower response time
SUMMARY
- Installation can be difficult and slow depending on obstructions, ceiling height, etc.
- Zoning is very difficult since pipes must follow joist bays under several rooms
- Perimeter spacing is the same as occupied spacing (determined by joist spacing)
- Usually 8” o-c, sometimes 7”, 9” or 10”
- Aluminum heat transfer plates are very important for efficiency and response
- High R-value insulation is critical underneath plates and at ends of cavities
- Higher water temperatures will be required as compared with above-floor installations
- Slower response time compared with pipes installed above the subfloor
- Outdoor reset control with continuous circulation is recommended, especially with light
gauge plates, to help avoid expansion noises and to improve response times
MANIFOLD LOCATIONS
MOUNTING
- Install in the back of a closet, or cabinet
- Leave enough room for all pipes to connect
- Mount manifold 30-40” above floor in an
accessible location
- Position manifold in its “final resting place”
so that pipes are routed correctly
- Ex: Build a support along framed walls
MANIFOLD LOCATIONS
MOUNTING
-
Install in the back of a closet, or cabinet
Leave enough room for all pipes to connect
Mount manifold 30-40” above floor in an accessible location
Position manifold in its “final resting place” so that pipes are routed correctly
Ex: On new slabs, make a support with rebar or wood studs
MANIFOLD LOCATIONS
ROUTING PIPES
- Place in permanent position
- Mount 2 - 4 feet above grade
- Mount level and secure
- May have to create supports
- Leave room for pipe access
- Note pipes passing under wall
MANIFOLD LOCATIONS
PLANNING THE LOCATIONS
- Find an opening the correct size
- Refer to the dimensional drawing
in the installation brochure
- Try to align the pipes!
Not a great example here!
MANIFOLD LOCATIONS
PLANNING THE LOCATIONS THROUGHOUT THE BUILDING
EXAMPLE: OPEN AREA, 2 MANIFOLDS FOR 10 CIRCUITS
MANIFOLD LOCATIONS
EXAMPLE: OPEN AREA, 1 MANIFOLD FOR 10 CIRCUITS
#10
#9
#8
#7
#6
#1
#2
#3
#5
#4
MANIFOLD LOCATIONS
MANIFOLD LOCATIONS
PVC BEND GUIDE INSTALLATION
STEP TWO
- Insert pipe into PVC Bend Guide
- Use 30” - 40” of pipe to reach
manifold
- Adjust all bend guides to same
height and even spacing
- These will be partially encased
in concrete and will be visible
PVC BEND GUIDE INSTALLATION
STEP TWO
- PVC Bend Guides look great when complete
- They protect and align the pipe and take
stress off pipe connections
INSTALL RAUPEX PIPE
STEP FOUR
TIPS FOR INSTALLING RAUPEX PIPES
- Bending radius of 5 times the pipe OD without heat; the tightest of all PEX pipes
- Bending radius of 3 times the pipe OD when heated; the tightest of all PEX pipes
- Pipes are less likely to kink when bending slowly
Pipe Size
(nominal)
Pipe OD
(actual) in.
5x Minimum 5x Minimum
Bend
Bend
Radius in. Diameter in.
3/8"
0.500
2.500
5.00
1/2"
5/8"
3/4"
1"
1 1/4"
0.625
0.750
0.875
1.125
1.375
3.125
3.750
4.375
5.625
6.875
6.25
7.50
8.75
11.25
13.75
1 1/2"
2"
1.625
2.125
8.125
10.625
16.25
21.25
r
Radius (r)
d
Diameter (2 x r)
INSTALL RAUPEX PIPE
STEP FOUR
- Minimum bend radius for RAUPEX pipe
is 5 times the pipe diameter when cold
- Bend slowly, especially in cold
weather
- Minimum bend radius is 3 times the
OD when pipes are heated above
250°F
- Use hot air gun (ONLY)
- Heat pipes only without pressure
- Fasten pipe at the beginning, middle
and end of each bend to prevent
“lifting”
- If pipe tends to lift, add extra
fastener(s)
See Page 5-5 REHAU RFH Technical Manual
INSTALL RAUPEX PIPE
STEP FOUR
- Attach pipe every 2 - 3 feet using approved fasteners
- Ensure pipe is straight and doesn’t “lift”
- If pipe seems to float, add more fasteners
- Mark circuit lengths and locations as you go
- Insulate pipe tails if necessary
- But don’t weaken the concrete
- Don’t cross pipes in “poured” applications
- Don’t weaken the concrete
Saw cut is very close
to top of pipes. Add
fasteners!
INSTALL RAUPEX PIPE
STEP FOUR
PROTECTION SLEEVING
- Install sleeves at penetrations
- Install sleeves at expansion joints
- Joist space sleeving prevents noise
INSTALL RAUPEX PIPE
STEP FOUR
- Start installing pipes on outside walls
so that hottest water (from Supply)
goes to perimeter areas first
- Keep pipes 6” away from walls,
holes, cabinet mounting points, and
toilet gaskets
- To reduce heat transfer
- For protection of pipes
- To prevent softening
AIR PRESSURE TEST
STEP FIVE (OPTION A)
AIR TESTS ARE ALLOWED BY REHAU AND ARE RECOMMENDED IN FREEZING CONDITIONS
- Pressurize pipes and manifold(s)
together through the manifold
- Normal test pressure is 1 1/2 times
working pressure or 100 psi (whichever
is higher)
- Re-pressurize at 10 and 20 minutes
to allow for expansion of pipes
- Keep constant temperature
- Maintain test pressure for 2 hours
- Note: Air tests are safe up to a
maximum of 200 psi as long as pipes are
used with brass manifolds, EVERLOC
fittings, and no plastic components
REHAU Air Tester Art. 257334
WHAT NOT TO DO
DON’T LET YOUR JOBS LOOK LIKE THIS!
- Don’t hang manifold crooked or
remove from brackets
- Don’t install without brackets
- Don’t leave pipe in the sunlight
- Don’t cut pipe with a hacksaw or
pocketknife
- Don’t let pipe float close to surface
- Don’t leave excessive gaps between
pipes to result in cold spots
- Don’t forget to clip or move nylon ties
Improper manifold mounting
WHAT NOT TO DO
- Don’t forget PVC bend guides at
manifolds
- Try to line them up!
Improper pipe positioning
WHAT NOT TO DO
- Don’t mix up Supply and Return
- Don’t lose track of pipes
- Don’t hang manifold crooked or
remove from brackets
- Don’t install without brackets
- Don’t cut pipe with a hacksaw or
pocketknife
- Don’t let pipe float close to surface
- Don’t leave excessive gaps between
pipes to result in cold spots
- Don’t forget to clip or move nylon ties
Improper manifold mounting

RADIANT FLOOR HEATING INSTALLATION TECHNIQUES

Transcription

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