Underfloor heating (UFH) is typically associated with residential builds or showrooms, but it’s increasingly being used in commercial and industrial settings. For warehouses, it offers uniform heating without ducting, improved energy efficiency, and better space utilisation. However, it also adds complexity to the slab design and isn’t suitable for all operational environments. This page breaks down where UFH works well in warehouse slabs, what it costs, and how to design it without risking failure.
All warehouse UFH slabs must include high-compression insulation to prevent heat loss into the ground. Rigid PIR or XPS boards rated for structural load should be laid below the UFH pipes. Avoid standard domestic EPS unless approved for industrial use. A full DPM should be placed beneath the insulation to prevent moisture migration and protect the heating zone.
Pipes should be buried under at least 50 to 75 mm of concrete to prevent damage from heavy rolling loads. In warehouse slabs, a full slab depth of 150 to 200 mm is common, with pipes typically fixed to mesh or insulation boards at the lower third. Avoid shallow coverage or placing pipes near slab corners, where cracking and deflection are more likely.
Heated slabs expand more than unheated ones. In warehouse spaces, this expansion must be managed with slip membranes, movement joints, and proper zoning of pipework. Control joints should not run directly over pipes. Always review thermal expansion values with a structural engineer if you're using jointless design or very large panel sizes.
Each UFH loop must be accessible via a central or zoned manifold. In warehouses, this means careful planning of the pipe layout to avoid conflicts with future racking or equipment. Long loops may require boosted flow or temperature compensation. Include accessible conduits and sleeves through the slab for future maintenance or pressure testing.
UFH systems must be pressure-tested before any concrete is poured. Hold the system at test pressure throughout the pour and for 24 hours after. Never activate the system for heating until the concrete has cured for at least 28 days. Bring the system up to temperature slowly to avoid thermal shock, which can cause slab cracking or damage to pipe loops.
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