UFHN was selected to design and supply a bespoke underfloor heating solution as part of an extensive renovation of Wadhurst Church, a historic building in East Sussex undergoing major refurbishment to support its journey towards net zero carbon operation.

Working closely with the architect, main contractor and M&E team, UFHN developed a specialist underfloor heating package that would deliver efficient, low temperature heating while respecting the unique challenges presented by the church’s historic structure and floor construction.

The Challenge

Historic building renovations often present complexities that are rarely encountered in modern construction projects and Wadhurst Church was no exception. The project required the installation of underfloor heating across 315m² of floor area beneath a mixture of existing and newly installed stone flooring. The church floor also contained a significant number of historic cast iron grave markers and substantial stone slabs, some measuring 150mm thick.

During excavation works, it became apparent that the existing floor levels varied considerably throughout the building. As the project progressed, the team had to adapt the design to accommodate four different floor build up depths across the site ranging from 70mm up to 125mm , while ensuring the finished floor remained structurally sound and suitable for the final floor coverings.

One of the most critical requirements was eliminating any potential floor movement or flex. The weight and historical significance of the stone floor demanded a robust solution capable of providing a completely stable subfloor while maintaining the thermal performance needed for an energy efficient heating system.

The Solution

This project was a real team effort, working collaboratively with all project stakeholders throughout the design and installation process, carrying out multiple site visits and making ongoing adjustments as site conditions evolved.

The final solution comprised of:

• 315m² Mercury Halo foiled floating floor system
• 315m² 20mm screedboard
• 315m² XPS 250 insulation boards beneath the routed layer

This carefully engineered build up provided the structural integrity required to support the historic stone flooring while delivering excellent thermal insulation and heat distribution. The Mercury HALO system was selected due to its stability for floating floor applications and its ability to provide respective, energy efficient heating when paired with the building’s air source heat pump.

The Outcome

Although the project is still being completed, the installed underfloor heating system has already exceeded the performance expectations of the originally proposed heating solution. By combining high performance insulation with low temperature underfloor heating and renewable heat generation, the church is expected to benefit from significantly improved energy efficiency and reduced running costs as part of the wider M&E refurbishment programme.

Wadhurst Church demonstrates how modern underfloor heating technology can be successfully integrated into sensitive heritage environments, helping historic buildings meet contemporary sustainability goals without compromising their character or structural integrity.