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RAUPANEL™ “DRY” SYSTEMSUPPLEMENTAL DESIGN AND INSTALLATION INFORMATION IN ADDITION TO THAT PUBLISHED IN THE RAUPANEL™ SYSTEM INSTALLATION GUIDE 855.625

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RAUPANEL SYSTEM INSTALLATION

- Technical summary- Advantages- Installation techniques (5)- Pipe layouts/samples- Routing to manifolds- Couplings- Wall heating- Features and Benefits summary

OUTLINE

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RAUPANEL SYSTEM

- Combination Aluminum (80%) and Plywood (20%)

- λ of Aluminum = 230- Aluminum is extruded with groove to hold

3/8” PEX pipes with excellent contact- Total thickness 5/8”- Components allow for 6” or 8” o-c

spacing- Lightweight, only 1.5 lbs/ft2

Infra-red photograph of RAUPANEL system

TECHNICAL SUMMARY

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RAUPANEL SYSTEM

- Suitable for both retrofit and new construction- No complicated scheduling and preparation- Fewer changes to overall construction- Eliminates other trade (thermal mass)- Design flexibility - easy to zone - Available when you want it- Install at your schedule- Low profile

ADVANTAGES OF THE RAUPANEL ALUMINUM SYSTEMFOR THE CONTRACTOR

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RAUPANEL SYSTEM

- 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

ADVANTAGES OF THE RAUPANEL ALUMINUM SYSTEMFOR THE DESIGNER

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RAUPANEL SYSTEM

- Aluminum panels - 6” wide x 6’ long

- Plywood return bends- 4’ long (depth varies)- 6” and 8” groove spacing

- Furring strips- 2” wide x 4’ long

- Carbide-tipped cutting blade - Not by REHAU

- Deburring tool

WARNING: Wear eye and ear protection when cutting plates, wear eye protection when installing plates and wear gloves when installing plates to prevent cuts

8”

SYSTEM COMPONENTS

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RAUPANEL INSTALLATION

1. Lay out Return Bends and Furring Strips (for 8” spacing)

Note: Leave 1/16” to 1/8” gap between ends of panels to allow for house movement

2. Drop Aluminum panels onto floor;align into notches with 8” Bends

COMPONENTS FIT TOGETHER AS A SYSTEM (1-2-3)

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Note: Leave 1/16” to 1/8” gap between ends of panels to allow for house movement


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3. Pipe is “walked into” the groove; a rubber mallet may be needed to set it in Note: No silicone is used. Pipes will not pop out


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WARNING: Wear gloves and eye protection when handling pieces

DEBURR FIELD CUTS WITH DEBURRING TOOL IN THE GROOVE

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- REHAU Reference Documents (CD) has Detailed Installation Drawings for installation techniques

- Example:

THE FOLLOWING INSTALLATION TECHNIQUES APPLY TO VARIOUS FLOORING CHOICES

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1. Install panels and pipes following the first Steps 1-2-3

2. Screw or nail Plywood 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”

SOLID HARDWOOD FLOORS

Note: Panel system may be loose and noisy until all hardwood is properly secured

It is recommended to use 8” spacing with furring strips when installing solid hardwood

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RAUPANEL INSTALLATIONSOLID HARDWOOD FLOORS


2. Screw or nail Plywood 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”


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RAUPANEL INSTALLATIONSOLID HARDWOOD FLOORS


- Use 8 screws per Return Bend- Use 5 screws per Furring Strip

- Screws:- Use fine-thread drywall screws or

deck screws- Nails:

- Use long, rough roofing nails or ring-shank nails

- No smooth nails

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RAUPANEL INSTALLATIONSOLID HARDWOOD FLOORS8” SPACING INSTALLATION WITH SOLID HARDWOOD

- Fasten plywood pieces as per instructions- Aluminum panels do not need to be fastened – let these float- Nail or staple hardwood flooring through plywood panels into subfloor, every 8”

8” spacing

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- If necessary for heat load this is possible- Aluminum panels and plywood pieces must 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

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- Must use 2” or longer cleats, nails or staples- 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

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2. Screw or nail Plywood 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

FREE-FLOATING AND GLUE-DOWN HARDWOOD FLOORS

- Use 8 screws per Return Bend- Use 5 screws per Furring Strip- Use 6 screws per Aluminum panel

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RAUPANEL INSTALLATIONFREE-FLOATING AND GLUE-DOWN HARDWOOD FLOORS


2. Screw or nail Plywood 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

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RAUPANEL LAYOUTSREADY FOR FREE-FLOATING FLOORS

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2. Leave Aluminum and Plywood panels as “free floating” - no screws or nails needed

