Underfloor heating with thermobeton HAKA GERODUR
Advantages
Space saving by avoiding radiators, complete freedom in the architectural design of the rooms.
Uniform and optimal room temperature distribution, without drying of the air, as required by human physiology.
Lower operating and maintenance costs (which soon recoup the higher installation costs).
Saving energy and money due to operation at low temperatures and therefore lower fuel consumption.
Ability to exploit renewable energy sources (air, sun, geothermal energy) through connection to a heat pump. Environmentally friendly operation.
Additional possibility of cooling the rooms in summer (in cooperation with a heat pump).
Possibility of mixed heating system, in combination with radiators or fancoils.
Lower operating temperature - mild environment.
Technical Description - Study
HAKA GERODUR is a member of the BVF (Federal Association of Floor Heating Manufacturers) in Germany.
The floor heating system HAKA GERODUR Germany consists of the following elements:
THE FLOOR HEATING PIPE
The HAKA GERODUR floor heating pipe is produced from 18X2 radiopaque polyethylene with oxygen barrier (PE-Xc DD). The meshing of the pipe is done by means of high energy radiation (electron accelerator). The maximum operating temperature is 95°C and the maximum pressure is 6 bar. Due to the 5-layer technology the pipe is suitable even for particularly harsh conditions.
Alternatively, a 16×2 multi-layer polyethylene - aluminium multilayer pipe can be used for floor heating. Both heat pipes are manufactured in Neustadt, in the HAKA-GERODUR factory in Germany and are SKZ (Suddeutsche Kunstoff Zentrum - South German Plastics Testing Centre) certified.
The floor heating pipe is covered by a 10-year warranty and a 10,000,000 Swiss franc indemnity from the insurance company Zurich Switzerland.
THE CIRCUIT DISTRIBUTION STATION
It is made of nickel-plated brass of 1″ or 11/4″ cross-section with Eurocone supplies (the latest European standardization).
At the departures of the circuits there are regulating switches - flowmeters that allow the regulation of the flow and, by extension, the temperature of the space covered by each circuit. On the returns of the circuits there are built-in thermostatic switches, suitable to accept electrothermal valves for the autonomy of the rooms. They also have 2 thermometers for direct indication of supply and return temperatures, an automatic ventilation system and an additional quick fill/empty and manual ventilation system for all circuits.
H SHAPED PLATE
The HAKATHERM shaped plate is made of high density (30kg/m3) extruded polystyrene and has a special coating of protective polyethylene film on its upper surface for extra protection, robustness, durability and waterproofing.
The shaped slab is laid on the original concrete slab and the underfloor heating circuits are formed on it, at a distance of 7.5cm or 15cm, depending on the thermal requirements of each room.
THE PERIMETER TAPE
The perimetric tape HAKAFLOOR is self-adhesive (with special wall adhesive) with dimensions of 8mm thickness and 15cm height and is placed perimetrically on the walls of each room to receive the perimeter expansion of the thermobeton. The bottom part is designed to be retained by the slab to prevent its unintentional removal by subsequent crews.
THE EXPANSION JOINT
The expansion joint HAKAFLOOR with dimensions 180cm (Length) X 12cm (Height) X 1cm (Thickness) is applied to large single surfaces of spaces in order to avoid cracks in the thermobeton and the coating surface (tiles) at points where surfaces of different widths meet.
THE THERMOBETON
The floor heating system is covered with concrete grout, the composition of which is described in DIN 18353/4109
The advantages of the floor heating system that we apply are the following:
- We use the special knot plate HAKATIEREM which is made of high quality (30kg/m3) extruded polystyrene PST, providing proper floor thermal insulation, robustness and durability, which is important in the substrate of floor heating.
- The layout of the nodes helps in the correct configuration of the circuits, which are determined by the thermal load requirements of the respective rooms and the available flooring to be underfloored. The integrated coating of the upper surface of the shaped slabs with a protective polyethylene film ensures the DIN-required waterproofing and at the same time enhances the resistance to stresses of the slab itself during the shaping of the circuits.The design of the node profile allows even the lower part of the pipe surface to be completely covered, in order to obtain optimum thermal conductivity as well as pipe protection due to the node protrusion of 5mm above the installed pipe.The pipe meander system (supply and return pipe routing, parallel and side-by-side), in combination with the increased heating surface due to the dense layer, offers a uniform and increased heat flow per unit area. This, in turn, provides us with additional reserves of required heat in bad weather conditions (especially low outdoor temperatures) and also the ability of the entire heating system to operate at lower boiler temperatures which translates into more economical operation.
