Metro Rail Installation Manual
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Metro Rail Underoor
Heating Installation Manual
Technical Helpline
0845 345 2288
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Product Information
Important Information
Expansion Joint
Laying Patterns
Installation
Pressure Testing
Screeding & Floor Covering
Information
Warranty
Pressure Test Report
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4
6
7
Contents
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9
If you require any help at any stage of the installation please call our helpline :
Warmup Technical Helpline 0845 345 2288
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IMPORTANT
Please read this manual before attempting
to install your under oor heating.
Incorrect installation will invalidate your
warranty.
Warmup Plc, accepts no liabilty, expressed
or implied, for any loss or consequential
damaged su ered as a result of
installations which in any way contravene
the instructions that follow.
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Product Information - Warmup® Metro Rail System
Floor Covering
Screed
Warmup pipe
Warmup Metro Rail
Warmup Polythene Membrane
Warmup Insulation
Sub oor with built in DPM
Warmup Perimeter Strip
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2
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4
5
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8
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System Description
The Warmup Metro Rail System uses pre-moulded retention clips. The
rail is located on top of the insulation layer and is separated by a plastic
membrane. The Metro Rail System allows pipes to be spaced at 50mm
intervals. The system holds the pipework into place until the screed is
applied.
It is suitable for almost any oor nish and in particular where the ooring
(wood, carpet or vinyl) may be replaced from time to time.
Technical Information
The sub oor below the Warmup Metro System must be smooth and level,
capable of supporting the oor zone and imposed loads. A Damp Proof
Membrane (DPM) may be required.
The Warmup Metro Insulation will meet both the relevant statutory and
thermal effi ciency requirements. Each insulation board covers an area
of 2.88m2 and is available in a choice of thickness from 25 to 100mm and
varying compressive strengths designed to meet the project’s exact
requirements.
On top of the insulation a plastic membrane of at least 500 gauge is
placed to act as a moisture barrier for the screed as it cures.
Warmup Metro Rails are then placed onto the membrane at
approximately 1m spacings and run parallel to each other. They come
with an adhesive back to stick to the membrane. Occasionally clips will be
required to assist the process.
The pipe is located into the rails and laid as per the approved design.
Once the system has been installed and pressure tested it should be
protected and screeded as soon as possible, screed is laid to a depth
normally of between 50 to 75mm.
Output from the system will be designed to meet your requirements
taking into account such criteria as oor nishes.
Components Required
Item Information
Warmup Pipe PEX-a - 16mm or
20mm
PE-RT/AL /PE-RT -
16mm
PE-RT - 16mm
Warmup Metro Insulation
Board
PIR or EPS Plain or
Gridded insulation
boards available
in 25mm -100mm
thickness.
Warmup Perimeter Strip
Part no. WHS-X-EDGE50
8mm x 150mm x
50m
Warmup Polythene
Membrane
Part no. WHS-X-POL500
Part no. WHS-X-POL1200
4m x 50m rolls
4m x 25m rolls
Warmup Pipe Conduit
protection
Part no. WHS-CL-CONDUIT
25mm conduit
available in 50m
lengths
Warmup Metro Clip Rail Suitable for 16
-20mm pipes
Length - 1m
Clypso clip Fixing Gun
Part no. Fix-1
Suitable for use
with all Warmup
clips
Clypso Clips available in
40mm,45m,60mm
& 65mm.
Warmup Pipe Bend Support
Part no. WHS-P-BEND
Suitable for use
with all Warmup
pipes
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Important Information
Before commencing installation, it is important that a site inspection is performed. You will need to con rm that all
measurements and other requirements on site match your building plans.
Ensure that all sub oors are the correct depth needed to incorporate the under oor heating. Check for anything that might
interfere with pipe installation such as concrete walls where they were not expected or changes to the oor layout.
Note: A redesign of the layout system may be required if any changes have been made.
Insulation
In accordance with Part ‘L’ of the current Building Regulations, a suitable layer of insulation material should be included
within the oor construction. It is the responsibility of the Architect or Builder to ensure compliance. The insulation must be
installed beneath the under oor heating system in order to ensure that any downward heat loss does not exceed 10W/m2, in
accordance with BS EN 1264.
