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St Pauls Catholic Primary School, Thames Ditton – Boiler & Water Heater Replacement project photograph
EducationHeating & Hot Water Plant Replacement

St Pauls Catholic Primary School, Thames Ditton – Boiler & Water Heater Replacement

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ClientSt Pauls Catholic Primary School, Hampton Court, Thames Ditton
Duration3 Weeks
Building usePrimary Education
Project scopeHeating & Hot Water Plant Replacement

St Pauls Catholic Primary School, Hampton Court, Thames Ditton — plant room refurbishment covering both space heating and domestic hot water generation, with new gas-fired condensing boilers, a new gas-fired water heater, a new flue system and new controls, delivered in three weeks.

Refurbished plant room with insulated distribution pipework, circulating pumps and a red expansion vessel on the floor.
Insulated distribution pipework, Grundfos circulation pumps and red expansion vessel.

Two systems, one plant room

Most school plant rooms carry two separate duties. One is space heating — the boilers and the distribution that warm the classrooms. The other is domestic hot water — the supply to kitchens, washrooms and cleaners’ sinks, which a school needs every day it is open regardless of the season.

At St Pauls both were replaced in the same works. New gas-fired condensing boilers were installed for heating, and a new gas-fired water heater was installed for hot water generation.

Those two assets rarely fail at the same time, and it is common to see them replaced years apart, with two separate strip-outs, two shutdowns and two sets of alterations to the same gas service. Replacing them together meant one shutdown, one set of gas service modifications, one flue installation and one commissioning exercise.

Andrews Water Heaters gas-fired cylinder with incoming yellow gas pipework and lagged hot water distribution.
Andrews Water Heaters gas-fired cylinder connected to yellow gas pipework and insulated services.
Two digital Mikrofill pressurisation units and a blue expansion vessel installed alongside boiler pipework.
Wall-mounted Mikrofill pressurisation units, blue expansion vessel and sealed system pipework.

Scope of works

  • Strip-out and disposal of the existing plant room equipment
  • Modifications to the existing gas service
  • Installation of new gas-fired condensing boilers
  • Installation of a new flue system
  • Installation of a new gas-fired water heater
  • Installation of new plant room equipment
  • Design and installation of new controls
  • Pre-commission cleansing
  • Testing and commissioning
  • Builders work in connection with the mechanical installation
  • Provision of record documentation
Cleared concrete plinth and plant room floor during strip-out works at St Pauls Primary School.
Plant room floor and concrete plinths during strip-out works, showing existing boilers and pipework.
Uninsulated steel pipework manifold and circulating pumps fixed to unistrut framework in the plant room.
Fabricated distribution pipework and Grundfos pumps mounted on channel supports prior to insulation.
Vertical view of twin circulation pumps on insulated pipework headers with pressure gauges and control valves.
Grundfos circulation pumps and insulated distribution headers fitted with gauges and isolating valves.

Programme

The works were completed in three weeks. Both the heating plant and the water heater were removed, replaced, cleansed and commissioned within that period, and the plant room was handed back with record documentation.

Where a school is planning capital works, dealing with heating and hot water generation in one programme is usually the lower-disruption route even though the individual scope is larger, because the building only loses its services once.

Enclosed plant control panel with indicator lights and rotary switches next to a yellow gas pipe and emergency switch.
Central control panel with indicator lamps and selector switches alongside the yellow gas supply pipe.
Touchscreen display showing a graphical system schematic for boilers, hot water cylinder and classroom heating zones.
Digital touchscreen interface displaying the plant room schematic, boiler status and heating circuits.

A second project at the same school

ComGas has also carried out a separate M&E and alarm services package at St Pauls, supporting the structural reinforcement of failing RAAC planks in the school’s corridors. That project is documented separately: St Pauls Catholic Primary School — RAAC remediation M&E enabling works.

Heating and commercial hot water systems are frequently replaced together in the plant room projects ComGas delivers for schools.

Twin boilers connected to stainless steel vertical flues and circulation pumps in the refurbished school plant room.
Twin boilers fitted with stainless steel flue headers and circulation pumps on lagged connections.
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