- The perimeter tape is made of a special foam material, in order to absorb the expansion of the thermobeton in the best way, so that the perimeter structural elements (e.g. walls) are not pressed.
- The internal expansion joint is made of a special foam material, in order to receive in the best way the expansion inside the rooms, at the points where they border each other. The hard double lateral reinforcement of this joint ensures the stability of its position during the laying of the concrete grout.
- The high-density polyethylene plastic pipe we use is the "heart" of the system. Its electron cross-linking gives it the most uniform cross-linking-strength across its cross-section. The oxygen barrier prevents oxygen from entering the water in the installation, which in turn would lead to a reduction in the lifetime of the installation (e.g. boiler)
- The collectors use double sealed racks, integrated factory built-in dimmer switches and heavy-duty EC flowmeters that contribute to the ease and accuracy of circuit adjustment to achieve the best possible temperature distribution.
- The crews are installers with long experience in floor heating constructions and in conventional heating-water installations, in order to ensure with the correct application of modern technical knowledge, the delivery of reliable and quality construction.
- The execution of the construction is carried out strictly on the basis of the study that has been preceded, with the supervision and guidance of a supervising Mechanical Engineer, with experience to cope with any problems that may arise during the course of the project.
- The study takes into account thermal insulation and loss factors of the premises, as well as the peculiarities of special use areas such as attics, lofts, etc.
- Our experience, our responsibility and the quality of the materials we use, offer the completion of a quality and functional construction.
- As is known according to the laws of physics, the sun warms the earth but not the air around it. It is the earth that in turn heats the air. With the construction of floor heating we transfer this model in the best way to the interior of your home, replacing the energy source called the sun with the boiler system.In conclusion, the end result is a system designed and constructed with the most modern means, which ensures the ideal climate in the living areas of your home, offering you daily warmth, tranquility and thermal comfort.
Attached files:
Access THD Haka Gerodur- The study of the floor heating installation is carried out by the company's design department, which is composed of Dipl. The data of the building (exact description of thermal insulation, floor plans, etc.) are entered into a special computer program, and the installation of floor heating is calculated, according to the new European regulation DIN EN 12831.After the completion of the study, the construction plan of the floor heating follows. Guided by this plan, the floor heating installation and the configuration of its circuits will be finally constructed by specialized manufacturers of the HAKA GERODUR system.
Attached files:
Cimentoconia - Armies
The laying of the cement mortar requires special care and good compaction, so that no gaps remain in the mass (which negatively affect its behavior) and to obtain a smooth, even and flat final surface, ready to receive the final coating (glued or floating floor).
The thickness of the cement mortar above the highest point of the circuit pipe shall not be less than 45 mm and not more than 80 mm
The need to add reinforcement (T131 structural mesh) should be considered on a case-by-case basis.
The cement mortar must completely surround the circuit pipe. For this reason it is necessary to have the pipe placed 10mm above the surface of the insulation layer.
The sand, preferably quartz or hard limestone sand, must come from a quarry and be free of harmful impurities such as clay, plant and other organic residues, loose materials, etc. The water must be clean and come from the water supply system. When rebars are used they should be clean and not oxidized.
Mortars shall be prepared with a mechanical mixer. Mixing by hand is prohibited. The mixer shall be clean and washed before use. It must also be washed at least every 3 hours if it is used continuously. The mortar being prepared shall not be allowed to remain in the mixer for more than 3 minutes during or after mixing.
The mortar shall be homogeneous and uniform, cohesive and workable and shall be stored until consumed in metal containers under conditions such that it cannot separate and its setting is not affected by loss of water. It must in any case be consumed before it begins to set.
Mortar that has been used or that is reprocessed (reclaimed) or has begun to harden must be removed from the project.
Laying the mortar with temperatures below +5ο C or above +30ο C is not allowed!
The spread mortar shall be protected for a period of time long enough for it to set smoothly and uniformly under normal ambient conditions and without exposure to strong air currents.
Expansion joints are necessary on surfaces that
- are larger than 40m²
- have a side greater than 8m
- the aspect ratio exceeds 1:2,5
- in any other case where the floor geometry so requires
In addition to the conditions for the preparation, spreading and curing of the cement mortar, the general requirements for the preparation, processing and protection during the curing of mortars (environmental conditions, work stoppages, etc.) must be applied.
