www.thermoboard.co.uk

Underfloor heating & cooling solutions by Wavin
Clever ideas don’t have to be
complicated. Technology is
best when it’s made easy to
understand and use.
Underfloor Heating Division
The Dart Building
Grenadier Road
Exeter Business Park
Exeter EX1 3QF
Need more information ?
Get straightforward guidance from
people who really understand UFH
Call us on:
or email:
We’ve solutions for screeded
and timber floor constructions,
for all floor levels. We also
offer straightforward support
should you need it.
01392 444122
Just like UFH from Thermoboard.
[email protected]
www.thermoboard.co.uk
UF425
For Screeded and Timber Floors
Step-by-step Installation Guide
Underfloor heating & cooling solutions by Wavin
Contents 2
Technology
that’s special
THERMOBOARD
UFH SYSTEMS
Installation Tips
– helpful hints
For Screeded Floors
– systems introduction
PIPE PATTERN EXAMPLES
4
What makes new technology
great ? It’s more than just its
ability to solve a problem or
deliver superior performance.
For Timber Floors
– systems introduction
5
For Raised Access Floors
– systems introduction
5
Technology is best when
it’s also made easy to
understand and use.
GENERAL INSTALLATION
GUIDANCE
That’s what makes
Thermoboard Underfloor
Heating special.
Preparation
6
– planning and preparing for
installation
General Techniques
7
– pipe cutting, edge insulation,
sealing
8-9
Typical Layouts
– single room shapes
– multi-room layouts
10
11
STEP-BY-STEP
INSTALLATION GUIDE
Staples system
12-13
System Plates system
14-15
Pocketed Polystyrene
system
16-17
Foiled Polystyrene system
– for Fully Floating Floors 18-19
– for Timber Joists
20-21
– for Timber Battens
22-23
Modular Wood system
– from Above
– from Below
24-25
26-27
Raised Access Floor
system
28-29
Pressure Testing
– procedures
30-31
Manifolds
– Composite Manifold
introduction
32
– Installation procedure
and system filling
33-34
Controls
– introduction
35
FURTHER ASSISTANCE
Contact Details
Back cover
Thermoboard Underfloor Heating in 6 systems
1
Staples
For SCREEDED floors.
2
Complete versatility for pipe
layout and independent
choice of insulation. It’s an
ideal solution for small and
irregularly shaped floors –
with lowest material cost.
4
Foiled Polystyrene
For TIMBER floors.
Insulation with machined
channels fitted with
aluminium foil diffusers,
to hold the pipe at
fixed centres.
System Plates
For SCREEDED floors.
3
Interlocking sheets with
vacuum-formed grid of clips
to hold 16mm UFH pipe.
Enables fast installation and
is easily configured to suit
individual projects.
5
Modular Wood
For TIMBER floors.
Standard tongue-andgroove panels with pre
fitted 10mm UFH Pipe.
Allows simultaneous
installation of floor and
UFH.
Pocketed Polystyrene
For SCREEDED floors.
Insulation with machined
channels to hold the pipe
at fixed centres. Extra
time-saving option.
6
Raised Access
Floors (RAF)
Ideal method of
incorporating warm water
underfloor heating/cooling
with standard RAFs.
3
Thermoboard UFH Systems 4
Options for SCREEDED floors
For installation on a solid floor slab
STAPLES
SYSTEM PLATES
POCKETED POLYSTYRENE
The Thermoboard UFH basic system. It gives
you full layout flexibility: you decide the pipe
spacing and choice of insulation.
A cleverly designed method for fast placement
of UFH pipe but which still gives you full layout
flexibility. You decide the pipe spacing and
choice of insulation.
A real time-saving option because it enables
you to fit insulation and the base for the UFH
pipe simultaneously. Insulation panels have
machined channels and screed pockets to
grip the pipe. This means the
pipe spacing is already
set for you at
consistent centres.
It’s especially suitable for small and irregularly
shaped floor areas.
Options for TIMBER floors
For suspended floor constructions and fully floating floors
FOILED POLYSTYRENE
MODULAR WOOD
Insulation panels with factory-fitted aluminium
foil diffusers for machined channels that hold
pipe in place. Versions for joisted, battened or
fully floating floors available.