3. Cover panel installation with plywood “underlayment”

4. Mark walls and plywood with pipe locations (to avoid) or furring strip locations (to hit)- Avoid holes in pipes

5. Screw underlayment through plywood or aluminum panels, into the subfloor- This creates a very stiff “composite”

flooring system

CARPET OR VINYL FLOORSMUST FIRST MAKE A FLAT SURFACE

8” spacing

- Use 1/4” or thinner plywood underlayment with maximum 8” grid spacing for screws

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- Use 1/4” plywood underlayment with 8” maximum grid spacing for screws

READY FOR CARPET OR VINYL FLOORSPIPE LOCATIONS HAVE BEEN TRACED FOR AVOIDANCE

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RAUPANEL INSTALLATIONTILE FLOORSUSING MORTAR BOARD AS ALTERNATIVE TO DIRECT PLACEMENT OF THINSET

8”spacing


2. Leave Aluminum and Plywood panels as “free floating” - no screws or nails needed

3. Cover panel installation with cement “mortar board”

4. Mark walls and mortar board with pipe locations (to avoid) or furring strip locations (to hit)- Avoid holes in pipes

5. Screw mortar board through plywood or aluminum panels, into the subfloor- This creates a very stiff “composite”

flooring system

- Use 1/4” or 3/8” thick mortar board with maximum 8” grid spacing for screws- A thicker mortar board is allowed if necessary

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Sample cutaway floor:- 1/4” thick mortar board

installed directly over RAUPANEL at 6” o-cspacing with maximum 8”grid spacing for screws

- Tile placed on thinset over mortar board

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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 under shower pan for warmth

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- 1/4” or 3/8” mortar board with 8” maximum grid spacing for screws

READY FOR TILE FLOORS

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1. If necessary, level floor with self-leveling thin-set2. Cover existing slab (or above the leveling layer) with a vapor barrier to stop moisture3. Install panels and pipes following the first Steps 1-2-34. 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

- Be sure not to penetrate any existing pipes, cables, etc. in existing slab floor- Follow all safety precautions for using concrete fasteners

OVER EXISTING SLAB

- Refer to REHAU Reference Documents(CD) for Detailed Installation Drawings

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RAUPANEL LAYOUTSADAPTABLE FOR ODD-SHAPED AREAS

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RAUPANEL LAYOUTSOPEN AREAS SHOULD BE FILLED WITH RAUPANEL

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RAUPANEL LAYOUTS

- Follow normal panel spacing in hallways- Sometimes there are too many pipes to fit

in a hallway, all within panels (too many circuits to supply)

- May have to route some pipes outside panels or may have to route some pipes through subfloor

HALLWAYS SHOULD BE FILLED WITH RAUPANEL

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RAUPANEL LAYOUTS

- Note: These pipes are too close to the end of the panels

ROUTING FOR PIPE TAILS: DRILL 1 INCH HOLE AT 45-DEGREE ANGLE IN SUBFLOOR

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RAUPANEL LAYOUTS

- Route pipes through floors and joist cavities to get to manifolds

ROUTING FOR PIPE TAILS: DRILL 1 INCH HOLE AT 45-DEGREE ANGLE IN SUBFLOOR

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- Avoid routing pipes to manifold on the subfloor – go below

RAUPANEL LAYOUTSROUTING FOR PIPE TAILS: RUN ALL THE PIPES IN ONE NARROW AREA? (NO!) THIS METHOD IS NOT RECOMMENDED (HOT SPOT)

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RAUPANEL LAYOUTS

Repairs are possible:- If pipes get damaged or coil runs short

use the 3/8” EVERLOC coupling within the floor

- Chisel a relief into the subfloor below the coupling for flush fit

- Allow 6 inches between aluminum panels for coupling

- Place furring strips on either side of coupling as “bridges”

EVERLOC COUPLINGS MAY BE USED

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- 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

APPLICATIONS IN WALLS AND CEILINGS

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RAUPANEL INSTALLATIONINSTALLED 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 tielboard installation

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RAUPANEL INSTALLATIONINSTALLED 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

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RAUPANEL LAYOUTS

- Use panels for walls where supplemental heat is needed- Very nice in bathrooms, tub/shower walls

APPLICATIONS IN WALLS AND CEILINGS

Interior drywall

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RAUPANEL

- High performance, very efficient, less downward loss, uses lower water temperature- Low-profile, may be used in portions of an area without big transitions- Low weight, should be no structural concerns- Can be installed with 6” or 8” on-center spacing- Allows for zoning, room-by-room, delivers better control- Adaptable to walls and ceilings- Fast installation at the schedule of the RFH contractor

FEATURES AND BENEFITS

© REHAU 4-Aug-09 -

RAUPANEL

- Technical summary- Advantages- Installation techniques (5)- Pipe layouts/samples- Routing to manifolds- Couplings- Wall heating- Features and Benefits summary

SUMMARY

ConstructionAutomotive

Industry

www.rehau.com

RAUPANEL™ “DRY” SYSTEMHIGH PERFORMANCE PANEL SYSTEM

Download - Raupanel installation guide

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