FoilBoard Install Guide

IG UFH 09.1

Storing the System
NOTE: If it is necessary to store the system once you have taken delivery, ensure it is kept in the following conditions: A dry, weather tight area Out of direct sunlight Away from sharp objects or chemical spillages All panels must be stacked horizontally and raised off the ground. It must not be exposed to moisture or high heat.

Storing the System

NOTE: If it is necessary to store the system once you have taken delivery, ensure it is kept in the following conditions:

A dry, weather tight area
Out of direct sunlight
Away from sharp objects or chemical spillages
All panels must be stacked horizontally and raised off the ground. It must not be exposed to moisture or high heat.

Stage 1
Key factors to follow The FoilBoard system is primarily designed for solid joists that can be notched to allow pipe to route from one joist bay to another, TJI & Truss /Posi style joists top and bottom chords must not be notched, this also applies to preformed roof truss structures. When working with any wood, insulation or acoustic based products, dust and particles become airborne and pose a hazard to health. This is particularly relevant when machine cutting or routing. Please follow all relevant safety guidelines on power tool use and reducing risk of dust inhalation regarding extraction and the use of particle masks and gloves. Unheated areas on the CAD design will not have any UFH materials or plain insulation supplied, same grade and thickness insulation “by others” should be used to infill these areas. Suitable working supports over joists must be employed at all times, FoilBoard panels are non-structural and form no part of the floor deck structural strength once installed. Please check with the flooring supplier that the proposed floor finish is suitable for use with underfloor heating. The minimum temperature for laying the pipe should be +5°C. If the pipe-work is kinked during the installation, the coil must be replaced or the pipe repaired with an OMNIE strait connector and then pressure tested. No connections should be made unless fully accessible following the completion of the finished floor.

Stage 1

Key factors to follow

The FoilBoard system is primarily designed for solid joists that can be notched to allow pipe to route from one joist bay to another, TJI & Truss /Posi style joists top and bottom chords must not be notched, this also applies to preformed roof truss structures.
When working with any wood, insulation or acoustic based products, dust and particles become airborne and pose a hazard to health. This is particularly relevant when machine cutting or routing.
Please follow all relevant safety guidelines on power tool use and reducing risk of dust inhalation regarding extraction and the use of particle masks and gloves.
Unheated areas on the CAD design will not have any UFH materials or plain insulation supplied, same grade and thickness insulation “by others” should be used to infill these areas.
Suitable working supports over joists must be employed at all times, FoilBoard panels are non-structural and form no part of the floor deck structural strength once installed.
Please check with the flooring supplier that the proposed floor finish is suitable for use with underfloor heating.
The minimum temperature for laying the pipe should be +5°C.
If the pipe-work is kinked during the installation, the coil must be replaced or the pipe repaired with an OMNIE strait connector and then pressure tested. No connections should be made unless fully accessible following the completion of the finished floor.

Stage 2
From the CAD design carefully determine and mark the joisted areas that requires FoilBoard panels. Secure the supplied “L” shaped supporting brackets to the top edge of either side of the joists bays. The top of the bracket should be flush with the top of the joist to ensuring panels will be tight against the underside of the floor deck when laid.

Stage 2

From the CAD design carefully determine and mark the joisted areas that requires FoilBoard panels.

Secure the supplied “L” shaped supporting brackets to the top edge of either side of the joists bays.

The top of the bracket should be flush with the top of the joist to ensuring panels will be tight against the underside of the floor deck when laid.

Stage 3
Lay the FoilBoard panels within each joist bay onto the “L” brackets, if possible use the off cuts to start the next bay of panels, ensuring that the cross channels line up. in some designs the pipe may exit the end of the panel and drop into the joist bay, if this happens all exposed flow and return pipe work must be fully insulated “by others”. NOTE: Suitable working supports over joists must be employed at all times, FoilBoard panels are non-structural and form no part of the floor deck structural strength once installed.

Stage 3

Lay the FoilBoard panels within each joist bay onto the “L” brackets, if possible use the off cuts to start the next bay of panels, ensuring that the cross channels line up.

in some designs the pipe may exit the end of the panel and drop into the joist bay, if this happens all exposed flow and return pipe work must be fully insulated “by others”.

NOTE: Suitable working supports over joists must be employed at all times, FoilBoard panels are non-structural and form no part of the floor deck structural strength once installed.

Stage 4
Installing the pipe The minimum temperature for Installing the pipe should be +5°C. Starting at the manifold and referring to the OMNIE CAD design, insert the pipe into the FoilBoard panels by piercing the foil layer. Where pipe passes from one joist bay to the next, joists will need to be notched following the guidelines as set out below (joist manufacture may have set guidelines an this should always take president when notching or drilling the joists) Flows and returns can be bunched together, insulated and run through the joists at the appropriate place or run individually through the tops of the joist. Notching and drilling in solid wood joists must be done in accordance with Building Regulations Part A such that: a) Holes should be drilled through the neutral axis and should be positioned between 0.25 and 0.4 times the joist span length. b) Must not be less than 3 diameters (of the hole) apart. c) Notches must not be greater than 0.25 times the joist depth. NOTE: If the pipe-work is kinked during the installation, the coil must be replaced or the pipe repaired with an OMNIE strait connector and then pressure tested. No connections should be made unless fully accessible following the completion of the finished floor. It may necessary to create channels for flows and return pipe in the panels (especially approaching the manifold), Use either a hot blade cutter (available from OMNIE) or a router with a 12mm tool (maximum depth of cut 12.5mm) following all relevant safety guidelines on power tool use and reducing risk of dust inhalation regarding extraction and the use of particle masks and gloves. (Image are indicative and pipe pattern may vary)

Stage 4

Installing the pipe

The minimum temperature for Installing the pipe should be +5°C.