Standard sized tongue-and-groove chipboard
panels with pre-fitted UFH pipe. Enables
simultaneous installation of floor deck and
UFH over joisted or battened floor.
Options for RAF
RAISED ACCESS FLOOR
Brackets plug into the pedestal caps of the
RAF, and the heating module sits on the
bracket. Brackets and modules can be
retro-fitted to older types of RAF and modules
can be repositioned at any time in the future.
5
General Installation Guidance 6
INSTALLATION – Project Preparation
Sub-floor
Heat source
z Ensure that the sub-floor is
z Confirm whether the UFH
– Flat and level
is to be connected to:
– Clean of loose debris
– An existing radiator circuit
OR
– Direct to the boiler
– Dry
If adding UFH to an existing
radiator circuit
z Identify suitable connection
point
z Decide position for UFH
manifold
z Check that the boiler
capacity is sufficient for
the needs of UFH
– Heating output
– Pump
If installing UFH in a house
extension and connecting
direct to the boiler
z Check that the boiler has
sufficient capacity to serve
the additional circuits
Insulation (screeded
only)
All Thermoboard UFH systems
for screeded floors require edge
insulation (see page 7 below).
If you are installing Staples or
System Plates, you will also
need rigid insulation panels to
cover the entire floor area.
If you are installing Pocketed
Polystyrene, insulation panels
are an integral part of the
system.
INSTALLATION – General Techniques
Cutting pipe
Edge Insulation (screeded only)
z Tape all joints between
When it is necessary to cut
or trim Thermoboard
16mm UFH pipe for jointing
or connection to the Manifold,
follow normal plumbing
Good Practice:
z Ensure pipe is cut square,
using an appropriate cutter
z DO NOT cut pipe with a
hacksaw, wheeled tube cutter
or utility knife
z Check the pipe end for burrs
and roughness – and remove
if found
Sealing (screeded only)
insulation panels
This is to prevent liquid screed
reaching the underside.
This helps to minimise heat
loss and allow for thermal
movement of the floor screed.
BEFORE installing
Thermoboard UFH system
z Place Thermoboard
Expansion Foam around
the perimeter: ensure the
integral gaiter is facing the
floor space
AFTER installing rigid insulation
panels and pipe
z Ensure the gaiter lies on top
of the installed insulation
panels and pipe
This gaiter will help ensure
screed does not reach the
underside of the insulation
panels.
Screeding (screeded
only)
This MUST NOT begin until
the installed UFH pipe circuits
have been pressure tested
(see pages 30-31).
z When screeding, keep pipe
under pressure so that any
fault can be immediately
detected
7
Installation Tips 8
1
General
Insulation
Pipe
Remember that underfloor
heating circuits should not
be installed in floor areas
that will be covered by major
fixtures: (e.g.)
1 Do NOT bend Thermoboard
UFH pipe more tightly than a
radius of 100mm
z Kitchens: EXCLUDE
3 Any fittings used to repair a
pipe must be kept accessible
for inspection
areas to be fitted with
cupboards, work surfaces,
oven, fridge-freezer etc.
z Bathrooms: EXCLUDE
areas to be fitted with bath,
shower, sanitaryware etc.
2 If pipe is kinked, it MUST be
repaired or replaced
4 During pipe placement, use
the pipe packaging to control
it while uncoiling
Pressure testing
z Use a Hydraulic Pressure
Tester (available
from most hire
shops)
Sealing (screeded only)
z Before screeding, ensure edge
gaiter is fully deployed around
room perimeter
Screed (screeded only)
Pipe convergence
(screeded only)
z Use curved pipe supports and
pipe clamps to secure
pipework where it converges
below the manifold
z Allow screed to dry naturally
z NEVER use heated UFH
circuits to accelerate the
drying and curing process
9
Typical Layouts 10
Your project may not precisely
match any of these examples,
but they can help you plan your
pipe layout.
