RAUPANEL DRY SYSTEM HIGH PERFORMANCE PANEL SYSTEM www.rehau.com Construction Automotive Industry
RAUPANEL SYSTEM OUTLINE - System Introduction - System advantages - System components - Installation techniques - Installing panels and pipes - Nail-down hardwood floors - Floating and glue-down floors - Carpet and vinyl floors - Tile floors - Over existing slab - RAUPANEL layouts - Routing pipe tails to manifolds - Installing EVERLOC couplings - Wall heating - Features and benefits summary - Comparison with other options - Performance testing - Installed cost comparisons REHAU 26-Mar-10 - Page 2
RAUPANEL SYSTEM INTRODUCTION - Aluminum is extruded with groove to hold 3/8 RAUPEX O 2 Barrier pipes with 270-degree contact - Total panel thickness is just 5/8 - Components allow for 6 or 8 o-c pipe spacing - Lightweight system, only 1.5 lbs/ft 2 - Combination of Aluminum and Plywood - λ of Aluminum = 230 Infra-red photograph of RAUPANEL system REHAU 26-Mar-10 - Page 3
RAUPANEL SYSTEM ADVANTAGES OF THE RAUPANEL ALUMINUM SYSTEM FOR THE DESIGNER - Ideal for kitchens, baths, entire house - May be used in floors, walls, ceilings - Efficient - Low-profile - Lightweight - High performance - Fast response time - Nighttime setback is an option - Solar gain problems are reduced - Easy to plan - Easy to install REHAU 26-Mar-10 - Page 4
RAUPANEL SYSTEM ADVANTAGES OF THE RAUPANEL ALUMINUM SYSTEM FOR THE CONTRACTOR - Higher efficiency thanks to reduced downward heat transfer and aluminum panels - May eliminate insulation under subfloors (over heated space below) - May eliminate double baseplates due to reduced floor thickness - No special equipment necessary (no wet thermal mass) - Faster response time than an overpour (lighter weight) - Suitable for both retrofit and new construction - No complicated scheduling and preparation - Fewer changes to overall construction - Eliminates other trade (thermal mass) - Design flexibility, easier to zone - Available when you want it - Everything is boxed - A complete system - Easy to carry - Low profile REHAU 26-Mar-10 - Page 5
RAUPANEL INSTALLATION COMPONENTS FIT TOGETHER AS A SYSTEM (1-2-3) 1. Lay out Return Bends and Furring Strips (for 8 spacing) 2. Drop Aluminum panels onto floor; align into notches with 8 Bends Note: Be sure that subfloor is clean before installation of panels REHAU 26-Mar-10 - Page 7
RAUPANEL INSTALLATION COMPONENTS FIT TOGETHER AS A SYSTEM (1-2-3) Note: Leave 1/16 to 1/8 gap between ends of panels to allow for possible house movement or shrinkage REHAU 26-Mar-10 - Page 8
RAUPANEL INSTALLATION COMPONENTS FIT TOGETHER AS A SYSTEM (1-2-3) 3. Pipe is walked into the groove; a rubber mallet may be needed to set it in Note: Be sure that panel grooves are clean before installation of pipes Note: No silicone is used to fill grooves. Pipes will not pop out when properly installed REHAU 26-Mar-10 - Page 10
RAUPANEL INSTALLATION DEBURR FIELD CUTS WITH DEBURRING TOOL IN THE GROOVE WARNING! Wear gloves and eye protection when handling pieces REHAU 26-Mar-10 - Page 11
RAUPANEL INSTALLATION THE NEXT STEPS: THE FOLLOWING INSTALLATION GUIDELINES APPLY TO VARIOUS FLOORING CHOICES 1. Nail-down hardwood flooring (over suspended subfloor) 2. Floating and glue-down flooring (over suspended subfloor) 3. Carpet and vinyl (over suspended subfloor) 4. Tile (over suspended subfloor) 5. Installations over concrete slabs Notes: - These are general guidelines for installation of RAUPANEL under common floor coverings - Certain floor coverings may have specific installation requirements which are not covered in this document - It is the responsibility of the installing heating contractor to work with other trades, including the installer of the finished floors, to ensure that the flooring manufacturer s requirements are adhered REHAU 26-Mar-10 - Page 12
