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Underfloor Heating Systems
JUNE 2012
EFFECTIVE: 1ST JUNE 2012
Technical Installation Guide

June 2012
CONTENTS
How to use this guide ............................................................................................................03
INTRODUCTION
About Polypipe Underfloor Heating........................................................................................04
An overview of Polypipe Underfloor Heating Systems .............................................................06
Selecting the right Polypipe Underfloor Heating System .........................................................07
System selection ....................................................................................................................08
Design service ........................................................................................................................09
Polypipe Registered Installer Network .....................................................................................10
What you can expect from your installer ................................................................................11
Guide to floor coverings for underfloor heating systems.........................................................12
INSTALLING THE SYSTEM
Solid Floor..............................................................................................................................14
Floating Floor .........................................................................................................................18
Suspended Floor ....................................................................................................................20
Modular Heating Panels (MHP)...............................................................................................24
Overlay...............................................................................................................................30
Overlay Lite ........................................................................................................................38
CONNECTING & CONTROLLING THE SYSTEM
Connecting to heat source .....................................................................................................40
Manifolds ..............................................................................................................................41
Water temperature controls ...................................................................................................42
Room temperature controls ...................................................................................................44
Single room applications ........................................................................................................50
System commissioning ...........................................................................................................52
TECHNICAL DATA
Heat output tables .................................................................................................................54
General system information ...................................................................................................55
FAULT FINDING CHARTS
Hydraulic fault finding chart ...................................................................................................56
Electrical fault finding chart (master connecting box)..............................................................57
STANDARDS
Accreditations, standards and guarantees ..............................................................................58
FORMS
Design enquiry form ..............................................................................................................59
Polypipe Underfloor Heating products, excluding manifolds and control products, are covered by a 50 year guarantee*, which protects
against defects in materials or manufacture of the heating system from date of purchase. This guarantee only applies if the system is
installed in accordance with the manufacturers recommendations contained within the Technical Installation Guide (the latest version of
which can be found at www.ufch.com), and is used in a normal domestic operation. This document should be read in conjunction with all
other documentation supplied with Polypipe products.
If you have any queries please contact our Technical Department on 01709 770000.
*Full terms and conditions for Polypipe heating products 50 Year Guarantee are available at www.ufch.com.
02
HOW TO USE THIS GUIDE
Important notice:
This publication is provided as a comprehensive guide on how to install Polypipe
Underfloor Heating Systems. It is an important document as we cannot accept
any liability, or honour any guarantee, for products and systems that have not
been installed in accordance with our published instructions.
From time to time our installation advice may be updated
at which time previous printed copies will become out of date.
The latest version of our installation advice, including a downloadable
version of the current Technical Installation Guide, can be found
at our trade website, www.ufch.com.
Selecting the right system

This guide is intended for competent trained plumbing and heating
installers and we assume that you will have already specified your
system of choice before consulting this publication for installation
advice. Basic information on selecting the right system is provided
in this guide. For more detailed guidance refer to our Design &
Specification Guide or visit our trade website at www.ufch.com
or consumer website at www.freeyourwalls.com.
Navigating the Technical

Installation Guide
Having read the general introductory sections at the front
of the guide, ensure that you have selected the correct system
for your floor type and project. Read the guide to floor coverings
to ensure that your system is compatible with your floor type.
Technical data
Towards the back of this guide you will find technical data such
as heat output tables, pipe data and general system information
as well as useful forms to use with our Product Selectors and
System Design Service.
Additional information
Should you have any questions at any time, or require any
kind of technical support, call our Technical Support team
on 01709 770000.
Online assistance is available at www.ufch.com, our comprehensive
website for installers, developers and merchants. As well as
information on technical advice and product benefits, you can
find useful case studies and details of Polypipe stockists.
Video instructions on underfloor heating installation are
also available to view.
For Polypipe Registered Installers we have created a dedicated
members area on our consumer site, www.freeyourwalls.com.
Here you can access full marketing resources, update your web
profile and see great promotional offers from our network partners.
Next, choose your selected underfloor heating system type from

the section Installing the system and follow the step by step
instructions. Everything should be straightforward but remember
that the Polypipe Technical Support team is always ready to help
answer any questions you may have.
Whichever Polypipe Underfloor Heating System you are installing
you will need to refer to the information provided in the section
Connecting and controlling the system. This section provides
all you need to know about manifolds and controls, connecting
your system to an appropriate heat source and commissioning
the system.
03
ABOUT POLYPIPE UNDERFLOOR HEATING
Polypipe is one of Europes largest manufacturers of specialist plastic plumbing,

heating, waste and drainage products.
Our market leading underfloor heating product range has been continuously
developed and improved with frequent innovative additions, the latest of which
are Modular Heating Panels (MHP) - a revolutionary solution for suspended floor
applications, and Overlay Lite - a lightweight floor panel to complement our
innovative over floor heating range.
Polypipe is a member of the Underfloor Heating Manufacturers Association (UHMA),
who set and enforce standards for materials, design and installation of underfloor
heating systems - standards that we embrace within every aspect of our range.
Polypipe Underfloor Heating Systems have been designed
with specifiers, installers and users in mind.
Our systems combine ease of installation with reliable long-term
performance, and we hold a range of stock ready for prompt
dispatch. Unique to the Polypipe service proposition is our
room and house packs concept. Recognising that underfloor
heating systems are difficult to specify using individual components,
we created a range of over 150 pre-set combinations that can
be ordered as complete kits. By simply specifying key variables
such as floor type and room size the right pack can be
specified in minutes. Its as easy as
. We have even
created a unique online product selection tool.
PRODUCT SELECTOR
for UFCH & OVERLAY
Following recent innovative product introductions, we have

categorised our range into 3 groups in order to make selecting
even more instinctive:
04
With a long established reputation for product quality

and value, backed by our strict trade-only distribution policy,
Polypipe has become the clear leader in the underfloor heating
category. Recent innovations ensure the Polypipe range is
the widest available from a single manufacturer, including
traditional underfloor heating systems for every floor type
as well as the innovative MHP and Overlay products.
Polypipe Underfloor Heating Systems are ideal for every
application, including new build, self build, renovation and
home improvement projects. Whole house, single floor and
single room projects are equally catered for in our extensive
product offering. Whatever job you are undertaking,
Polypipe has the product to suit.
Polypipe is a recognised and respected brand, and is well
established as the system of choice for domestic homes by
many installers. All Polypipe Underfloor Heating Systems are
supplied as a complete system, and require no additional
components for installation. Polypipe Underfloor Heating
Systems are rigorously tested, and comply with (or exceed)
all relevant UK standards. We use an integrated flexible
plumbing system, incorporating polybutylene pipes and
a range of push-fit fittings. The systems are also designed
for use with copper pipes, allowing the integration of rigid
pipes when necessary.
Easy installation
Flexible approach
Polypipe Underfloor Heating Systems have been designed with

ease of installation in mind. Innovative product designs ensure
minimal disruption to existing heating and electrical supplies
during installation. As our systems are compatible with standard
central heating boilers, connectivity is also streamlined. Polypipe
Underfloor Heating Systems can be installed up to 20% quicker
than radiators.
Polypipe Underfloor Heating Systems use the flexibility of

polybutylene pipe to provide a solution for all house and room
types. We also have a range of unique and innovative products,
including the Zonal Regulation Unit (ZRU) which is an excellent
enabler allowing underfloor heating systems to be incorporated
into single rooms or refurbishment projects with minimal
disruption to existing heating and electrical supplies.
Polypipe Underfloor Heating Systems are installed in one stage,

eliminating the need for a time consuming second fix. Underfloor
heating components are much easier to manoeuvre on site than
large, bulky radiators; reducing handling issues and potential
damage. Unlike radiators, there is also very little theft value
during installation.
For more information on our single room applications see

pages 50 and 51.
Details of each type of Polypipe Underfloor Heating System

can be found on page 6.
Maintenance free
Once installed, a Polypipe Underfloor Heating System is virtually
maintenance free. There are no joints in the pipe work within the
flooring, significantly reducing the possibility of leaks. Polypipe
Underfloor Heating products are subjected to rigorous testing
and meet a number of exacting standards, full details of which
can be found on page 58. All our manufacturing processes are
monitored and controlled in accordance with the international
quality standard BS EN ISO 9002.
Choosing underfloor heating also eliminates a number of general
maintenance and decoration requirements, normally associated
with radiators, such as painting the radiator or removing it to
paint the wall.
Demonstrating the utmost confidence in product performance,
and providing our customers with peace of mind, Polypipe
Underfloor Heating Systems are covered by the Polypipe 50
year guarantee (full details can be found at www.ufch.com).
Easy to control
Polypipe manufactures a range of water and room temperature
control solutions, allowing you to source a complete, integrated
system from a single supplier. The range includes a number of
control products, with options to suit a variety of lifestyle
patterns, and the abilities to control different rooms independently.
Excellent service
At Polypipe we understand that selecting the right solution for
each application involves detailed consideration. This is why we
offer extensive customer service support, including free system
design and full technical support if any problems arise. We want
to ensure that your installation runs smoothly from the beginning
and our technical support staff can assist you with any questions
you might have.
During installation we offer:
U Pre-project training at one of our training centres
U Pre-project training by distance learning
U On-site assistance
We also provide an extensive back up service:
U Technical representation available to discuss systems
in general and particular projects
U www.ufch.com
U vii>V
U Technical Installation CD
U Specialist Technical Hotline on 01709 770000
Energy efficient
Underfloor heating systems can be more economical to run than
radiator based systems. As they demand a low temperature
rise output from the boiler, they are ideally suited to achieving
maximum economy from a condensing boiler or heat pump.
However, they are just as efficient with higher temperature heat
sources, for example solar and solid fuel, where the correct water
temperature can be set at the point of distribution.
Full details of Polypipe control products can be found on pages

44 to 49.
05
AN OVERVIEW OF POLYPIPE
UNDERFLOOR HEATING SYSTEMS
Polypipe has the widest available range of underfloor heating systems, with a
product available for every conceivable floor type or residential heating project.
With Polypipe, underfloor heating is not restricted to new build developments or
self build projects. Our unique Overlay system is particularly well suited to single
room projects such as kitchens, bathrooms, conservatories, extensions and loft
conversions. Polypipe Modular Heating Panels (MHP) were developed to provide an
innovative and practical solution to installing underfloor heating into upper floors.
The notes below provide a brief overview of the methodologies
employed to install underfloor heating systems for various floor
types. Refer to the overview on the page opposite. Full installation
instructions for each floor type can be found in the section titled
Installing the system on pages 14 to 39.
Solid Floor
Polypipe Underfloor Heating can be permanently built into solid
concrete or screeded floors. As required by current Building
Regulations, insulation is built into the floor directly beneath the
unique Polypipe lightweight plastic floor panel. The heating pipe
is simply slotted into the panel and then permanently covered by
the screed. Suitable for all floor coverings, solid floor systems can
incorporate 15mm or 18mm pipe.
The floor panels form a simple grid for the quickest possible
pipe laying and provide a precise guide to achieve the minimum
bending radius. Panel castellations are set at exact centres and
hold the pipe against movement when screeding. The floor panel
holds the pipe above the insulation allowing full screed surround.
Optimum screed depth is 65mm from the panel base, i.e. 40mm
from the pipe top. Insulation below and at the edges of the floor
screed is required by Building Regulations. Edge insulation also
acts as an expansion joint.
Floating Floor
When installed in floating floors, Polyplumb pipe is simply pressed
in to the pre-formed heat spreader plate, which sits in grooves
within the floating floor insulation panel. The floating floor
system is then covered with 18mm chipboard sheeting.
Suitable for all floor coverings, floating floor systems can
incorporate 15mm or 18mm pipe.
06
Suspended Floor
For installations in suspended floors, Polypipe Underfloor Heating
uses double heat spreader plates. Alternatively, pipes can be laid
on top of insulation between joists. Standard tongue and groove
floorboards are laid on top of the system. Suspended double heat
spreader plate systems use 15mm pipe.
Modular Heating Panels (MHP)

