Manor House Upgrade.
Gasway Services was appointed to deliver a full plant room upgrade at a large, privately occupied manor house in Essex. The existing heating system had become increasingly unreliable, with three standard-efficiency boilers nearing end of life. One boiler had already failed completely, with obsolete components making repair unviable.
The client required a future-proof, high-efficiency solution that could be delivered with minimal disruption to a sensitive and historic property.
Scope of Work
The project involved a comprehensive upgrade of the plant room and associated systems, including:
- Safe isolation, draining, and removal of three obsolete boilers
- Removal of uninsulated pipework, hot water cylinders, and circulation pumps
- Installation of a new gas supply from the meter to the plant room, including an emergency gas safety shut-off system
- Supply and installation of three Vaillant ecoTEC 64kW commercial boilers and two AIC Silox units
- Installation of a plate heat exchanger to protect new boiler components from legacy system contaminants
- Replacement of 46 radiator valves throughout the building, upgrading to thermostatic radiator valves where possible
- Adaptation of all electrical systems and installation of a full weather-compensating control system
Specialist Coordination & Risk Management
Due to the nature of the property and the complexity of the works, careful planning and specialist coordination were essential.
Key risk mitigation measures included:
- Occupied Property Management: Major works were scheduled while the family were away to remove any risk to occupants and ensure uninterrupted progress.
- Asbestos Handling: Following an asbestos survey, Vertex, a specialist asbestos removal contractor, safely removed all confirmed asbestos-containing flue materials.
- Working at Height: Allwin Access erected specialist scaffolding to allow safe installation of new flue systems.
- Gas Safety: Branch pipework was isolated and integrity-tested before and after installation to confirm full system soundness.
- Freeze Protection: While the property was unoccupied, all heating, hot, and cold water systems were fully drained to eliminate the risk of frozen pipework.
- Site Control: Scrap materials were removed immediately and secured in vans to maintain a safe and tidy working environment.
Project Delivery
The project was delivered by a multidisciplinary team of Gasway engineers, electricians, apprentices, and specialist contractors. Regular progress updates and photographs were provided throughout, ensuring the client remained fully informed at every stage.
Despite the scale and sensitivity of the works, the project was completed on time and within budget, with the upgraded system commissioned ahead of the originally discussed completion date.
Outcome
The completed installation provides the manor house with:
- A highly efficient, reliable heating system
- Improved system protection and longevity through separation and filtration
- Enhanced building efficiency via thermostatic radiator controls and weather compensation
- A modern, compliant plant room designed for long-term performance
Client Feedback
“On behalf of the family, I would like to thank you and your team for carrying out such a sizable project at a very delicate property with maximum care and in a very professional manner.
Your team’s commitment to excellence made the project run smoothly and be completed earlier than discussed. It is always reassuring to see a project progress to completion without complications, which was certainly the case here.
Darrel’s dedication as project manager was outstanding. His communication, attention to detail, and ability to resolve emerging issues gave us complete confidence throughout. We have been very impressed with the efficiency of the team and the continual updates provided, which are not always forthcoming from other contractors."
This client was looking for someone "knowledgeable and able to react accordingly" if you have a large scale property, and you want to upgrade your heating system, choose Gasway