For individual rooms
A
Basic Square
Spiral
Pattern
F
B
Conservatory
D
E
Irregular Shape
Serpentine
Pattern
Spiral
Pattern
C
L Shaped
Spiral
Pattern
Conservatory & Kitchen Extension
Spiral
Pattern
A serpentine pattern
(as shown above) is
recommended for Staples
installations. Pocketed
Polystyrene machined
channels also use this pattern.
Irregular shape to avoid
major fittings: this could be
for a kitchen
G
One-bedroom Flat
T
T
T
MANIFOLD
Serpentine
Pattern
For multi-zone projects
Spiral
Pattern
11
Step-By-Step Installation
1
Preliminary
z Ensure flat and level sub-floor
z Lay plain insulation
z Use staggered joints to
cover the whole floor
area, as illustrated above
z Place edge insulation
around the room perimeter
(see page 7)
3
Placing Pipe
z Place the pipe into
position in accordance
with the marked layout
z Feed the pipe from the
centre of the coil:
DO NOT REMOVE
THE PACKAGING
FROM THE PIPE COIL
Insulation
Panels
z Seal joints with tape or
cover with vapour barrier
as applicable
4
Securing Pipe
2
Staples 12
Mark Out Pipe Layout
z Start from the point in
the room nearest to the
location of the manifold
and heating supply
z Follow a serpentine pattern,
with pipe at 200mm centres
z Pipe runs should preferably
follow the longest direction
of the room
Alternative layout
z Use a spiral pattern, with
pipe at 200mm centres
5
Completion and
Commissioning
z Secure the pipe to the
insulation at regular intervals
using Thermoboard Staples
at approx. 500mm intervals
z A Staple Gun is available:
this enables stapling from a
standing position
z To ensure loop turns are
secure, staple the pipe at the
apex of each turn, as shown
The final stages include:
z Pressure testing
(see pages 30-31)
z Installation of, and
connection to, the
Manifold
(see pages 33-34)
z Screeding (see page 7)
z Controls (see page 35)
13
Step-By-Step Installation
Preliminary
z Ensure flat and level sub-floor
2
System Plates 14
Position System Plates
z Place edge insulation
around the room perimeter
(see page 7)
z Place the first System Plate
1
in the corner of the room
with the large plain faced
nodule in the corner
Insulation
Panels
z Lay plain insulation
z Note position of
cover the whole floor area,
(as illustrated page 12)
Placing Pipe
overlapping castellations
z NOTE: For pipe spacing,
each castellation
group = 75mm
castellations showing
rectangles on their faces:
other plates should be laid
in the same orientation
z Use staggered joints to
3
z Lay and fix other plates,
4
Fixing Bends or Loops
z Follow block laying
sequence guide to minimise
cutting and wastage
5
Completion and
Commissioning
z Insert pipe carefully
z Start 75mm from wall
securing gaiter of edge
insulation foam under the
first run of pipe
z Place pipe in a spiral
pattern (see Tips page 8)
with 450mm centres to the
centre of the room - then
reverse out to achieve
225mm centres
between nodules:
MINIMUM 225mm
diameter for any turns –
to relieve pipe stress
z Then reduce to desired
spacing
z When creating offsets it
may be necessary to crush
smaller castellations
The final stages include:
z Pressure testing
(see pages 30-31)
z Installation of, and
connection to, the
Manifold
(see pages 33-34)
z Screeding (see page 7)
z Controls (see page 35)
15
Step-By-Step Installation
Pocketed Polystyrene 16
1
Lay End Panels
2
Lay Main Panels
z Lay main pocketed
panels to cover the
remainder of the floor
z Ensure the machined
Preliminary
z Lay loop return end
panels at each end of
the room
z Ensure flat and level sub-floor
z Place edge insulation
channels match up with
channels in adjacent
panels and/or in the
loop return end panel
around the room perimeter
(see page 7)
3
Placing Pipe
4
Completion and
Commissioning
The final stages include:
z Pressure testing
(see pages 30-31)
z Installation of, and
z Feed pipe into channels,
pressing down carefully
into the pre-cut channels
connection to, the
Manifold
(see pages 33-34)
z On long runs, pipe can be
z Screeding (see page 7)
unrolled from a standing
position, and pressed into
place with your foot
z Controls (see page 35)
17
Step-By-Step Installation
for Fully Floating Floors
Preliminary
z Ensure flat and level sub-floor
1
2
Foiled Polystyrene 18
Lay Main Panels
z Lay main foiled panels
to cover the remainder
of the floor
Lay End Panels
z Trim main panel lengths
as necessary
z Ensure the machined
channels match up with
channels in adjacent
panels and/or in the loop
return end panel
z Lay loop return end
panels at each end of
the room
3
Placing Pipe
z Feed pipe into channels,
pressing down carefully
into the pre-cut channels
z On long runs, pipe can be
unrolled from a standing
position, and pressed into
place with your foot
4
Completion and Commissioning
The final stages include:
z Pressure testing
(see pages 30-31)
z Installation of, and
connection to, the
Manifold
(see pages 33-34)
z Laying of Floor deck
z Controls (see page 35)
19
Step-By-Step Installation
2
for Timber Joists
Preliminary
Crawling boards should be
used at all times.
