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The team at Vulcan Flue Systems are experts in the design, supply and installation of a wide range of exhaust air flue systems tailored to the specific requirements of each appliance type, fuel type and heat output size. Our services include the design, co-ordination and construction of new, pre-fabricated, single walled stainless steel flue systems and twin walled insulated stainless steel flue systems, various re-lining techniques for pre-existing chimneys, flue systems and ducting systems that require repair. All of our flue systems and re-lining systems are required and utilised on a vast array of appliances like, communal central heating boiler plant (condensing and non-condensing), water heaters, Combined Heat & Power plant (CHP), back up diesel powered generators, fireplaces & pizza ovens, to name a few.
Problem solving is our forte. We have the experience and technical understanding that enables a quick and thorough prognosis of those pre-existing, disfunctional flue systems. We also invest heavily into systems that help us with that. We are able to undertake internal visual inspections via our CCTV inspection camera, flue gas pressure tightness testing, room pressure differential testing (4Pa test) and flue sizing calculation programmes amongst others.
Our projects range from large-scale domestic refurbishments to extensive commercial developments requiring complex chimney lining and flue system installations.
With over 50 years of combined experience in the flue industry, Vulcan Flue Systems applies engineering excellence and in-depth product knowledge to ensure the most suitable solution is offered on each and every project. Design, safety and functionality sit at the core of every boiler flue, CHP flue and chimney lining project undertaken.
Vulcan Flue Systems handle large-scale commercial installations, domestic projects and residential refurbishments with high-specification engineering requirements.
Every project is bespoke with flue solutions offered from a number of manufacturers depending on their suitability for the project. The team at Vulcan are also certified and factory trained installers of the popular and highly effective Furanflex lining system, used predominantly to line existing chimneys and flues whilst causing minimal restriction to the flue size.
Through Vulcan’s experience working with both commercial and domestic clients, the team are hugely proud of the reputation they have built within the industry.
An inherent attention to detail sits at the forefront of every flue project we undertake from the initial design phase, all the way through to flue system construction. Our designs and advice will always prioritise regulatory conformity whilst adhering tightly to all relevant standards and guides to good practice. Our flue fitting teams are issued with and work to a company and job specific \'standard of workmanship guide\', outlining the high standards that are expected of a completed flue system installation. We understand the importance of continued communication and coordination throughout the duration of each project.
We work in partnership with Engineering Consultants (M&E), Facilities Managers, Project Managers Main Building Contractors, Architects, Surveyors, Planners and Estimators as well as private clients.
We embrace and apply cutting edge and emerging technologies to enable us to develop complex technical design specifications.
With over 50 years of combined experience, we operate across London and the Home Counties, providing our customers with engineering excellence and in-depth product knowledge. It is this experience that ensures our clients will receive the best advice and support available, giving them complete confidence and leaving other contractors to concentrate on other areas of the site.
Safety is paramount to us, we take our certification seriously with a continued commitment to staff training and work to the highest safety standards at all times. Our customers can rest assured knowing our experienced team of multi-accredited flue installation engineers are working to the highest level of workmanship and knowledge – and can be trusted to work safely and efficiently onsite.
Site safety courses ensure that our engineers are CSCS H&S certified. As a business we are also Safecontractor & CHAS accredited and carry public liability cover up to £5,000,000, employer\'s liability covers up to £10,000,000 and professional indemnity cover to £1,000,000.
Situation
As part of a large scale residential refurbishment that included a range of different size apartments, ranging from 1 bedroom pied-a-terre to an impressive 3-storey penthouse, it was required that 18 contemporary, open fronted, natural gas fireplaces should be included. At the initial survey stage, the building was a pre-cast concrete shell with no pre-existing chimneys or flues, only cast holes within the concrete slab at each level. A full flue design was required that would involve detailed route planning that should coordinate with all other mechanical, electrical & plumbing services (MEP). With a combination of misaligned, pre-cast holes at each level and the required fireplace locations, it made for very complicated flue route requirements. Based on the required routes, we were doubtful that the flue systems would operate under natural draught.
Solution
All flue routes were mapped out on CAD, including support detail, provisions for ongoing maintenance and coordinated with all other services. Flue sizing calculations were carried out which concluded insufficient natural draught and the requirement for mechanical chimney fan assistance. All chimney fans were sized and selected to deal with the flue system resistances and flue gas volumes present on each system.