Damage
Inspect the site for possible hazards that could damage the WARMUP pipe, such as nails, staples, materials or tools. Remove
any items or potential hazards before installing pipe.
When handling the WARMUP PIPE it is important to protect the pipe from damage.
Uncoiling the pipe
DO NOT pull of the coil while it is sitting at. It must be unwound from the coil, pulling from the top or the bottom of the coil.
This will require one person to hold the pipe o the ground, or the use of an uncoiling device such as the WHUF-UNWINDER.
Bending Radius of the Pipe
When laying the pipe, do not force the pipe into bends. It is easier to lay the pipe with a large radius and then gently pull the
pipe to the required bend.
The maximum bending radius is 5 times the diameter of the pipe.
Kinking
Pex- a pipe only
Excessive bending of the pipe can cause it to kink, where this occurs ow may be obstructed or reduced. Kinked pipe must be
repaired. To repair a kink, straighten the pipe and simply heat the area with a hot air gun until the kink disappears.
NOTE: DO NOT use an open ame to heat the pipe.
Heat around the pipe to evenly heat the surface. Ensure that you do not overheat the pipe as this will result in damage . The
maximum temperature that the PEX-a pipe can withstand is 95°C.
NOTE: Do not try to bend the pipe in the same spot.
Where the pipe is not Pex-a the circuit will need to be replaced with a new pipework.
Cutting the pipe
Use a pipe cutter designed for plastic pipe ensuring that there are no burrs on the pipe ends. It is important to achieve a clean
cut.
NOTE: If you accidentally damage a Warmup under oor heating pipe BEFORE covering it with screed or other coverings,
under the Warmup Safetynet guarantee you may return the damaged coil of pipe to Warmup, who will replace the coil FREE
OF CHARGE with pipe of the same length and type.
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Important Information
Pipe Installation
Install the pipe along outside walls rst so that the hottest (supply) water goes to the coldest areas. Pipe should not be in-
stalled under appliances such as freezers.
If a pipe circuit is installed under oor coverings such as carpet and tile, install pipe under the high R-value area rst if possible,
as this area will require a higher water temperature.
Keep pipe at least 15 cm from the edges of slabs, walls or other permanent objects in order to prevent damage. This will help
to prevent damage to the pipe when these items or
ooring materials are being installed.
The pipe must not overlap when encased in a Screed as this will reduce the thickness of the Screed possibly leading to dam-
age and/or “hot spots”.
Plan the circuit layout ensuring that pipes can connect to manifolds without crossing each other.
Ensure that all circuits have been planned in advance to minimize areas where the pipe passes through expansion joints.
Locations where pipes pass through expansion joints, door frames, walls or where the pipe could get damaged by sharp
edges will require protection.
In con ned areas it may not be possible to use the designed spacing. To avoid cold spots always use tighter spacing and
more pipe rather than wider spacing and less pipe.
In the areas where pipes are closer than 10 cm such as near manifolds, if the thickness of the Screed permits, insulate the
pipes with conduit to prevent “hot spots”.
Protecting the Warmup Pipe
Pipe Bends
Protection will be required where the Warmup pipe enters the screed.
The recommended method for protecting the pipe is the rigid PVC Bend
Guide, which holds the pipe in a 90° bend, as well as protecting the pipe
from damage.
To install PVC Bend Guides, simply insert the WARMUP pipe through the
PVC Bend Guide to the appropriate length, (50-75 cm) .The PVC Bend Guide
should be positioned so that the pipe rises straight to the manifold with
approximately half the guide within the oor.
Conduit Sleeving
Using the Warmup pipe conduit protection sleeve across all construction
joints in oor. Locations where pipes pass through expansion joints, door
frames, walls or where the pipe could get damaged by sharp edges will
require protection.
When installing the conduit cut along the length of the conduit and clip onto
pipe.
Use the Warmup Pipe Bend
Support where it enters the oor.