Please refer to relevant
health & safety regulations
for further information.
3
Notch Joists
1
Lay Panels
z Lay loop return end panels
Fix Panel
Supports
at each end of the room
z Lay long foiled panels
between the loop return
end panels
z Fix L brackets or battens
to both sides of each joist
at a depth such that the
insulation panels will sit
with the top surface
proud of the joist by
1-2mm
4
Foiled Polystyrene 20
Placing Pipe
z Trim main panel lengths
as necessary
5
Completion and Commissioning
The final stages include:
z Pressure testing
(see pages 30-31)
z Installation of, and
z Plan the pipe layout
and notch joists where
necessary
z Feed pipe into channels,
pressing down carefully
into the pre-cut channels
and the connecting
notches
connection to, the
Manifold
(see pages 33-34)
z Laying of Floor deck
z Controls (see page 35)
21
Step-By-Step Installation
1
for Timber Battens
Foiled Polystyrene 22
Lay Battens and Panels
z Fix batten to one edge of room
Preliminary
z Lay loop return end panels up
z Ensure flat and level sub-floor
against batten at both ends
z Lay main foiled panels between
the loop return end panels
z Trim main panel length as
necessary
z Fix next batten up against
insulation panels just laid
z Continue laying battens and
panels to cover the floor area
2
Notch Battens
3
Placing Pipe
4
Completion and Commissioning
The final stages include:
z Pressure testing
(see pages 30-31)
z Installation of, and
z Plan the pipe layout
and notch battens
where necessary
z Feed pipe into channels,
pressing down carefully into
the pre-cut channels and
into the connecting notches
connection to, the
Manifold
(see pages 33-34)
z Laying of Floor deck
z Controls (see page 35)
z On long runs, pipe can be
unrolled from a standing
position, and pressed into
place with your foot
23
Step-By-Step Installation
From Above
1
2
Modular Wood 24
3
Lay Panels
z Lay tongue-and-groove panels
Insulate
z Install insulation between
the joists to minimise
downward heat loss
Notch
z Make a small notch in
according to layout drawings
provided, leaving a minimum
10mm expansion gap around
periphery of the deck
the joist to take tails into
joist bay
z Fully glue all tongue-and-
groove edges
z Screw, or nail and glue all
panels to joists
z Lay the panels so the piped
end is positioned on the
centre line of the joist
4
Connect Pipe Work
z Connect the pipe tails to
flow and return pipes as
shown in the layout
drawings provided
z Trim the opposite end to
sit on the centre line of the
relevant joist, or support
with suitable noggin/dwang
5
Pressure Test
z It is important that fittings
should be exposed during
the Pressure Test
(see pages 30-31)
z Once the pressure test
has been completed
satisfactorily, fit an
Access Panel, to cover
over the fittings and
interconnecting pipe
25
Step-By-Step Installation
From Below
1
Modular Wood 26
Lay Panels
z Lay tongue-and-groove panels
according to layout drawings
provided, leaving a minimum
10mm expansion gap around
periphery of the deck
z Fully glue all tongue-and-
groove edges
z Screw, or nail and glue all
panels to joists
z Lay the panels so the piped
end is positioned on the
centre line of the joist
2
Connect Pipe Work
3
Pressure Test
z Pull back pipe tails
z Trim the opposite end to
sit on the centre line of the
relevant joist, or support
with suitable noggin/dwang
4
Insulate
z Make a small notch in
15-20cm from end
of panels
the joist to take tails into
joist bay
z Connect the pipe tails to
flow and return pipes as
shown in the layout
drawings provided
z P-clip flow and return
pipework to joists at
300mm centres
z It is important that fittings
should be exposed during
the Pressure Test
(see pages 30-31)
27
Step-By-Step Installation
1
2
Attach Brackets
Refer to plans supplied.
