TorFloor Suspended Install Guide

IG UFH 04.2

Before Starting
As OMNIE continues to develop and improve product information and instructions it is recommended you check the OMNIE website (www.omnie.co.uk) for the latest Datasheets & Install Guides that may have been superseded post delivery of your system. Please read all stages of this install guide before proceeding with the installation.

Before Starting

As OMNIE continues to develop and improve product information and instructions it is recommended you check the OMNIE website (www.omnie.co.uk) for the latest Datasheets & Install Guides that may have been superseded post delivery of your system.

Please read all stages of this install guide before proceeding with the installation.

Storage and floor preparation
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 chipboard, woodboard or plywood must be stacked horizontally and raised off the ground It must not be exposed to moisture or high humidity Ensure that all areas are correctly prepared, dry and protected from the weather. Check all joists are: Level and even Clean from debris Without any surface deviations such as knots or nails

Storage and floor preparation

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 chipboard, woodboard or plywood must be stacked horizontally and raised off the ground
It must not be exposed to moisture or high humidity

Ensure that all areas are correctly prepared, dry and protected from the weather.

Check all joists are:

Level and even
Clean from debris
Without any surface deviations such as knots or nails

Stage 1
IMPORTANT The way that the TorFloor Suspended system will be installed depends on access to the floor void below and/or site sequences or requirements. If floor void IS NOT accessible from below: Stages 3-7 will need to be completed room-by-room, starting at the room furthest from the manifold. Access panels will be required for installing the flow and return pipe work. If floor void IS accessible from below: Stages 3-7 can be completed for the whole floor deck at once. No access panels will be required as the pipe can be handled from below and can be run between joists. NOTE: TorFloor is a structural panel and therefore cannot be routed to allow extra channels for flow and returns or for any other reason. See install procedure for flow and returns below. Measure the moisture content of the TorFloor panels and plywood layer this should be no higher than 8-10% ideally acclimatised together before installation. NOTE: When working with any wood or insulation based products, dust and particles can become airborne and pose a hazard to health. This is particularly relevant when machining, cutting or routing. Please follow all the relevant health & safety rules regarding required personal safety equipment and extraction/ventilation requirements are also followed.

Stage 1

IMPORTANT

The way that the TorFloor Suspended system will be installed depends on access to the floor void below and/or site sequences or requirements.

If floor void IS NOT accessible from below: Stages 3-7 will need to be completed room-by-room, starting at the room furthest from the manifold. Access panels will be required for installing the flow and return pipe work.

If floor void IS accessible from below: Stages 3-7 can be completed for the whole floor deck at once. No access panels will be required as the pipe can be handled from below and can be run between joists.

NOTE: TorFloor is a structural panel and therefore cannot be routed to allow extra channels for flow and returns or for any other reason. See install procedure for flow and returns below.

Measure the moisture content of the TorFloor panels and plywood layer this should be no higher than 8-10% ideally acclimatised together before installation.

NOTE: When working with any wood or insulation based products, dust and particles can become airborne and pose a hazard to health. This is particularly relevant when machining, cutting or routing. Please follow all the relevant health & safety rules regarding required personal safety equipment and extraction/ventilation requirements are also followed.

Stage 2
Lay the first panel in a room into a corner, leaving a minimum 10mm gap between the end and edge of the panel and the walls. The two groove edges of the panel should be placed in the corner. the opposite end of the panel must sit on the centre line of a joist.

Stage 3
Lay the panels in a run, ensuring the end of each panel falls on a centre line of a joist. Use the off-cut of each run to start the following run of panels. Ensure that each row of panels has a group of return loops at each end. When cutting the TorFloor panels, TRADA recommends that the shortest length of panel should be supported across a minimum of three joists. For example, if the supports are set nominally at 400mm centres, the shortest panel length should be 800mm. It is recommended that carpenters should NOT fit very short lengths which are supported by only two joists, one at each end, unless supported by noggins.

Stage 3

Lay the panels in a run, ensuring the end of each panel falls on a centre line of a joist. Use the off-cut of each run to start the following run of panels. Ensure that each row of panels has a group of return loops at each end.

When cutting the TorFloor panels, TRADA recommends that the shortest length of panel should be supported across a minimum of three joists. For example, if the supports are set nominally at 400mm centres, the shortest panel length should be 800mm. It is recommended that carpenters should NOT fit very short lengths which are supported by only two joists, one at each end, unless supported by noggins.

Stage 4
All panels must be glued with appropriate PVA adhesive on BOTH sides of the tongue and groove and fully driven together (in order to withstand loads specified in EN12871). The panels should then be screwed and glued to the joists. At each joist, 5 no. fixings should be used x 3 screws equidistant between each routed channel then 2 screws 25mm from each top edge taking care when drilling near the pipe. A pilot hole should be drilled at these points with no.8 Particleboard screws to fix the panels to the joists. The screws should be 2.5 times the panel thickness in length. Screws should preferably be hand-tightened. NOTE: If access panels are required, do not glue/screw these boards until the pipe has been installed.