Final flooring - Cost analysis
- The final floor (coating) can be marble, ceramic tiles, wood or carpet.With underfloor heating it is possible to combine almost all the materials of final coatings without problems as long as the instructions of the manufacturer of the underfloor heating installation and the supplier of the coating materials are strictly applied.
When choosing the coating, the thermal resistance of the final coating material, which expresses its insulating capacity, must be taken into account. More expertise is required for wooden floors
Especially for wooden floors, we use wood with limited moisture content and with the guarantee of the supplier company. The moisture content of the wood must be between 6 and 10%.
Special adhesives suitable for installation on underfloor heating installations, offered or recommended by timber suppliers, should be used for the installation of the boards.
System construction:
1. plaster
2. skirting boards
3. perimeter thermal insulation tape
4. flooring
5. thermobeton
6. pipe HAKATHERM PE-Xc
7. yellow plate with integrated thermal and sound insulation
8. vapour barrier to protect against moisture
9. concrete slabINSTRUCTIONS FOR INSTALLING WOODEN FLOORING
The wooden flooring is laid glued or floated on a perfectly flat, smooth and clean surface. If these conditions are not met, then the surface must be subjected to the necessary preparation (dulling, sanding, cleaning, etc.) before the flooring can be laid.
The adhesive flooring is applied by directly gluing the boards onto the substrate (cement mortar). In this case, the joints of the cement mortar continue into the coating. An important role in successful installation is played by the choice of the appropriate adhesive (1 mm thick). The floating floor is applied without cutting on the cement mortar, but with the insertion of a thin insulating sheet of corrugated paper, cork, etc. The boards are only glued together. The joints of the cement mortar are not continued in the coating. A gap of 5 mm must be left at the perimeter of the floor, at the positions of the doors and at the lines for changing the coating material.
For the filling of joints and their covering, special products (sealing cords, grout covers) are available from suppliers of wooden floors, suitable for application on underfloor heating installations.
The success of the combination of underfloor heating with the wooden floor depends on the moisture content of the substrate (cement mortar) during the installation of the coating. This should be much lower than the tolerable humidity of the wood (6-10%), so as not to affect the behaviour of the coating (swelling, cracking, peeling) during the operation of the installation.
The cement mortar shall be allowed to cure and dry naturally for 21 days from the time of its spreading. The installation is then put into operation for 14 days and its temperature is increased by 5ο C every day until it reaches 2/3 of the maximum operating temperature. During the last 5 days the operating temperature is kept constant at the maximum (45ο C). The plant must be operated continuously on a 24-hour basis and the room must be well ventilated during the drying period (21 + 14 days).
The operation of the installation is stopped 2 days before the start of the installation of the coating.
The application of the coating must be carried out at a room temperature of not less than 15ο C and room humidity between 50 and 60%.
The above drying methods are followed faithfully, regardless of the time and weather conditions.
At the start-up of the underfloor heating installation, the floor heating should be gradually increased by 5ο C every day until the upper final temperature (28ο C). This must be done for each heating period.
During operation of the system, it must be avoided that the maximum final temperature of the wooden floor surface is exceeded (28ο C).
| TYPE OF MATERIALS AND WORK | COST OF MATERIALS | LABOUR COSTS | |
| Phase A | 1. Vertical pipe and panel materials. Includes all materials between the boiler room and the underfloor piping. It depends on the distance from the boiler room to the panels and the quality of the panels and collectors. | ||
| 2. Labour Placement | |||
| Phase B | 3. Integrated system materials. Includes sound insulation boards, pipes, insulating tapes, mesh, brackets, nylon, etc. The material companies offer free of charge the underfloor heating and at the same time pre-calculate the cost of their materials | ||
| 4. Screeding system. Whoever bears the cost of the total installation before the screed is laid | |||
| 5. Cement dust. It consists of sand, cement and liquid admixture. | |||
| 6. Cement Screed Worker. The cost includes labour up to the delivery of the finished surface before the final floor is well laid. | |||
| Phase C | 7. Boiler room materials. Boiler room costs are the same as for all other heating systems | ||
| 8. Boiler room works. The fees of the technicians are the same as in all other systems and are calculated for all work until the complete delivery of the boiler house. | |||
| TOTAL | |||
| TOTAL TOTAL | |||
