When fire and EMS personnel need to make a quick break from base camp, the last thing they need is to contend with are the hazards of snow and ice.

That's why - when the new, 40,000 s.f. two-level West Friendship Volunteer Fire Department headquarters was completed earlier this year as one of the largest facilities of its kind in the Northeast, an 18,000 square foot snow melt system was installed in the heavy concrete slabs around the building.

Fortunately, the thought of in-slab radiant didn't escape the consideration for interior comfort, too, so the quick-responders at this facility get the benefit of radiant heat all winter long. That is, until the alarm sounds, alerting them of the next emergency need.

The very essence of quick response is predetermined here. The West Friendship Volunteer Fire Department was organized by the Minutemen of Company 769 in Howard County. The Minutemen were organized during World War II to protect the citizens from acts of sabotage. As the war drew to a close, the group was disbanding. At their final meeting on September 4, 1944, they instead chose to form a volunteer fire department.

Several descendants of that group today enjoy the new facility, an unchanged public service mission and the greatly improved base camp facility built to enable quick response. "Around here, we can now say that fire and ice are dealt with accordingly," said Fire Chief Mickey Day.

The L-shaped facility in Howard County, MD, is home to EMS personnel and equipment on one side, and large fire equipment bays on the other. Common areas were placed at the "L-bow" joint, providing room for food service, office and training areas.

According to Chief Day, the facility is the base of operations for two full-time and 10 part-time personnel and 85 volunteers. In the enclosed, radiantly-heated bays, 10 pieces of equipment are kept in mint condition: two engines, two tankers, one tower truck, two ambulances, one brush truck (for brush and wild fires) and two utility vans.

"The equipment actually has it a bit better than the personnel do," joked Chief Day. "The radiantly-heated slabs provide warmth for the equipment bays, but not inside the facility's common and bunk areas."

The West Friendship Fire Company job - typical of the commercial work done by Gaithersburg, MD-based Mallick Plumbing & Heating, Inc. - billed-out at about $1.5 million. The 58-person-firm had revenues of 18 million in 2008, with 95 percent of earnings stemming from commercial and industrial work. A small percentage of work comes from residential service and retrofit work.

According to Mike Mallick, general superintendent and project manager for Mallick Plumbing & Heating, said that the jobsite foreman for the project was Greg Green. The engineered design was developed by Timonium, MD-based Schlenger Pitz and Associates, Inc.; the project mechanical engineer was Jennifer Varacalle.

The job at West Friendship Fire Company entailed the installation of a large hydronic system with radiant heat, snow melt, and hydro-air heat for the common and bunk areas. Mallick professionals tapped the design and on-site expertise of manufacturer's rep firm Cummins-Wagner for, among other system components, 32,000 lineal feet of Watts Radiant EPDM synthetic rubber Onix tubing and manifolds, two pre-engineered, prepackaged HydroNex system panels from Watts Radiant for equipment bay radiant heating and one larger, custom-built HydroSkid package built specifically for the project to control the snow-melting operation outside.

"We prefer working with Onix because of its flexibility and ruggedness," said Mallick. "It doesn't kink and bounces right back if it's crushed. It's also unaffected by exposure to the sun, which would've been a concern if we had done the job with PEX tubing. It also has an aluminum oxygen barrier layer, and Kevlar for tensile strength."

Mallick and jobsite foreman supervised installation crews that were at work on the fire station mechanical system for about nine months.

For snow-melting, a single boiler provides the heat with low temperature valves in the supply and return piping so that it can't bring less than 70°F fluid back into the boiler, avoiding the risk of condensate accumulation. The system heats 660 gallons of 50/50 glycol mix for the exterior slabs. The 18,000 s.f. of un-insulated, 8-inch concrete slab - divided into three separate, 6,000 s.f. slabs - operates off of one outdoor temperature-and-humidity-sensitive sensor.

"Facility managers can over-ride the automatic activation of the system if they know from weather reports that a winter storm is coming in," added Mallick. "That way, they can turn on the outside slab heat before the sensor would pick it up."

The HydroSkid package is a skid-mounted mechanical unit by Watts Radiant designed to keep mechanical projects on schedule and on budget. The units are built entirely to specification, greatly simplifying involvement at the jobsite. UL-listed components are used, and they are custom engineered and manufactured in a factory-controlled environment to assure quality control. The number of zones, flow requirements and component choices determine overall footprint and height.

"The snowmelt operation is actually quite simple," said Mallick. "When the snowmelt system is activated, all loops are warmed at once. There are two pumps on the Hydroskid: one serves six manifold sets and the other operates seven manifold sets."