Starting at the manifold and referring to the OMNIE CAD design, insert the pipe into the FoilBoard panels by piercing the foil layer. Where pipe passes from one joist bay to the next, joists will need to be notched following the guidelines as set out below (joist manufacture may have set guidelines an this should always take president when notching or drilling the joists)

Flows and returns can be bunched together, insulated and run through the joists at the appropriate place or run individually through the tops of the joist. Notching and drilling in solid wood joists must be done in accordance with Building Regulations Part A such that:

a) Holes should be drilled through the neutral axis and should be positioned between 0.25 and 0.4 times the joist span length.

b) Must not be less than 3 diameters (of the hole) apart.

c) Notches must not be greater than 0.25 times the joist depth.

NOTE: If the pipe-work is kinked during the installation, the coil must be replaced or the pipe repaired with an OMNIE strait connector and then pressure tested. No connections should be made unless fully accessible following the completion of the finished floor.

It may necessary to create channels for flows and return pipe in the panels (especially approaching the manifold), Use either a hot blade cutter (available from OMNIE) or a router with a 12mm tool (maximum depth of cut 12.5mm) following all relevant safety guidelines on power tool use and reducing risk of dust inhalation regarding extraction and the use of particle masks and gloves.

(Image are indicative and pipe pattern may vary)

Stage 5
Suitable working supports over joists must be employed at all times, FoilBoard panels are non-structural and form no part of the floor deck structural strength once installed.

Stage 6
Once the panels and pipe have been installed, the circuits should be hydraulically pressure tested. It is preferable for the pipe to be kept under pressure while the covering deck is laid. If this is not possible, the pressure test must be carried out for a second time once the covering deck has been installed.

A Quick Guide to Filling the System
1. If the manifold is being used to pressure test all circuits at once, close both primary isolation valves. 2. Connect a pressure tester to any drain valve, vent the system of air and increase the pressure to 6 bar. 3. Once at this pressure, leave for 60 minutes. If the pressure has dropped examine the pipework. It may be necessary to pressure test individual circuits to determine if there has been damage to the pipe. 4. If the pressure is maintained and passes the test, record the results on the pressure test certificate. Have the test witnessed and certified by a third party. 5. Maintain this test pressure whilst the floor deck and finish are being laid. SEE MANIFOLD INSTALLATION GUIDE (DOCUMENT CODE: IG UFH 17) FOR FULL INSTRUCTIONS

A Quick Guide to Filling the System

1. If the manifold is being used to pressure test all circuits at once, close both primary isolation valves.

2. Connect a pressure tester to any drain valve, vent the system of air and increase the pressure to 6 bar.

3. Once at this pressure, leave for 60 minutes. If the pressure has dropped examine the pipework. It may be necessary to pressure test individual circuits to determine if there has been damage to the pipe.

4. If the pressure is maintained and passes the test, record the results on the pressure test certificate. Have the test witnessed and certified by a third party.

5. Maintain this test pressure whilst the floor deck and finish are being laid.

SEE MANIFOLD INSTALLATION GUIDE (DOCUMENT CODE: IG UFH 17) FOR FULL INSTRUCTIONS

Notes For Wood Floors
When hardwood floors are laid, the moisture-content of the timber should be 8-10%. Please check with the flooring supplier that the proposed floor finish is suitable for use with underfloor heating. Tongued and grooved joints in the floor deck should be glued with PU adhesive or a PVAc adhesive conforming to durability class D3 of BS EN 204. It is essential that a clear gap of at least 10mm is left all the way around the periphery of a timber floor deck, under the skirting to accommodate any swelling of the floor deck due to change in moisture content. All wedges used during the floor deck installation, to press panels together, must be removed when the floor deck is complete. During the initial heat up, the mixing valve should be set to supply temperature between 20°C and 25°C which needs to be maintained for at least 3 days. After this period, the flow temperature can then be increased to the design maximum and should be held for a further 4 days to complete the process.

Notes For Wood Floors

When hardwood floors are laid, the moisture-content of the timber should be 8-10%. Please check with the flooring supplier that the proposed floor finish is suitable for use with underfloor heating.

Tongued and grooved joints in the floor deck should be glued with PU adhesive or a PVAc adhesive conforming to durability class D3 of BS EN 204. It is essential that a clear gap of at least 10mm is left all the way around the periphery of a timber floor deck, under the skirting to accommodate any swelling of the floor deck due to change in moisture content. All wedges used during the floor deck installation, to press panels together, must be removed when the floor deck is complete.

During the initial heat up, the mixing valve should be set to supply temperature between 20°C and 25°C which needs to be maintained for at least 3 days. After this period, the flow temperature can then be increased to the design maximum and should be held for a further 4 days to complete the process.

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