Hornbeam Park Developments

Challenges

A key challenge from the outset was designing and installing air source heat pump systems with underfloor heating in industrial-style spaces, where achieving suitable internal design temperatures during winter months required careful system selection, detailed heat loss assessment and precise commissioning to maximise efficiency and occupant comfort.

The original phasing strategy also changed significantly during the project. What began as separate phases of 8 units followed by 10 units was later revised to deliver 16 units within the same footprint, creating increased pressure on plant space, service routes and coordination. Our team developed practical space-saving solutions to accommodate the revised layouts while maintaining performance and compliance across all units.

Further complexity arose from the positioning of external air source heat pump condensers mounted on perimeter walls. Routing flow and return pipework from these external locations back into centrally positioned plant rooms serving internal units required detailed coordination, careful planning of penetrations and efficient service routes to ensure both performance and aesthetics were maintained.

The project also experienced multiple design changes throughout the programme, requiring continual adaptation of layouts and installation sequences. In addition, Phase 1 marked our first installation using Mitsubishi heat pump equipment, which brought the challenge of integrating a new manufacturer’s systems, establishing supplier relationships, and familiarising installation teams with new products and controls.

Despite these challenges, the completed development now benefits from efficient, future-ready mechanical services that provide sustainable heating, practical functionality and reliable long-term performance across all units.

Our Approach

This development provided an opportunity to deliver a modern low-carbon mechanical solution across a phased industrial scheme while strengthening a new contractor relationship. During Phase 1, we quickly identified that elements of the Stage 3 design required refinement to suit practical installation and performance requirements. At the same time, working with new suppliers presented early challenges, as their technical support and procurement processes were not yet aligned with the level of service we were used to from established partners.

Rather than allow this to impact progress, we worked closely with our internal design team and supply chain to resolve issues quickly, identify missing procurement items and improve system performance as the project developed. Our design team played a key role in refining heat output calculations and helping optimise the systems for the style of units being constructed.

As the scheme progressed into Phase 2, we again adopted a flexible and solution-led mindset when the number of units increased significantly within the same footprint. This required rapid redesign, close manufacturer collaboration and practical engineering decisions to maintain viability, performance and programme.

The Solution Delivered

During Phase 1, we successfully installed Mitsubishi air source heat pump systems and underfloor heating despite the learning curve of new products and new installation methods, including stapling UFH systems to mesh reinforcement. Through efficient site management and strong teamwork, these challenges were overcome and the first phase was delivered to a high standard.

Plant room installations were completed with a quality finish, and we worked directly with manufacturers to improve our understanding of specialist requirements such as insulation and lagging standards. These learnings added further value to later phases of the project.

In Phase 2, when the scheme increased from the planned 10 units to 16 units in the same overall area, service coordination became significantly more complex. We introduced an Ecoflex underground distribution system to efficiently route flow and return services through constrained spaces. To offset additional costs, we also engineered savings by reducing the kilowatt size of the air source heat pump systems through revised design calculations.

Plant room spaces were further condensed through the use of alternative manufacturer solutions requiring less internal equipment, allowing the increased unit numbers to be accommodated without compromising functionality.

Outcomes

The project was successfully delivered across both phases, resulting in a modern commercial development with efficient, sustainable and future-ready mechanical services throughout.

Our adaptability, technical capability and consistently high standard of workmanship gave the contractor confidence to award us Phase 2 following the successful completion of the initial 8 units.

By the end of the project, we had not only delivered a strong result for the client but also built a valuable new contractor relationship, with our performance recognised as a key factor in strengthening future opportunities together.