RAUPANEL INSTALLATION NAIL-DOWN HARDWOOD FLOORS 1. Install panels and pipes following the first Steps 1-2-3 2. Screw or nail Return Bends and Furring Strips to subfloor (use maximum 8 spacing between screws or nails) 3. Let the Aluminum panels float between plywood panels no need to screw these down 4. Install hardwood directly over RAUPANEL system (perpendicular in direction to panels) 5. Nail or staple hardwood boards into plywood components or through aluminum/into subfloor if necessary - Fasten boards every 6-8 It is recommended to use 8 spacing with furring strips when installing nail-down hardwood Note: Panel system may be loose and noisy until all hardwood is properly secured REHAU 26-Mar-10 - Page 13
RAUPANEL INSTALLATION NAIL-DOWN HARDWOOD FLOORS - Minimum 8 screws per Return Bend - Minimum 5 screws per Furring Strip - If subfloor is not even or has excessive deflection ( bounce ), then more fasteners may be required to prevent noise - Fasten as necessary - Screws: - Use fine-thread drywall screws or deck screws - Nails: - Use rough roofing nails or ringshank nails, not smooth nails, which could work loose - Nails must be long enough 8 spacing 8 spacing Note: Panel system may be loose and noisy until all hardwood is properly secured REHAU 26-Mar-10 - Page 15
RAUPANEL INSTALLATION NAIL-DOWN HARDWOOD FLOORS 6 SPACING INSTALLATION WITH HARDWOOD - If 6 spacing is necessary for heat load, this installation is possible - Aluminum panels and plywood pieces must be fastened to subfloor following instructions - Nail or staple hardwood flooring through aluminum panels into subfloor, every 6 - Must use 2 or longer cleats, nails or staples - It is recommended to use 5/8 or 1/2 thick hardwood to ensure most secure fastening 6 spacing REHAU 26-Mar-10 - Page 17
RAUPANEL INSTALLATION NAIL-DOWN HARDWOOD FLOORS 6 SPACING INSTALLATION WITH HARDWOOD - Must use 2 or longer cleats, nails or staples for good bite into subfloor - With 3/4 solid hardwood, a 2 fastener will have 5/8 length bite into subfloor - It is recommended to use 5/8 or 1/2 thick hardwood to ensure most secure fastening 2 Long REHAU 26-Mar-10 - Page 18
RAUPANEL INSTALLATION TYPICAL INSTALLATION WITH NAIL-DOWN HARDWOOD FLOORS REHAU 26-Mar-10 - Page 19
RAUPANEL INSTALLATION FLOATING AND GLUE-DOWN FLOORS 1. Install panels and pipes following the first Steps 1-2-3 2. Screw or nail Return Bends and Furring Strips to subfloor (use maximum 8 spacing between screws or nails) 3. Fasten Aluminum panels 3 times per side - Total 6 per panel per 6-foot length 4. Install flooring as per manufacturer s recommendations - Avoid contacting glue onto pipes - Use 8 screws per Return Bend* - Use 5 screws per Furring Strip* - Use 6 screws per Aluminum Panel* *Per full length components Note: Always feel free to add extra fasteners if movement or noise is suspected REHAU 26-Mar-10 - Page 20
RAUPANEL LAYOUTS TYPICAL INSTALLATION WITH FLOATING FLOORS REHAU 26-Mar-10 - Page 22
RAUPANEL LAYOUTS TYPICAL INSTALLATION WITH FLOATING FLOORS REHAU 26-Mar-10 - Page 23
RAUPANEL INSTALLATION TILE FLOORS USING MORTAR BOARD AS ALTERNATIVE TO DIRECT PLACEMENT OF THINSET Sample cutaway floor: - 1/4 thick mortar board installed directly over RAUPANEL at 6 o-c spacing with maximum 8 grid spacing for screws - Tile placed on thinset over mortar board Note: When using panels at 6 o-c install screws at 6 o-c spacing also to avoid hitting pipes REHAU 26-Mar-10 - Page 27
