Concrete spalling is a serious structural issue that occurs when concrete surface layers break away, exposing reinforcing steel to corrosion and weakening the overall structure. Our specialized spalling repair service addresses both the symptoms and underlying causes to restore structural integrity and prevent future deterioration.
Understanding Concrete Spalling
Spalling typically results from multiple factors working together:
- Corrosion Expansion: Rusting reinforcement steel expands, creating internal pressure that fractures concrete
- Freeze-Thaw Cycles: Water infiltration and freezing causes expansion and contraction damage
- Chemical Attack: Chlorides, sulfates, and other chemicals weaken concrete bonds
- Structural Overloading: Excessive loads beyond design capacity cause cracking and spalling
Comprehensive Spall Assessment
Our repair process begins with thorough evaluation:
- Visual Inspection: Document extent and severity of spalling damage
- Core Testing: Assess concrete strength and depth of deterioration
- Corrosion Survey: Evaluate reinforcement condition and corrosion potential
- Structural Analysis: Determine load capacity and safety implications
Professional Repair Methods
We utilize proven repair techniques tailored to specific conditions:
- Concrete Removal: Careful removal of deteriorated concrete to sound material
- Steel Preparation: Cleaning and treatment of exposed reinforcement
- Corrosion Protection: Application of protective coatings to prevent future corrosion
- Concrete Restoration: High-performance repair mortars designed for long-term durability
- Surface Protection: Protective coatings and sealers to prevent water infiltration
Advanced Repair Materials
Our spalling repairs use state-of-the-art materials:
- Polymer-modified repair mortars for enhanced bond and flexibility
- Corrosion-inhibiting admixtures for long-term protection
- High-strength, rapid-setting formulations for minimal downtime
- Fiber-reinforced systems for improved crack resistance
Preventive Measures
Beyond repair, we implement preventive strategies to avoid future spalling and extend structure lifespan through comprehensive waterproofing and protective systems.
