Concrete Spalling Repair Guide: All Your Questions Answered


Concrete spalling is a common issue that can significantly impact the integrity of commercial and industrial structures.  While on the surface it may seem like a minor issue, spalling can lead to serious damage and structural problems if left unattended. That becomes a serious, costly problem when large-scale commercial and industrial constructions are involved, such as parking garages, facades, and bridges, which are especially susceptible, making timely repair essential.

This comprehensive guide covers the causes of concrete spalling, its symptoms, and the best approaches to repair and prevention. Whether you’re a building manager, architect, or construction professional, understanding these aspects can help you address and prevent spalling effectively.

What Is Concrete Spalling and What Are Its Causes

Concrete spalling refers to areas of concrete that have become cracked and delaminated from the substrate.

It can be minor, looking like flakes of concrete chipping away from the surface. In time, spalls can end up being very wide and also deep, sometimes reaching the topmost layer of the reinforcing metal within the concrete construction.

Some of the most prominent causes of concrete spalling include:

  1. Freeze-thaw cycles: Temperature fluctuations weaken concrete.
  2. Deicing salts: Particularly harmful to infrastructure like bridges and roadways.
  3. Chemical exposure: Corrosive substances degrade concrete over time.
  4. Alkali-silica reaction (ASR): A chemical reaction within the concrete, also known as “concrete cancer.”
  5. Corroded reinforcement: When a rusting rebar expands, it can crac the surrounding concrete.
  6. Poor materials or techniques: Inadequate concrete mix, poor finishing, or insufficient concrete cover.

 

Environmental factors: Exposure to humidity, pollution, or other external elements.


Signs and Symptoms of Concrete Spalling

In the beginning, concrete spalling may be difficult to notice. As the issue remains unattended, it will progress and the signs are going to get much more widespread.

Some of the first issues that people notice in connection to concrete spalling include:

  • Concrete cracks or bubbling
  • Concrete flaking and chipping
  • Rust stains on the surface of the concrete structure
  • Discolouration of the spalled areas
  • Exposed aggregate (the small stones within the concrete mix)
  • Exposed reinforcements

 

Once identified, immediate action is critical. Spalling does not resolve itself and will worsen over time without intervention.


Why Concrete Spalling Repair Is Important

Spalling is one of those problems you simply can’t ignore. In the absence of a fix, the consequences of concrete spalling can be disastrous.

 

For a start, concrete spalling ruins the aesthetics of a construction. While that’s a small issue, especially in the context of other expected problems, it can still have a serious impact as far as a builder’s or a company’s reputation goes. Spalling also creates hazards due to the falling debris and concrete bids. These will be small flakes in the beginning but eventually, larger chunks of concrete may start coming off the structure.

 

When left unattended, spalling accelerates and the scope of the issue becomes massive. After enough time, the structure could become unstable, which will necessitate much more comprehensive reinforcements and structural work. The value of constructions affected by concrete spalling also goes down. So, if you’re considering the eventual sale of a commercial or residential property, you have to make sure that spalling hasn’t occurred or that it has been addressed in due time.


Concrete Spalling Repair Methods

If you’re wondering how to repair concrete spalling, you’ll need to understand that the fix is heavily dependent on the extent of damage.

Some of the most common techniques employed to address concrete spalling, especially in commercial structures, include:

Patching:

  • What it is: Apply a thin concrete layer over the damaged surface.
  • Best for: Minor, localised spalling.
  • Limitations: Temporary; spalling may reoccur.

Sealing:

  • What it is: Using topical or penetrating sealers to protect the underlying concrete.
  • Best for: Slowing spalling progression.

Resurfacing:

  • What it is: Applying a specialised resurfacing compound to strengthen the surface.
  • Best for: Moderate damage as an interim fix.
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Epoxy Injections:

  • What it is: A technique where epoxy resin is injected into cracks or voids in concrete using specialised equipment. The resin bonds to the surrounding concrete, restoring its structural integrity and preventing further spalling or cracking.
  • Best for: Repairing fine to moderate cracks in structural concrete where restoring load-bearing capacity and waterproofing is essential. Ideal for addressing internal damage that has not yet caused large-scale surface deterioration.

Concrete replacement:

  • What it is: Removing and replacing damaged concrete.
  • Best for: Severe spalling or structural damage.
  • Limitations: Higher upfront costs but offers long-term durability.


Preventing Future Spalling

Introducing preventative measures is, needless to say, a much better approach than doing concrete damage repair in the aftermath of spalling.

A few simple things can be done to improve the structural integrity of the concrete and slow down the deterioration that’s bound to occur with the passage of time.

  • Moisture protection: Moisture plays a major role in spalling. Using a high-quality sealing product slows down the deterioration caused by water
  • Regular inspections:  Inspections are non-negotiable and when large commercial projects are involved, getting professionals to carry out the routine procedure will be the right approach. An expert team will look for signs of damage and check the areas that are most vulnerable and susceptible to spalling. 
  • Avoid harsh chemicals: De-icing salts and other corrosive substances can damage the concrete and make it prone to spalling. If possible, avoid the use of such chemicals in the vicinity of concrete buildings.


Choose RCR for Concrete Remediation – Here’s Why

Choosing an expert team that specialises in concrete restoration will help for the quick and effective addressing of the issue, preventing spalling from becoming a bigger hazard.

The Roof and Concrete Remedial (RCR) team has extensive knowledge of concrete issues and the best approaches to yield a lasting outcome. Each team member is properly trained and we have extensive know-how, as well as the equipment required to deal with the most extensive and specific types of concrete damage.Contact us today and let us know what problem you’re dealing with. Our experienced team will recommend a personalised approach that will yield long-lasting results meant to stand the test of time.