Worcester Racecourse, part of Arena Racing Company (ARC), opened its new state of the art Weighing Room in June 2024. The facility provides a modern, energy efficient environment for jockeys to get changed, make their preparations for racing and spend some time relaxing. On the upper floor there is a canteen and social area, a physiotherapy studio and warm-up room. A Stewards’ Room for weighing-in and use by race officials, together with a TV Broadcast office are situated on the ground floor. Unico System’s Small Duct High Velocity (SDHV) cooling, heating and ventilation technology was specified to provide the perfect indoor environment all year round for everyone using the facilities.

Unico System is an all-in-one system that maximises the potential of heat pumps to offer air conditioning, heating, hot water and integration with mechanical ventilation and heat recovery systems (MVHR). The technology was specified for the Weighing Room as a versatile, practical and financially attractive alternative to a traditional fossil fuel-based HVAC system.

Its specification was the result of close collaboration between Worcester Racecourse & Arena Racing Company, Unico’s principal UK distributor Bell Plumbing and Unico Specialist Installation Partner, Butco of Sutton Coldfield. The overall cost and energy efficiency of the Unico System were not the only considerations and indeed sustainability was a key focus for the whole Weighing Room project. The steel frame building has been constructed on the site of the original weighing room and features a green living roof to tie in with the natural riverside landscape and provide biodiversity. Solar photo-voltaic panels capture the sun’s energy and convert it into electricity for the building.

The cooling capabilities of the Unico System were considered particularly important.  Throughout the summer racing season indoor temperatures within the weighing room complex can be uncomfortably high.  The ability to set draft free even temperatures, as well as providing precise instant cooling is a major benefit.

Two Air Source Heat Pumps (Vaillant aroTHERM Plus) located on the terrace outside the Weighing Room provide the renewable energy source for three separate Unico AHUs, sited in the Plant Room on the upper floor. One ground floor unit provides climate control within the male and female changing rooms through the Unico 3642 AHU whilst the Stewards Room and TV Broadcast office are served by a Unico 3036 AHU. The higher capacity third unit caters for the first floor canteen, rest/social area, warm-up and physiotherapy areas. The Unico 4860 AHU has a14-17.5 kW cooling capacity and 8.5-22.3 kW capacity for heating.

From the outset, installer Butco worked closely with Bell Plumbing’s Solutions team. They evaluated the project and subsequently proposed a truly value engineered HVAC solution that would mean significantly lower initial capital outlay and immediate lower running costs. It took into consideration the higher seasonal demand and virtually 24/7 usage of the Weighing Room over the National Hunt season as well as the projected significantly lower usage of the Weighing Room over the winter and early Spring.

Detailed calculations for heating, cooling and hot water demand were drawn up so that the most suitable and correctly sized Unico Air Handling Units and a combined MVHR unit, which would bring additional energy saving benefits of heat recovery, could be specified without any unnecessary over capacity.

Comprehensive schematic and working installation diagrams were generated with the latest CAD software by the solutions team at Bell Plumbing Supplies. Technical support was provided from start to finish of the project with Bell plumbing Supplies also addressing the evolving requirements and complexities of the project including revisions to room plans and usage. One of the challenges was how to incorporate the three Unico AHUs, the 2300m3 (Airflow Developments) MVHR unit and a (Mixergy) intelligent hot water cylinder as well as main supply ducting in the Plant Room, located in a tight area behind the canteen servery. There were significant height restrictions under the mono pitched roof, but thanks in part to the small footprint, compactness and horizontal configuration of the Unico AHUs, Bell Solutions were able to configure a layout that maximised use of the available space.

Two main central ducts, with Climaver thermal insulation for high efficiency and retention of energy within the system, lead from the AHUs and distribute conditioned air to multiple branches of Unico sound attenuated and insulated flexible supply tubing. Some 97% of system energy is retained and delivered into the conditioned spaces through room outlets. With the aspiration principle of operation, small jets of cooled or warmed air are driven at high velocity into the different areas of the Weighing Room with temperature differentials of no more than +/- 1º C floor to ceiling and no drafts. This creates an ideal environment and optimum comfort levels for all users in all areas of the building.

The lightweight, easy assembly central ductwork and the small diameter, flexible Unico supply tubing simplified installation for Butco.  The tubing could be cleverly fed above suspended ceilings and through small voids behind cavity/partition walls to all the ground and upper floor rooms, connecting with either linear or round room outlets.

Operating with extremely low noise levels (<30 decibels) and visually unobtrusive, the outlets blend into the interior decor of each room. Standard white finish linear outlets are used extensively in front of floor to ceiling windows and the canteen servery to form a conditioned air curtain that helps to keep room temperatures to desired preset levels. Round outlets have been carefully positioned around ceilings to ensure uniform delivery of conditioned air within each space, preventing hot or cold spots and maintaining a consistent temperature throughout. Indoor Air Quality levels throughout the building are also consistently high thanks to lower humidity levels and the ability of Unico technology to remove up to 30% more humidity than would be achievable with traditional air conditioning technology.

Ensuring compliance with the requirements of Building Regulations Part F (ventilation), Part L (energy efficiency) and Part O were essential requirements for the Unico proposal. Part O covers thermal efficiency, overheating and limiting solar gain through windows inside a building. The floor to ceiling windows and extensive glazing throughout the Weighing Room, coupled with the building’s high levels of insulation and overall air tightness, meant that overheating was a potential problem. This has been overcome through the levels of cooling provided by Unico.

For Worcester Racecourse management, the ability to set temperatures for each area and control the complete Unico installation remotely from an office located in the Grandstand is very convenient. An iPad with Nest programming is a low cost and very user-friendly means of setting and adjusting preferred cooling and heating levels all year round. Three compatible wall mounted smart Nest Learning Thermostats have also been provided within different areas of the Weighing Room.

Opened in time for the very popular Ladies Day meeting on June 1, the Weighing Room is in use throughout the National Hunt racing season which ends in October, and it will also have usage over the winter months. Butco met the strict timelines put in place for completion of the installation, despite interruptions caused by repeated local flooding from the River Severn.

The installation at Worcester Racecourse has demonstrated that in the light commercial sector, Unico SDHV technology is a viable environmentally friendly alternative to traditional fossil fuel-based heating/air conditioning with a BMS system. James Tough, xxx (TBC) of Butco is positive about involvement in further Unico projects of this type: “With the support of Bell Solutions in assessing a potential project, designing the system as well as providing technical back up throughout the specification and installation process, we are confident in taking on further projects where Unico offers the best solution.”

Cliff Arnold, Bell Plumbing’s HVAC Technical Manager, comments: “We offer in-depth training and marketing support to any HVAC installer looking to get involved with Unico SDHV technology. They will then be able to give their residential and commercial customers the opportunity to consider and move to environmentally friendly heating and air conditioning systems at a time when significantly reducing carbon emissions from buildings is critical.”