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Expansion Joints
Heated screeds will expand and contract slightly during use. The perimeter insulation will allow for a certain amount of ex-
pansion in the slab but expansion joints may also be required. As per BS EN 1264-4 expansion joints should be used for every
40m² at a maximum length of 8m and an aspect ratio of 2:1.
One joint is always required between a heated
screed slab and an unheated screed slab.
The pipe must be protected using the expan-
sion joint pro le and the corrugated sleeve,
extending to at least 300mm either side of the
joint.
Where these joints occur, the pipework circuits
crossing them should be kept to a minimum.
Where pipes are to cross over a screed
expansion joint, use a small section of conduit
over the pipe, up to a minimum of 300mm
either side of the joint.
It is important that all planned joints must be
marked on the design drawings.
For further information regarding oor screeding requirements for under oor heating systems please refer to BS8204-1.
Laying Patterns
The following laying pattern should be used when installing the Metro system.
Single Meander
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Warmup® Metro rail system - Installation
Step 1
Ensure that the installation area is dry and sealed to the elements and that you
have a at even oor surface.
Step 2
Install the Warmup perimeter strip around the perimeter of the room.
Ensure that the strip is positioned above screed level using glue or staples.
Always ensure that there are no gaps that could allow contact between the
screed and the structure.
NOTE: Care must be taken to ensure any damp proof membrane in the wall is
not perforated.
Step 3
Lay the Metro Insulation over the entire floor area butting the boards up to the
perimeter strip. The Boards should be laid in a brick wall pattern with all the
boards butted tightly against each other.
Make sure all joints are be taped together to prevent screed slipping down
between the insulation boards.
Fix the The polythene overlap of the perimeter strip to the tacker board using
tape .
Step 4
Lay the polythene DPM sheet over the oor insulation. Ensure that the sheet
is placed above the nished oor height and that the sheets overlap each
other by 80mm. Ensure that all joints are taped to ensure that the membrane is
watertight.
Step 5
Fix the Metro cliprail to the insulation using the Warmup clips every 400mm
approximately 1m apart. Ensure that the rails are xed and that all of the slots
are aligned to ensure correct pipe spacing.
Fix the rails 800mm from walls to allow enough space for the pipe bends. Use
Rails in areas where the pipe bends to ensure even spacing.
Step 6
After establishing the area to be covered by the circuit, connect to the
manifold holding the pipe at a 90° bend using the Warmup pipe bend support.
(See page 5)
Step 7
Start laying the pipe clipping into the rail at the set spacings as per the
under oor heating design.
Locations where pipes pass through expansion joints, door frames, walls or
where the pipe could get damaged by sharp edges will require protection.
Using the Warmup pipe Conduit protection cover the pipe.
Spilt the sleeving along its length and fix over the pipe.
Step 8
Fix pipe bend to the return pipe and connect to the manifold.
Step 9
Complete Steps 6-8 for each circuit.
Prepare the sub oor
Install the perimeter strip and the Metro
insulation
Lay the Warmup Polythene Membrane
Fix the Metro cliprail to the insulation and x
the pipe.
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Screeding & Floor Coverings
Pressure Testing
A system pressure test MUST be carried out before the screed has been laid. The system should be lled and each circuit
purged of air.
Connect the pressure tester to the drain valve and increase the pressure test to 6 bar.
Leave at 6 bar for 1 hr. If the pressure level remains stable record the results on the pressure test certi cate.
If you see that the pressure has dropped you will need to inspect the pipework for damage and ttings for proper attachment.
Once the pressure test is complete reduce the system pressure down to 3 bar during screeding to protect the pipework.
Ensure that the screed has fully cured before using the under oor heating system as this may reduce the moisture content of
the screed.
Once the screed has cured and has undergone its rst heat cycle, minor micro cracking may occur within the screed. This does
NOT a ect the performance of the screed. However, nal oor coverings must NOT be laid until the oor has cooled down
completely.
When installing an under oor heating system the thermal conductivity of the nal oor covering must be considered at the
design stage.
Ensure that the oor covering is suitable for use with under oor heating. It is also important to check that any adhesives used
with the oor covering are suitable and can tolerate the oor surface temperatures.
Timber oors
The important factor is the oor moisture content.
