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Located in one of London\'s most sought-after areas overlooking Hyde Park, Park Modern project is an ultra-luxury development consisting of 52 apartments, 3 penthouses and 2 mews houses, all accompanied by a health and leisure suite, residents lounge, games room and cinema. This £450m development spans a sizeable footprint of 190,000 square feet, consisting of 10 levels from ground level to penthouse level, plus an additional 3 levels below ground. All in all, a very impressive project that we were proud to be a part of.
As part of the mechanical package, there was a requirement to include natural gas-fired heating boilers to service the heat and hot water needs of the building, a diesel-powered generator to power a pump for the sprinkler system and natural gas-fired CHP\'s to assist with heat and power to the building.
As with any combustion appliance, flue design, flue supply and flue installation would be required to ensure all products of combustion are safely evacuated to the atmosphere for each and every combustion appliance.
The first stage required us to work aside the mechanical design contractor, giving professional flue advice on regulatory/ performance criteria and running flue sizing calculations to enable coordination of mechanical services and preparation of first draught drawings to be put forward for relevant pre-construction approvals. As with most construction projects, changes happen which have a knock-on effect and do require a staged approach to flue design which we worked through to the end with the mechanical design team to see it through to construction phase.
Once our final draught construction drawings were uploaded and given approved status, it was time to begin construction phase which was required to be staged to fit with construction schedules and general building progress. All chimney flue materials were manufactured specific to our requirements and delivered directly to site in stages due to the quantity and space that it took up on site. All flue components were of a twin wall insulated flue type. The flue to serve the heating boilers was manufactured to suit positive pressure conditions where condensate would be present. For the CHP flue, it was manufactured to suit high pressure conditions where flue condensate would also be present. The diesel generator flue was manufactured with additional insulation to handle the higher flue gas temperatures whilst being capable of high pressures.
Altogether, over 300m of twin wall insulated flue was successfully installed at Park Modern with relevant flue pressure tests undertaken to ensure flue leakage rates were within required parameters.
As constructed drawings were provided along with all relevant operation and maintenance manuals.
Situation
An interesting project that saw the complete destruction of the existing building to make way for a new 22 storey development that would include 163 residential units and a ground floor retail area. Also included within the ground floor, would be a plantroom that would service the heating and hot water demands of the building. The plant would consist of 3 banks of 3 module boilers, totalling just over 1500Kw and a combined heat & power unit (CHP), all of which required flue systems to serve them that would terminate above roof level.
Solution
Flue routes were designed to fit with the building layout and coordinated with the MEP team to work with all other services. Flue sizing calculations were conducted to ensure optimal flue performance across the plants operational range and needed to include flue draught stabilisation due to the sheer height of the building. Corrected chimney height calculations were made to determine a flue termination height that complied with the Clean Air Act
Result
The design was completed and signed off by the main contractor and then followed with a 2 stage installation which saw over 200 metres of flue installed across a 6 day period. All appliances were commissioned by the heating engineer and then handed over ready for operation upon project completion.
Situation
As part of a large scale residential refurbishment that included a range of different size apartments, ranging from 1 bedroom pied-a-terre to an impressive 3-storey penthouse, it was required that 18 contemporary, open fronted, natural gas fireplaces should be included. At the initial survey stage, the building was a pre-cast concrete shell with no pre-existing chimneys or flues, only cast holes within the concrete slab at each level. A full flue design was required that would involve detailed route planning that should coordinate with all other mechanical, electrical & plumbing services (MEP). With a combination of misaligned, pre-cast holes at each level and the required fireplace locations, it made for very complicated flue route requirements. Based on the required routes, we were doubtful that the flue systems would operate under natural draught.
Solution
All flue routes were mapped out on CAD, including support detail, provisions for ongoing maintenance and coordinated with all other services. Flue sizing calculations were carried out which concluded insufficient natural draught and the requirement for mechanical chimney fan assistance. All chimney fans were sized and selected to deal with the flue system resistances and flue gas volumes present on each system.
Result
All flue systems were completed over a 3 month period to suit site specific progression. Chimney fans were connected to their controllers and corresponding flue systems at the commissioning stage. All systems tested, fully functioning and ready to go.
