Radiant heating

Recently, the Mechanical Hub team took part in a two-phase, two-state trip to visit Viega’s North American manufacturing in McPherson, Kansas, and toured the brand new HQ and Seminar Center in Broomfield, Colo. Impressive is the first thing that comes to mind when describing both facilities.

The McPherson manufacturing facility exudes the company’s philosophy of both progress and vision for the future. “We are constantly looking past the immediate future and into the distant future,” Eric Wicker, director, manufacturing, Viega.

This summer, Viega completed a two-year building program in McPherson that included: a 90,000-sq. ft. expansion of a manufacturing plant, completed in Dec. 2017; a new 205,000-sq.-ft. manufacturing plant, completed in June; and a new 25,000-sq.-ft. tool shop and apprentice building, completed in July. And, the company is currently building a 55,000-sq.-ft. logistics expansion—a high-bay storage and retrieval area for inventory.

Mimicking some of the processes from its global HQ in Germany, robotics and machining take center stage throughout the meticulous McPherson plant. Fear not, all of this new-fangled technology is not taking jobs away, rather increasing them. Currently at approximately 300 employees, the company hopes to hit the 500 mark by years ’23-’24.

McPherson is where Viega produces its PureFlow line of PEX product, as well as select fittings from the ProPress Copper and 80,000 sq. ft. dedicated to its MegaPress product lines. McPherson is also home to Viega’s master distribution center for North America.

Continued expansion is a testament to the company’s progressive philosophy. For instance, the company has dedicated 270,000 sq. ft. to the copper fitting production. “The goal is to be producing the majority of copper fittings sold in the U.S. right here in the states,” says Wicker.

 

 

The state-of-the-art distribution center incorporates the latest technology and automation, as well as an upgraded warehouse management system that provides faster product turnaround. With additional metals products being manufactured in McPherson, a larger distribution center for both metals and PEX products was necessary.

Although media wasn’t allowed to shoot photography inside the plants—understandably—the tour started in the 36,000-sq.-ft. Plastic Injection Molding area which exemplified the company’s high investment in tooling. Twenty machines produce approximately seven million fittings per month. This particular building was well lit and comfortable, due, in part, by the implementation of its own radiant heating and cooling technology.

Quality is never understated at Viega; we strolled through the Quality Assurance Lab where dedicated staff monitor product and equipment through a series of rigorous testing.

Next, we toured the 200,000-sq.-ft. Extrusion Area where the plastic piping is made. Once made and exported from Georgia, Viega now produces its own resin—which is transformed into pellets—onsite. The rejected pellets are not repurposed, yet recycled and sold.

There is a Special Extrusion Area where plastic metal plastic tubing extrusion is performed. The only company in America making this, the plastic piping is integrated with aluminum so it can better hold its shape rather than returning back to its original form. (Nearby is a 40,000-sq.-ft. dedicated machine shop.)

We then toured the 270,000 sq. ft. of ProPress copper fittings production area and 80,000 sq. ft. of the MegaPress/Metals production area. Strategically, it makes sense for Viega to start producing here in the states. With press technology introduced here in 1999, education and awareness of the process and technology have helped contractors nationwide run a more efficient business. Viega system solutions are designed to work together in plumbing, heating, cooling and pipe joining applications, making the contractor’s work fast, easy and safe.

The following day we were flown to Denver to tour the recently opened Viega North American headquarters and Seminar Center in Broomfield, Colo. The 55,000-sq.-ft. headquarters resembles a pipe fitting, and its interior is the real testament to Viega innovation. I can’t express enough how beautiful these two buildings are, and, of course, amid the breathtaking backdrop of the Rocky Mountains. The HQ building opened in January and the first official training took place April 8, and weekly training is booking fast. “Viega is absolutely committed to its customers and their success in the field,” says Bo DeAngelo, manager, technical training at the center.

Yet, I am always interested: when a new facility is built, does it incorporate its own products? While the cross-laminated timber beams are imported from Austria, the exposed ceilings give employees and visitors a clear view of the many uses of Viega’s innovative technology.

Potable water is carried through copper pipes connected with ProPress fittings. The carbon steel fire sprinkler system is joined with MegaPress fittings. Radiant heating and cooling keeps the building comfortable, while a snowmelt system keeps the courtyard free of ice and snow. Manifolds ensure the systems operate smoothly and efficiently. The restrooms feature wall-hung bowls and no exposed tanks, thanks to in-wall carrier systems and Visign style flush plates.

The new 23,000-sq.-ft. Broomfield Seminar Center next door supplements Viega’s Nashua, New Hampshire Seminar Center, which has trained thousands of people since opening in 2006. The new center is an innovative training experience and is equipped with four classrooms, two hands-on labs, and interactive displays throughout, which allows attendees to see, touch and experience Viega products. “Demand for training has been increasing steadily. This facility will allow us to continue to provide and expand on the training that our industry deserves,” says CEO Dave Garlow.

Viega experts lead single- and multi-day classes in everything from radiant system design and fire protection to hydronics and pathogen prevention. Despite being open only since April, it is on track to host more than 2,100 students this year, says DeAngelo.