Timber oors can be laid directly over the screed if they have a moisture content of 10-11% which when heated will reduce to
8-9% and may cause a small amount shrinkage.
The oor will re-absorb some moisture when the heating is not operating and the moisture content will increase to 12-13%.
The timber oor nish should not exceed 18mm in thickness. Timber ooring carries a 27°C surface temperature limit.
Carpet
The thermal resistance of carpets and underlay is fundamental in attaining good heat transfer.
The most popular underlay type is sponge with a waffl e pattern molded into the underside.
These allow good heat transfer. Felt and rubber crumb underlay should be avoided. These products can seriously reduce the
e ectiveness of an under oor heating system, as they insulate the oor surface and prevent heat transfer. For optimal system
performance choose an underlay with a maximum TOG value of approximately 0.5. The maximum combined TOG value of
carpet should not exceed 2.5 TOG.
Tiles
These oor coverings work well with under oor heating. The Tiles should be laid on a full bed with no air gaps. It is important
that the design of the supporting oor structure is stable and rigid to prevent cracking. It is recommended that exible
adhesives and grout be used.
Vinyl
Check the oor surface temperature indicated by your vinyl supplier for compatibility with under oor heating.
Vinyl ooring carries a 27°C surface temperature limit.
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Warmup Plc Limited Warranty – Hydronic Floor Heating Pipe
PLEASE REGISTER YOUR UNDERFLOOR HEATING SYSTEM ONLINE AT: www.warmup.co.uk
Registration can be completed online at www.warmup.co.uk. In the event of a claim, proof of purchase is required, so keep
your invoice and receipt - such invoice and receipt should state the type of pipe that has been purchased.
THIS WARRANTY DOES NOT EXTEND TO OTHER COMPONENTS WHICH ARE COVERED BY SEPARATE WARRANTIES. THIS
WARRANTY DOES NOT AFFECT YOUR STATUTORY RIGHTS.
Limited Warranty:
Warmup® underfloor heating pipe is warranted by WARMUP PLC (“Warmup”) to be free from defects in manufacturing under
normal use and maintenance, and is warranted to remain so subject to the limitations and conditions described below.
This warranty period begins on the date of purchase. Registration is confirmed only when confirmation of receipt is forwarded
by Warmup PLC.
Warranty Duration
•The Pex-a Underfloor heating pipe is warranted for the LIFETIME of the floor under which it is fitted,
except as provided below; your attention is drawn to the exclusions listed and the end of this warranty.
•The Pe-rt Underfloor heating pipe is warranted for a period of 50 years from date of purchase, except
as provided below; your attention is drawn to the exclusions listed and the end of this warranty.
•The Pe-rt-Al-Pe-rt Underfloor heating pipe is warranted for a period of 50 years from date of purchase,
except as provided below; your attention is drawn to the exclusions listed and the end of this warranty.
Notification of a suspected failure must be received in writing by Warmup within thirty (30) days of the suspected breach.
Products believed to be defective must be made available to Warmup for testing and determination of cause.
Upon acceptance of any warranty claim, Warmup shall have ninety (90) business days in which to investigate and determine
whether it recognises responsibility for any believed defects in material or workmanship and determines the appropriate
course of action to be taken.
It is expressly agreed that the sole remedies under this limited warranty shall be at the discretion of Warmup, Plc. to either:
issue a refund, repair or replace any article which is proven to be defective. Any and all allowances made to customers for
transportation, labour, repairs or all other work, are at the exclusive discretion of Warmup and shall be authorised in writing,
in advance, by Warmup. Such cost does not extend to any cost other than direct costs of repair or replacement by Warmup
and does not extend to costs of relaying or repairing any floor covering or floor.
The warranty applies to the products identified above only if they:
1.are registered with Warmup within 30 days after purchase;
2.are selected, designed and installed by a qualified contractor according to installation instructions provided by Warmup
which are current as of the applicable Installation Date;
3.are connected to appropriate power and water supplies;
4.are installed according to all applicable building code requirements;
5.are not exposed to pressures and/or temperatures that exceed any limitations printed on the warranted product or in the
applicable Warmup product installation manual;
6.remain in their original installed location, such that the floor covering or screed over the product is not damaged, lifted,
replaced, repaired or covered with subsequent layers of flooring;
7.do not show evidence of accidental damage, misuse, lack of care, tampering, or repair or modification without the prior
written approval of Warmup Plc.
