Match ready!

New undersoil heating system keeps the ice away at Blackburn Rovers

Overview

When Blackburn Rovers FC decided to upgrade its under-pitch heating system in June 2023, it contacted Viessmann Climate Solutions who called upon nearby Burnley-based combustion equipment, HVAC and energy management specialists, Proctor Process Plant Ltd. to lead the turnkey installation of two Vitocrossal 200 Type CRUs. The project was completed within five weeks of the design sign-off ready for the start of the 2024/25 football season.

Two Vitocrossal 200 Type CRUs 32 1280.png

Game on!

Under-soil heating is used in sports stadia with grass surfaces to heat the underside of the pitch and protect it from bad weather, such as snow and ice. Calling off a football match due to a frozen pitch is not good for business, with clubs facing significant fines and potential points penalties should fixtures be postponed.

The first installation of under-soil heating at a football club was at Everton’s Goodison Park stadium in 1958. Now commonplace in English Premier League Clubs, Blackburn Rovers, which competes in the EFL Championship, the second level of the English football league system, first installed under-soil heating at its Ewood Park ground in 1994.

The original 1990s boiler was getting old and replacement parts were becoming obsolete. A replacement heat generator was sought by the customer to increase reliability, reduce fuel consumption and running costs, and to lower emissions.

Proctor Process Plant successfully tendered for the design and build project, which included two Viessmann Vitocrossal 200 Type CRU 800 kW high efficiency (up to 98% standard season efficiency) boilers. The Vitocrossal range offers quiet operation with a modulation range of 1:6 care of its MatriX-Disk burner. It also features a corrosion-resistant Inox-Crossal heat exchanger made from stainless steel.

Other system elements installed as part of the Blackburn Rovers project included a specialist design flue system, 50m in length with colour coded external components; hydraulic separator with air and dirt separation; four TPE high efficiency pumps; prefabricated DN150 welded distribution header pipes; water treatment equipment and thermal insulation.

The plant and equipment reside in the existing plantroom, located under the Bryan Douglas Darwen End grandstand. The heating system delivers 70m3 per hour warm water to the large network of plastic under-pitch pipes. The system is controlled by a bespoke plantroom control panel – designed with input from Blackburn Rovers’ groundsman – with pump and cascade boiler control, gas leak detection and BMS compatibility.

New undersoil heating system keeps the ice away at Blackburn Rovers

Viessmann Climate Solutions commissioned the system in June 2024.

“We leapt at the chance to deliver this project for Blackburn Rovers, in partnership with Viessmann Climate Solutions,” said Nathan Proctor, Director of Proctor Plant Process. “We were already familiar with the Vitocrossal boiler range having selected them in more industrial settings such as canning plants where we offer process water solutions that require heating water to very specific temperature levels.
“The Vitocrossal is the perfect boiler for under-soil heating. It is a high efficiency modulating unit that will give the club the reliability it needs to clear snow and ice, while working within strict temperature parameters so as not to shock and damage the grass.”

Lynsey Talbot, Head of Operations at Blackburn Rovers Football Club, said “Having nursed our old system through the last couple of winters it was reassuring to bring our new Viessmann boilers into Ewood Park in readiness for the 2024/25 campaign underpinned by the knowledge and expertise provided by Proctor Plant Process and the team. The installation was quick and on schedule with further ongoing support as and when it has been needed.”

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