Modular Heating Panels offer a revolutionary new way to solve
the issue of installing underfloor heating into upper floors.
MHP is available in two widths and two lengths to fit all standard
joist spacings. All components and circuitry is pre-configured
into the panels which are simply installed between the joists,
linked together and connected to the manifold.
Overlay
Overlay allows underfloor heating to be installed into existing
spaces quickly, easily and practically. This unique system is
supplied with a choice of patented low profile panels to suit
all types of floor coverings. Overlay is laid over existing solid
or timber floors.
SELECTING THE RIGHT POLYPIPE

UNDERFLOOR HEATING SYSTEM
Polypipe Underfloor Heating Systems

Product selection: Typical applications and features
New build
Existing floor
Underfloor
SOLID
FLOOR
All floor
coverings
High mass
system
Typical ground
floor or beam
and block
construction
FLOATING
FLOOR
Over floor
SUSPENDED
FLOOR
All floor
coverings
except natural
wood / thick
laminates
OVERLAY
LITE
OVERLAY
Lightweight
floor coverings
Tiles or
natural wood
Larger areas
Wet areas
Multiple rooms
Lightweight
construction
No wet trades
required
SUSPENDED
FLOOR
MODULAR
HEATING
PANELS
All floor
coverings
All floor
coverings
Fit from above
Fit from
above / below
Traditional
joists
Traditional
heat source
Traditional
or engineered
joists
Traditional or
renewable heat
sources
07
SYSTEM SELECTION
PRODUCT SELECTOR
for UFCH & OVERLAY
Polypipe has removed the mystique from specifying the correct underfloor
heating solution for a given project and the need to calculate all of the individual
components required. Our unique
Product Selector, which is available
online at www.ufch.com and also at www.freeyourwalls.com, uses a simple 3 step
process to calculate your requirements using basic project data that you provide.
The system includes a range of over 150 pre-configured systems that contain all
the parts and components you need. Once you have determined the correct pack
for your project it can be ordered under a single item code via your merchant.
PRODUCT SELECTOR
for UFCH & OVERLAY
To use the Polypipe Product Selector you first decide

whether the project is a single room, a whole house solution,
or requires a bespoke design. You then simply input data
for each room, providing floor type and room size to calculate
the required pack.
All packs have a single order code and include all the necessary
flooring materials, pipe, distribution (manifolds, ZRU, etc.) and
water temperature controls.
To select the appropriate solution, choose from the
following options:
Room packs
Room packs are designed for single room applications: i.e. kitchens,
bathrooms, conservatories, loft conversions and extensions.
This range of underfloor heating packs contain all the flooring
and control equipment required for a single project, in solid floor,
our traditional Overlay and our NEW Overlay Lite systems.
All room packs have a maximum heat output of 100W/m2.
House packs
House packs provide you with a quick and easy way to select
and order from our range of underfloor heating products,
without the need to submit a design. The packs are designed for
solid, floating or suspended (double heat spreader plate) systems,
OverlayTM and OverlayTM Lite projects.
Packs can be applied to all new build or renovation properties
that fall into the following criteria:
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Lite floors
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08
Design services
For projects that fall outside the scope of the room packs
or house packs, Polypipe offers a fully bespoke system design
service. To utilise this facility, simply complete the enquiry form
on page 59, or at www.ufch.com, and submit your drawings
to Polypipe. You will then receive a complete design and
component list for the project.

Our revolutionary new MHP panels, designed to make underfloor
heating easier to install between ceiling joists for upper floor
suspended floor applications, have their own product selector,
which is also available online at www.ufch.com or
www.freeyourwalls.com.
DESIGN SERVICE
For projects that fall outside the scope of the room packs or house packs,
Polypipe offers a fully bespoke system design service. To utilise this facility,
simply complete the enquiry form on page 59, or at www.ufch.com, and submit
your drawings to Polypipe. You will then receive a complete design and
component list for the project.
Our comprehensive system

design service includes:
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09
POLYPIPE REGISTERED
INSTALLER NETWORK
When you select Polypipe as your underfloor heating brand of choice,

we want you to know you will receive a professional installation service.
To ensure you get this peace of mind we have developed a nationwide network
of Registered Installers who have the skills and experience to install our systems
to the highest standards.
Finding a Polypipe
Registered Installer
Finding a member of the Polypipe Registered Installer Network
couldnt be easier. Simply visit www.freeyourwalls.com and
locate the stockist finder quick link at the bottom left hand corner
of the home page.
You will now see a list of members of the Polypipe Registered

Installer Network in your area, with the closest shown first.
To find out more about a particular installer, click on
Installer Details next to their entry to display their profile.
The installers profile will be displayed, showing details of their

project expertise, areas covered, number of employees and
recent projects.
You can also check their location via the Google Maps link.
Enter your postcode, select Installer and click on the Find button
(installers can also use this function by selecting Stockist to search
for local stocking merchants).
10
Once you have selected one or more installers you can email them
directly from the website or use the displayed contact details to
get in touch by phone.
WHAT YOU CAN EXPECT

FROM YOUR INSTALLER
Polypipe Registered Installers are vetted based on their experience and expertise
in installing Polypipe Underfloor Heating Systems. Your contract is directly with
the installer, and we cannot provide any guarantee in respect of their work.
We do, however, provide extensive warranties on our products. In the unlikely
event that you experience a problem with any aspect of your experience with
a Polypipe Registered Installer you should notify us on 01709 770000.
All Polypipe Registered Installers are provided with a personalised certificate to prove their
authenticity. You should be shown this but if not, please ask to see it.
Choosing the right system

Your installer will assess your needs, based on the floor and room type, size and the way
in which you want the heating controls to operate.
Using our unique product selectors, your Polypipe Registered Installer will be able to select
exactly the right system configuration for your underfloor heating system.
Providing you with a quotation
We also provide our Registered Installer Network with a personalised quotation tool. Your installer
will be able to use the results of the needs assessment and product selection process to produce you
a tailored quotation for all aspects of your underfloor heating system, including all parts and labour.
Getting started
Once you have agreed the quotation, your installer will provide you with a contract setting out
all aspects of the project, confirming the costs and also detailing things like access requirements.
Once you have agreed a start and completion date and both signed the contract, the materials will
be ordered and your system installation will be underway.
Design service
For complex projects that may fall outside the scope of our product selector and pack system
we offer a bespoke design service. This can be accessed by your Registered Installer or self builders
can use it directly. A design service form is included in the back of this brochure.
Further information
If, at any stage, you require any further information please get in touch with our underfloor heating
team at the Doncaster address on the back cover of this brochure or call our technical support line
on 01709 770000.
Want to join the network?
If you are an installer and are interested in joining the Polypipe Registered Installer Network,
visit www.ufch.com/installers/become-an-installer.php. Complete the form and we will send
you an application pack by return.
11
GUIDE TO FLOOR COVERINGS

FOR UNDERFLOOR HEATING SYSTEMS
Underfloor heating systems will work efficiently with any floor covering, as long as it
is well insulated underneath. However, each covering has different thermal conduction
properties, and harder surfaces offer better conductivity and, therefore, better heat
output rates. The following notes provide some guidance on each type of covering.
Carpet and underlay
Stone and ceramic tiles,

marble or flagstones
Suitable for all Polypipe Underfloor Heating Systems:

The nature and thickness of the carpet underlay is fundamental
in determining good heat transfer. The most popular underlay
type is sponge with a waffle pattern moulded into the underside.
These allow good heat transfer. Felt and rubber crumb underlay
should be avoided. These products can seriously reduce the
effectiveness of an underfloor heating system, as they insulate
the floor surface and prevent heat transfer.
The TOG value of carpet and underlay should be available
from the respective manufacturer. For optimal system
performance choose an underlay with a maximum TOG value
of approximately 0.5. The maximum TOG value of carpet should
be approximately 1.0 to 1.5.
12

These types of floor finishes are usually cold underfoot.
However, with floor heating they are transformed into warm,
comfortable surfaces. Each of these finishes is essentially
brittle and it is imperative that the design of the supporting
floor structure is stable and rigid to prevent cracking.
It is recommended that flexible adhesives and grout be used.
Vinyl
Timber
Suitable for Polypipe solid floor and suspended floor systems:
Sheet vinyl is sensitive to long term exposure to heat. There are

two categories of vinyl; one is limited to constant temperatures
of around 26C and the other to 30C. Check the floor surface
temperature indicated by your vinyl supplier for compatibility
with underfloor heating. If unsure contact the Polypipe hotline
or the vinyl floor manufacturer.
Concerns regarding the effect of heat on a timber floor are

misplaced. The more important issue is the floor moisture
content. Timber floors should be laid at a moisture content
of 10-11%, which when heated will reduce to 8-9%, and cause
only a very small amount of shrinkage. The floor will re-absorb
some moisture when the heating is not operating and the
moisture content will increase to 12-13%. Further details
on installing timber floors over Polypipe Underfloor Heating
Systems can be found on page 17.
Laminate

Laminate flooring should be laid on roll type floor leveller,
rather than the rigid panel type. Movement that occurs must
be accommodated by an expansion gap around the floor deck.
13
SOLID FLOOR
Polypipe Underfloor Heating in solid or screeded floors incorporates the

unique Polypipe screeded floor panel. The lightweight plastic floor panels
nest for easy storage and carrying.
Polypipe has the perfect solution for installing underfloor
heating into solid or screeded floors. Utilising our unique
lightweight plastic floor panels, which are quick and easy
to cut to size, it is possible to fit Polypipe Underfloor Heating
into any shaped room.
The panels are laid above pre-installed insulation and the

system includes edging insulation strip to ensure maximum
performance and efficiency.
Polypipe solid floor panels form a simple grid to ensure the

fastest possible pipe laying and also provide a precise guide
for the pipe, ensuring that the minimum pipe bending
radius is achieved.
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14
Polypipe Underfloor Heating Systems can be used with

the following solid floor constructions:
Sand & cement screed (4:1 mix)
Pumped screed systems (anhydrite, etc.)
Fine or heavy concrete
Polymer modified screeds
Pre-installation requirements
The sub floor must be swept clean and be free from mortar residues.
Maximum coverage per circuit
Step 3:
The floor panels are laid over the pre-installed insulation
Key design and installation information

Maximum heat output
Recommended design flow temp
Maximum circuit length
Fitting the floor panels
and should be overlapped at the edges.
Approx. 100W/m
50C
100m (15mm pipe)
120m (18mm pipe)
12m2 at 100mm centres
30m2 at 300mm centres*
*(18mm pipe only)
2
Material requirements (approx)