RAUPANEL INSTALLATION TILE FLOORS USING MORTAR BOARD AS ALTERNATIVE TO DIRECT PLACEMENT OF THINSET Sample cutaway floor: - 1/4 thick mortar board installed directly over RAUPANEL at 6 o-c spacing - Tile placed on thinset over mortar board - Panels installed directly under shower pan for warmth REHAU 26-Mar-10 - Page 28
RAUPANEL INSTALLATION TYPICAL INSTALLATION WITH TILE FLOORS - 1/4 or 3/8 mortar board with 8 maximum grid spacing for screws REHAU 26-Mar-10 - Page 29
RAUPANEL INSTALLATION OVER EXISTING SLAB 1. If necessary, level floor with self-leveling thin-set 2. Cover existing slab (or above the leveling layer) with a poly or tar paper vapor barrier (not aluminum) to block possible moisture permeation 3. Install panels and pipes following the first Steps 1-2-3 4. Depending on the flooring to be used, follow that typical installation technique: - When anchoring panel pieces, overlayment or mortar board, use proper fasteners for anchoring to concrete (ram-sets may work; masonry screws do work) - Be sure not to penetrate any existing pipes, cables, etc. in existing slab floor - Follow all safety precautions for using concrete fasteners REHAU 26-Mar-10 - Page 30
RAUPANEL INSTALLATION SEE REHAU REFERENCE DOCUMENTS CD - REHAU Reference Documents (CD) has Detailed Installation Drawings for installation techniques - Example: REHAU 26-Mar-10 - Page 31
RAUPANEL LAYOUTS HALLWAYS SHOULD BE FILLED WITH RAUPANEL TO AVOID COLD FLOORS, BUT THERE MAY NOT BE ENOUGH SPACE FOR ALL CIRCUIT TAILS IN HALLWAYS - Sometimes there are too many pipes to fit in a hallway, all within the panels (too many circuits to supply) - May have to install some pipes outside panels, or you may have to install some pipes through the subfloor to reach the manifold REHAU 26-Mar-10 - Page 38
ROUTING PIPE TAILS TO MANIFOLDS MACHINE OR ROUTER YOUR OWN PLYWOOD CUSTOM RETURNS REHAU 26-Mar-10 - Page 39
ROUTING PIPE TAILS TO MANIFOLDS DRILL 1 INCH HOLE AT 45-DEGREE ANGLE IN SUBFLOOR USE EVERLOC COUPLINGS TO EXTEND TAILS TO MANIFOLD REHAU 26-Mar-10 - Page 40
ROUTING PIPE TAILS TO MANIFOLDS DRILL 1 INCH HOLE AT 45-DEGREE ANGLE IN SUBFLOOR RUN PIPES THROUGH THE JOIST CAVITIES TO MANIFOLD - Note: These pipes are too close to the end of the panels. Not a good example REHAU 26-Mar-10 - Page 41
ROUTING PIPE TAILS TO MANIFOLDS DRILL 1 INCH HOLE AT 45-DEGREE ANGLE IN SUBFLOOR USE EVERLOC COUPLINGS TO EXTEND TAILS TO MANIFOLD REHAU 26-Mar-10 - Page 42
ROUTING PIPE TAILS TO MANIFOLDS DRILL 1 INCH HOLE AT 45-DEGREE ANGLE IN SUBFLOOR RUN PIPES THROUGH THE JOIST CAVITIES TO MANIFOLD REHAU 26-Mar-10 - Page 43
ROUTING PIPE TAILS TO MANIFOLDS JIGSAW A SLOT IN THE FLOOR RUN PIPES THROUGH THE JOIST CAVITIES TO MANIFOLD - Route pipes through floors and joist cavities to get to manifolds REHAU 26-Mar-10 - Page 44
ROUTING PIPE TAILS TO MANIFOLDS RUN ALL THE PIPES IN ONE NARROW AREA? NO! THIS METHOD IS NOT RECOMMENDED (HOT SPOT) - Avoid routing pipes to manifold on the subfloor go below REHAU 26-Mar-10 - Page 45
WALLS AND CEILINGS APPLICATIONS IN WALLS AND CEILINGS - Use panels for walls where supplemental heat is needed - Very nice in bathrooms, tub/shower walls, behind large mirrors, tubs Interior drywall REHAU 26-Mar-10 - Page 47
WALLS AND CEILINGS APPLICATIONS IN WALLS AND CEILINGS - Use panels for walls or ceilings where floor space is limited (bathrooms, kitchens, mudrooms) - May be the same circuit of pipe, same water temperature - Keep panels within 3 feet of floor to prevent future pipe punctures - Use furring strips on edges of studs above panels to make walls flush for drywall - Insulate behind panels at outside walls or ceilings REHAU 26-Mar-10 - Page 48
