The concept and purpose of crimping
Pressure testing is carried out before pouring the screed in order to identify leaks in advance
Installation of underfloor heating requires a high-quality system - pipes without defects and leaks. Pressure testing is the creation of excess pressure, which allows you to detect breaks in connections and hidden pipe problems. At the end of the work, you can correct the existing problems and fill the screed.
Testing the pipeline by pressure is necessary to check:
- hidden factory defects of pipes;
- strength and integrity of radiator casings, heat exchangers, reinforcement elements;
- quality of fasteners;
- holding valves, gate valves, manometers and taps.
Through complex measures, you can check the quality of hot water supply, sewer drain, well.
Pressing is allowed to be performed in the unconnected boiler mode or when one room is ready.
What is crimping and its purpose
The installation of a water heating system under the floor covering will be considered incomplete if not organized quality control checks, called underfloor heating pressure testing. It is carried out according to the approved algorithm, creating overpressure in order to make sure that all joints are tight and that there are no hidden defects in the pipes themselves. Therefore, it is recommended to perform crimping of a warm floor installed with your own hands with full responsibility.
Upon completion of this event, it is possible to eliminate the problems that have manifested themselves, to make sure that the water circuit is functioning effectively. After that, you can safely fill the screed.
Underfloor heating scheme with a ready-made module
Crimping technology
In order not to dismantle the water heated floor, it is possible to create conditions of increased pressure before starting. Testing is also done post-assembly to determine leaks, breaks, and corroded areas. The procedure consists of pressure testing and flushing the line, checking and replacing units, restoring the insulation coating. Depending on the state of communications, you can select the appropriate technology.
Using water
Excessive pressure in the pipes should be 2 times higher than the norm. The system must withstand 2 days in this mode.
Before pressing the warm floor, install the collector box and connect the water circuits for heating. The system is filled with water from the supply valve - the caps are screwed on the return manifold, in the supply mode the valve is brought to the open position. Fluid enters the line, displacing air through the vent, as evidenced by a hiss.
To bleed the air masses, the return valve of one or more circuits is opened. The steps must be repeated until air is pumped out of the pipes. At the end of the bleeding, the manifold inlet valve is closed.
The hydraulic method is also divided into several types.
Control check produced with a gradual increase in operating temperature. Initially, +20 degrees water is supplied to the circuit, after a few hours the temperature indicator rises by 5 degrees. After that, joints, external sections of the pipeline, and attachment points are checked.
If there are leaks, the water is drained from the system and the malfunctions are rectified. After re-supplying the coolant and reaching the desired temperature, the system is not operated for 2 days.Breakdowns are determined visually, the temperature is lowered to a cool state, then the screed is poured.
Overpressure injection created by filling the line with cold water. The pressure parameters should exceed the norm by 1.5-2 times. The valves are closed, the circuit is not operated for 24 hours.
During this time, water flows out of ruptured pipes or connections. The damaged areas are determined visually. The repair is started after the coolant has been removed. At the end of the work, re-control is carried out and the system is filled.
The optimal pressure indicator is from 2.3 to 2.8 atm.
Air pressure testing
If there is no water in the house, pneumatic pressure testing is carried out, increasing the pressure by 2 times
The procedure for crimping the underfloor heating system with air is performed when it is not possible to test them with water. To create excess pressure, a floor compressor, an automobile pump or a sprayer with a pressure gauge is used. The air pressing technology is implemented as follows:
- Checking the condition of the cranes. They are hermetically sealed.
- Removing the automatic air vent, installing a temporary plug in its place.
- Connecting a pressure supply device. A hose is attached through the fitting, and then a tap.
- Creation of increased pressure. They work only with pipes, the area from the collector to the boiler is not tested so as not to damage the heating devices.
- Shutting off the valve after the required pressure is reached. The line remains in the received condition for 24 hours. The pressure indicator is constantly monitored.
- Inspection and clarification of damage. Leaky joints are treated with soapy water. Soap bubbles indicate the need for repair.
- If the pressure test is successful, the air remains in the communications until the screed is poured.
If the system operates under a pressure of 1.5 to 2 atm., It is necessary to test at a pressure of 4 to 5 atm.
Crimping underfloor heating with water
The underfloor heating pipe must already be rolled out and attached to the manifold.