As part of the refurbishment and conversion of a listed building into high end residential units, there was a requirement to install new gas fires into each of the apartments. We completed CCTV camera surveys of the existing flues in the property and found the majority to have suffered severe deterioration over time, leaving holes and gaps which smoke could leak through, making the flues unsuitable for use. The client was keen to retain original opening sizes for each fireplace - our challenge was to line the flues whilst adding the least amount of restriction.
We lined each of the flues using Furanflex RWV which is suitable for open solid fuel and DFE appliances. Furanflex RWV is a thermo setting lining system and is inflated and steamed after insertion into the flue. Throughout the curing process, the lining’s thermosetting resin softens and moulds to the internal shape of the flue, before setting harder than steel, enabling the flue to be lined with the least amount of restriction. Once completed, working fire opening size tests were carried out, documented and passed on to the fireplace contractor to aid in their works.
Each of the lining systems were installed in a day, the original fire opening sizes remained the same and were left ready for use by DFE gas appliances that would be fitted by the fireplace contractor at a later date.
Situation
This modern and stylish hotel based in Farringdon, London required an update of its heating system to ensure all 97 rooms and suites continued to stay warm in the cooler months and that its hot water demand could be met at throughout their busiest periods. All in all, 6 x Ideal Evomax boilers at 150kW each, totalling 900kW of power to replace a tired, inefficient, and unreliable heating system. The flue serving the old boilers had a list of problems of its own, subsequently requiring a collaborative approach between us and the nominated heating contractor to get things back up to scratch.
Timing was crucial. The hotel had a very small window of opportunity where they could be without heat and were keen to avoid the additional costs associated with temporary heating provisions.
Access to the service riser where the old flue would need removing and the new flue would need installing was tricky. There were no access platforms at each level, just one open shaft from top to bottom, spanning 8 levels. With very limited space, crammed full of MEP services, any form of purpose-built scaffold would be out of the question.
Solution
To ensure the new heating and hot water boilers had a flue system that was up to current relevant standards/ regulations, and that the flue was capable of lasting the lifetime of the new appliances that would be connected to it, it would be necessary to completely strip out the old flue system and replace with new. Our recommendations were to split the total power load across 2 x flue systems, 450kW on each/ 3 boilers on each. There would be multiple benefits from configuring the flues in this way. Risk would be split if there were to be a fault with the flue system in the future. The turn down ratio on each system would be reduced, enhancing optimum flue performance across a smaller operational range, making those flue gas discharge velocity targets set out within the Clean Air Act, more achievable.
Result
We got to work fast! Flue design was put together and put in front of the heating contractor to ensure there would be no clash of services. A schedule of works was put together collaboratively between us, the heating contractor, and other associated trades to ensure we kept certain areas free at certain times, that we weren't working on top of each other and of course, to meet that all important deadlines. Flue materials and bespoke components were instructed for manufacture well in advance to ensure all our pieces were in place and ready to go.
Access plans were put into place, making use of our specialist flue installations abseiling team to navigate the service riser.
All works were completed successfully in a matter of days. The hotels downtime was kept to an absolute minimum which kept eve happy. We have since been asked back to look at several their hotels where they are looking to update their heating infrastructure.
Situation
We were approached by a mechanical consultancy company who were employed to give attention to the boiler and flue arrangement intended to serve individual gas fired boilers for a multiple occupancy residential building located near Marble Arch, London. In total, there were 42 residential apartments that had old and tiring heating boilers in need of replacement as they had become unreliable and inefficient. The previous chimney flue arrangements consisted of an attempt to be configured as a shared chimney and flue system for domestic gas appliances, being fed by individual heating boilers split over multiple levels positioned in sperate apartments. The existing combined flue systems had been constructed of what appeared to be waste pipe rather than a correctly designated flue system. The flue joints had corroded. No adequate provision for the drainage of flue gas condensates had been included. The list goes on..