Clip brackets onto each
pedestal adjacent to the
planned line of the pipe.
3
Lay Pipe
Install the pipe into the
grooves as per the design.
Recommendation:
At the end of pipe runs,
secure the pipe in the
module by wrapping a
300mm length of tape
around both.
Raised Access Floor 28
Fit Modules
Line up each module end on
the centre-line of a bracket
(i.e. so that the end of the
next in-line module can share
that same bracket). When
pressing each module into
the brackets, ensure it is
orientated so that the pipe
groove is away from the
pedestal head.
4
Flow and Returns
Run multiple flow and return
pipe runs in the brackets as
required. Modules are not
needed for these.
Recommendation:
Secure flow and return pipes
in brackets using cable ties.
29
Step-By-Step Procedure
1
Introduction
Once the pipe has been laid,
each circuit should be pressure
tested. This is to ensure that
there are no leaks in the pipe
or connections.
THIS MUST BE DONE
BEFORE SCREEDING.
3
Recording
Preparation
Ensure circuit is complete:
z Close isolation valves on
primary connection to the
manifold
z Open all circuit valves on
Flow and Return
z Connect a hydraulic
pressure tester to one
fill/drain port
4
2
Pressure Testing 30
Testing
z Raise pressure to 1bar.
Hold this for 45 minutes
and inspect system for
leaks. If fittings are present
within the system, it is
recommended that they
are flexed during this
inspection
z Reduce the pressure to
2 bar. Hold this for
45 minutes and
inspect for
leaks
z Increase pressure to 6 bar.
Hold this for 15 minutes
and inspect for leaks
After Testing
z Safely depressurise
system
z Record time and date
of test
31
Step-By-Step Procedure
Composite Manifold 32
Introduction
z Entirely modular
– Start with a Composite Manifold Starter Pack
– Pick any number of ports, from 1 to 12
– Connect to the Control Pack
z Lightweight and simple to install
z Retrofit another circuit to the manifold in
minutes and at any time
z Install with ports facing up or down as
required
z Unique 'Memory Ring' enables circuit
isolation and balancing without tools
z Suitable for cooling as well as heating
z BBA certificated for 25 year service life
Installation procedure and system filling
1
Manifold Packs
z Starter
2
Assembling
Arms
a
– A full Composite Manifold Installation Guide is also available
3
a
Installing
Gauges
b
4
Connecting
Circuits
a
b
z 1 Port
b
c
c
z 3 Port
d
c
33
Step-By-Step Procedure
5
6
Quick Circuit Balancing
a
b
c
d
Flushing and Filling
b
c
e
Circuit Longest
Length
-10m
-20m
-30m
Setting
10.8
9.6
8.4
12.0
a
Composite Manifold 34
-40m -50m -60m -70m -75m+
7.2
6.0
4.8
3.6
3.0
Circuit Setting = (Circuit Length - Longest Circuit Length) x 0.12 + 12
Controls
z Mains powered standard Control Centre
z Can control up to 14 heating zones
z 'Pick and Mix' thermostats to fit your lifestyle: Mix hard wired
and wireless, programmable and non-programmable, all
compatible with one Control Centre
z 'Install now - assign later' design: eliminates cross wiring and
associated costs
z Wireless thermostats means no chasing through walls and
avoidance of wiring costs where used
z Thermostat operation self explanatory: makes setting heating
to personal preferences extremely easy for homeowners
z Ideal for use in new build, extensions and renovations
z See Control System Installation Guide for full details of
connection and operation procedures
Need any help ? Call us on: 01392 444122
35

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