Pipe
Floor plate usage
Edging insulation strip

Conduit pipe
8.2m/m2 at 100mm centres

3.3m/m2 at 300mm spacing*
*(18mm pipe only)
1 plate/m2 allowing
for cutting
(Actual 12m2/plate)
1.1m/m2
2m/circuit
Installation
NOTE: The castellation should overlap the castellation. The first

panel should be laid with the castellation edge against the wall.
Fitting insulation
Panels can be cut by simply using a saw or snips or it can
Step 1:
be overlapped to the nearest castellation fit.
In accordance with Part L of the current Building Regulations,
Floor panels should not be used at the base of the manifold
a suitable layer of insulation material should be included within
as pipes need to be closer together than the floor panels allow.
the floor construction. It is the responsibility of the architect or

builder to ensure compliance. However, in all instances insulation
Pipes around this area should be secured using pipe clips which can
must be installed beneath the underfloor heating system in order
also be used intermittently to secure the clip plate to the insulation.
to ensure that any downward heat loss does not exceed 10W/m ,
When a pumped (liquid) screed is to be used it is essential that all of
in accordance with BS EN 1264.
the panel joints are made correctly and that no panels are allowed to
Fitting the edge insulation strips
simply butt-up as this may allow the screed to penetrate below the
Step 2:
Using edge insulation strip allows the free expansion of the floor
screed. The insulation strip should be installed around all perimeter
walls and fixed constructions such as columns, steps and access doors.
Edge insulation strip is bent at 90 near to the base to form
a double sided self-adhesive strip which bonds the floor plates
to the floor insulation. Edge insulation strip should be fitted in
addition to perimeter insulation required by Building Regulations.
underfloor heating system and cause the panels to rise up. Similarly
the panels should be firmly secured around the perimeter of the room
using staples so as to prevent possible risk of the panels lifting.
Preparing the pipe
Step 4:
You will need to remove the coil from the bag, leaving the shrink
wrap on, uncoiling from centre of the coil.
Laying the pipe
Step 5:
Once you have completed laying the solid floor panels the pipe
can be fitted starting at the manifold position in line with the
pre-designed centres. 15mm and 18mm pipe can be laid
at 100mm or 200mm centres as required, 18mm pipe can
also be laid at 300mm centres.
The minimum bend radius is achieved by encircling two
castellations for a 90 bend or three castellations for a 180 bend
(see diagrams on next page).
15
90
180
Step 6:
Circuits being laid at 100mm or 200mm centres must be laid in a spiral
configuration. The first loop of pipe should be laid around the perimeter
of the area to be covered by that circuit. The next loop of this circuit
should be laid either 200mm from the first loop of pipe for 100mm
centres or 400mm from the first loop of pipe for 200mm centres.
18mm pipe installation formation

Where 300mm centre spacing is require (18mm pipe systems only)
a meander pattern can be used. The pipe simply crosses the room
from one side to the other encapsulating 3 castellations at each
return bend.
Step 7:
Continue to loop the pipe into the centre of the panels leaving
enough space to form a double return (S shape in the centre
of the loop).
Conduit pipe
A 400mm length of conduit pipe should be fitted over the underfloor
heating pipe in any situation where damage may be caused to the
pipe i.e. where the pipe passes through internal walls or doorways,
where the pipe emerges through the floor up to the manifold
or where the pipe passes through either an expansion or day joint.
Preformed long radius bends can also be used to provide a neater
solution if required.
A section of conduit pipe 400mm long should be fitted around the
heating pipe where the pipe passes through the edge insulation strip,
e.g. room to room, or through expansion joints within the floor.
Conduit pipe should also be used where the pipe leaves the floor
adjacent to the manifold. This can be threaded down the pipe
after the pipework has been installed.
Step 8:
Now work back out from the centre by filling the space between the
inwardly spiralling loop of the primary circuit ensuring the pipe is laid
at the correct spacing centres.
16
Pipe
Conduit
Insulation
Sub floor
Finishing
Expansion joint
BS EN 1264-4 recommends that an expansion joint is constructed
in stone and ceramic finished screeds for every 40m2 of floor area
at a maximum length of 8m and an aspect ratio of 2:1.
Timber floors
Many people are concerned by the effect of heat on a timber
floor, but this concern is misplaced. The important factor is
the floor moisture content.
An expansion joint is also required in long narrow areas such
Timber floors can be laid directly over the screed at a moisture
as corridors, etc.
content of 10-11% which during the heating season will reduce
The image below shows a typical arrangement where the pipes
to 8-9% and may cause a small amount shrinkage.
pass through either an expansion or a day joint. A strip of edge
The floor will re-absorb some moisture when the heating is not
insulation is used to provide the expansion capacity.
operating and the moisture content will increase to 12-13%.

Application of timber floors over solid floor systems
Where solid oak flooring is to be laid on a solid floor, joists can
be fitted at 1m centres to provide a fixing point for the boards.
Insulation, solid floor panels and pipe can be laid between
the joists and screed laid level with the top of the joists
(see diagram below).
For further information regarding floor screeding requirements for

underfloor heating systems please refer to BS8204-1 or the BISRIA
Guide: Screeds with Underfloor Heating.
Testing
Step 9:
Once the pipes circuits have been installed and pressure tested the
screed cover can be applied. Care should be taken to ensure that
the screed is tightly compacted around the pipe to ensure that no
voids are present. The system should remain under pressure (6 bar)
in order to prevent the risk of any damage being caused to the
walls of the pipe whilst the screed is being applied.
Laying the screed
Step 10:
The overall quality and thickness of a sand and cement screed
should meet the requirements of BS8204-1 which stipulates that
in domestic or light commercial applications a minimum thickness
of 65mm should be used. The thickness of alternative coverings,
such as anhydrite or polymer modified screeds, may differ depending
Individual circuits of pipe are then laid between each set of joists
with care being taken to ensure the screed is completely dry prior
to fitting the solid oak covering (see diagram below).
on construction requirements. This information should therefore

be provided by the specialist screed manufacturer/supplier.
After the screed has been laid the floor should be covered
with a membrane to retard the drying out process, particularly
in warm weather. The floor should be allowed to cure and dry
naturally until full strength is reached in accordance with relevant
British Standards and manufacturers instructions (approx 30 days
for sand and cement and concrete floors). Under no circumstances
should the underfloor heating system be used to artificially dry/
cure the screed as this could cause the screed to crack and seriously
undermine the integrity of the floor construction. Once the screed
has fully cured the underfloor heating system can be switched
on and the manifold flow temperature slowly increased up to
the calculated design temperature.
Screed
Timber floor covering
Solid floor plate
Joist at 1m spacings
17
FLOATING FLOOR
The Polypipe floating floor system is designed for use in applications where a solid
floor installation is not suitable due to structural weight limitations or where a
dry build floor option is required. Suitable for use in either new build or existing
properties, the floating floor panels can be installed directly on top of both solid
and timber floors.
The 50mm thick high density polystyrene panels have a
thermal value of 0.036W/mK and can be used to enhance
the thermal insulation requirement of the floor structure as
required under current Building Regulations. However, care
should be taken when installing floating floor panels on top
of a primary insulation layer to ensure that excessive deflection
does not occur in the final floor construction.
18
It is therefore recommended that any other insulation

materials used below the floating floor panels are of a high
density construction (100kN/m2 @ 10% compression min).
The sub floor must be swept clean and be free from mortar residues.

Maximum heat output
Approx. 70W/m2
60C
80m (15mm pipe)
100m (18mm pipe)
25.8m2 at 300mm centres
(15mm pipe)
(18mm pipe)
Laying the pipe

Step 3:
Once you have completed laying the floating floor panels and heat
spreader plates the pipe can be fitted into the pre-formed grooves of
the heat spreader plate. Start at the manifold position and use the
grooves in the floating floor panel to loop round the entire room.
The maximum circuit length is 80m using 15mm pipe or 100m
using 18mm pipe. Pipe should be laid in the pattern shown below.

Pipe
Floating floor panel
Single spreader plate

1 panel/1.4m2
3 plates/m2
Installation
Laying the floating floor panels
Step 1:
Lay the 1200 x 1200 x 50mm floating floor panels directly over
the entire floor area to be heated, ensuring the panel grooves are
aligned. The panels can be cut to fit where necessary.
Polyplumb
barrier pipe
Single heat
spreader plate
Insulated floating
floor panel
A void in the insulation is often retained around the edge of the

room to allow for distribution pipes to be laid from the room
to the manifold.
NOTE: Areas of potential high point loading, e.g. under heavy

furniture kitchen units and appliances, will require additional floor
support. Timber battens (50mm x 50mm) should be positioned
between the floating floor panels and notched to allow the
passage of pipes.
Testing
Step 4:
Once the pipe circuits have been installed and connected to
the manifold the system should be pressure tested to 6 bar
for a minimum of 1 hour before the timber floor covering is laid.
It is recommended that the system remains under pressure whilst
the flooring is laid.
Finishing
Laying the spreader plates
Step 2:
Single heat spreader plates that have pre-formed grooves at
300mm centres need to be laid on top of the floating floor panels.
These plates ensure an even spread of heat across the floor area
and hold the pipe firmly within place in the floating floor panel.
The room can then be finished by fitting 18mm or 22mm tongue and
groove sheets of chipboard, glued on the edge, over the floating floor
system. Mark the position of the pipe where door thresholds or carpet
strip are to be installed.
When laying a ceramic or stone floor covering ensure that any
deflection in the floor is minimised. It is recommended that a slip mat
or uncoupling membrane is used rather than a second layer of wood.
19
SUSPENDED FLOOR
Designed for use in timber suspended or battened floors the Polypipe suspended
floor system uses aluminium double heat spreader plates to transmit the heat
evenly across the finished floor surface.
Suitable for joist widths of 300mm to 450mm the spreader
plates are simply fixed to the joist using small nails or staples.
The pipe is then run in to the preformed grooves of the
panels which are designed to hold the pipe securely at
225mm average centres.
450mm
1000mm
A layer of insulation below the panels will ensure that almost

all of the heat generated passes up in to the room.
The Polypipe suspended floor system is also suitable for use
with sprung flooring systems as used in sports halls, etc.
20
250mm
Any other services, such as drainage or electrical wiring, should be

installed below the insulation layer.
Maximum heat output

double heat spreader plates (15mm)
The floor joists then need to be notched or drilled in accordance

with Building Regulations. This facilitates the passage of the pipe
between the joist gap to allow the entry and exit of the pipe
to and from the room.
Approx. 70W/m2
60C
80m (15mm pipe)
17m2 at 225mm average
centres
Pipe
Double heat
spreader plates
4.5m/m2
Heat spreader plates
2 plates/m2
Installation
The spreader plates can then be fixed evenly across the joists
and in accordance with your installation design.
Laying the pipe
Step 3:
Once the spreader plates have been fixed in place the pipe can
be fitted in to the grooves in a meander pattern. It is recommended
that the flow pipe from the manifold be taken to the furthest point
of the room when installing the circuit as this ensures that sufficient
heat is provided around the perimeters of the room.
Fitting insulation
Step 1:
Return
Flow
Before installing a suspended floor system it is necessary to insulate

between the joists. Polypipe recommend that a rigid polystyrene
or foam insulation material is used.
Double heat
spreader plate
Fitting the spreader plates

Step 2:
The insulation layer should fit tightly between the joists directly
below the spreader plate to ensure that the spreader plate is
supported and therefore remains in contact with the underside
of timber floor covering. This is necessary to eliminate any air
gaps or draughts between the underfloor heating system
and the floor.
Pipe
Joists notched to
accept pipe returns
Care should be taken when installing the pipe to ensure the

spreader plates are not pushed downwards and away from the
underside of the timber finished floor covering as this could lead
to potential under performance of the system.
Testing
Step 4:
Once the pipe circuits have been installed and connected to
the manifold the system should be pressure tested to 6 bar for
a minimum of 1 hour before the timber floor covering is laid.
It is recommended that the system remains under pressure whilst
the flooring is laid.
Tongue & groove flooring

