velta case studies

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Industrial Flooring Solutions



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Heating and cooling applications for Industrial projects


velta one – floor heating and cooling system

Benefits of the velta one system

The velta one system is an embedded pipe system within the structural ground floor slab, which can be activated with warm water or cool water to provide both heating and cooling in a building.

Installed in the same construction sequence as the floor slab the system provides programme benefits compared to alternative systems, which have to have a separate programme period. The standard velta systems can be incorporated into traditional flood pour construction of the floor, but the velta one system has been specifically designed for installation in floors utilising modern laser screed floor laying techniques. This allows fast and accurate installation of the concrete floor with the embedded velta system in one operation.

The velta system provides many benefits

• Low maintenance costs – minimal moving parts and all maintenance at floor level. • Long life expectancy – the system is designed to last the life of the building. No replacement costs throughout the life of the building. • Environmental - No disposal issues of used equipment. • Health and Safety – No high level maintenance required • Links with renewable energy sources – velta system can utilise most forms of renewable energy sources due to the low temperature heating water and high temperature cooling water requirement • Low running costs for energy • Heating/Cooling provided at the occupied floor level • High radiant component with the system reducing energy requirements for the building by 6 – 12% • Freedom of space – invisible system • Future flexibility of heating/cooling source to supply the built in velta system • velta service – design, supply, installation and commissioning with directly employed velta staff




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Design Philosophy


The Design philosophy for the building should be undertaken utilising the high radiant effect associated with floor heating. This philosophy usually leads to a reduction in the internal design temperature, as operative temperature should be utilised and not air temperature. It is common for operative to be up to 2 ºC lower than air temperature and this can lead to energy savings of approximately 12%.

With the floor surface acting as the emitter the heat load demand can be based on the occupied zone which is usually the first 2.5m of space rather than the total height or volume of the building which is often the case for other heating systems.

This leads to a reduction in the heat loss for the building and can lead to a reduction in the plant required for the heating and cooling load.



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B&Q SuperstoreNew Malden - London

Client B&Q RetailArchitect Black ArchitectureMain Contractor Simons Construction.M&E Consultant McBains CooperM&E Contractor L J MonksStructural Engineers Bradbrook Consulting

The award winning designed, flagship B&Q store in New Malden, London which will benefit from having 10% of its energy needs catered for by renewable energy sources on site.The concept for this store was to demonstrate the store design and construction of the future, utilising renewable energy sources though energy piles and solar panels.

The systems used within the building and the construction methods also had to adopt this philosophy and demonstrate environmental benefits.

A velta classic heating and cooling system was incorporated into the retail floor area extending to 9,000 m².

The system was installed in the composite structural floor consisting of precast concrete units and structural concrete topping. The installation was undertaken with the concrete flooring programme, causing no delays and the system set to allow a bolt drilling zone for floor fixings.

Single warranty for both floor heating and concrete slab – offering total piece of mind for the client.

Area of project 9000m²Heating Flow Temperature 36°cHeating Return Temperature 28°cCooling Flow Temperature 14°cCooling Return Temperature 19°cRequired heating output 60W/m²

Slab Thickness 125mmSlab loading capabilities UDL of 35kN/m² Racking Leg Load 50kN Total number of pour days 9Specialist Info Flood poured structural topping to pre-cast concrete beams

// Project Team

// Floor Design Considerations// velta Design Considerations



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Capital PrintBeckton Waterfront

Client Capital PrintArchitect McLaren Const.Main Contractor Simons Construction.M&E Consultant BSDM&E Contractor Walter MilesStructural Engineers T. R. Collier

The integration of a velta one industrial heating and cooling system cast directly into the floor slabs and fed from a closed loop ground source heat pump to provide low temperature heating and cooling was an attraction.The site received a BREEAM assessment rating of ‘very good’ for its carbon friendly initiatives.

The project was a world first to incorporate a floor heating system directly into a structural high tolerance concrete floor slab laid with laser screed techniques.


Area of project 12500m²Heating Flow Temperature 45°cHeating Return Temperature 32°cRequired heating output 44W/m²

Slab Thickness 275mmSlab loading capabilities UDL of 50kN/m² Racking Leg Load 50kN Total number of pour days 9Specialist Info Piled, steel fibre reinforced floor Slab placed using a laser screed with a coloured dry-shake finish.

