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New Piping Option Offers Big Material Cost Savings

Carr Residence, HVAC
Products Used
Blue Pipe®
Location / Date
Bexley, OH
September - November 2012

Aquatherm Advantages

  • The heat fusion connections made the piping system installation quick and simple
  • Aquatherm's PP-R is a heat-stabilized thermoplastic, so it holds dimensions under high heat and pressure
  • An estimated 70% savings in material and labor compared to conventional materials and installation

The Challenge

The aging heating system in the Dan Carr residence had become inefficient and required replacement.


The Solution

A new boiler was installed along with several hundred of feet of Aquatherm's PP-R piping, reducing labor times and eliminating lost energy due to corroded metal piping.

 An outdated boiler and home heating system resulted in wasted energy and money for an Ohio family

carrresidence2carrresidence3Built in 1928, Dan Carr’s 3,112-sq-ft home, which is located in the Bexley suburb of Columbus, OH, was in dire need of a renovation. Carr had given contractors the lofty task of removing part of the original first floor to lower its elevation and create a new kitchen and family room that would share the same floor level.

The contractors were challenged to brace and maintain structural support of the second floor, and yet allow enough working space for the new radiator piping to be hidden within the structure. Jeff Persons, president, Geo Source One, Inc. and his Columbus-based team were put to task for this repiping project and selected Aquatherm Blue Pipe® (formerly Climatherm) for the job because its flexibility allows it to be used through captive soffits and confined floor joists, where rigid pipe could not be easily fit and hung.

The original heating system in the home was a coal-fired boiler, which changed to oil and then finally to natural gas in the early 1960s. The boiler served over 3,000 sq. ft. of the home with a gravity distribution system on double 3-in. mains, and cast iron radiators. A simple central power-pile thermostat controlled the aging gas valve, telling the massive boiler when to fire.

The latest boiler, installed in the 1960s, was a natural draft boiler with a 10-in. flue venting into a 30-ft. chimney. The boiler was rated for 380,000 Btuh output and 480,000 Btuh input. The draft was calculated on the 10-in. flue at 711 cfm, made up by infiltration air to the structure. After accounting for stand-by losses, Carr was fortunate if 52% of the annual gas bill actually provided usable heat for the home.

The challenge for the repiping conversion was brought on by a major remodeling project that called for lowering the floor above the main basement and boiler area by 16 in. This required removal of the boiler supply and return mains, and connected radiator run-outs to both the main and second floor of the dwelling. A total of 14 out of 20 radiator run-outs were directly affected and repiped as a result of the renovation.