Modern Building Services

MODERN BUILDING SERVICES MARCH 2021 21 FEATURE HEATING To meet the specification for the centralised plant within the design parameters, our Packaged Plant Solutions subsidiary supplied six Remeha Quinta Ace 115 boilers on a prefabricated skid, complete with pipework, pumps and Plate Heat Exchangers (PHEs). The existing utility cupboard spaces within each property also needed refurbishing. We supplied a Baxi HIU unit, together with controls and a heat meter, pre-assembled the Megaflo ECO cylinders with the associated pipework, and provided first fix rails for a time-saving solution. Using prefabrication paid dividends. “The major advantage for us was the time saved on site,” said Ian Winterflood, Head of Electrical and Mechanical Services at Peabody. “The works began at the start of the year, so with COVID-19 restrictions in place just a few months later, we were running a little behind. “However, thanks to the solution provided, Milverdene, the project contractor, was able to complete the changeover in just one day and then refurbish five properties a day, putting us firmly back on schedule. We also didn’t have to worry about multiple deliveries or materials being left on site as the solutions arrived pre-assembled and ready for installation just when needed.” Certainty factor Prefabrication also benefits smaller-scale projects such as boiler replacements. Whether it’s a one-off heating upgrade or a series or plant room refurbishments, using turnkey heating solutions can help meet tight project schedules and minimise system downtime. Take Remeha’s bespoke boiler rig and cascade systems. These mini plant room systems provide manufacturer design input with pumps, boiler configuration and other components matched to deliver the required performance in an arrangement tailored to the specific site constraints. The design opportunities are virtually limitless, with options for wall-hung or floor-standing boilers – or even a mix of the two – and low loss headers or PHEs. Ancillary items such as dosing pots and pressurisation units as well as project-specific controls can also be integrated into the design to maximise seasonal efficiency and performance. Like the larger-scale solutions, they are designed using BIM tools and 3D computer-aided design (CAD) systems, so stakeholders can collaborate on the system design and fully evaluate the functionality before the build begins. In this way, onsite snags are avoided. Once the design has been agreed and the unit is built, it is delivered to the plant room either as a single wheeled unit or in easily connected modules with insulated pipework set, ready for rapid connection. The certainty of speedy installation and reduction in number of workers, skills and time required to be spent on site aremajor benefits at all times, but particularly working in COVID-19 times. Increased productivity The time savings from using prefabricated solutions was central to the successful delivery of a major heating refurbishment programme by consultants CJR Midlands and M&E contractor ASBN for Nottinghamshire Police. Time was the critical challenge as the heating systems at all seven police stations needed to be refurbished in just three months. CJRMidlands specified a combination of Gas 220 Ace floor- standing boilers with Remeha offsite fabricated cascade arrangements to meet the requirements. Working with both CJR and ABSN, Remeha prepared 3D drawings of the boiler cascade arrangement to the specified layout for each of the sites and integrated Low Temperature Hot Water (LTHW) and gas headers, pump sets and a PHE into the design. For ABSN, a major advantage of using offsite fabrication was the ability to prepare the connecting pipework before delivery of the boiler modules. “Having the detailed, co-ordinated dimensioned designs for each plantroomallowed us both to procure and to preinstall pipework in readiness for the boiler delivery,” said ABSN Director Nick Clews. “This helped speed up the installation process considerably.” Rise of offsite Given the considerable advantages of prefab, both on smaller and larger-scale projects, from refurbishment to newbuild, its rise in use is unsurprising – and particularly so in the COVID-19 scenario. By encouraging early engagement of stakeholders prior to the build, this approach ensures a quality solution that optimises certainty and safety while delivering the all-important time savings. The consultant engineer has the necessary design flexibility tomeet all project and customer requirements and the assurance that it retains the original specification detail. And it’s easier for contractors to plan ahead and ramp up productivity by putting skills to use on other areas or projects. With our comprehensive commercial heating portfolio and established prefabrication expertise, we look forward to supporting consultants and contractors with our bespoke offsite heating solutions to deliver prefab benefits both during COVID times and beyond. “Having the detailed, co-ordinated dimensioned designs for each plantroomallowed us both to procure and to preinstall pipework in readiness for the boiler delivery”