Double heat
spreader plate
Ceiling
Polyplumb
barrier pipe
Polystyrene
or foam insulation
Supporting joists
21
Finishing
Laying a timber floor covering
Step 5:
Battern systems
It is strongly recommended that the timber floor covering is laid

immediately after the underfloor heating pipes have been installed
and pressure tested to eliminate any risk of damage to the system
by other trades.
Where it is not possible or desirable to drill or notch the floor joists,
Either traditional tongue & groove floorboards or 18mm/22mm

chipboard can be fitted directly on top of the spreader plates.
These can be fixed directly through the spreader plate down in to
the joists below. It is important to indicate the position of pipework
in areas where the additional fixing of items such as carpet grip rod
or door threshold strips may be fitted at a future date.
Used for spans greater than 450mm or less than 350mm.

and the floor height can be raised, spreader plates can be used.
Fitting insulation with a battern system
Step 1:
To prevent downward heat transmission, insulate between the
voids in the joists with appropriate foam insulation.
Fitting the batterns
Step 2:
Lay 75mm x 25mm battens across the existing joists at 450mm centres.
Polypipe does not recommend the application of two layers of

timber floor covering as this will severely reduce the heat output
of the underfloor heating system.
Trim the ends of the batten back to the last joist at alternative ends.
Correct application
Lay spreader plates between the battens and pin in position.
Incorrect application
Laying the pipe
Fitting the spreader plates

Step 3:
Step 4:
Lay pipe into the spreader plates in accordance with the installation
instructions on the previous page, ensuring you follow the
testing procedure.
Polyplumb
barrier pipe
Double heat
spreader plate
75mm x 25mm
battens at
450mm centres
If a manufactured timber floor is to be used then it is recommended

that this be of a suitable load bearing quality. (Please request advice
from the specialist flooring supplier).
22
Joists at spacing
greater than 450mm
or less than 350mm
Pipe only systems

The use of heat spreader plates is recommended, as they assist the
response time and heat dispersion. However, in some circumstances,
simply laying pipe in an air void between foil faced reflective
insulation and the underside of the floorboard will be adequate.
The space between the top of the insulation and the underside
of the floor deck should be kept to a minimum (20mm) and care
should be taken to ensure that the insulation is sealed at the
edges and ends.
Pipe only applications are suitable in areas where the heating response
is less important, e.g. bedrooms, and is not recommended in living
spaces or over unheated spaces, e.g. rooms above garages.
Polyplumb
barrier pipe
Pipe clip
25mm thick dry

mix screed
Insulation
Tongue and
groove flooring
Joists
Joists at spacing
greater than
450mm or less
than 350mm
Enhancing pipe only systems

The effectiveness of pipe only systems can be enhanced by laying
a weak (1:6) dry mix screed approximately 25mm thick between
the joists.
In order to apply this, extra support may be required below the
insulation. Although pipe only systems are designed to operate
at 60C flow temperature, the flow temperature may be reduced
in these circumstances.
Before this system is considered it is suggested you consult
a structural engineer to confirm its suitability.
23
MODULAR HEATING PANELS (MHP)
A new concept
in underfloor heating
Modular Heating Panels* are an exciting new product concept from Polypipe
that enable quick and simple installation of underfloor heating into suspended
floors in both new build and renovation projects.
Installing underfloor heating into upper floors can be
challenging, even in new build projects. Most conventional
underfloor heating systems comprise a single section of pipe,
housed or placed within another part of the system structure,
such as floor panels, which are cut to size on site. This works
fine as there are no interruptions to the laying of the pipe.
In suspended floor installations however, the pipe, plates and
insulation have to fit within an obvious obstruction:
the supporting floor joists. It is working around the joists,
and avoiding other services, that has often led to underfloor
heating being avoided in upper floors.
As the name suggests, a Modular Heating Panel (MHP)

is a pre-configured solution, where all of the floor heating
system components are supplied fitted within complete panels,
which are simply fitted and connected together on site.
Thanks to MHP it is now possible to fit panels quickly
into the existing joist voids and connect them to a standard
heat source.
MHP works with both traditional and engineered joists
and can be fitted from above or below.
*Patent pending.
24
Maximising heat efficiency

Due to their high output at relatively low flow temperatures, Modular Heating Panels are ideal for maximising heat efficiency
and lowering energy consumption. In most installations it is not necessary to cover the entire floor area. MHP panels work like
underfloor radiators, applying enough heat to only those areas of the floor that need to be heated and using just enough
of them to maintain a suitable room temperature.
For a room temperature of 20C, for example, only 80% floor coverage is required to provide 70W/m2 or around 60% for 50W/m2.
This unique product benefit also makes MHP an ideal solution when using heat pumps.
The flexibility of panel placement provided by MHP means that floor areas to be covered by items such as built-in wardrobes
or baths and shower cubicles can be avoided without detriment to the overall heating provision.
Product options
MHP is available in 6 panel sizes comprising 2 lengths and 3 widths:
MHP available lengths: 1.3m and 2.0m
MHP available widths:
330mm, 380mm and 490mm
Each MHP panel contains pre-installed pipe circuitry, 30mm

of insulation, and is covered in heat diffusing foil. Pipe circuitry
is based on 10mm diameter pipe. A 500mm length of pipe
extends from each panel allowing connection to the flow and
return pipe work from an underfloor heating manifold.
MHP panels are easily installed from either above or below
and suit the joist widths of both composite I beam joists and
traditional timber joists. Up to 3 MHP panels can be connected
together in series and the recommended maximum room area
per circuit is 20m2.
Heat diffusion foil
30mm insulation
10mm pipe circuit
25
Designing your layout

Designing the ideal room layout for an MHP installation
and selecting the required products couldnt be simpler.
Follow the steps below or use the online product selector tool
at www.ufch.com or www.freeyourwalls.com.
Select panel width
Step 1:
The spacing of joists and the available gap will determine
which MHP panel width will be most suitable for each project.
Select the MHP width nearest to the gap width, ensuring that
this does not encroach on the space for other services.
The 490mm width panel will normally be fitted in the wider joist
spacing used by composite joists and I beams.
Select panel length
Step 2:
The span of the joists in each room will determine which MHP panel
length should be selected. The span is defined as the free space
from wall to wall that needs to remain uninterrupted by trimmers
or other services. Ideally, install MHP panels prior to other services
whenever possible.
Use the table below as a quick guide to suitable arrangements
of MHP panels leaving a 200mm gap for pipe connections.
Arrangement
Span
1 x 1.3m Panel
1.4m to 2.2m
1 x 2.0m Panel
2.2m to 2.8m
2 x 1.3m Panels
2.8m to 3.5m
1 x 1.3m Panel +
1 x 2.0m Panel
3.5m to 4.2m
2 x 2.0m Panels
4.2m to 5.0m
26
Planning your room arrangement

Step 3:
Calculating the amount of floor area to be covered by MHP will be
based on the required heat output (see our heat output tables on
page 29) and will take into account areas of the floor that do not
require heating, such as under built-in wardrobes, baths and
shower cubicles.
The diagram below illustrates a typical layout that
might be considered.
27
Planning
Installation from below
Before installing MHP panels ensure you have planned out the
When installing MHP panels from below you will need to mark
positioning of the required panels avoiding all other services such
out the positioning of the panels to ensure you have them
as electrics, gas and water supply.
situated in the correct places for heating the room above.
You will not need to do any specific preparation for the
Once you have checked the marked out positioning, the MHP
installation in a new build property as there will be no ceilings
panels can be slotted into place and fixed to the underside
or floors in place.
of the floor using 1 x 8 woodscrews with M6 x 30 dia washers.
For existing room refurbishment, you will need to take up your

floor if fitting from above or take down the ceiling if fitting from
below. Ensure that the area where the MHP panels are to be
positioned is free from any debris before commencing installation.
It is advisable to use 6 fixings per panel ensuring you avoid the

moulded pipe marking on the underside of the panel and fix
each panel securely.
IMPORTANT NOTE: Polystyrene can cause deterioration to cable
insulation when it comes into direct contact with it.
Installation
Always ensure that electrical cables are not in physical contact

with the MHP panels using tape or a polythene strip.
Installation from above

To install MHP panels from above simply fit support bearers to
each side of the joists. These support bearers should be positioned
30mm from the top of the joist and the MHP panel is then simply
laid on to these supports.
Finishing
Once you have connected your system up to the manifold and
tested it you can then finish the room by fitting the floor or ceiling
in the normal way depending on whether you have installed MHP
from above or below.
Testing
Where possible installations should be tested at 20C to
18 bar pressure. Any installations once connected to the manifold
have a maximum test pressure of 6 bar.
28
Panel layouts
1 Panel layout
2 Panel layout
6
15mm Polypipe flow and return

connections to manifold
1
Part No: PB010

10mm
Straight Coupling
15mm Polypipe flow and return

connections to manifold
3
Part No: PB1115

15mm - 10mm
Reduced Branch Tee
Part No: PB015

15mm
Straight Coupling
+
Part No: PB1815
15mm - 10mm
Socket Reducer
Part No: PB010

10mm
Straight Coupling
Part No: PB1115

15mm - 10mm
Reduced Branch Tee
+
Part No: PB1815
15mm - 10mm
Socket Reducer
Part No: PB1115
15mm - 10mm
Reduced Branch Tee
+
Part No: PB1215
15mm - 10mm
Reduced Branch
Spigot Tee
Product information
Heat output
Product
Code
No of panels
per pack
MHP 490mm (W) x 2.0m (L)
MHP49020
MHP 490mm (W) x 1.3m (L)
MHP49013
MHP 380mm (W) x 2.0m (L)
MHP38020
MHP 380mm (W) x 1.3m (L)

MHP 330mm (W) x 2.0m (L)
MHP 330mm (W) x 1.3m (L)
Maximum floor area for flow and return 20m2

Room at 20C
Heat output per panel
Flow
temp (C)
Av. floor
temp (C)
MHP49020 MHP49013 MHP38020 MHP38013 MHP33020 MHP33013

(W)
(W)
(W)
(W)
(W)
(W)
40
25.0
63
42
49
33
42
29
MHP38013
45
25.8
75
50
58
39
50
34
MHP33020
50
26.6
86
58
67
45
58
39
MHP33013
55
28.9
120
80
93
62
80
53
60
30.8
147
99
114
77
98
66
Approximate coverage required:

For 70W/m2 room
= 80% coverage
For 50W/m2 room
= 60% coverage
Connect up to 3 panels in series

Maximum coverage per circuit 20m2
29
TM
OVERLAY
Underfloor heating
that fits over
existing floors
Overlay is a registered trademark of Polypipe Ltd.