Result
All flue systems were completed over a 3 month period to suit site specific progression. Chimney fans were connected to their controllers and corresponding flue systems at the commissioning stage. All systems tested, fully functioning and ready to go.
As part of the refurbishment and conversion of a listed building into high end residential units, there was a requirement to install new gas fires into each of the apartments. We completed CCTV camera surveys of the existing flues in the property and found the majority to have suffered severe deterioration over time, leaving holes and gaps which smoke could leak through, making the flues unsuitable for use. The client was keen to retain original opening sizes for each fireplace - our challenge was to line the flues whilst adding the least amount of restriction.
We lined each of the flues using Furanflex RWV which is suitable for open solid fuel and DFE appliances. Furanflex RWV is a thermo setting lining system and is inflated and steamed after insertion into the flue. Throughout the curing process, the lining’s thermosetting resin softens and moulds to the internal shape of the flue, before setting harder than steel, enabling the flue to be lined with the least amount of restriction. Once completed, working fire opening size tests were carried out, documented and passed on to the fireplace contractor to aid in their works.
Each of the lining systems were installed in a day, the original fire opening sizes remained the same and were left ready for use by DFE gas appliances that would be fitted by the fireplace contractor at a later date.
Located in one of London\'s most sought-after areas overlooking Hyde Park, Park Modern project is an ultra-luxury development consisting of 52 apartments, 3 penthouses and 2 mews houses, all accompanied by a health and leisure suite, residents lounge, games room and cinema. This £450m development spans a sizeable footprint of 190,000 square feet, consisting of 10 levels from ground level to penthouse level, plus an additional 3 levels below ground. All in all, a very impressive project that we were proud to be a part of.
As part of the mechanical package, there was a requirement to include natural gas-fired heating boilers to service the heat and hot water needs of the building, a diesel-powered generator to power a pump for the sprinkler system and natural gas-fired CHP\'s to assist with heat and power to the building.
As with any combustion appliance, flue design, flue supply and flue installation would be required to ensure all products of combustion are safely evacuated to the atmosphere for each and every combustion appliance.
The first stage required us to work aside the mechanical design contractor, giving professional flue advice on regulatory/ performance criteria and running flue sizing calculations to enable coordination of mechanical services and preparation of first draught drawings to be put forward for relevant pre-construction approvals. As with most construction projects, changes happen which have a knock-on effect and do require a staged approach to flue design which we worked through to the end with the mechanical design team to see it through to construction phase.
Once our final draught construction drawings were uploaded and given approved status, it was time to begin construction phase which was required to be staged to fit with construction schedules and general building progress. All chimney flue materials were manufactured specific to our requirements and delivered directly to site in stages due to the quantity and space that it took up on site. All flue components were of a twin wall insulated flue type. The flue to serve the heating boilers was manufactured to suit positive pressure conditions where condensate would be present. For the CHP flue, it was manufactured to suit high pressure conditions where flue condensate would also be present. The diesel generator flue was manufactured with additional insulation to handle the higher flue gas temperatures whilst being capable of high pressures.
Altogether, over 300m of twin wall insulated flue was successfully installed at Park Modern with relevant flue pressure tests undertaken to ensure flue leakage rates were within required parameters.
As constructed drawings were provided along with all relevant operation and maintenance manuals.
Situation
An interesting project that saw the complete destruction of the existing building to make way for a new 22 storey development that would include 163 residential units and a ground floor retail area. Also included within the ground floor, would be a plantroom that would service the heating and hot water demands of the building. The plant would consist of 3 banks of 3 module boilers, totalling just over 1500Kw and a combined heat & power unit (CHP), all of which required flue systems to serve them that would terminate above roof level.
Solution
Flue routes were designed to fit with the building layout and coordinated with the MEP team to work with all other services. Flue sizing calculations were conducted to ensure optimal flue performance across the plants operational range and needed to include flue draught stabilisation due to the sheer height of the building. Corrected chimney height calculations were made to determine a flue termination height that complied with the Clean Air Act
Result
The design was completed and signed off by the main contractor and then followed with a 2 stage installation which saw over 200 metres of flue installed across a 6 day period. All appliances were commissioned by the heating engineer and then handed over ready for operation upon project completion.
