Dandenong Market Dandenong Market, VIC

Nitoflor range rejuvenates eroded concrete market floor

One of the oldest markets in Melbourne, Dandenong Market is a thriving hub of shoppers and traders attracting more than 5 million visitors per year.

As its asset owner, the City of Greater Dandenong needed a solution to resurface the market’s waste area. Although only 10 years old, the existing slab had eroded badly due to the acids released by food waste.

Resurfacing this busy market's waste area came with a series of unique challenges:

• the slab was located in an area open to the elements (with a roof, but no walls)
• the market would continue operating, and the project team was asked to minimise disruption to traders and shoppers
• the waste area is in the heart of the market, adding to the project's complexity.

Help from the specialists at Fosroc ANZ

Dandenong Market management reached out to Fosroc ANZ to discuss the project and seek our advice. Our specification team, including Victorian industrial flooring specialist Greg Smith, then met with the City of Greater Dandenong on site.

Fortunately, Fosroc quickly identified a critical issue. Our technical product experts have vast experience in the construction industry, which they bring to every tailored solution.

“The falls to the drains weren’t working,” Greg explains. “The council weren’t aware of this issue, but we could see this was a major contributor.  Where the acids were pooling, the concrete erosion was accelerating.”

“Understanding the project and its challenges allowed us to design a long-term solution.”

Armed with this information and a detailed product specification, the council looked to appoint a contractor.

Tailoring a fit for purpose specification

Fosroc ANZ tailored a specification to deliver maximum durability to the resurfaced concrete.

• Nitoflor N – the ‘star’ of the specification, this two part, solvent free novolac epoxy floor coating is ideal for acid proofing, offers high resistance to aggressive chemicals plus excellent wear and abrasion resistance. “It provides really excellent resistance to the organic and inorganic acids formed from food waste,” explains Greg.
• Nitomortar F4 Fillers – added to Nitoflor N, this graded silica sand product created a chemically resistant mortar screed.
• Nitoflor PU200 – this low odour, low VOC cementitious polyurethane top coating provided a fast curing, hard wearing, chemically resistant anti-slip texture for the final coat.
• Nitoseal SC600 – designed for sealing joints exposed to aggressive chemical environments, this product also copes well with movement. “The last thing you want is acidic liquid getting into the subsoil through the joints,” says Greg.
• Nitoflor PA – this UV and abrasion resistant top coat was used for the safety lines and offered added chemical resistance plus fast cure time.

Getting the preparation and application right

The council took the project directly to applicators experienced with Fosroc's Nitoflor range, who tendered for the work. ASCOAT Contracting was selected for the job and worked with Fosroc ANZ to plan and execute the project.

“Our specification enabled ASCOAT Contracting and the City of Greater Dandenong to map out a workable timeline that factored in the many challenges of this complex project,” Greg explains.

The project team followed these steps:

• High pressure water blasting to remove waste solids and scrabbling to produce a sound surface to bond to.
• Concrete reinstating was next, as well as profiling the area so it drained properly.
• Application of Nitoflor N with Nitomortar F4 Fillers to create a chemically resistant mortar screed at a 5mm trowel finish.
• Application of non-slip texture top coat of Nitoflor PU200.
• Joints were re-cut and caulked with Nitoseal SC600.
• Colour highlighting to avoid tripping hazards with Nitoflor PA.

Exceptional results

“This was a relatively small project in Fosroc terms, but came with a very high degree of difficulty,” Greg says.

The City of Greater Dandenong are thrilled with the results, in particular the durability and surface longevity delivered by ASCOAT Contracting’s expert application of our fit-for-purpose products.