// Project Team




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Royal Opera House Production Workshops

Client Manoukian BrothersArchitect McLaren Construction.M&E Consultant ArupM&E Contractor Swiftline Engineering Structural Engineers WSP

The integration of a velta one industrial heating and cooling system cast directly into the floor slabs and fed from a closed loop ground source heat pump to provide low temperature heating and cooling was an attraction. The building had varying room heights that benefited from a heating/cooling system that worked specifically in the occupied zone.

The floor was pour using the laser screed machine meaning high levels of tolerance were achieved for the slab


Area of project 3300m² Heating Flow Temperature 47°cHeating Return Temperature 39°cCooling Flow Temperature 16°cCooling Return Temperature 19.8°cRequired heating output 60-80W/m²

Slab Thickness 175mmSlab loading capabilities UDL of 50kN/m² Racking Leg Load 50kN Total number of pour days 3 Specialist Info Laser screed finish.

// Project Team




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Brendon Powerwashers Industrial Unit

Client Brendon PowerwashersArchitect Stone and Partners Main Contractor C. S. Williams Structural Engineers Andrew Waring

The integration of a velta one industrial heating and cooling system cast directly into the floor slabs and fed from a closed loop ground source heat pump to provide low temperature heating and cooling was an attraction. The building had varying room heights that benefited from a heating/cooling system that worked specifically in the occupied zone. The floor was pour using the laser screed machine meaning high levels of tolerance were achieved for the slabSingle warranty for both floor heating and concrete slab – offering total piece of mind for the client.

Area of project 1250m²Heating Source Used Standard Gas Boiler Heating Flow Temperature 45°cHeating Return Temperature 36°cRequired heating output 63W/m²Total length of pipework installed into the floor 5000m+

Slab Thickness 150mmSlab loading capabilities UDL of 35kN/m² 50kN Point Load Total number of pour days 2 Specialist Info Standard flood pour with a drilling zone of 75mm maintained throughout the slab

// Project Team




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Chatterley Valley Blue Planet, Stoke-on-Trent

Client Gazeley UK LtdMain Contractor McLaren ConstructionM&E Consultant KTAM&E Contractor C A SothersStructural Engineers Capita Symonds

The scheme was to build one of the world’s greenest business and logistics parks in North Staffordshire.

The pioneering new project called Blue Planet Chatterley Valley was developed by Gazeley UK Ltd and hosts ultra-green sustainability credentials for the 385,000sq ft warehousing facility.

Built by Main Contractor McLaren Construction, the velta one system was incorporated directly into the ground bearing slab in conjunction with a laser screed machine. Working alongside Stuarts Industrial Flooring the pipework was integrated into the slab without causing any time delays. Daily production of up to 1,800m² of completed floor incorporating the velta one system was achieved.


Area of project 33000m² Heating Flow Temperature 39°cHeating Return Temperature 31°cRequired heating output 39W/m²

Boarder zone in front of dock levellers 68W/m²

Slab Thickness 225mmSlab loading capabilities UDL of 50kN/m² Racking Load 100kN Total number of pour days 18 Specialist Info Laser screed finish

// Project Team




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Chessington Garden CentreExtension to Retail Area

Client Chessington Garden Centre Architect A.J. Younger ArchitectsMain Contractor Segment EngineeringStructural Engineers Segment Engineering

The offering of slab insulation, underfloor heating, concrete slab and floor finishes was an attractive offer to the main contractor and one that he could not refuse. A combined warranty covering all aspects from slab design, underfloor heating installation and floor finishes with one point of contact made the main contractor’s life much easier. The co-ordination of the works was seamless as one company had the responsibility of giving a full heated floor back to the main contractor from start to finish.