I walked away very impressed, telling DeAngelo I—and I’m sure the clients that visit—can’t help but feel energized the minute I walk in this facility. Shaking his head in agreement, “That’s what Dave Garlow tells me every day he walks in here,” responded DeAngelo.

Make no mistake, there is a lot of money, time and resources invested in Viega North America. But it’s a huge testament to the dedication the company believes is its biggest investment: its customers and its employees.

 

 

Forced air is still the traditional method of heating homes, but radiant heat is gaining significant momentum as an alternative. According to HGTV, the growth rate of in-floor radiant heating systems was estimated at 30 to 50 percent per year.

At the heart of this shift is not just one single benefit. It’s a variety of advantages that radiant floor heating systems bring to the table, the combination of which enhance the daily lives of a home’s occupants:

Even Heat Distribution

When a house is heated by a forced-air system, it will always be warmest near the vents that distribute the air. This can lead to “hotspots” on one end of a room while the other side of the room remains cool. And because hot air rises, upstairs rooms will be warmer than those downstairs.

With radiant floor heating systems, homeowners control how heat circulates in their home. Rather than heating the surrounding air, the heat that radiates from the floor warms other objects in the room and is evenly distributed without the potential for heat loss.

Improved Air Quality

While air pollution is more often associated with the outdoors, indoor air can be dirty as well. Whether it’s dust, pet dander or chemicals from fragrances (among other sources) that pollute the air, forced-air systems exacerbate the problem for allergy sufferers. That’s because the forced, heated air will stir up and mix with these airborne particles.

Since radiant floor heating systems don’t move air to deliver heat, the circulation of indoor particles is minimized. With less pollutants blown around, indoor air quality improves, which benefits allergy sufferers.

No Ductwork

The ductwork in forced-air systems further contributes to air pollution. When it’s riddled with cracks and holes, more dust and odors can enter and circulate. Without proper insulation, these same cracks and holes can cause air to leak out of the system and hinder its overall efficiency.

With no ducts, radiant floor heating systems reduce the churn of dust and allergens while curtailing heat loss. The absence of ducts means less work for homeowners as it eliminates the need for repairs like cleaning out ducts clogged with particles or adding insulation when heat loss mounts.

Energy Savings

With their uneven distribution of heat and potential for heat loss, traditional heating systems can be energy hogs.

Depending on how well a house is insulated, radiant floor systems can save up to 30 percent compared to forced-air systems. In terms of bills, the impact is quite significant as space heating is the largest energy expense for the average U.S. home, accounting for around 45 percent of energy bills.

Noiseless Operation

Homes should be quiet, but forced-air systems can be noisy as furnaces cycle on and off, gaps in the ductwork whistle and loose parts rattle.

By comparison, radiant floor heating systems are exceptionally quiet.

As consumers learn more about the advantages of radiant heating, its popularity will continue to grow.

Josh Quint is product manager, heating and cooling, for Viega LLC.

Recently, ProStaff member Andy Mickelson, Mickelson Plumbing & Heating, Missoula, Mont., responded to a call that had the homeowner—with a family of four—frustrated. The old Quietside boiler had flashed its last flow switch error. In fact, Quietside isn’t even in operation in the U.S., and parts and tech support is non-existent. It was time for an upgrade. Mickelson needed to provide domestic hot water for the entire home and is zoned for approximately 3,000 sq. ft. of radiant heat in the basement and upstairs bathrooms. (Mickelson explained that the trend in Missoula about 10 years ago was to build a home with part-radiant and part forced-air heat/cooling, which this home was.)

https://youtu.be/7hQ0tCiBDdk

Mickelson chose the reliable Lochinvar Noble (NKC 199) Combi Boiler because he believes it is the most competitively priced fire-tube combi unit on the market. “I don’t even mind paying a little extra for the unit because of fire-tube heat exchanger. It’s very serviceable, the parts are readily available, it features an English display—no code—and for its excellent domestic hot water (DHW) capabilities. Mickelson explains that the unit features more hot water out of the box because of the required use of a mixing valve—per the manufacturer specs—which translates to a higher flow rate of DHW. A two-man job, Mickelson was in and out the home in seven hours, with a very satisfied customer.

https://youtu.be/sIgKKcwbaug

Lochinvar Noble (NKC 199) Combi Boiler Specs

• SMART CONTROL Enhanced Operating System
• Three Sizes 110,000, 150,000 and 199,999 Btu/Hr
• 95% AFUE Efficiency
• Industry-Leading DHW Delivery Up to 4.8 GPM
• True Instantaneous Response
• Easy Installation and Serviceability
• User-Friendly Interface
• Designed, Engineered and Assembled in the USA

Learn More at lochinvarnoble.com

Uponor’s Ecoflex pre-insulated piping system was chosen for our latest project in Duluth, MN because of its flexibility and weight. I’ve worked with a few similar products but none have been as easy to order, handle and install. Here’s a video from the install day, more to come when we install the boiler system.

If you want technical details or more information please visit uponorpro.com.

For more videos and pictures from our #duluthbuild project please check us out on Instagram!