Thames Water – Little Marlow Cake Barn
THE CHALLENGE
Thames Water’s Little Marlow Cake Barn in Buckinghamshire plays a crucial role in the utility’s water treatment process, converting residual sewage into “sludge cake” for agricultural reuse. With no room for site expansion and increasing population pressure, Thames Water identified the need to remove structural bays within the Cake Barn to improve processing capacity by 30%.
However, this redevelopment posed a significant challenge: the flooring, already subject to constant heavy-duty usage, would be irreparably damaged. The replacement needed to be exceptionally hardwearing, chemical resistant, quick-setting, and suitable for an environment with sensitive equipment and constant operational demands.
Ultimate Coatings Limited was entrusted with delivering a solution that could meet all these critical performance requirements within tight timeframes and with minimal disruption.
OUR SOLUTION
As a Sika® certified installer, the Ultimate Coatings Limited (UCL) team was well-positioned to deliver a high-performance solution tailored to the demands of this critical infrastructure upgrade. Following a detailed assessment of the site’s operational requirements and environmental challenges, UCL specified Sika® Ucrete® IF—an industry-leading industrial resin flooring system recognised for its exceptional durability, chemical resistance, and suitability for harsh processing environments.
Over seven weeks, our experienced team installed 1,600 sqm of Ucrete® IF flooring during the project’s first phase. Despite adverse site conditions, including cold weather and a leaking roof, the installation progressed efficiently and safely, with operatives working under full PPE throughout.
UCL deployed innovative mechanisation techniques wherever possible to ensure quality and worker welfare. These included the use of electric barrows, robotic jet-cleaning systems, winches for heavy sledge movement, and a helicopter-inspired hover trowel—helping to minimise manual handling and optimise application precision.
Key Benefits:
- Unrivalled Durability
Sika® Ucrete® IF provided the robust, long-lasting surface needed to withstand constant mechanical and chemical stress.
- Rapid Return to Service
The fast-setting nature of Ucrete® allowed for minimal downtime and uninterrupted operations at the treatment facility.
- Operational Safety
Our strict adherence to safety standards and use of innovative tools ensured a zero-injury project outcome.
- Future-Proof Investment
With Thames Water’s £15m upgrade, the flooring system will help reduce tanker movements and protect infrastructure long-term.
- Certified Expertise
Our Sika® contractor accreditation ensures continued excellence in installation and product compatibility for complex industrial environments.
Ultimate Coatings Limited is proud to have played a central role in supporting Thames Water’s strategic infrastructure upgrade. The successful installation at Little Marlow Cake Barn is a testament to our commitment to quality, innovation, and collaboration.
By choosing the right materials and ensuring our team was fully trained and certified, we delivered a high-performance flooring solution that supports Thames Water’s operational goals now and into the future.
For industrial flooring solutions that stand up to the harshest environments, trust Ultimate Coatings Limited – where performance meets precision.
