Thames Water – Little Marlow Cake Barn
Introduction
Thames Water's Little Marlow Cake Barn in Buckinghamshire processes residual sewage into sludge cake for agricultural reuse. A £15m structural redevelopment to increase processing capacity by 30% required the complete replacement of 1,600 m² of heavily trafficked flooring with a system capable of withstanding continuous mechanical and chemical stress in an operational treatment facility.
Our Solution
As a Sika® certified installer, UCL specified Sika® Ucrete® IF — an industrial polyurethane resin flooring system recognised for its chemical resistance and durability in demanding process environments. Installation was completed across seven weeks during the project's first phase, with operatives working under full PPE throughout. Adverse conditions, including cold weather and a leaking roof, were managed without programme delay. UCL deployed mechanised handling techniques to reduce manual handling risks and maintain application quality, including electric barrows, robotic jet-cleaning systems, winch-assisted sledge movement, and a hover trowel for precise surface finishing. All work was carried out in compliance with relevant health and safety requirements and Sika® installation standards.
Key Benefits
- 1,600 m² installed across a live wastewater treatment facility with no reportable safety incidents
- Sika® Ucrete® IF delivers verified chemical and mechanical resistance suited to sludge processing environments
- Fast-cure system minimised operational downtime and supported phased programme delivery
- Mechanised application techniques reduced manual handling exposure and maintained consistent installation quality
- Sika® certified installation ensures full product warranty compliance and long-term performance accountability
- Supports a 30% capacity increase at a strategically critical water treatment asset
Conclusion
UCL successfully delivered a high-performance industrial resin floor at a live, operationally critical water treatment facility, on programme and without injury. This project demonstrates UCL's capability to manage complex flooring installations in demanding process environments where quality and safety cannot be compromised.