Warranty
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Without limiting the foregoing, this Warmup Warranty does not apply to:
1.damage or repairs required as a consequence of faulty installation, application or abnormal operating conditions;
2.damage caused during installation, screeding, laying of the ooring or oor nish, or any other remedial works to the oor
that are done post installation;
3.damage as a result of oods, res, winds, lighting, accident, corrosive atmosphere, ultraviolet light or other conditions
beyond the control of Warmup Plc;
4.use of components or accessories not compatible with this product;
5.products installed outside the country of original intended destination when specied by Warmup.
6.Normal maintenance as described in the installation and operating manual.
7.Parts not supplied or designed by Warmup.
8.Any damage caused by frozen or broken heat transfer uid pipes in the event of equipment failure.
9.Changes in the appearance of a product that does not aect its performance.
NOTE: It is important to check that the pipe is pressure tested as specied in the installation manual, prior to screeding or nal
ooring/nishes being laid.
The above Limited Warranty is the full extent of explicit warranties provided by Warmup Plc.
By mutual agreement of all parties, it is agreed that this limited warranty, any claims arising from breach of contract, any
breach of warranty, or any other claim arising, shall be governed under the laws of England and Wales. It is expressly
understood that Warmup Sales Representatives, Engineers, Distributors, Sub-contractors and Sales and Technical Support
Team Members have no authority whatsoever to bind Warmup to any agreement, warranty or remedy of any kind without the
express written consent of Warmup Plc.
WARMUP PLC. DISCLAIMS:
•ANY WARRANTY NOT PROVIDED HEREIN INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR
A PARTICULAR PURPOSE.
•ANY STATUTORY OR IMPLIED WARRANTY OF HABITABILITY AS WELL AS ANY RESPONSIBILITY FOR LOSSES, EXPENSES, AND
INCONVENIENCES, SPECIAL, INDIRECT, SECONDARY, INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING FROM POSSESSION
OR USE OF THE PRODUCTS AND ITEMS SOLD HEREUNDER.
THIS WARRANTY DOES NOT AFFECT YOUR STATUTORY RIGHTS.
The Warmup Safety Net Installation Guarantee for Underoor Heating Pipe
The Guarantee:
If you accidentally damage a Warmup underoor heating pipe BEFORE covering it with screed or other coverings, you may
return the damaged coil of pipe to Warmup, who will replace the coil FREE OF CHARGE with pipe of the same length and type.
Exceptions:
1.The Safety Net Guarantee does not cover any other type of damage, misuse, or improper installation due to improper
adhesive or suboor conditions. Limit of one free replacement coil of pipe of a maximum of 125m in length per customer,
installer and/or property.
2.If at any point Warmup believes the damage to be malicious or intentional, they shall reserve the right to withdraw this
guarantee.
3.Damage to the pipe that occurs after installing your system is not covered by the Safety Net installation guarantee.
4.You must purchase the Warmup Underoor Heating system from a recognised reseller, and follow all recommended
installation procedures written in the, at time of purchase, current Installation Manual. Failure to follow the instructions will
result in the revocation of the guarantee.
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Room / Area Circuit no. Pass Notes
Installer Name :
Address :
Client :
Installation Address :
Completion Date :
Signed by Tester : Print Name : Date:
Witnessed by: Print Name : Date:
Underoor Heating Pressure Test Report
This form must be completed and a copy sent to Warmup to validate the system warranty.
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Warmup PLC
702 & 704 Tudor Estate
Abbey Road
London
NW10 7UW
Web: www.warmup.co.uk
Email: uk@warmup.com
Tel: 0845 345 2288
Fax: 0845 345 2299
The WARMUP word and associated logos are trade marks. © Warmup Plc. 2014 – Regd. TM Nos. 1257724, 4409934, 4409926, 5265707. E & OE.
V1.0 2014
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