How It Works: Retrofitting Radiant Wall Heating Using Clay Plastering

Installation instructions

Our radiant wall heating kit for plastering is a system kit that has been optimised for retrofitting existing wall surfaces as radiant heating and for integrating the heating surfaces into the existing heating system. The wall heating system in the plaster version can be used for all common plaster materials. Suitable plasters are: gypsum, lime and clay plaster.

All required components are included in a single kit. The FLEXIRO heating pipes are laid on the wall quickly and cleanly in the previously installed honeycomb pipe support elements. The installation and connection of the wall heating to the existing heating system are simplified by the use of plug-in connections and KOMPA boxes for controlling the individual room temperature, so that FLEXIRO is equally suitable for professional installers and do-it-yourself enthusiasts. The following panels illustrate the steps for installing a wall heating system with clay plaster and a test setup approximately 2 m² in size.

Retrofitting FLEXIRO wall heating with plaster systems

Click on the picture panels to open the slideshow with larger picture versions

Clicking on Clicking on brief explanation of the installation

 

A PDF installation guide with more detailed descriptions can be found below the gallery

SCOPE OF DELIVERY FLEXIRO-10 KIT WALL HEATING FOR PLASTER SYSTEMS

You can find the detailed scope of the kit in the PDF installation guide.

 

You will also find further accessories and suitable tools in the FLEXIRO Shop.

IMPORTANT NOTES BEFORE STARTING THE INSTALLATION

The wall on which the FLEXIRO wall heating system is to be installed must have a sufficient load-bearing capacity and be suitable for plastering.

The arrangement of the individual wall heating surfaces must be determined when beginning the installation work. The FLEXIRO honeycomb elements (150 mm x 150 mm) can be slotted together as required. Usually the height of the wall heating is limited to about 2 metres. All installations in the wall surface, such as light switches or sockets, etc., should be installed before installing the FLEXIRO wall heating system. The honeycomb elements are omitted at these points. The edge junctions around the wall surface must then be filled later with a permanently elastic sealant.

IMPORTANT INSTRUCTIONS BEFORE STARTING THE INSTALLATION

Determine the arrangement of the heating circuits. The installation position of the KOMPA Box should be chosen so that the heating pipes from all heating circuits can be routed directly to the KOMPA Box without extending the heating pipes. NOTE: Kit 2.7 m2 corresponds to one heating circuit, Kit 5.4 m2 corresponds to 2 heating circuits, Kit 8.1 m2 corresponds to 3 heating circuits, Kit 10.8 m² corresponds to 4 heating circuits. The arrangement of the KOMPA Box on the wall surface should be chosen so that the indoor air can easily reach the thermostatic head and at the same time it is ensured that the KOMPA Box can be easily operated.

FITTING THE FLEXIRO HONEYCOMB ELEMENTS TO THE EXISTING WALL

Before mounting the honeycomb elements to the wall, make sure that you do not damage any electrical wiring or water, gas or heating pipes that may be installed in the wall when pre-drilling to insert the plastic nails. The wall must be prepared ready for plastering. If necessary, the plaster primer should already have been pre-painted or a concealed/adhesive plaster primer applied. The individual honeycomb elements are slotted together in the desired arrangement.

FITTING THE HONEYCOMB ELEMENTS TO THE EXISTING WALL

Position the honeycomb elements against the wall and pre-drill 6 mm holes for inserting the plastic nails. Fix the honeycomb elements by tapping in the plastic nail anchors. In general it is sufficient to fix every second honeycomb element.

INSTALLING FLEXIRO HEATING PIPES

When laying the heating pipes, you should optimally start near the distributor fingers in order to keep the pipe length required for the connection as short as possible. Various installation patterns for laying out the pipes are possible, for example meander- or snail-shaped installation.

INSTALLING FLEXIRO HEATING PIPES

The minimum distance between the heating pipes is 7.5 cm. The distance between the wall heating and the room walls should be at least 5 cm. It is important to avoid kinking the pipes when bending them. If the bend is raised from the ground, the loops can be fixed with dowel hooks.

The pipes should be laid without any twisting.

INSTALLING FLEXIRO HEATING PIPES

Kinked or damaged areas on the heating pipe should be cut out. The pipe must be reconnected with a permanently tight coupling (see Plug-in connector under Accessories). The coupling must be protected from direct contact with the plaster or surface covering by wrapping it in PE film. The position of the coupling must be marked. The same procedure should be followed if the pipes have to be extended.

CONNECTING TO THE KOMPA BOX

The distributor arms are connected to the KOMPA Box using the Eurocone connector. The Eurocone has a self-sealing effect while the metal screw connection has a purely safety-related function. Over-tightening should be avoided as this would compromise the safety of the heating system.

CONNECTING TO THE KOMPA BOX

The following illustrations show the arrangement of the heating pipes in the KOMPA Box. The heating pipes are connected to the distributor arms using the simple plug-in assembly. The heating pipes that have just been cut and possibly shortened are inserted directly into the plug-in connections of the distributor arms up to the stop.

 

You can find detailed information in the installation instructions as a PDF file.

CONNECTING TO THE HEATING SYSTEM

Make sure that the supply and return lines are correctly connected in the KOMPA Box. Mixing up the supply and return lines in the KOMPA box will disable the thermostatic valve and even prevent the flow through the FLEXIRO wall heating system.

 

You can find detailed information in the installation instructions as a PDF file.

PRESSURE TESTING THE HEATING SYSTEM

Make sure that the system and all associated components are correctly installed before putting the wall heating system into operation.

Follow our detailed instructions for the pressure test in the PDF installation guide.

TESTING THE WALL HEATING

Make sure you conduct a trail run before sealing the wall surface with plaster. This is the last opportunity to correct installation errors or damage.

Follow the detailed instructions for the trial run in our PDF installation guide.

APPLYING THE PLASTER LAYER

All common plaster materials approved for wall heating, such as gypsum, lime or clay plaster, are suitable for plastering over the wall heating system. When selecting the plaster material, however, it is essential that you observe the manufacturer's instructions for use.

 

APPLYING THE PLASTER LAYER

Before you start applying the plaster, make sure that the wall heating system is completely turned off. If operating, the wall heating can severely disrupt the curing process of the plaster material and even damage it.

The edge connection joints to the adjacent building components are sealed with elastic joint sealants.

COMMISSIONING (HEATING UP PROCESS)

On completing the plastering and once the plaster material, paints or surface coverings have naturally cured, the heating system can be put into operation. It is essential that you observe the plaster manufacturer’s special instructions for heating up the heating system.

 

During the first hours of operation, the desired surface temperature is set on the KOMPA Box by turning the thermostatic valve head. The FLEXIRO wall heating system is a radiant heating system. The sense of warmth is very direct. Adjust the temperature according to your sense of comfort and not according to the value you read on a thermometer. This enables you to save heating costs and still feel comfortable.

INSTALLATION DRAWING

Wall heating in plaster version for approx. 2.7 m², laying pattern: meander-shaped

 

Despite the simplified installation, we must point out here that we as the manufacturer can only guarantee perfect factory delivery, but not the installation and connection by third parties. Please also observe the currently valid standards and regulations for heating systems and for the execution of plastering work.