Overlay patent no GB2388181.
30
Overlay is a unique low profile floor

heating system ideal for both renovation
and new build projects.
TM
Installed over the existing floor and only 18mm in depth, Overlay allows
underfloor heating to be installed where traditional underfloor systems would
either require expensive excavation or would require the floor to be raised
to an unacceptable level.
The Overlay system is available in 2 panel types to allow for installation
to all build types and floor coverings.
Overlay floor panel is a fibrous panel used for heavyweight floor coverings
such as ceramics, or where the floor covering needs to be secured directly to
the panel, e.g. solid wood.
Overlay Lite is a high compressive strength, lightweight insulated panel
used for lightweight floor coverings, e.g. laminate, engineered wood and carpet.
Due to its ease of handling and cutting it is also more suitable for larger areas
and multiple room installations.
Overlay systems use a 12mm pipe at 150mm pipe centres and provide
excellent response times and heat output compared with traditional built
in underfloor heating solutions and are therefore ideal for both traditional
heating systems and low temperature renewable systems.
31
End return
Suitable for:
tiles, hard wood,
carpet or vinyl**
Cover board
12mm pipe circuit
18mm floor panel
600mm x 800mm
Overlay
floor panel
TM
Overlay
Fits over concrete

or floorboards
Choosing
your Overlay
floor panel
Floor finish
Cover detail*
Ceramic tiles
Overlay accommodates all types of project

and floor coverings and the only choice, is that
of which panel will be most appropriate for the
installation. Both Overlay and Overlay Lite can
be used for the majority of projects, however the
choice of Overlay is determined by floor covering
selection. Overlay and Overlay Lite can be
used as appropriate in the same project.
The more structural nature of Overlay however
makes it ideal for direct tiling or application of
floor finishes which need to be fixed or screwed
to the panel.
32
OverlayTM
Direct
Flexible grout and adhesive
Optional cover layer
10mm Ply / 6mm MDF
Fix ply using OverlayTM glue plus

screw where necessary
Optional cover layer
6mm Hardie backer board
Use tile adhesive conforming

with EN12004-Type C
Solid wood, engineered

wood & laminate
Direct
Secret fixing to OverlayTM floor

panel through T&G
Carpet - with cover layer
10mm Ply / 6mm MDF

6mm Hardie backer board
Use tile adhesive conforming

with EN12004-Type C
10mm Ply / 10mm MDF

or
Vinyl** - with cover layer
Fixing method
Cover board thickness indicated are minimum. The maximum thickness of any cover
board is 18mm. Sheet products other than those shown may also be suitable.
** If using Karndean or Amtico type flooring, refer to manufacturers for suitable

floor finish.
End return
Engineered wood,
laminate or carpet
Cover board
Heat diffusion foil
12mm pipe circuit
18mm floor panel
600mm x 1244mm
Overlay Lite
floor panel
TM
Overlay Lite
Fits over concrete
or floorboards
Overlay Lite is the ideal solution for laminate and engineered wood
floors which should be laid directly over the system.
Overlay Lite products are easy to install making it ideal for larger
floor areas.
Floor finish
OverlayTM Lite
Cover detail*
Engineered wood
Laminate
Carpet - with cover layer
Fixing method
Direct
Direct
10mm Ply / 6mm MDF
Glue with contact adhesive

Maximum heat output
Approx. 100W/m2
45 to 50C
80m
12m2

Overlay floor panel
Coverage 0.48m2
Overlay Lite floor panel
Coverage 0.75m2
Pipe
7m length/m2
End returns
1 return bend per floor panel
12mm x 80m coil of pipe
1 coil per circuit
15mm x 12mm adaptors & stiffeners
1 pack per circuit
Cover board thickness indicated are minimum. The maximum thickness of any cover
board is 18mm. Sheet products other than those shown may also be suitable.
33
Planning
Example of squaring off an irregular room plan
Planning the Overlay system beforehand will save time during

installation and minimise product waste.
The direction the pipe runs to and from the ZRU or manifold
and use of the return bends will be the main considerations.
The end returns have a flat panel which forms a channel to allow
the routing of pipes to multiple circuits in the room. This can be
removed where necessary.
Floor areas which dont require pipe circuitry, e.g. beneath kitchen
cupboards or sanitary ware, can be blanked using 18mm plywood
or chipboard. This will make better use of the Overlay products.
This can also be used to square off rooms with irregular walls.
Example of blanking on kitchen plan
Room layouts
The following diagrams show some examples of room shapes,
pipe requirements and interruptions (pillars, hearths, etc.)
which need to be accommodated.
Room with 2 circuits
End return
with panel
removed
Example of blanking in a bathroom
End return
Room with pillars/hearth
End return
with panel
removed
End return
34
Pipe layouts in multiple room installations

Multiple room installations require several circuits and careful
planning is required close to the manifold to allow for all pipes
to be accommodated.
1
Wherever possible pipes can simply go through, rather than
round, walls to eliminate the number of pipes requiring access

through the entrance of the manifold cupboard.
2
Alternatively leave voids at the edge of the panels.
Using return bends as routers or
using supply pipes
to heat corridors are all ways of managing the installation

in this area.
35
Overlay
for heavyweight floor coverings
Installation
Laying end returns
Step 1:
Start by fixing two end returns to the floor in a corner of the room.
Laying the panels

Step 2:
Clean down the edges of the panel and apply a 3mm bead
of adhesive to the top edge. Then lay it, ensuring you line up
the grooves in the panel with those in the end returns.
Continue to lay the first row of panels gluing each joint
to achieve a secure installation.
Remove the pipe panel if not required as per your floor plan.
This should be done by using suitable screws in the screw holes
of the end return panels when fixing to a wood floor, or by using
Overlay adhesive (code PB777) to bond the end returns
to solid floors.
Return bends with pipe
plate removed
First panel
Room wall
Return bends
with pipe plate
remaining
First row
Subsequent row
When gluing the ends, ensure there is no residual glue in the pipe
grooves and use short lengths of pipe to help with panel alignment.
36
Step 3:
When you get close to end of the first row fit two end returns
against the wall as in step 1 and if necessary cut an Overlay floor
panel to fit and complete the first row.
Cutting the panels
Laying the pipe

Step 5:
Starting from your manifold position and allowing enough pipe
for connections lay the pipe into the grooves of the Overlay floor
panel in accordance with your plan.
Panels can be cut using a hand saw or jigsaw set at a low speed.
Cutting these panels will generate dust so should either be done
outside or in a ventilated room. Ensure you wear a particle mask.
Finishing
Step 4:
Once you have completed the first row begin the process again,
gluing the ends and sides of each panel, staggering the panels
in the second row in a brickwork pattern and continue until the
room is complete.
Using a floor filler/grout fill any gaps and voids, and fill around
any pipework.
Tiles can be laid directly on to the Overlay floor panels
or a cover board can be fitted prior to tiling.
When tiling directly over Overlay floor panels, use a sealant
with flexible adhesive and grout.
If fitting solid wood floors they can be discretely screwed through
the tongue and groove directly into the Overlay floor panel,
avoiding pipe circuitry, to minimise movement in the floor covering.
Example showing 10mm plywood cover
37
Overlay Lite
for lightweight floor coverings
Laying the panels

Step 2:
Installation
Lay the panel ensuring you line up the grooves in the panel with
Laying end returns
using short lengths of pipe to help with panel alignment.
those in the end returns, then continue to lay the first row of panels
Step 1:
Start by fixing two end returns to the floor in a corner of the room.
Remove the pipe panel if not required as per your floor plan.
This should be done by using suitable screws in the screw holes
of the end return panels when fixing to a wood floor or by using
Overlay adhesive (code PB777) to bond the end returns to
solid floors.
Return bends with pipe
plate removed
Step 3:
When you get close to end of the first row fit two end returns
against the wall as in step 1 and if necessary cut an Overlay
Lite floor panel to fit and complete the first row.
First panel
Cutting the panels
Room wall
Panels can be cut using a sharp knife and a metal rule.
Return bends
with pipe plate
remaining
First row
38
Subsequent row
Step 4:
Laying the pipe
Once you have completed the first row begin the process again with
Step 7:
the second row, staggering the panels in a brickwork pattern.
Starting from your manifold position and, allowing enough pipe for
connections, lay the pipe into the grooves of the Overlay Lite floor
panel in accordance with your plan.
Step 5:
Use the self adhesive foil tape along the long panel joints to securely
fix the panels to the adjacent row.
Step 8:
Once you have finished laying the pipe use the self adhesive foil tape
to secure the panels and pipe, running across all the panel joints, and
do the same across the joints where the panels meet the end returns.
Step 6:
Now continue this process, completing the whole room.
Finishing
Laminate and engineered wood can be laid directly over Overlay
Lite floor panels. Where carpet is being fitted, first fix a 6mm MDF
or 10mm plywood using a contact adhesive, then continue to lay the
floor covering as normal. It is advisable to mark out pipe positioning
to avoid stapling pipes when fitting carpets.
39
CONNECTING TO HEAT SOURCE
Polypipe Underfloor Heating Systems are designed to be connected

to a variety of heat source options.
Gas and oil boilers
Heat pumps
When connecting to any heat source it is essential that the

underfloor heating manifold(s) are fed directly from the heat
source with a dedicated set of flow and return primaries, to
enable total independent hydraulic control of the underfloor
heating system. Under no circumstances should this primary
feed be connected into any other heating pipework, such as
radiator or domestic hot water primary circuits.
Polypipe Underfloor Heating Systems are ideal for use with heat
pump systems due to the lower operating temperatures that
are produced by this type of heat source. However, to provide
temperature limitation protection and sufficient system flow
rate for the underfloor heating installation, it is recommended
to fit the manual blending valve and pump pack as supplied
by Polypipe Building Products Ltd.
To provide independent hydraulic control of the entire system, it is

important that the installation is designed as an S Plan or S Plan Plus
configuration which allows for a two port zone valve to be fitted to all
primary circuits and at each underfloor heating manifold (see diagram).
It is the responsibility of the system design/installer to ensure that

the heating circulation pump supplied with the heat pump,
and any associated primary pipework, is capable of providing
sufficient duty to meet the demand up to the underfloor heating
manifold assembly. This also applies if a buffer tank has been
fitted to the heat pump installation.
IMPORTANT NOTE: Under no circumstances should a Polypipe

Underfloor Heating System be connected in to a Y Plan (flow share)
system as this will result in serious system operating problems.
To ensure that the correct operating temperatures and system flow
rates are maintained for the underfloor heating system, the manifold(s)
should be fitted with a manual blending valve and circulating pump
(see section Water temperature controls). However, it is the
responsibility of the designer/installer to ensure that the boiler and
system pump are capable of providing sufficient outputs in order
to meet the requirements of the primary pipework, the underfloor
heating system and any other equipment installed in the system.
Typical S Plan Plus configuration
A buffer tank or thermal store is often fitted between the heat

pump and the underfloor heating system. This is to provide
a sufficient quantity of stored water to feed the underfloor heating
system and to ensure that the heat pump flow rates are maintained,
thereby reducing the risk of cycling. By using a buffer tank
installation there is no need to use open circuits at the underfloor
heating manifold, therefore allowing individual room control.
The Underfloor Heating Manufacturers
Association (UHMA) do not recommended
that the underfloor heating system be used
as an open circuit, to provide the flow rate requirement for
the heat pump installation, as this could lead to problems
with system control at a later date. For further information
regarding the installation of the system please contact the
Polypipe Technical Hotline on 01709 770000.
Solid fuel and wood burners

Typical S Plan Plus configuration via thermal store
Under no circumstances should a Polypipe Underfloor Heating