The three equally-sized slabs are found outside the EMS bay (entry and exit), and on both sides of the drive-through fire equipment bays. Though the exterior slabs are un-insulated, the interior bays, six-inches thick, are insulated from below, and along the perimeter.

A Higher Calling

With all that gear and personnel, a new and larger facility (and some kindly harassment from neighboring fire companies for the superb mechanical system) comes an added expectation that - should a large-scale need arise, the resources of West Friendship could be called on to serve.

After all, Howard County is a mere 40 miles from the nation's capitol.

Such a need would likely come with little warning, and that's why fire and rescue personnel recognize the need for 24/7/365 readiness, a mission that harks back to the early days of Minuteman soldiering.

Maryland Emergency Management Agency Deputy Director of Operations, Ed Hopkins, said that there are "mutual aid" agreements in place all over the country. These are designed to get emergency resources quickly into an area of need. If the capitol would be threatened by attack, acts of terrorism, or struggle with an actual, large-scale need, these mutual aid agreements come into play, calling-in resources in ever-widening perimeters.

The World Trade Center attack drew-in resources from many miles away. So did the more recent flooding in Iowa and coastal hurricanes.

In this regard, the focus at West Friendship is no different than at fire stations nationwide: maintain readiness at all times. Yet, with the national capitol within a stone's throw, there's the realization that a higher calling could always arise.

West Friendship is ready to serve.

Plumbing & mechanical contractor Dave Yates admits occasional frustration at customers who seem unwilling to make decisions and waffle 'til it hurts. But on this sales call, he came face-to-face with the biggest communications challenge of all: a group of customers who simply couldn't speak for themselves.

Yates is president of F. W. Behler, Inc., a York, PA-based plumbing and mechanical firm that specializes in radiant heat. He's been in the business a long time, so it's hard to surprise him with something entirely new. But he knew quickly that there was something unique about this visit when, following his invitation into the kitchen, a young kangaroo sauntered over to his place at the table as if to say, "you're in m' spot, bub."

Yates was introduced to Owen, the larger of several macropods at the non-profit animal rehabilitation, breeding and release center in rural Dillsburg, PA. Wendy Looker, who manages Rehabitat, Inc. (www.rehabitat.org), explained that, thought their budget was tight, the many animals there would benefit from the comfort of radiant heat. Soon afterward, she and Dave agreed on the scope of the job, and a price that worked because she could muster a large volunteer work force.

The system they settled on for the new, 1,800 square foot building would be divided into three distinct areas: office/dogs; raptors; and macro-pods. To further reduce installation time, Yates would install a pre-manufactured "HydroControl" injection panel made by Watts Radiant.

And, during their first winter with radiant comfort, the warm macro-pods, raptors, and canine critters were comfortably cuddling up to the warm concrete slab, resting well and healing remarkably well. Radiant heat was just what the doctor ordered.

Remember Volkswagen's Fahrvergnügen campaign? Translated, it means, "driving with zeal." Today, the automaker insists that the same sense of excitement happen in the showroom, and has invested with zeal to make it happen. "We want our new showrooms to be a thrill for buyers, places of exquisite comfort," said an executive at Volkswagen of America.

One auto dealership in York, PA, when planning construction of its new dealership, took the "exquisite comfort" directive seriously. A vast radiant heat system provides comfort for buyers and employees alike, even (and especially) in the auto maintenance bays. The system extends outdoors, as well, so that sidewalks and entryways remain free of snow and ice all winter long. And for the ultimate in fuel efficiency they get the heat at no cost by burning used motor oils and hydraulic fluid.

York VW's new facility is proudly one of the newest "Marketplace" dealerships, designed and subsidized by substantial investment from Volkswagen.

In keeping with its hip image, Volkswagen designed the Marketplace dealerships to provide customers with a uniquely European setting, upscale showrooms, internet access stations and colorful play areas for kids. The newly constructed, 20,000 square foot York VW facility is purely cool. It's an innovative and wide-open retail environment boldly accentuated by glass and metal and volumes of natural light.

"Showroom comfort" in the service bays

"But it's in the winter that we see the greatest transformation," said Chris Bernlohr, general manager of York Volkswagen. "Customers are immediately aware of the unusual comfort they have in a facility with whole walls of glass - just the opposite of what you'd expect." York VW's commitment to comfort extended beyond the public areas and offices and into the extensive, 24-bay service area, and a place of work for mechanics that's now as comfortable as the showroom.