WALLS AND CEILINGS INSTALLED IN A WALL SURROUNDING A SHOWER Sample cutaway wall: - 1/4 thick tileboard board installed directly over RAUPANEL at 8 o-c spacing - Tile is placed on thinset over tileboard - Furring strips are used on stud edges above panels to flush out the walls before tileboard installation REHAU 26-Mar-10 - Page 49
WALLS AND CEILINGS INSTALLED IN A WALL SURROUNDING A SHOWER Sample cutaway wall: - 1/4 thick tileboard board installed directly over RAUPANEL at 8 o-c spacing - Tile placed on thinset over tileboard - Great for warming tub/shower area - Adds supplemental heat to entire bathroom, kitchen or mudroom REHAU 26-Mar-10 - Page 50
RELATIVE OUTPUT OF RFH SYSTEMS VTECH STUDY RESULTS: COMPARISON OF FLOOR OUTPUT WITH 110 F INPUT WATER TEMPERATURE Output with 110 F Input Water Temperature Position System Output BTU/hr-ft 2 1 2 3 4 5 6 7 8 9 10 RAUPANEL 6" spacing RAUPANEL 8" spacing MDF board with foil face, 8" spacing (ThermalBoard) Expanded PS base with aluminum plates, 6" spacing (Roth) Gypsum cement overpour 1 1/2" thick, 8" spacing Joist Space with heavy gauge extruded aluminum plates, 8" spacing (Thin-Fin) Thin plywood with aluminum backing, 7" spacing (Quik-Trak) Structural plywood with aluminum facing, 12" spacing (WarmBoard) Joist Space, no heat transfer plates, 8" spacing Joist Space, aluminum louvers in air cavities, 24" spacing (Ultra-Fin) 30 28 19.5 19.1 18.5 18 18 17.5 7 5.6 REHAU 26-Mar-10 - Page 60
RELATIVE OUTPUT OF RFH SYSTEMS VTECH STUDY RESULTS: COMPARISON OF FLOOR OUTPUT WITH 110 F INPUT WATER TEMPERATURE Radiant Floor Heating System Relative Output 35 30 25 20 15 10 5 0 Output, BTU/hr per Square Foot with 1/4" thick plywood covering RAUPANEL 6" spacing RAUPANEL 8" spacing MDF board w ith fo il fa c e, 8" spacing Expanded PS base with alum imum plates, 6" G ypsum cement overpour, 1 1/2" thick, 8" spacing Joist Space with extruded aluminum plates, 8" Thin plywood with alum inum backing, 7" Structural plywood with alum inum fa c ing, 1 2 " Joist Space, no heat transfer plates, 8" Joist Space, aluminum louvers in air cavities, 1 2 3 4 5 6 7 8 9 10 Commercial Radiant Floor Heating Systems Tested, 110 F Water Temperature REHAU 26-Mar-10 - Page 62
RAUPANEL ADVANTAGES HIGHER PUMPING EFFICIENCY (LOWER HEADLOSS) RAUPANEL uses 3/8 PEXa pipe: - 3/8 RAUPEX pipe has 1/3 the headloss of 5/16 PEX pipe - Smaller pumps can be used - Longer circuits are possible - Lower Delta-T across manifold Example: 0.4 GPM, 250 ft circuit designed to deliver 4,000 BTU/hr - 5/16 hepex: 18.6 ft headloss - 3/8 RAUPEX: 6.3 ft headloss Head Loss (feet of head) with 120 o F (49 o C) Water 5/16" (10 mm) PEX** Flow Rate Loss 100 foot 150 foot 200 foot 250 foot GPM per foot* circuit circuit circuit circuit 0.1 0.0063 0.63 0.95 1.26 1.58 0.2 0.0215 2.15 3.23 4.30 5.38 0.3 0.0445 4.45 6.68 8.90 11.1 0.4 0.0744 7.44 11.2 14.9 18.6 0.5 0.1109 11.1 16.6 22.2 27.7 0.6 0.1537 15.4 23.1 30.7 38.4 Head Loss (feet of head) with 120 o F (49 o C) Water 3/8" RAUPEX Pipe Flow Rate Velocity 100 foot 150 foot 200 foot 250 foot GPM ft/sec circuit circuit circuit circuit 0.1 0.32 0.21 0.32 0.43 0.53 0.2 0.63 0.73 1.10 1.46 1.83 0.3 0.95 1.51 2.26 3.02 3.77 0.4 1.26 2.52 3.78 5.04 6.30 0.5 1.58 3.76 5.64 7.52 9.40 0.6 1.89 5.21 7.81 10.4 13.0 REHAU 26-Mar-10 - Page 63
RAUPANEL DRY SYSTEM HIGH PERFORMANCE PANEL SYSTEM www.rehau.com Construction Automotive Industry