System be connected directly to this type of heat source.
Instead, the burner should be used to provide indirect heat via
a thermal store or similar neutraliser. The low temperature feed
from this store can then be pumped to the underfloor heating
manifold, as with a heat pump installation.
Please seek specialist advice from the heat source supplier
or manufacturer before commencing the installation.
40
MANIFOLDS
Manifolds are common to all systems above 30m2, independent of the underfloor heating
system. Manifolds are supplied complete and fixed to the wall mounting bracket.
The manifold comes complete with a drain and air vent assembly,
which can be positioned on either end of the manifold. Isolation
valves are supplied separately for the supply end of each manifold.
The bottom manifold is the flow and the top manifold is the
return. Each manifold port comes complete with a Polyplumb
push fit connection. Pipes are connected to manifolds by
inserting a pipe stiffener into the pipe and simply push fitting
the pipe into the port.
The flow meter on each flow port of the manifold provides
a visual indication of the flow through each circuit.
Both manual and lockshield balancing can be undertaken
by either using the blue cap on the return manifold for manual
adjustment, or removing the blue cap and adjusting using the
key supplied with each manifold.
62
80
50
Preparing and installing

the manifold
Outlets
L (mm)
2
190
3
245
4
300
5
355
6
410
7
465
Remove the manifold from the box and arrange the flow and
return manifolds to ensure that the inlets/outlets are pointing
downwards. Remove the air vent and drain valve from the
packaging and connect to the desired end of the manifold.
Outlets
L (mm)
9
575
10
630
11
685
12
740
13
795
14
850
Dimension
A (mm)
B (mm)
C (mm)
Ensure the seal is correctly in place before tightening the

compression nut by hand on to the manifold. To ensure
the valves are securely connected to the manifold, use a
38mm spanner or wrench to tighten by a further half turn.
8
520
1
39
64
86
Remove the isolating valves (supplied separately) from the packaging

and connect to the opposite end of the manifold. As with
the air vent and drain valve, ensure the seal is correctly in
place before tightening the compression nut by hand on to
the manifold. Then, complete the connection by using a 38mm
spanner or wrench to tighten by a further half turn.
Fix the manifold horizontally in the desired position utilising
both screw holes on each bracket.
B
C
The manifold is now in position and ready to be connected

to the mains from the boiler and the underfloor heating pipe
circuits. A set of self adhesive stickers are included to help
identify each circuit on the manifold. The stickers also provide
the opportunity to record the number of turns required for the
correct flow rate through each circuit (for further information
on testing and commissioning see pages 52 and 53).
41
WATER TEMPERATURE CONTROLS
The temperature of water required in underfloor heating systems is less than

that required for radiators or stored hot water. If these other services are
connected to the same boiler it will be necessary to control the water
temperature using one of the Polypipe water temperature control units.
Pre assembled UFH

control packs
Alpha UFH control pack (PB970020) Modulating pump version
Compact UFH control pack (PB970016) Standard pump version
These pump units control water temperatures between
30C and 60C. The inclusion of these pump units ensure
that the flow to the underfloor heating circuits is automatically
adjusted to allow for the opening and closing of actuators
when individual room temperature is required. The unit is
suitable for manifolds demanding up to 15kW heat load.
The thermostatic mixing control is factory set to provide 45C
mixed water to the heating manifold. The mixed water flow
temperature can be adjusted and locked very simply to suit
the design flow temperature within the range of 30-60C.
These pump units are fitted directly to the manifold at either
end by turning the pump through 180. An additional zone
valve is required when using an Alpha pump unit supplied by
other manufacturers.
42
Site assembled UFH

control pack (PB970015)
Underfloor heating control pack (PB970015)
The pack controls water temperatures between 35C and 60C,
and incorporates a fixed head pump and a 22mm 2-port zone
valve, which is suitable for manifolds demanding up to 15kW heat
load. The set temperature of the water is shown on the wheel head.
Manifold bends (PB12735)

The water temperature control packs can be fitted at 90 to
the manifold using the manifold bends. This allows manifolds
and pump units to be corner mounted where space is at a
premium, e.g. in an understairs cupboard.
The control pack is fitted directly to the manifold at either end,

as both left hand and right hand connector bends are supplied
with the unit.
Dimensions of assembled unit
155mm
110mm
50mm
30mm
Manifold bend installed with underfloor heating control pack can also be used with Alpha UFH control pack.
130mm
40mm
NOTE: The valves shown on this diagram are purchased

separately and not supplied with the unit.
43
ROOM TEMPERATURE CONTROLS
A comprehensive range of Polypipe room temperature controls are available

to compliment Polypipe Underfloor Heating Systems, designed to maximise
comfort and efficiency of the system, whilst providing ease of use to occupants.
They provide perfect control solution for underfloor heating systems and are
available in both Wired and Radio Frequency (RF) options.
Controlling underfloor heating

Whilst regulations permit all of our control systems to be
used with any of our floor types we would recommend that
some control systems are more appropriate than others due
to floor type, use of space, type of project, and the user
or occupant. All our control systems allow individual room
temperature control as a minimum with our programmable
controls providing independent time and temperature control
of each room.
Time and temperature control of each room
(Programmable Room Thermostats)
This control method uses programmable room thermostats
and allows each room to be individually programmed ensuring
that rooms are heated to the level required, when required.
Each room can be programmed differently for each day of
the week ensuring that rooms are only heated when occupied.
This option is available in both Wired and RF ranges.
This control method also provides setback and optimum
start functions:
U -iL>Vq/ii>iiVVi`]
a minimum temperature level is pre set by the user.
This is important when using high mass systems such as
the Polypipe solid floor system. The response time of the
system is slower than that of other Polypipe systems and we
therefore recommend that this method be used to ensure
that rooms are heated to an appropriate level when required
U ">q/vV>ii>
learn the heat up profile of each room individually.
This allows the user to set a warm by time rather than
an on time ensuring that the room is always to temperature
by the time required
44
Temperature control of each room

(Time Clocks and Room Thermostats)
This method allows the user to set the on/off time for all
rooms served by a single manifold and provides individual
room temperature control. This option is most suited for low
mass systems that have a quicker response e.g. OverlayTM,
where setback is not required.
The room temperature control can either be provided
by means of a Digital Display Thermostat (Digi stat) or
traditional Dial type stat. All options are available in both
Wired and RF ranges.
Room temperature control operation
In all cases the control setup will consist of room thermostats,
a master wiring centre, slave units (for multiple room control)
a zone valve and actuators.
In essence the operation is the same where the room demand
is sensed by the room thermostat. This then opens an actuator
on each circuit of pipe supplying the room and also opens the
zone valve serving the manifold. When the zone valve is open
the underfloor pump is activated and a 230V or Volt free signal
is sent to the boiler for firing.
Schematic switching diagram - relays not shown
Room
thermostat
room 1
demand
Room
thermostat
room 2
satisfied
Boiler
on
Zone
valve open
UFH Pump
on
Actuator
room 1
open
Actuator
room 2
closed
Circuit
room 1 open
Circuit
room 2 closed
Building regulations
requirements
U }iii>ì}iii}>i>
In order to comply with the room temperature control
U -iL>V}>>LiV>iiViììi`
greater than 70% of the total area, individual room controls

are not required
requirements for domestic buildings under the Buildings
floors are thicker than 65mm*
Regulations (Part L). The following should be adhered to
* Although the recommended thickness of Polypipe solid floor system is 65mm

we recommend that programmable stats are used on this floor type.
as a minimum.
NOTE: this applies to installations connected to both domestic
gas boilers and heat pumps
U >V`Liìì>
programmable thermostat. Where 2 rooms have a similar
function e.g. kitchen and utility room It may be possible to
use one thermostat to control both rooms
Polypipe room temperature controls selection

All control options provide temperature control to each room
as required, a summary of the options is shown below.
Control type
Time control
Per room
Display / operation
Per manifold
Digital
Programmable
Wired Thermostats
Programmable
RF Thermostats
Dial
Connectivity
Wired
Wireless RF
Digital Wired
Thermostats
Digital RF
Thermostats
Dial Wired
Thermostats
Dial RF
Thermostats
45
Control equipment
- Room Thermostats
Dial Room Thermostat (PBRS) and RF version (PBRS RF)
Programmable Room Thermostats (PBPRP)
This thermostat is used in conjunction with the time clock
and RF version (PBPRPS RF)
(PB2CTC or PB4CTC RF). All are provided with a wet room
The programmable room thermostats offer
sensor connection.
This traditional dial type room thermostat combines accurate

comfort control with a familiar dial type user operation.
the following outstanding features:

U `>}>}
U -iL>V>`>
U iV
U `>>`Lì
U ii}>vi>}>}
U -iiìwi`}>}
U Wet room sensor connection
Time Clocks 2 Zone Clock (PB2CTC)

and 4 Zone Clock RF (PB4CTC RF)
The digital time clocks are used in conjunction with digital and
dial thermostats. The time clocks offer the following features:
U `>}>}
U i>v`Viiì*
/
U {i{>v`Vi,* {
/
,i
U iV
U `>>`Lì
Digital Room Thermostats (PBDIG)
U ii}>vi>}>}
and RF version (PBDIG RF)
U -iiìwi`}>}
The digital room thermostat provides simple temperature
U i>v>ViV
control with a large easy to read digital display. Used in

conjunction with the time clock (PB2CTC or PB4CTC RF) they
provide stylish and accurate room control. All are provided
with a wet room sensor connection.
46
Wiring centres
Ancillary items
Single Zone Master Unit (PB1ZM)
Wet Room Sensors (PB23020)
and RF version (PB2ZM RF)
Where temperature control needs to be provided to a bathroom

or other wet area, this sensor is installed in the wet area and
connected to any of the room thermostats which can be installed
in an adjacent dry area.
The sensor is supplied with 3m of cable which can be extended
to a maximum of 10m providing NTC 10k cable is used.
The sensor can be removed from the housing and used as a floor
sensor where sensitive floor coverings are used.
The master wiring centres enable simple wiring and switching of

all common components in the system. For multiple zone systems
this is used in conjunction with the slave units. Neon indicators
show the status of the connections.
These wiring centres allow connection of:
U i>}>]1]i>i>`VV
U 6>`viiLiV}ViV
U
iVv>}ii>iì
and 2 room thermostats in the RF version
Single RF Receiver (PBREC RF)

The receiver accepts a signal from any RF Thermostat or clock
and allows RF clocks and RF stats to be used with wired master
or slave units.
U *}ViVi>iviiV
Slave Units - 4 Zone Slave (PB4ZS and 6 Zone Slave PB6ZS)

and 4 Zone RF version (PB4ZS RF)
These units are always used in conjunction with the master unit
and provide simple wiring of actuators and room thermostats for
multiple zone control. Neon indicators show room activation.
47
Wiring centres - for wired controls

Single Zone Master (PB1ZM):
When used in a single zone application the master wiring centre (PB1ZM) provides the wiring connections for the underfloor heating pump,
two-port zone valve, boiler switched live connection (230V or volt free) and the programmable room thermostat.
Wiring details for Single Zone Master Unit (PB1ZM)
RF Room Stat Options

PBPRPS RF
PBDIG RF
PBRS RF
Hard Wired
Room Stat Options
PBPRP
PBDIG
PBRS
Remove Link if
Time Clock Fitted
230v
Supply
L N E
E N L
OR
RF Clock
PB4CTC RF
NC
End Switch
2 Port Zone Valve
RF Receiver
230v
Supply
L N
Note:
Only use this
connection when
using a Single
Room Thermostat.
If using Slave do
NOT use.
Power Supply
L N
C 1
Remove Link if
Zone Valve Fitted
Clock
C 1
RF Receiver
OR
Volt Free
Contact
Boiler
230v S/L
Connection
Boiler
UFH Pump
Time Clock
Not fitted when using
programmable stats
4 & 6 Zone Slave Unit (PB4ZS and PB6ZS):

Where multiple room control is required the master wiring centre should be used in conjunction with the 4 or 6 zone slave units PB4ZS
or PB6ZS. The slave units provide wiring connections for the programmable room thermostats and the manifold 2-wire actuators.
Up to 4 actuators can be connected per zone.
The 4 and 6 zone slave units (PB4ZS & PB6ZS), must be used in conjunction with
the Single Zone Master (PB1ZM). The slave unit simply plugs into the master unit
to provide additional connections for the required number of control zones.
Wiring details for 4 & 6 Zone Slave Unit (PB4ZS and PB6ZS)
Hard Wired
Room Stat Options
PBPRP
PBDIG
PBRS
RF Room Stat Options

PBPRPS RF
PBDIG RF
PBRS RF
RF Receiver
OR
230v
Supply
2 Wire Actuators
PB00401, Max
4 per zone
48
1 Zone shown only

Repeat for further Zones
Must be used with Master Unit
Wiring centres - for RF controls

2 Zone Master Unit RF (PB2ZM RF):
The PB2ZM RF master unit provides electrical connections for the UFH pump, motorised valve, actuators, boiler
and up to 2 control zones.
Wiring details for 2 Zone Master Unit RF (PB2ZM RF)
PB4CTCRF Four
Channel RF Time Clock
(if using PBDIG RF or PBRS RF
type room thermostats)
Remove Link if
Time Clock Fitted
Room Thermostat Options