York VW managers took several additional steps on their own to assure the comfort of employees and customers, and to reap the rewards of an investment in a "heat-for-free" concept that performed remarkably well during its first and second winter seasons. Waste oil boilers are coupled with an extensive layout of Watts Radiant Onix EPDM tubing to provide heat in the most needed space of all - a state-of-the-art service area where mechanics are greeted on any subzero day with a heated concrete floor. Not only does Onix take jobsite abuse, it stands up to concrete cracking and shifting slabs like no other tubing- an important factor when considering the weight of the cars sitting on the showroom floor.

"It's one thing to get the heat for free. It saves us a ton of money. But it's an entirely different thing to get the very finest heat at no cost, enjoyed by customers and employees alike," said Bernlohr. "We feel real good about that."

Wrenches in th' works? Sure, there were a few at this little job in rural Mount Joy, PA. But this mechanical contractor was drawn to a challenge. What he found when he got there - with tasks that would be tied to an extensive remodeling project - was an ancient, fuel oil-guzzling cast iron boiler, uninsulated walls and plans for a new kitchen to be perched above a "rock quarry."

"The challenges certainly gave the job some personality," said Dave Yates, president of F. W. Behler, Inc., based in York, PA, chosen by the homeowners to do the mechanical system upgrades.

The Martins, a family of four, live in a 2,400 square-foot log home that dates back to the time of the Revolutionary War. The home had some serious cold weather comfort issues. Home renovations entailed a new kitchen and laundry room, and a complete rehab of the mechanical system. Attached to the new boiler: a Watts Radiant HydroControl Panel with outdoor reset control, Onix tubing to deliver hot water to some new and existing baseboards, and a few Onix staple-up zones.

While making the heat load calculations, the kitchen became an interesting challenge for Yates and Bob Seiger, one of his chief installers. The room was a bit troublesome because of its location above the "rock quarry," homeowner Bruce Martin's favorite description of the centuries-old pit, filled with rocks, rubble, old timbers, glass and pottery shards, a thoroughly worked-over cache of walnuts and corn cobs, and - Heike was certain - one of the oldest, continuously-inhabited 'mouse condos' in all of Lancaster County.

Today, the Martins are 100% comfortable, and 50% more energy efficient!

A new condominium development in Ohio has rolled out the ultimate warm welcome to homeowners. As prospective buyers toured the homes this winter, they were encouraged to remove their shoes to feel that warmth in a way that leaves a lasting, positive impression.

"We took a bit of a gamble with it, but we knew - especially at this time of year when temperatures are at their lowest - that when people felt it, they'd be struck by its comfort. There's really nothing quite like it for its coziness in the winter months," added Terry O'Keefe. "Of course, we also knew that by making this development exclusively radiant, we'd have a nice way to differentiate our development, and these homes, from those offered by others."

All of the homes are heated hydronically. The second story areas are all heated by staple-up application of highly flexible Onix tubing, an EPDM/synthetic rubber tubing also manufactured by Watts Radiant.

"We're pretty fixed on Onix because it's so easy to install," said Tony Fischer, project manager for Columbus-based Freeland Contracting Company, the firm that is installing all of the heating systems at Bishopsgate. "It has the feel and flexibility of installing a three-quarter inch piece of hemp rope - it's got substance and great flexibility at almost any temperature. Attempting to do PEX staple-up in the spring, fall and winter is like a wrestling match. Onix goes where you want it with no fight at all. It comes off the spool perfectly."

"Another key advantage is that, when it's stapled-up, it flattens slightly," added Fischer. "That's exactly what it's designed to do. The flattening of the tubing against the subfloor above increases the surface contact with the wood, dramatically improving thermal transfer from the pipe to the floor above. That's why heat transfer plates aren't needed with Onix. That saves a lot of time and expense. Of course, we use foil-faced insulation from below to complete installation of the staple-up sections."

"Radiant heat is a great investment for homeowners," he added. "Not only do you get incomparable comfort, and the highest energy efficiency available - typically, a 25% to 40% improvement over forced air - but with no air grates, radiators or baseboard to factor-in, there's also no interference with room function or furniture layout."

The radiant heat system adds about $7,500 to the cost of each home, an investment that will - because of the higher operational efficiency - reward homeowners with full "payback" in six to seven years.

"It's an amenity that complements the feel and luxury of the 39 detached condominiums at Bishopsgate," said Katie O'Keefe. "The homes have the look and feel of English country cottages, with steep roofs and stone veneer chimneys. But they also have a contemporary, open floor plan with high ceilings and lots of attention to detail and convenience."

"All of the Bishopsgate homes feature spacious master suites with vaulted ceilings, two walk-in closets and a luxurious bathing area, including a large whirlpool tub," said Chris Reese, Metro II Realty, the Columbus realty firm chosen by O'Keefe to market the properties. "Kitchens are elegantly designed with abundant cabinetry, large center island, and easy access to a private patio and an open view of the great room."