Area of project 1200m²Heating source used Ground Source Heat Pump Heating Flow Temperature 45°cHeating Return Temperature 35°cRequired heating output 50W/m²

Total length of pipework installed into the floor 4500m+

Slab Thickness 150mmSlab loading capabilities UDL of 5kN/m² Racking Load 100kN Total number of pour days 3 Specialist Info Traditional flood poured slab with the inclusion of the Installation of floor finishes on top of completed heated slab

// Project Team




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Cricklewood Bus DepotEdgware Road - London

Client London TransportArchitect Cornish ArchitectsMain Contractor Fitzpatrick ConstructionM&E Consultant Silcock Dawson & PartnersStructural Engineers SDP Consulting

The velta one system was used in this application to maintain a high level of comfort to the warehouse area. The heat was in the occupied zone which helped achieve the comfort levels required. The thermal mass of the system means that the system is instantly reactive to sudden changes in temperature due to the doors opening and closing as the buses come and go. The plant to serve an air system would need to have been over 35% larger to cope with the demands on the building usage.

The system had a built in drill zone of 75mm to enable fixings into the slab.


Area of project 1000m² Heating Flow Temperature 45°cHeating Return Temperature 35°cRequired heating output 70W/m²


Slab Thickness 200mmSlab loading capabilities UDL of 5kN/m² 3t Fork Lift Truck Load Total number of pour days 2 Specialist Info Laser screed pour in warehouse, traditional flood pour to offices

// Project Team




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LAPICIDA Tile showroomHarrogate (Leeds)

Client LAPICIDAArchitect SMC Gower LeedsMain Contractor HACS ConstructionM&E Contractor Robinsons Mechanical and ElectricalStructural Engineers GHA Livigunn

This luxury tile showroom used a combination of the standard velta slab system and velta one system to deliver a dual purpose system.

In the showroom the standard velta slab system was used to showcase the comfort achieved by utilising a tile finish underfoot.

In the warehouse area the system was used to dry the stone imported in from Italy. The warehouse system was designed to achieve an output in excess of 120W/m² and due to the stable heating effect of radiant heating this helped to decrease the standard drying times of the stone significantly.


Heated Area of project 3200m²Heating Flow Temperature 55°cHeating Return Temperature 27.8°c/47°cRequired heating output 60-120W/m²


Slab Thickness 160mmSlab loading capabilities UDL of 50kN/m² 27kN FLT Wheel Load Total number of pour days 2 Specialist Info Traditional flood pour method used for showroom Laser screed pour in warehouse area

// Project Team




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Wanis - Cash and Carry Warehouse - Leyton

Client Wanis FoodsMain Contractor CostainM&E Contractor Walter MilesStructural Engineers T. R. Collier

The integration of a velta one industrial heating and cooling system cast directly into the floor slabs and fed from a closed loop ground source heat pump to provide low temperature heating and cooling was an attraction. A velta classic heating and cooling system was incorporated into the warehouse floor area extending to 9,500 m².

The system was installed in the concrete slab at a depth of 50mm above the sub-base. The installation was undertaken with the concrete flooring programme, causing no delays and the system set to allow a bolt drilling zone for floor fixings.


Area of project 9500m²Heating Flow Temperature 39°cHeating Return Temperature 32°cCooling Flow Temperature 16°cCooling Return Temperature 20°cRequired heating output 45W/m²

Slab Thickness 225mmSlab loading capabilities UDL of 50kN/m² Rack Leg Load 50kN Total number of pour days 6Specialist Info Laser Screed Pour achieving High Tolerances

// Project Team




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Olympic VelodromeStratford - London

Client ODAArchitect Hopkins ArchitectsMain Contractor ISG ConstructionM&E Consultant BDSPM&E Contractor Imtech AquaStructural Engineers Expedition

The 6,000 seat Velodrome will host the Olympic and Paralympic track cycling events in 2012. After the Games, the legacy Velodrome will be used by elite athletes and the local community and will include a café, bike hire and cycle workshop facilities. The heating was incorporated within the main in-field areas as well as transient spaces on the upper and first floor levels. Heating was also incorporated into the competitors changing areas and officials changing areas to give maximum comfort prior to any competition.


Heated Area of project 5000m²Heating Flow Temperature 44-50°cHeating Return Temperature VariesRequired heating output 45W/m²

Total length of pipework installed into the floor – 12000m+

Slab Thickness 100/125mmSlab loading capabilities UDL of 20kN/m² Total number of pour days 18Specialist Info Traditional flood pour method used. Infield slab installed using steel fibre reinforcement, concourse areas using macro-synthetic fibres.