PBDIG RF
PBRS RF
Max 2
PBPRPS RF
Remove Link if
Zone Valve Fitted
OK
L N E
230VAC
Power Supply
PB2CTC 2 Channel
Hard Wired Time
Clock option
2 Port Zone Valve
Pump
Zone 1
(if using PBDIG RF

or PBRS RF type
room thermostats)
230V AC
Boiler Connection
L N E
2 Wire Actuators
PB00401, Max
4 per zone
Zone 2
For further zones

use the PB4ZS RF
Volt Free
Boiler Connection
4 Zone Slave Unit RF (PB4ZS RF):

Where more than 2 zones of control are required, the PB4ZS RF is used with the PB2ZM RF master unit above to provide up to 4
additional control zones. The unit provides wiring for up to 4 actuators per zone and 4 built in zone receivers.
OK
Wiring details for 4 Zone Slave Unit RF (PB4ZS RF)
Room Thermostat Options

PBPRPS RF
PBDIG RF
Max 4
PBRS RF
2 Wire Actuators
PB00401, Max
4 per zone
1 Zone shown only

Repeat for further Zones
Must be used with Master Unit
49
SINGLE ROOM APPLICATIONS
All Polypipe Underfloor Heating Systems can be installed

in single rooms and connected to the existing wet heating
system. In rooms greater than 30m2 it is recommended that
the connection to the underfloor heating system is made via
a manifold and installed in the same way as a multiple room
installation with single area control.
Connections to the existing

wet heating system
Areas of up to 30m2 should use the Polypipe Zonal Regulation

Unit (ZRU) as this provides a simpler method of connecting
into the existing system, without the need for expensive
hydraulic or electrical alterations.
A small number of boilers can be affected hydraulically

by the use of a second pump in the system.
200mm
Thermostatic
blending valve
Pipe
thermostat
260mm
Pump
The pipe work connections to the ZRU are for 15mm diameter
pipe and the ZRU should not be connected to the system from
any pipe smaller than 15mm.
NOTE: Check with the boiler manufacturer to ensure

compatibility with the ZRU.
The preferred connection to the ZRU is to the main flow and
return pipe work of a 2 pipe system, i.e typically from 22mm
distribution pipe work. However it can also be connected to
the nearest existing radiator.
Pipe connection to operate underfloor heating
at the same time as the boiler
Connection
from main
distribution
pipe work
Pump speed
control
Heating
return
Tees and spigot
elbows for
second circuit
if required
Heating
flow
Underfloor
heating flow
Underfloor
heating return
The ZRU simply connects to the existing heating

system providing:
U 7>iii>iVc
c
for the underfloor heating

U /iViVy>iviìyi>}
U >V>Vi>`vv>>L
pipe thermostat
U }ViVv>i>
or wireless sensor
U
>LiViViì>iiìyi>i`
room independently with the existing system
Connection
from nearest
radiator
The diagram above shows the ZRU connected to operate with the
boiler on / off firing. Due to the quick response of low mass systems
(Overlay, Overlay Lite, MHP, etc) this is likely to be suitable.
Using this method for solid floor installations may require the
timings of the existing heating to be altered to allow the
underfloor heating system to reach comfort temperature.
If the room is to be controlled independently of the existing
central heating system, a zone valve needs to be installed
between the boiler and the ZRU.
Pipe connection to operate ZRU / underfloor
heating independently
Programmable room thermostat
Zone
valve to
underfloor
heating
Zone valve
to radiator, etc
50
Connection
from main
distribution
pipe work
The pipe supplying the ZRU should be connected to the main boiler
distribution pipe prior to the connection of other zone valves.
A programmable room thermostat can be used to operate the
zone valve and, in turn, the end switch within the zone valve
can provide a signal to fire the boiler.
Filling the underfloor

heating system
Use the heating system to fill the underfloor heating circuits
and ZRU.
Blanking off the ZRU
Installation of ZRU
Step 1:
The ZRU can be positioned either in the room where the

underfloor heating is installed or in an adjacent area, 300mm
from the finished floor level to allow for pipe connections.
Remove the underfloor heating return pipe from ZRU and blank
off the ZRU underfloor heating return port with a short pipe
with a blank end or a blanking plug.
Filling the ZRU
Fitting the ZRU
Step 2:
Step 1:
Allow open ended underfloor heating return pipe to drain

into a bucket or hose.
Screw unit to wall.

Connecting the ZRU
Step 3:
Step 2:
Connect heating pipe work via an isolation valve (as shown).
Open the flow isolation valve to the ZRU.

Step 4:
Step 3:
Connect underfloor heating circuit(s) using an isolation valve.

Use tees and spigot elbows to form connections for 2 and 3
circuit systems.
Step 4:
When uninterrupted flow is seen from the underfloor heating

return pipe, close the isolation valve and re-connect the
underfloor heating return pipe to the ZRU.
Step 5:
Open all the valves.
Connect mains wiring (as diagram below) via a fused spur.
Step 6:
Vent the ZRU through the air vent and pump vent.
Wiring details
IMPORTANT NOTE: If in any doubt you should contact
a qualified electrician.
The water temperature must be 45C to operate the unit.
Wiring diagram
Room stat (example) - not supplied
Blank off
underfloor
heating
return to ZRU
Open
underfloor
heating
flow isolation
valve
Vent underfloor
heating system from
underfloor heating
return pipe
Remove
link if
using a
room
thermostat
PRODUCT SELECTOR
Room packs
for UFCH & OVERLAY
A range of room packs containing all flooring

and ZRU are available
Type
Solid Floor
Overlay
Overlay Lite
Area
12m2 (So12Z)
12m2 (O12Z)
12m2 (OL12Z)
20m (So20Z)
20m (O20Z)
20m2 (OL20Z)
30m2 (So30Z)
30m2 (O30Z)
30m2 (OL30Z)
Pump
A 5m2 Overlay Bathroom Pack (O5B) is controlled

with a temperature limiting valve rather than the ZRU
Boiler feed thermostat

Mains
42C close
(Fused spur)
31C open
3amp
51
SYSTEM COMMISSIONING
Once installed, Polypipe Underfloor Heating Systems should be tested thoroughly

to ensure they are working effectively, including initial filling of the system
and system balancing. If you require any further information please contact
the Polypipe Technical Team on 01709 770000.
Initial system filling

Flow adjusting
valve
System balancing
Once the system is up and running it is necessary to balance
the system in accordance with the design data provided.
This should be done using the following method:
Ensure that the boiler and main system duty pump are operating
correctly and that sufficient heat input and flow rates are being
provided at the manifold(s).
Set the underfloor heating controls to call for heat and

check to see that the two-port zone valve and manifold pump
are energised.
2
Manifold
flow meter
Close the manifold isolating valves (1) & (2). Connect a hosepipe
to manifold return drain off point (4) and take to a drain.
Connect a second hose pipe to the manifold filling point (3) and
attach to mains cold water supply (3 bar max). The connections
to the manifold drain and fill points are BSP. Use flexible
tap connectors for the simplest method of connection.
Close all of the flow adjusting valves on the return manifold rail
by turning the blue caps in a clockwise direction. Open all of
the manifold flow meters on the manifold flow rail by turning
them in an anti-clockwise direction using a radiator vent key.
Open the first circuit on the manifold by turning the blue cap
anti-clockwise and then open the drain and fill points (4) & (3).
Using the mains cold water supply flush out and fill the
first circuit. Once this circuit is running clear and free from air,
open the second circuit on the manifold and repeat the process
until all of the circuits are fully opened and purged of air.
Close the drain and fill points.
IMPORTANT NOTE: All of the manifold flow meters must be
fully opened prior to flushing and filling the manifold circuits.
52
Remove the blue cap from the manifold flow port and,
using the bleed key provided, turn the flow adjustment spindle
clockwise to completely close the circuit.
NOTE: The isolating valve fitted to the manifold flow meter

is not used for balancing purposes.
If it becomes necessary to close off a manifold completely,
this can be done by using a brass cap with a suitable rubber
washer insert.
Once all of the circuit flow rates have been adjusted the
system should be left to operate for a short period whilst any
remaining air is removed. Once this has been done the flow
rates should be re-checked and adjusted if necessary before the
actuator heads are fitted. If the actuator heads are not likely
to be fitted for a while then it is recommended that the blue
caps are used in order to protect the flow rate settings and
prevent any debris from entering the flow valve assembly.
Slowly open the valve by turning the spindle anti-clockwise
until the required flow rate in l/min is achieved in the flow
meter window.
When adjusting the manifold flow rates care should be taken

to ensure that the adjustment spindle is not left with any of the
thread showing.
In order to carry out any maintenance to the installation it is
possible to isolate individual circuits by closing both the flow
and return ports, as shown in the diagram below.
IMPORTANT NOTE: When using the PB970014 Modulating

Pump Unit, ensure that the primary boiler flow temperature
provided at the manifold is at least 15C hotter than the
required manifold operating temperature. This is due to
the fact that this manifold uses an injector method to mix
down the primary water. Furthermore, when balancing the
system with this particular manifold kit please ensure that the
modulating pump is set to a fixed head speed whilst making
any adjustments.
53
TECHNICAL DATA
Heat output tables
Overlay and Overlay Lite
The tables below show typical performance data for the

various Polypipe Underfloor Heating Systems.
Solid floor
Mean water
temperature C
Pipe
spacing mm
Output
W/m2
Surface floor
temperature C
Pipe
spacing mm
40
150
150
68.0
26.3
79.0
28.1
55
150
101.0
30.1
60
150
124.0
32.0
25.7
45
100
76.2
27.0
50
100
91.6
28.3
55
100
95.0
28.6
40
200
50.8
24.9
45
200
63.6
26.0
50
200
76.3
27.0
55
200
77.0
27.2
40
300*
42.8
24.2
45
300*
53.6
25.1
Mean water
temperature C
Pipe
spacing mm
50
300*
64.3
26.0
40
90
55
300*
66.7
26.9
40
225/300
Output
W/m2
31.7
Surface floor
temperature C
23.1
45
225/300
40.2
23.9
50
225/300
49.2
24.7
55
225/300
50.0
24.8
60
225/300
52.3
25.0
25.8
150
60.9
Pipe
spacing mm
61.0
Surface floor
temperature C
45
100
Mean water
temperature C
Output
W/m2
50
40
Suspended and floating floor
54
Mean water
temperature C
Output
W/m2
52.0
Surface floor
temperature C
25.0
45
90
64.0
26.0
50
90
76.0
27.0
55
90
100.0
29.0
60
90
124.0
31.0
TECHNICAL DATA
General system information
Maintenance
Many of the components within Polypipe Underfloor Heating