O'Keefe describes his interest in radiant heat as something of a conversion. "It's time that more people learn about it, and to discover the incredible comfort it offers," he concluded.

There's one thing many professionals in the HVAC industry usually agree on: that, in the northern reaches of the country, heat pumps are outmatched by cruel winter temperatures. But this family of central PA, fought back and, this time, Old Man Winter took a beatin.'

Two winters ago, with outside temperatures hovering around 20°F for weeks on end, their heat pump couldn't push inside temperatures above 55°. "If it got colder outside - down to 5° or so, which it did for several days - we got colder, and the only thing we could do was to add more clothes during the day, and more blankets at night" said the resident.

It's one thing to deal with some discomfort. But it's another, even tougher source of discomfort, when the electricity bill arrives. Their monthly electric bills during the winter of '02-'03 ranged between $200 and $300. "We felt like we were throwing lots of money away, literally. The house wasn't warm, we were uncomfortable, and the utility bills kept getting higher and higher. We decided to fight back."

Following a friend's referral, the family called on Dave Yates, president of F. W. Behler, Inc., a plumbing, heating and air conditioning firm based in York, PA. Though they admitted to a fairly tight budget, they also spoke of their interest in radiant heat.

Yates, who specializes in radiant, presented his plan to install a small, high-efficiency boiler, retaining the heat pump for summer duty, and adding a hydronic coil that would provide warmth for the second floor. He would also install a two-zone, eight-loop staple-up radiant system heat for the entire first floor.

About 1,200 lineal feet of Watts Radiant "Onix" tubing was ordered for the home's staple-up radiant system. "We like the material because of its excellent heat transfer when stapled-up - without metal heat transfer plates," said Yates. "Its rope-like flexibility gives Onix two other key advantages for a job like this. It's easy to install, so we spend a lot less time on the installation - unlike PEX which has a mind of its own. And - most important for this job - Onix was the only tubing we could use to weave between the thousands of protruding metal nails driven through the subfloor when the home's hardwood flooring was applied."

"After several winters in our home where we just endured the cold, it's hard to describe the comfort we have today." Another source of comfort has been the greatly-improved monthly energy bill. Recently, the electric utility audited electric use at their house. Their monthly budget amount dropped from $161/month to $78/month. "Substantial savings with no compromise to comfort, we can live with that."

The Chambers residence near Kalispell, Montana, is a custom-built log home with 6,500 square feet of pure comfort. In this home, Doug Davis, Davis Plumbing & Heating, Columbia Falls, MT, used 3/8" Onix tubing for every room of the house, encasing it in lightweight concrete.

"I've used Onix tubing for 12 years and haven't once been disappointed," he says. Davis also designs and installs his own injection systems. "I'm not afraid of complex radiant jobs," he added. "In fact, we like a good challenge - and this has helped us to differentiate ourselves from other installers. Builders in this area recognize that we take our work seriously, and that we're reluctant to use anything but the very best materials availabel; Watts Radiant products have been a key ingredient from the beginning."

For Davis, who's been in business since 1986, radiant is the only heat source he offers. Typical jobsites are new custom homes in the $1 million to $4 million range.

They say seeing is believing. Simple to say, sometimes not so easy to prove. So, what would be the worse installation condition for a radiant system: How about slab on grade in the middle of a winter storm? No problem.

To show how Onix can tackle even the toughest Mother Nature can deliver; a slab was mocked up at Watts Radiant. Here we prepared a slab base and with 6x6 rewire mesh. Then we waited for the elements to change. With the temperature near 20 degrees Farenheit and the white stuff falling, Onix showed it could go toe-to-toe with the storm.

This beach bar on top of a hotel in California wanted to extend its season but the cold ocean breeze was putting the excitement on ice. Onix was installed underneath the sand and in the benches of this rooftop bar. They needed to install a product that was flexible and able to lay flat under the sand without lifting. Sitting under 9 inches of sand and with dozens of active patrons, Onix performs flawlessly, keeping every square foot warm. Once word got out, the hotel had another problem to contend with- over crowding. Soon the sand covered rooftop bar was the place to be.

Brick pavers don't like winter. Chemicals attach them and plows chip them. This resident wanted to keep his driveway, patio and steps snow and ice-free during the harsh Massachusetts winters.

The installer insisted on using Onix due to ease of installation. Onix was installed quickly and easily to the wire mesh. Sand was then applied above the Onix with the use of a power buggy (wheel barrow). No worries there- Onix easily resists crushing. Using Onix saved the radiant and paver installers time, money, and hassle.