Case Study: Hot Water Ring Main Replacement for a Multi-Level Building

Overview

East Plumbing Co. was engaged to replace a failing hot water ring main system within a multi-level building. The existing Aquatherm pipework had developed multiple splits and bursts, resulting in active leaks and ongoing reliability concerns.

The objective of the project was to deliver a long-term, durable solution while minimising water shutdown time and disruption to building occupants.

The Challenge

An initial site inspection and review of hydraulic as-built drawings identified widespread issues with the existing Aquatherm hot water pipework. Multiple failures were present, including active leaks on lower levels of the building.

Key challenges included:

• Ageing Aquatherm pipework prone to repeated failure

• Active leaks impacting building operations

• A complex ring main system spanning multiple levels

• The need to minimise hot water downtime during replacement

A coordinated approach was required to ensure the system could be upgraded efficiently and safely.

The Solution

The project was delivered as a single, coordinated upgrade, replacing the remaining Aquatherm pipework with a new 316 stainless steel hot water ring main designed for long-term performance.

Works included:

• Project management, SWMS, and insurances

• Supply and installation of 316 stainless steel pipework and press fittings

• Construction of a new ring main extending throughout the building and up to the roof-level hot water supply bank

• Cutting and forming ceiling and plaster penetrations to route new pipework

• Scanning and core drilling new penetrations within water meter cupboards

• Fire-rated sealing of all new penetrations

• Sealing and capping of redundant penetrations following removal of existing pipework

• Connection of the new ring main to existing water meter manifolds

• Installation of pipe clips, supports, and hangers

• Installation of 25mm hot water–compliant lagging

• Application of solar heat–compliant lagging to roof-level pipework

• Installation of isolation and air bleed valves on flow and return lines

• Rectification of existing leaks during shutdown

• Servicing of the hot water plant area

• Removal of all waste materials from site

To minimise disruption, the final cutover was completed with a single planned water shutdown day, supported by a dedicated on-site team.

The Outcome

The completed works delivered a robust stainless steel hot water ring main, eliminating the recurring failures associated with the previous Aquatherm system.

Outcomes included:

• Improved system reliability and durability

• Reduced risk of future leaks and unplanned outages

• Minimal disruption to occupants during the upgrade

• A compliant, maintainable hot water system designed for long-term use

Why This Matters

Hot water ring main failures can result in repeated shutdowns, property damage, and increased maintenance costs. Upgrading to stainless steel pipework provides a long-term solution that supports operational reliability and reduces lifecycle costs.

This project demonstrates East Plumbing Co.’s capability to manage complex, multi-level plumbing upgrades with careful planning, safety compliance, and minimal disruption.