// Project Team




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Cooling and heating design data

Control and zoning

Manifolds

Typical data associated with a system of this nature would be as follows:

Winter mode Summer modeInternal temperature 18°C 26°CHeating/ Cooling Output: 60 W/m2 up to 40 W/m2Flow water temperature: 37°C 14 °CReturn Water temperature: 31°C 18 °CAv. temp. of the concrete surface 24.5°C 20.5 °C

The building can be split into a series of zones and each individual zone controlled to different conditions, allowing for future flexibility for re-design of the building function and layout.The velta one system can be controlled from standard BMS systems.

The velta industrial manifold can serve up to 450m² and can be used to serve dedicated zones. These zones can be controlled individually if required or as a one for the entire building. The control philosophy can be changed at a future date as long as sufficient zoning is designated in the initial design.

Each zone can be either in cooling or in heating mode. We suggest that the decision of changeover between heating and cooling is based on the whole building and not individual zones.

velta manifolds can be located vertically on walls and concealed in cabinets or they can be placed horizontal within the floor slab itself with the appropriate steel covers.

Primary pipework to the manifolds can be treated in a number of ways. Overhead solutions can be considered or the pipework can be embedded under or within the structural slab. Alternatives have also been constructed with the primary pipework running underground external to the building.




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Ground floor slab construction

Joint requirements

Concrete joint formation

The velta one system can be incorporated into most concrete floor slabs with insignificant modification to the floor slab depth and construction.

The system has been used with Lafarge Extensia concrete, which eliminates the requirement for reinforcement and minimises the use of joint profiles due to the low shrink properties of the new material. This provides environmental benefits and can also be polished to provide the permanent floor-wearing surface. The properties of Extensia also allow the floor slab depth to be reduced.

Structural engineers are responsible for planning joints in the structural concrete floor and the velta heating system is not a critical factor due to the low temperature of the water used to heat the floor and the high temperature of the water used to cool the floor.

Standard bay sizes and pour profile proportions apply dependant upon the concrete and the reinforcement utilised.

Standard joint profiles such as Alpha type, can be used with the velta system and velta request a joint plan in order to coordinate the pipework circuits and the connecting pipework to minimise the crossing of formed joints.


This is an alternative to the terrazzo floors currently used. A single monolithic construction producing the heating and cooling with the finished wearing surface of the floor.



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Expansion / Movement Joints

Induced / Sawn Joint

The velta system does not influence expansion joint planning.

Heating pipes that cross expansion joints should be protected using velta 1m protective pipe sheathing due to the anticipated mechanical loading in the area of the joint.

Pipe design should be undertaken such that no movement joints are crossed.

A velta protective pipe sheath is not required for induced or sawn joints. The joints can be sealed by making a subsequent cut of approx. 25mm depth and using a suitable special sealing compound with partial filling using cellular rubber. Other standard joint profile techniques can also be used.

1. Wearing course / floor finish2. Concrete3. velta heating and cooling pipe4. Seperation / sliding layer / Damp proof membrane5. Foundation course6. Expansion joint7. Protective pipe sheathing8. Joint sealing compound9. Cellular rubber

1. Wearing course / floor finish2. Concrete

3. velta heating and cooling pipe

4. Separation layer / Sliding layer / Damp proof membrane5. Foundation course6. Joint sealing compound

7. Cellular rubber

8. Dummy joint9. Fine crack

Floor FixingsThe foundations of racking or equipment are often anchored in the concrete floor. Velta must be informed of the depth of these foundations or anchoring in the concrete slab. There is rarely a danger that these will penetrate as far as the level of the heating pipes. However, if this occurs due to insufficient thickness of the concrete, then the heating pipe in this area should be omitted.

1. Wearing course / floor finish

2. Concrete

3. velta heating and cooling pipe

4. Separation layer / Sliding layer / Damp proof membrane

5. Foundation course6. Reinforcement support

7. Fixing rail

8. Spreader plate9. Anchor fixings




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Offering a complete flooring solution

velta one floor heating and cooling system to include: • Design development and Contract management • Design – drawings and calculation • PE- Xa pipe coils • velta fixing grid and fittings • Manifold and isolation valves • Installation and pressure testing • Commissioning of system • Warranty and certification • Supply and installation of floor slab and velta one system can be undertaken as a single contract with associated single warranty


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