How to Fit Polypipe Solid Floor Panels

How to fit Solid Floor Panels

Panel 1

Typical heat output at 50ºC mean water temperature

91W/m² at 100mm pipe spacing

Maximum circuit length


Maximum coverage per circuit



8.2m/m² at 100mm centres

Floor panel usage

1 panel/m² allowing for cutting (Actual 1.2m²/panel)

Clip rail usage




Staple usage


Edge expansion strip


Conduit Pipe


Product dimensions

1.2m x 1m

Solid Floor Systems - Panel installation guidance

Panel 2

Step 1: Fitting Insulation

In accordance with Part ‘L’ of the current Building Regulations, a suitable layer of insulation material should be included within the floor construction. It is the responsibility of the architect or builder to ensure compliance. However, in all instances insulation must be installed beneath the underfloor heating system in order to ensure that any downward heat loss does not exceed 10W/m2, in accordance with BS EN 1264.

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Step 2: Laying the insulation panels

When laying the insulation boards, ensure that the joints of each board are staggered and securely taped so as to minimise any risk of movement.

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Step 3: Fitting the edging strip

Using edge expansion strip allows the free expansion of the floor screed. The expansion strip should be installed around all perimeter walls and fixed constructions such as columns, steps and access doors. The edge expansion strip comes with a self-adhesive strip which bonds the panel to the wall. The edge expansion strip also comes with a plastic skirt which lays over the top of the insulation to prevent the screed seeping in to the join between the insulation panel and edge expansion strip. Edge expansion strip should be fitted in addition to perimeter insulation required by Building Regulations.

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Step 4: Fitting the floor panels

The floor panels are laid over the pre-installed insulation and should be overlapped at the edges. 

The 1⁄2 castellation should overlap the 3⁄4 castellation. The first panel should be laid with the 1⁄2 castellation edge against the wall. Panels can be cut by simply using a saw or snip, or it can be overlapped to the nearest castellation fit. 

Floor panels should not be used at the base of the manifold as pipes need to be closer together than the floor panels allow. Pipes around this area should be secured using pipe clips which can also be used intermittently to secure the clip panel to the insulation. The plastic skirt should be laid over the door panel and the outside run of pipe pushed into the skirt covered castellations to create a seal around the edge of the area. 

When a pumped (liquid) screed is to be used it is essential that all of the panel joints are made correctly and that no panels are allowed to simply ‘butt-up’ as this may allow the screed to penetrate below the underfloor heating system and cause the panels to rise up. Similarly the panels should be firmly secured around the perimeter of the room using staples so as to prevent possible risk of the panels lifting. 

Preparing the pipe: You will need to remove the coil from the bag, leaving the shrink wrap on, uncoiling from centre of the coil.

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Step 6: Laying the pipe

Once you have completed laying the solid floor panels the pipe can be fitted starting at the manifold position in line with the pre-designed centres. 15mm and 18mm pipe can be laid at 100mm or 200mm centres as required, 18mm pipe can also be laid at 300mm centres. The minimum bend radius is achieved by encircling two castellations for a 90° bend or three castellations for a 180° bend.

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Step 7: Laying the circuits

Circuits being laid at 100mm or 200mm centres must be laid in a spiral configuration. The first loop of pipe should be laid around the perimeter of the area to be covered by that circuit. The next loop of this circuit should be laid either 200mm from the first loop of pipe for 100mm centres or 400mm from the first loop of pipe for 200mm centres.

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Step 8: Loop the pipes

Continue to loop the pipe into the centre of the panels leaving enough space to form a double return (‘S’ shape in the centre of the loop)

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Step 9: Check spacing

Now work back out from the centre by filling the space between the inwardly spiralling loop of the primary circuit ensuring the pipe is laid at the correct spacing centres.

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Step 10: Formation

Where 300mm centre spacing is required (18mm pipe systems only) a meander pattern can be used. The pipe simply crosses the room from one side to the other encapsulating 3 castellations at each return bend.