Twin wall flue header and riser above boilers in a hospital plantroom
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Flagship project Boiler and water heater flues GE4022, GE4023, GE4037

Reading Hospital

Boiler and water heater flues across three hospital plantrooms, including one stripped out and rebuilt in a day.

Site
Reading Hospital
Town
Reading, South East
Sector
Healthcare
Status
Plant Room 3 complete

Key facts

plantrooms on the hospital site
3
boilers, each on a Ø150 primary
120 kW
twin wall insulated headers and risers
Ø250
water heater flues
Ø130
to strip out and rebuild Plant Room 3
1 day

The challenge

The hospital was replacing boilers and water heaters in three plantrooms, and every one needed new flues.

The plantrooms are working hospital space, with permits, inductions and protected grass between the access point and the plant.

In Plant Room 3 the new boiler spigots were not where the old ones had been.

What we did

Each boiler connects on a Ø150 primary into a Ø250 twin wall insulated header, with bespoke tees, new flashings and the old flues taken out.

The water heaters have their own Ø130 flues.

In Plant Room 3 we moved cherry pickers across the protected grass, loaded the materials in, stripped out the old flue and set strut channel supports.

Because the spigots had moved, we designed and built the route on site to keep alignment, fall and clearances.

The result

Plant Room 3 was stripped out and rebuilt in one day, working from 7:30 am to about 9 pm.

Hot works paused while a safe grinding zone was agreed away from homes nearby.

Certificate of conformity issued for Plant Room 3 at the end of October 2025.

On site.

5 photographs. Tap a photo to see it larger.

Reading Hospital, Reading. Plant Room 3: the new header and riser.
Reading Hospital, Reading. The plant room header and riser.
Reading Hospital, Reading. New twin wall header with tees above the boilers, tied into the riser.
Reading Hospital, Reading. Header hung on drop rods, rising into the riser.
Survey photo. Reading Hospital, Reading. The existing water heater flues at survey.

The drawing.

From the survey.

Hand survey sketch, side view of a plantroom with a boiler, flue riser, test length and drain length
Survey sketch, side view: a test length and drain length in each primary.

Finishing details

The details we leave behind.

  • Survey sketch of a test and drain length

    Test and drain lengths

    A test length and a drain length in each boiler primary, set at survey.

  • Header hung on drop rods

    Hung on drop rods

    Headers carried on drop rods and strut channel, with tees into the riser.

  • Header and riser in Plant Room 3

    Built to the new spigots

    Route designed on site to keep alignment, fall and clearances once the spigots had moved.

Handover

What the client got.

The documents on record for this job. Handover documents normally go into the customer's project folder before the engineers get home.

  • Survey and sketchesEach plantroom measured and sketched
  • Flue calculationsPlant Room 3
  • Job-specific RAMSPlant Room 1, October 2025
  • Completion reportPlant Room 3, 29 October 2025, with photos
  • Certificate of conformityPlant Room 3, October 2025

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