Solution
To ensure that the flue systems would conform to all current regulations, standards, and guides to good practice, as well as being capable of lasting the lifetime of the newly proposed heating appliances, replacement would be necessary. Understanding the rarity of building management infrastructure that comes with adequate technical understanding on what is required to manage a shared flue system for multiple domestic gas appliances, the mutual decision between us and the mechanical design team was to include for individual flues to serve each boiler.
Due to access difficulties with getting scaffold into each of the lightwells, the best access solution for each flue installation would be to make use of our abseiling team.
Result
Over a period of 5 weeks, our team worked tirelessly alongside the heating contractor to ensure minimal downtime and that the residents of the apartments had the least amount of disruption as possible. Altogether, almost 800m of flue was successfully installed, all via rope access.
Situation
A redevelopment that, once finished, would see the beginning of a brand new, exclusive wine club and restaurant right in the heart of London. It would be open to private members only, to which prospective members would be selected and invited by the club owner. The club would be set within the lower 3 floors of a 6 storey building. Included within the redevelopment package was a requirement for 3 large fireplaces that would contain decorative fuel effect fires (DFE). There were no existing fire openings or flues to serve the fireplaces, leaving a requirement for a complete flue design and installation service. Site conditions combined with required fireplace locations meant that the flue routes were not going to be simple.
Solution
After a number of joint reviews on available flue routes with the building design team, we agreed on acceptable flue routes between us that would work, not only from a technical perspective but also one that satisfied the finished look that the client was after and also one that satisfied the local planning department. The flue routes were going to be complex, running horizontally whilst internally to the building, then running vertically on the external rear wall of the building, following the pitch of the mansard roof at termination level. It was proposed by the building design team, that the flue should be enclosed externally by a metal frame that would be cladded with brick slips to blend in with the building. This design addition required careful co-ordination with the design team and metal frame fabricators to ensure it all worked together with our flue systems and that it included our flue maintenance provision requirements. The complex flue routes combined with large fire opening size requirements meant that the flue would not perform under natural draught suction and would require mechanical chimney fanned assistance to which we included within our package.
Result
After a long but well coordinated design phase that saw the final sign off of all design drawings, we then installed 3 stainless-steel, insulated flue systems with the inclusion of Exodraft mechanical chimney fans to ensure consistent suction through each flue system. The works were staged to suit site requirements with a total duration of 5 days. Fire opening size tests and updraught tests were conducted and performed perfectly. The project was then complete, signed off and handed over to the main contractor.
Situation
The heating and hot water at this site was still being served by a bank of old atmospheric type boilers that were at the point of requiring far too frequent repairs. The decision had been made to completely strip out all pre-existing plant and replace for a bank of 4 x new condensing boilers. Due to higher efficiencies and different operational characteristics, the existing flue system would no longer be suitable to serve the newly proposed appliances and would require a newly designed flue system, capable of containing condensate and the positive pressures presented from the new heating appliances.
Solution
The difficult part here was making the flue system work in an incredibly tight space. Available head height was not on our side and the finished height of the boiler casings had increased from what was there previously, to allow for their frames and low loss header kits. Fortunately, these particular types of appliances can provide a certain amount of over-pressure on the burners, allowing us to design our flue system, utilising that over-pressure as motive force to aid in the evacuation of combustion products which in turn, combined with higher efficiency levels, allows us to include a significantly smaller diameter flue system for similar heat demands. The reduction in flue size allowed us to use the existing insulated metal flue as a shaft/ sleeve that would house our new stainless steel flexible lining, then connecting to a combined stainless-steel, rigid sectional, combined header system to serve all 4 boilers within the plantroom.
Result
A successful design was achieved, meeting all required design criteria that would satisfy all related standards and regulations as well as technical guidance notes included within the boiler manufacturers literature. Installation was completed within 1 day and handed over to the heating engineer for commissioning.
Situation
An independent, co-educational day school for pupils ages 4-18, located in south west London that saw the addition of a beautifully designed 1925 square metre refectory. As part of the project, there was a requirement for room heating and hot water that would need to have a flue design, supply and install service. The flue system would need to be contained and supported within a metal framed service riser, designed to contain a number of services and would require careful co-ordination.