Stage 4

All panels must be glued with appropriate PVA adhesive on BOTH sides of the tongue and groove and fully driven together (in order to withstand loads specified in EN12871).

The panels should then be screwed and glued to the joists. At each joist, 5 no. fixings should be used x 3 screws equidistant between each routed channel then 2 screws 25mm from each top edge taking care when drilling near the pipe. A pilot hole should be drilled at these points with no.8 Particleboard screws to fix the panels to the joists. The screws should be 2.5 times the panel thickness in length. Screws should preferably be hand-tightened.

NOTE: If access panels are required, do not glue/screw these boards until the pipe has been installed.

Stage 5
Before installing the pipe work, it is advised to sweep or vacuum the floor area as debris may have fallen into the channels.

Stage 6
Referring to the OMNIE CAD design, insert the pipe into the TorFloor panels. NOTE: The minimum temperature for laying the pipe should be +5°C. If the pipework is kinked during the installation, the coil must be replaced or the pipe repaired with an OMNIE connector and then pressure tested. No connections should be made unless fully accessible following the completion of the finished floor. All exposed pipework within the joist spaces must be insulated. Access Panels If there are any access panels, drill a 12.5mm hole at a 20 degree angle through the TorFloor panel at the point at which the flow pipe needs to drop into the batten space.

Stage 6

Referring to the OMNIE CAD design, insert the pipe into the TorFloor panels.

NOTE:

The minimum temperature for laying the pipe should be +5°C.
If the pipework is kinked during the installation, the coil must be replaced or the pipe repaired with an OMNIE connector and then pressure tested. No connections should be made unless fully accessible following the completion of the finished floor.
All exposed pipework within the joist spaces must be insulated.

Access Panels

If there are any access panels, drill a 12.5mm hole at a 20 degree angle through the TorFloor panel at the point at which the flow pipe needs to drop into the batten space.

Stage 7
Feed one end of the pipe through the hole from above through to the manifold, notching or drilling as required (Figure 2). Where there is limited access, a plain access panel can be created and/or 12mm interconnecting fittings used. Once the pipe work has been installed into the room, the access panel can then be glued and screwed as per Stage 5. Running pipe between joists Where flow and return pipework runs through the joists, there must be a notch or hole. 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 deeper than 0.125 times the joist depth, and they should not be closer to a support than 0.07 times the span, not further away than 0.25 times the span. Continue laying the panels and pipe until all circuits are complete. 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.

Stage 7

Feed one end of the pipe through the hole from above through to the manifold, notching or drilling as required (Figure 2). Where there is limited access, a plain access panel can be created and/or 12mm interconnecting fittings used.

Once the pipe work has been installed into the room, the access panel can then be glued and screwed as per Stage 5.

Running pipe between joists

Where flow and return pipework runs through the joists, there must be a notch or hole. 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 deeper than 0.125 times the joist depth, and they should not be closer to a support than 0.07 times the span, not further away than 0.25 times the span.

Continue laying the panels and pipe until all circuits are complete.

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.

Stage 8
A 6mm flooring grade ply covering laid in the opposing direction to the TorFloor panels glued and screwed to complete the structural deck. The covering should be positioned so that each ply panel overlaps the tongue and groove edges of the TorFloor panel by 300mm.

Stage 9
To glue the covering down, apply sufficient PVA glue in a serpentine pattern to the 50mm wide strips of exposed TorFloor panel. Do not apply glue to the foil strips of the TorFloor panel. To ensure a good contact between the overlay and TorFloor panels, Screw (screws at least 25mm long) the ply at 150mm centres 18mm from the edge of each ply sheet then at 150mm centres across the whole panel preferably in the centre line between the pipe runs, Making sure to avoid any of the pipework straights & loops. NOTE: It is best practice to predetermine and mark the pipe & screw positions on the top surface of the ply layer to avoid the straights and loop ends of the pipe runs.

Stage 9

To glue the covering down, apply sufficient PVA glue in a serpentine pattern to the 50mm wide strips of exposed TorFloor panel. Do not apply glue to the foil strips of the TorFloor panel.

To ensure a good contact between the overlay and TorFloor panels, Screw (screws at least 25mm long) the ply at 150mm centres 18mm from the edge of each ply sheet then at 150mm centres across the whole panel preferably in the centre line between the pipe runs, Making sure to avoid any of the pipework straights & loops.

NOTE:
It is best practice to predetermine and mark the pipe & screw positions on the top surface of the ply layer to avoid the straights and loop ends of the pipe runs.

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 is suitable 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 is suitable 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.

TorFloor Suspended Install Guide

PRODUCTS

INFORMATION

FOLLOW US

NEWS & UPDATES