Hard-wearing solution for damaged concrete floors in busy food processing facility Perth, Western Australia

Years of damage require expert solution and support

The concrete floors at this Perth food processing facility are exposed to heavy machinery, constant foot traffic, sticky spills, and rigorous cleaning 24 hours a day. The degradation over time required a durable, long-lasting solution to repair and restore them.
"These floors had taken more hits than Mike Tyson, and required a very robust system to repair the damage and ensure they were fit-for-purpose moving forward," explains Fosroc's WA industrial flooring expert, Sales and Specification Support Specialist Ron Ierino.
"The asset owner wanted a hard-wearing solution to ensure long-lasting performance, easy sanitation, and a safe working environment, helping the facility operate efficiently while meeting strict hygiene standards."

Preparation the key

Ron worked with applicators PM Industries and asset owners Ital Cabinets, to devise a comprehensive preparation and repair approach.
The first step in the preparation process was to shot-blast the floors to achieve an open, porous surface.
"Grinding would have been insufficient in getting to all the low spots," explains Ron. 
The floors were then thoroughly cleaned to remove any debris and contaminants from the substrate prior to priming.

Application steps

PM Industries undertook the following application steps:

• Step 1: Prime the floor with Nitomortar 903
• Step 2: Mix Nitomortar 903 with Nitomortar F4 fillers to achieve a flowable screed, then apply evenly across the floor with a squeegee
• Step 3: After curing, a diamond grinder was run over the top to knock down any high or rough areas
• Step 4: 2 x coats of Nitoflor PA were applied as a topcoat, with Nitoflor Antislip Grains 02 to achieve slip resistance

About the products

A proven product combination ensured an effective, durable solution on this project:

• Nitomortar 903 - this solvent free epoxy resin binder system offers early development of initial hardness to minimise maintenance disruption. It is unaffected by a wide range of acids, alkalis and industrial chemicals and delivers up to 90MPa compressive strength
• Nitomortar F4 Fillers are used with Nitomortar 903 and are graded silica sand which has been cleaned and dried.
• Nitoflor PA is a two-component solvent-free polyaspartic coating that is abrasion, chemical and UV resistant, fast curing and offers a convenient 1:1 mix ratio (by volume)
• Nitoflor Anti-Slip Grains 02 offer effective slip resistance in diverse environments.

A hard-wearing system delivers superior results

As Ron explains, this Fosroc system offers a proven solution for damaged concrete floors. "Nitomortar 903 is a terrific primer that bonds beautifully to porous floors, and can be sand filled with F4 fillers to make a very durable concrete repair product.  "Nitoflor PA is a quick drying, UV stable and robust product. When combined with Anti-Slip Grains 02 it provides a safe, strong and slip resistant surface, which is exactly what is required in a food processing facility."

Excellent results, happy clients

The asset owner and applicator were both thrilled with the results on this project. A testimonial from Adriano Petagna at Ital Cabinets says it all: "[The team] went over and above to create new epoxy floors for our food production areas and front of house showroom. The end product lifted the whole value of our commercial property."

Find out more 

For expert advice and a high performing solution on your next concrete flooring project, contact your local Fosroc ANZ specialist using the form at the bottom of this page.