Solution
All relevant documents within the design package and scope were reviewed, paying particular attention to the heating equipment schedule. Visits to the site were made to check actual measurements and site conditions. Then it was into the flue design stage which included flue sizing calculations based on the required flue route that followed with CAD drawings that had to be co-ordinated with the other required services, packed tightly into the service riser. Once our flue design drawings were approved it was time to follow on with the installation of a combined, stainless steel flue system.
Result
A smooth process from the design stage through to completion and handover. Our flue system was installed across 2 visits to suit the main contractor who had to make site adaptions before the second stage could commence.
Situation
As part of a plant room maintenace contract held by one of our regualr heating engineering clients, it was required that we attend site to assess the condition of an existing stainless steel flue system that was connected to 2 x condensing heating boilers as they had been in place for quite some time. The heating engineer had concerns that the flue system might be due a replacement as it was leaking condensate from most of the flue joints. Upon inspection, it was also visible that the evaporation of condesates had caused a concentration of sulphur build up on the leaking joints of the flue system and was beginning to corrode the metal.
Solution
Flue sizing calculations were conducted to assess the performance of the existing flue system, to ensure any proposal offered the very best of flue performance. We found that the existing flue system was over sized and with a few little design tweaks, we found that we could improve the flue performance on a reduced size flue system which also offered the benfit of a reduced material cost.
Result
The existing flue system was removed and followed with installation of the new flue system all in one day. Due to site requirements, these works were also completed on a Saturday.
Situation
We were connected with a well known consultant within our industry via a mutual connection with regard to a problematic project where 3 communal flue systems (CFS) had previously been installed. Each communal flue system served as a balanced exhaust system and raised through 8 storeys where multiple boilers were connected at each level. There were a number of issues surrounding the condition, design and operation of the combined flue systems, that required correction. Our works would need to be well coordinated with the commissioning heating contractor, the fire safety specialist team, the main contractor and the consultant.
Solution
A documented condition report of the existing communal flue systems was carried out with detailed measurements being taken simultaneously for planning purposes and flue sizing calculations. A full replacement of the 3 communal flue systems was advised, backed up by the condition report to which the client agreed was necessary. All design calculations were undertaken and documented to ensure optimal flue operation across all varying conditions. Site conditions required that bespoke flue parts would need to be included within the system, to which we designed and coordinated with the flue manufacturer to follow removal of the old system and installation of the new flue system. Coordination really was key on this project, not only with the other trades involved, but also with the buidling management team and residents for access to each apartment. Each communal flue system connected to 8 seperate apartments.
Result
All existing flue systems were stripped out with the new communal flue systems being installed at intervals, allowing the fire-stopping team to do their part around all flue penetration points as the flue system raised through the building. Works were complete across all flue systems in just over 2 weeks, handed over and ready to use problem free.
We were called out to site by a heating engineer to investigate a boiler fault which suggested that the originally installed flue was causing issues. The system comprised of 2 x condensing boilers on a common flue system, although the second boiler to fire would go into 'lockout' when the demand for heat was high enough. An issue that had been occurring for quite some time without resolve. To add to that, the flue showed signs of significant condensate leakage on most of the flue joints, causing a sulphur build up that was deteriorating the flue. Being a high dependency building, we had to come up with a quick solution that would leave the occupants without heat and hot water for the minimum amount of time possible.
We carried out a number of calculations to simulate the existing setup and look at how it was performing. Our results showed an undersized flue that contained very high resistance levels within the primary flue sections. The total flue resistance with both boilers firing, far exceeded the capabilities of the internal boiler fans. We continued to design a flue system with softened bends off of the boilers and directed their entry points into the combined header in direction of flow, whilst also increasing the flue size.
We planned in a very long day, removing the whole of the existing flue system and installing the newly designed flue system within one day, allowing the heating engineer to re-commission the boilers and have them back on by the evening.
This central London restaurant was installing a new kitchen as part of a general refurbishment and required an upgraded cooking extraction system for the new kitchen appliances which needed to be fire rated. The service shaft running to the roof had a multitude of redundant and existing services contained within it as well as the structure altering in dimensions and alignment which made it incredibly difficult to utilise traditional metal ducting methods at their required sizes. Extract air volumes meant that downsizing in duct size would result in too higher air movement velocities which would then equate to noise throughout the building, which was not an option.