The manifold (see photo) must have shut-off ball valves (indicated by arrows):
There are also valves for the inlet-drain of the system (they are not visible in the photo, they are on the right). So, the system can be filled through any of the installed taps by connecting a hose from the water supply system. The pressure to be created must be 2.5 ... 2.8 atm. (if so much does not work for some reason, then at least 2 atm.)
In the photo above, the manifold is already with the pipes connected, flow sensors, and a mixing unit. At the very beginning, the ball valves are closed (it is assumed that the coolant has already reached the mixing unit, is in it).
The warm floor is filled in the direction of movement of the coolant, that is, from the supply. First of all, close all the caps (which are blue in the photo) on the return manifold. Then we open the ball valve to the supply manifold (just this moment in the photo). As the pipes are filled with coolant, a hissing sound will appear - the air exits through the Mayevsky cock (or automatic air vent) installed on the supply manifold.
We open one of the taps on the return and bleed the air through the tap to drain the system on the return manifold.
We close this circuit on the return line and open the next circuit here ... And so on, let us release the air from all circuits.
Then we close the valve in front of the supply manifold, and open it before the return ...
After filling the system and bleeding the air, we leave it under pressure, observing whether there is a leak or not. (Of course, if there is a leak, we will fix it.)
Pressure testing of a warm floor with water, if there is no water supply
If the water supply system has not yet been connected, but desalination needs to be done, then it is still possible.You will need a pump of the "Kid" or "Trickle" type, a pair of hose with a diameter of 20 mm and a pair of clamps for fastening the hose.
Pour the clean coolant into a clean container, lower the pump into it.
The ball valves in front of the manifold must be closed.
We connect the pump and manifold fittings with a hose:
- fastening the hose with clamps.
Attention! The caps on the air vents are unscrewed. The ball valve on the manifold union is open before starting the pump.
The scheme is the same as described above in the presence of a water supply.
Air will escape from the air vents with a hiss. And we monitor the reading of the manometer and the presence of water in the tank. If necessary, stop the pump and add water.
Nuances of choosing technology
Before pouring the screed, the hot coolant circulates in the system for several days, then it is poured with concrete
To press underfloor heating correctly, you should take into account the features of the pipeline. In the presence of metal-plastic fittings, the test is carried out with cold water at a pressure of up to 6 bar and leave them for a day. In the absence of pressure changes, a screed is made.
A polyethylene pipe is tested with a pressure of 2 times the working pressure, but not less than 6 bar. 30 minutes after the decrease in the indicator, the working value is restored.
Before starting to fill the coolant, the check is done twice. At its end, the pressure indicator is returned to its primary state, the pipes are kept for at least 48 hours. An indicator of less than 1.5 bar indicates a successful test, the health of the heating.
After water pressure testing, re-work must be carried out. A hot coolant is pumped into the communications, which is heated gradually. The circuit functions in this way for several days. When leaks are formed, the joints are tightened. If the system is in good working order, the water in the pipes is cooled and re-pumped without a decrease in the pressure indicator.
Air pressure testing is the best option for the cold season, because with the onset of a cold snap, water can freeze and burst pipes.
Water pressure testing process
Professional equipment is used for crimping
The use of the hydraulic method provides for pressurization up to 6 bar, but in fact the indicator in the system is 3 bar. Several devices are used to obtain the optimum level.
Pressure Operator - Professional Equipment
Manufacturers produce manual and electric models, the main difference between which is cost. It is advisable for a home craftsman to use a manual crimper:
- The hose of the device is connected to the system, water is poured into a special container.
- Pumping is performed in manual mode with periodic opening and closing of the valve.
When working with an electric pressurizer, you will need to connect it to a water supply system or a water tank. Further actions are carried out according to the manufacturer's instructions.
Garden sprayer
You can use a garden sprayer
The device is selected according to the working pressure parameters indicated on the body or in the passport. In the process of using the sprayer you need:
- Pour water into the tank.
- Connect the hose of the device to the supply valve.
- Create a pressure of 4 to 6 bar - one full tank is enough for this.
- Pump it manually until the required pressure is reached.
One filled container is enough for one circuit.