Systems are drawn from our well established Polyplumb system
of pipes and plumbing fittings. Polyplumb is suitable for use
in hot and cold water supply and both radiator and underfloor
heating systems. Polypipe polybutylene pipe provides flexibility
and freedom when designing pipe layouts, whilst Polyplumb push
fit fittings are fast to install and secure in use.
Polypipe systems require no maintenance, other than checks

on the inhibitor level in heating systems.
Strength
The Polyplumb system is suitable for use in working applications
up to 12 bar / 20C (6 bar / 90C). Pipes are suitable for bending
to a radius of 12 x diameter when unsupported or 8 x diameter
when supported.
Connections and fittings are tested to BS 7291: Class S for
thermal cycling test, long term pressure tests, rapid pressure test
and pull-out strength.
System malfunction
temperature
Polyplumb pipes and fittings are tested to BS 7291: Parts 1 and 2,
which incorporates a pressurised thermal cycling test and a test
regime at temperatures of 114C and 3.5 bar pressure for 1,000
cycles at a duration of 30 minutes per cycle. See British Standards
website for further details.
Gases
The Polyplumb pipe system is not suitable for the transportation
of gases.
Standard Polypipe polybutylene pipe is oxygen permeable and
is only suitable for all domestic water and heating installations.
Polypipe recommends that corrosion inhibitors are introduced to,
and maintained in, all heating systems, whether they use standard
or barrier pipe. Due to the long pipe runs used in underfloor heating
systems, we recommend barrier pipe is used throughout to
minimise the potential for oxygen ingress into the system.
Light
Polyplumb pipe and fittings should be protected from UV light.
Standard decorating paints form adequate protection. Polyplumb
pipe insulation forms adequate protection for external use. All Polypipe
polybutylene pipe is delivered in light-protective packaging.
Thermal
The co-efficient of thermal expansion of Polypipe polybutylene
pipe is 1.3 x 10-4m/mC. It accommodates expansion by its
modulus of elasticity.
Water
The polybutylene material used in Polyplumb pipes and fittings is
WRC / WRAS approved. It is resistant to the build-up of scale.
Short term chlorination for disinfection of supply pipe work and
normal levels of chlorine in UK domestic water supplies will not
have an adverse effect on the integrity of the pipe. Polypipe pipe
is not suitable, however, for systems that carry a high concentration
of chlorine, for example supplies to swimming pools.
Acoustic
The flexibility of Polypipe polybutylene pipe provides better
acoustic performance than rigid pipe systems in terms of low
noise transmission and low water hammer effect.
Electrical
As Polypipe polybutylene pipe does not conduct electricity,
installations generally require less equipotential bonding than
metal systems. Both the IEE and the IoP give guidance on the
earth bonding requirements of plastic pipe systems.
Where Polypipe polybutylene pipe breaks the continuity
of existing metal pipe, which may be used for earthing
or bonding, this continuity should be reinstated by affixing
permanent earth clips and a section of earth cable between
the ends of the copper pipe.
Side-effects
Polypipe believes there to be no side-effects from handling
or using its pipes and fittings.
Compatibility
Polypipe polybutylene pipe connects to rigid pipe systems
and is compatible with all recommended inhibitors.
For details of compatibility with specific building materials,
such as filler foam and wood worm treatments, please consult
the Polypipe Technical Hotline on 01709 770000.
Polypipe pipes and fittings can be painted using emulsion or
undercoat and gloss. Cellulose based paints, strippers or thinners
must not be used.
Durability
Polypipe Underfloor Heating products, excluding manifolds and
control products, are guaranteed for 50 years against defects
in materials or manufacture from the date of purchase (exclusions
apply). Visit www.ufch.com or www.freeyourwalls.com to a
view a full copy of our current guarantee(s).
55
FAULT FINDING CHARTS
Hydraulic fault finding chart

Before using this flow chart please ensure that both the primary and
underfloor heating systems are full and that all isolating valves are fully open.
Please also ensure that the room thermostats are calling for heat.
YES
Boiler fault
NO
Electrical fault
(see electrical fault
finding guide)
START
Is the boiler firing
and the primary
pump operating?
NO
Check for 230V signal

to boiler from master
wiring centre
NO
Check if the
underfloor heating
zone valve is open
YES
Is there hot water
present prior to
underfloor heating
mixing valve?
YES
Primary flow and

return crossed or
debris in mixing valve
NO
YES
Is hot water passing

through underfloor
heating manifold?
NO
Check 230V signal

to zone valve from
master wiring centre
YES
Zone valve fault
Check temperature
adjustment on
underfloor heating
mixing valve
NO
Electrical fault
(see electrical fault
finding guide)
YES
YES
Is there a visible flow

present through
all underfloor
heating circuits?
NO
YES
Fault finding
complete
56
NO
Check 230V signal to

pump from master
wiring centre
YES
Pump fault
Check if the
actuators are open
NO
Check 230V
signal to actuator
from slave unit
NO
Electrical fault
(see electrical
fault finding
YES
Actuator fault
YES
YES
Is the system
performing
correctly?
Underfloor
heating pump
operating
NO
Ensure that manifold

lockshield valves are
fully open
Adjust pump speed
and set flow rates
in accordance with
the system design
data as provided
Electrical fault finding chart (master connecting box)

This testing procedure should only be carried out by fully qualified persons.
Testing should be done with all switches on and room thermostats calling.
Is the fused spur
switched on?
START
NO
Turn the fused spur on
NO
Replace 3A fuse in spur
NO
Replace fuse on PCB

(2.5A 230 Vac Type 5x20)
NO
Faulty PCB replace unit
NO
Faulty room thermostat replace unit
NO
Relay 1 faulty replace PCB
NO
Relay 2 faulty replace PCB
YES
System operating correctly
YES
Is there 230V at
L terminal on PCB?
YES
Is Green Power
LED illuminated?
YES
Is 230V present on
all T2 terminals?
YES
Is 230V present on
all T1 terminals?
YES
Are the zone valve
and underfloor heating
pump operating?
YES
Is there 230V to NC Boiler
switch live connection?
(Check operation
of Volt free relay
connections if using 24V)
YES
Check boiler connection
NO
Is the boiler firing?
57
Accreditations, standards
and guarantees
One of Europes largest manufacturers of plastic plumbing and
heating products, Polypipe Building Products Ltd has developed
a unique range of underfloor heating solutions. Designed
for installation in to both existing and new build projects all
Polypipe products are manufactured and tested to the highest
standards to ensure maximum quality and performance.
For further quality assurance all Polypipe products carry the
following Standards and System Approvals:
Manufacturing
quality assurance
FM00318
In accordance with BS ES ISO 9001:2000 (BSI registered firm

Certificate FM00318).
Installation standard
British Gas - has accepted the Polypipe Polyplumb

Class S Polybutylene pipe system as being acceptable for open
vented and sealed central heating systems and is eligible for
acceptance onto Three Star Central Heating System Cover.
P.B.P.S.A. Polypipe Building Products Ltd is a member of the

Polybutylene Piping Systems Association, which is a recognised
association of the companies whose aim is to promote the
features, benefits and best practice installation techniques
of polybutylene pipe systems, as well as providing a wide range
of technical information and support.
Polypipe is a member of the Underfloor Heating

Manufacturers Association.
Guarantee
To follow the recommendations of BS5955 - Part 8 2001

Plastic Pipework (Thermoplastic Materials).
British standard
Class S Rated to BS7291 Part 1 and Kitemark Licence Number

38148 to BS7291 Part 2.
WRAS Listed in the WRAS Water Fittings and Materials Directory.

KIWA/KOMO Certificate numbers K14341, 14342 and 14343.
BBA Polypipe polybutylene barrier pipe, fittings, accessories

and Underfloor Heating Systems are covered by BBA
Certificate No. 00/3699.
58
Polypipe Underfloor Heating products, excluding manifolds

and control products, are covered by a 50 year Guarantee*,
which protects against defects in materials or manufacture
of the heating system from date of purchase. This guarantee
only applies if the system is installed in accordance with
the manufacturers recommendations, and is used in a
normal domestic operation. This document should be read
in conjunction with all other documentation supplied with
Polypipe products. If you have any queries, please contact
our Technical Hotline on 01709 770000.
UNDERFLOOR HEATING SYSTEMS

DESIGN ENQUIRY FORM
CLIENT DETAILS
Project:
(Polypipe use only)
Project Reference No:

Contact:
Client:
Address:
Telephone:
Post Code:
Mobile:
SENDERS DETAILS
Client:
Contact:
Address:
Post Code:
Telephone:
Designs to be returned to
Client
Mobile:
Sender
UNDERFLOOR HEATING REQUIREMENTS

Floor Type
(Solid, Suspended, Floating, MHP, Overlay, Overlay Lite)
Manifold Position(s)
(Please also indicate on drawing)
Ground Floor
1st Floor
2nd Floor
NOTES
CONSTRUCTION DETAILS If NOT to current Building Regulations
U Value
(W/m2 deg C)
External Walls
Roof
Windows
Please return your completed form to:

Underfloor Heating Design, Polypipe Building Products Ltd, 1 Neale Road, Doncaster, DN2 4PG, England
Tel: 01709 770000 Fax: 01709 770001
www.ufch.com
59
Technical Installation Guide

Underfloor Heating Systems
Polypipe Building Products
Broomhouse Lane
Edlington
Doncaster DN12 1ES
Tel: 01709 770 000
Fax: 01709 770 001
2410 London Road
Mount Vernon
Glasgow G32 8XZ
Tel: 0141 778 8822
Fax: 0141 778 2703
Dromore Road
Lurgan, Craigavon
Co. Armagh BT66 7HL
Tel: 028 38 881270
Fax: 028 38 882344
www.polypipe.com
Polypipe Underfloor Heating Systems trade website: www.ufch.com
Polypipe Underfloor Heating Systems consumer website: www.freeyourwalls.com

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TIG7

Underfloor Heating Systems

EFFECTIVE: 1ST JUNE 2012

Technical Installation Guide

HOW TO USE THIS GUIDE

Selecting the right system

Navigating the Technical

Next, choose your selected underfloor heating system type from

ABOUT POLYPIPE UNDERFLOOR HEATING

Polypipe is one of Europes largest manufacturers of specialist plastic plumbing,

Following recent innovative product introductions, we have

With a long established reputation for product quality

Polypipe Underfloor Heating Systems have been designed with

Polypipe Underfloor Heating Systems use the flexibility of

Polypipe Underfloor Heating Systems are installed in one stage,

For more information on our single room applications see

Details of each type of Polypipe Underfloor Heating System

Full details of Polypipe control products can be found on pages

Modular Heating Panels (MHP)

SELECTING THE RIGHT POLYPIPE

Polypipe Underfloor Heating Systems

Fit from above

To use the Polypipe Product Selector you first decide

Modular Heating Panels (MHP)

Our comprehensive system

When you select Polypipe as your underfloor heating brand of choice,

You will now see a list of members of the Polypipe Registered

The installers profile will be displayed, showing details of their

WHAT YOU CAN EXPECT

Choosing the right system

GUIDE TO FLOOR COVERINGS

Carpet and underlay

Stone and ceramic tiles,

Suitable for all Polypipe Underfloor Heating Systems:

Suitable for all Polypipe Underfloor Heating Systems:

Suitable for all Polypipe Underfloor Heating Systems:

Suitable for Polypipe solid floor and suspended floor systems:

Sheet vinyl is sensitive to long term exposure to heat. There are

Concerns regarding the effect of heat on a timber floor are

Suitable for all Polypipe Underfloor Heating Systems:

Polypipe Underfloor Heating in solid or screeded floors incorporates the

The panels are laid above pre-installed insulation and the

Polypipe solid floor panels form a simple grid to ensure the

Polypipe Underfloor Heating Systems can be used with

Maximum coverage per circuit

Key design and installation information

Fitting the floor panels

and should be overlapped at the edges.

Material requirements (approx)

Floor plate usage

Edging insulation strip

8.2m/m2 at 100mm centres

NOTE: The castellation should overlap the castellation. The first

Panels can be cut by simply using a saw or snips or it can

be overlapped to the nearest castellation fit.

In accordance with Part L of the current Building Regulations,

Floor panels should not be used at the base of the manifold

a suitable layer of insulation material should be included within

as pipes need to be closer together than the floor panels allow.

the floor construction. It is the responsibility of the architect or

must be installed beneath the underfloor heating system in order

also be used intermittently to secure the clip plate to the insulation.

When a pumped (liquid) screed is to be used it is essential that all of