A detailed CCTV inspection of the service riser was required to help determine riser dimensions and detail throughout, and to aid in the coordination of services that had the potential to be moved to free up more space. Furanflex RKV was the product that we specified as being most suited due to its high temperature class combined with its ability to flex and mould around the contours of a misaligned service riser with varying dimensions.
We manufactured bespoke mezz framed connectors for both ends of the service riser to enable the connection of Furanflex RKV to the extract ductwork being installed. The shaft was lined in one day, the ductwork was connected and the extractor units were tested and commissioned by the client’s M&E contractor.
The plant room in this student accommodation unit housed a number of condensing heating boilers and separate hot water heaters. Whilst the boilers were in working order, little design consideration had been applied, resulting in incorrectly sized flue systems with a product selection unsuitable for the types of appliances that were being used. The flues serving the boilers were over-sized and leaking condensates which were damaging the fabric of the building. The water heaters had a combined flue system that was undersized and bifurcated at high level, causing flue performance issues. The flue routed through multiple student bedrooms, placing sound restrictions on us that meant mechanical fan assistance wasn't achievable without significant space for flue attenuation lengths. We just didn't have the space.
After calculating flue requirements for the boilers, we designed flue routes using systems suitable for the existing condensing boilers and maximised on flue performance. As the diameter of flue riser required was too large to install solid sectional or flexible stainless steel flue liners we designed a system using a stainless steel header combined with a Furanflex black riser. The flue system serving the water heaters was slightly more complex due to the high level bifurcation and the restriction that represented in getting a large enough flue system to cater for the water heater needs. We coordinated our design requirements with the construction team, who made the necessary structural alterations to accommodate the necessary design changes.
The existing flues were removed and new flue systems installed over two consecutive days so the boilers could be tested, commissioned and turned on without delay.
“We have dealt with Vulcan since their formation and have always had swift response and dealings with them throughout this time. Nothing is too much for them to achieve the desired finish and the completion of projects to clients specifications in both application, research and design including those awkward to overcome problems.”
“I have worked with Vulcan Home Ltd on quite a few projects now and the experience each time has been a pleasure, Ben and his team share great interest in design & installation to the highest standards and deliver each project in accordance with the appropriate guidelines and regulations.
A very professional service every time and I look forward to working with them more in the future.”
“I have been working alongside Vulcan for several years and during that time I have found the company very easy to work alongside.
The guys are very knowledgeable but at the same time are never afraid to ask advice when something crops up that requires more specialist design.
I look forward to working alongside Vulcan in the future and strengthening our companies relationships”
“We have full confidence in Vulcan Home’s expertise, advice, execution and prices in all matters relating to flues and fireplaces. Vulcan are always helpful, no matter how minor the query, and their enthusiasm has turned a dull part of our projects into something quite fascinating!”
“We have used Vulcan Flues a number of times over the past few years, on commercial boiler installation projects and flue inspections; every time their professionalism, attitude to the tasks in hand and completed works has been impeccable. We would have no hesitation in recommending their work.”
“We approached Vulcan Homes for the design, supply and installation of all associated fireplace flue works for a large high end residential project in the heart of Mayfair on behalf of Clivedale. Ben was very hands on and easy to work with throughout the design phase. His installation team were hard working and diligent, hitting all programme dates given to them. Commercially they have been user friendly throughout their contract. I would certainly recommend their services and will be using them again on any future Ellmer projects with Flue requirements.”
“ As a fireplace retailer we cater for almost all requirements within our field, however the only other specialist we call upon when needed is Vulcan Home Ltd. With Vulcan’s speciality and experience within complex flue systems we look no further for the more complicated projects that we work on. We’ve called upon their expertise for many projects over the years and cannot fault their service, product and workmanship. Real Flame have no hesitation in recommending Vulcan Home Ltd to anyone that should be seeking high end flue services within the UK ”