Deep Well Vibrating Pump
The devices create pressure up to 6 atm., Therefore, they are excellent for crimping. The work is carried out with an assistant - one person opens the taps, and the second monitors the pump. The vibrator hose is connected to the manifold.
The pump is activated after opening the valve. The return hose is connected to the complete container. After complete bleeding of air from the circuit, the return valve is closed.Next, you need to monitor the indicator of the manometer until a pressure of up to 6 atm appears. After that, the supply tap closes and at the same time the pump turns on.
The maximum level of pressure drop during pressure testing for metal-plastic pipes is 0.2 atm., For polyethylene pipes - 0.5 atm.
Verification and test run
After assembling the system, you need to find out its operability and eliminate installation defects. The check is carried out at the end of flushing and filling with a coolant. If successful, the system is operated in a test mode.
Testing methods
You can find the flaws in the installation of underfloor heating and check the communications as follows:
- Run at operating temperature. The indicator rises gradually to 20 degrees, and after 2-3 hours it rises by another 5 degrees. If there is a leak, the system stops, breakdowns are eliminated. The coolant is brought to the design temperature, the line is kept for 2-3 days.
- Overpressure testing. Water works at a standard temperature, but the pressure rises 1.5-2 times. If it falls by no more than 1.5 bar, there is no leak.
- Dry pressure testing. Air is pumped into the pipeline at a pressure 2-3 times higher than the norm. The work is performed before pouring the screed with the design water temperature.
Air pressure testing is not suitable for underfloor heating with antifreeze due to its increased fluidity.
Test run sequence
The system is tested at full operating temperature for 2 - 3 days, eliminating leaks if they form
Before hiding the contours under the screed, a test run of the system is performed:
- The valves are closed up to the distributor and the circulation of the "boiler - collector" zone is organized. The heating boiler is connected, but not at maximum power, and the circulation pump. The fastener points are inspected.
- The circuit valves open. After the boiler has heated up, the temperature difference between the supply and return zones should be 5-10 degrees.
- The second circuit opens, as evidenced by a hiss.
- The temperature regime of warm floors is brought to a maximum of 60 degrees, if it is the only source of heat.
- In the presence of a combined heating system, the operating temperature mode is set on the thermostats.
- The system is at a maximum temperature of 6 hours.
The screed is started to be poured only after pressure testing and test run.
Do-it-yourself crimping features
Leaks are additionally crimped with fittings
It is possible to pressurize a water-heated floor made by hand using a hydraulic or pneumatic method.
- Preparation taking into account the type of coating. For concrete screed, pressure testing is performed before pouring. In the presence of a polystyrene or wooden surface - but closing the heating main with plywood or gypsum board.
- Communication testing. All heating circuits are connected to a manifold and tested individually. The areas are filled with water until the air is completely expelled. For regulation, return and supply valves are used.
- Cold testing of metal-plastic communications. It can be made with a cold coolant with a pressure of 6 bar and the system can be kept for 24 hours. If the pressure has not increased, the line is in good order.
- Inspection of polyethylene pipes. The system is loaded with a pressure of 2 times the standard pressure, but not less than 6 bar. After 30 minutes, the indicator is restored. The operation is carried out three times, then the pressure is brought into the pressure test mode and left for 24 hours. If the reading has dropped by less than 1.5 bar, the system is working properly.
Additional testing is performed by injecting the pressure of the heat carrier, which is at a temperature of 81-86 degrees for 30 minutes. At this time, the fittings are inspected, if they are loosened, they are tightened.
Before operating a water-heated floor, it is necessary to fill it with a coolant. The line is brought to the operating temperature mode gradually, with preliminary pressure testing. The work allows you to identify breakdowns, leaks, installation defects.
What to do after crimping?
The next stage after water has been poured into the system or air has been pumped in - check all connections for leaks. If the underfloor heating is pressed with water, then, as they say, water will show. If pressing with air, then all connections must be washed with soapy water. We check not only the connections, but also the contours (suddenly you broke the pipe somewhere during installation, or it was originally defective).
After pressure testing, we leave the entire system under pressure for 24 hours, so that leaks, if any, are revealed in a day. It should be borne in mind that with temperature drops during the day, the pressure in the system will drop slightly - you do not need to be afraid of this, this is natural, because when the air or water cools down, they shrink. But such a pressure drop will not be more than 0.5 atm.
