Concrete Spalling Assessment

Sydney & Greater NSW

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Owing to its strength and durability, concrete is the most used construction material in the world. Although well-maintained concrete buildings can last for around a century, the material comes with its unique issues. One of these issues is concrete spalling.

Have you ever noticed rust stains on building walls or paint and concrete chipping off into a pitted mess? This occurs when the steel mesh inside the structure begins to rust and expand. The problem spreads unabated if you do not address it in time and can start making sections of your roof and walls fall.

If your residential or strata building in Sydney and/or Greater New South Wales shows signs of concrete spalling, we can help you assess the extent of the damage. At Endeavour Engineering, we are experts in a variety of structural issues and we know how to recognise and test concrete spalling and cancer.

Let’s discuss the nuances of this problem, its causes and standard treatment methods in detail.

The Difference Between Concrete Spalling & Concrete Cancer

These terms are often used interchangeably, however they are different.

Concrete spalling and concrete cancer can be said to be two stages of one reaction. Spalling refers to the condition where the concrete begins deteriorating, and cancer is the spread of that damage throughout the concrete matrix. 

Buildings made of concrete have a steel skeleton to reinforce them. When moisture reaches this steel mesh, the metal begins to rust and expand up to six times in size, causing the brittle concrete to expand alongside it and crack. The damage you see at this stage can be in the form of rust stains on your concrete walls, crumbling concrete, bubbling and scarring, and leaks. This is concrete spalling. 

As cracks appear, they expose more fresh untouched concrete to air and more steel to moisture, making the process spread and repeat. This is called concrete cancer. The condition accelerates further as concrete is highly porous and absorbs and diffuses the acid created during spalling throughout its structure, speeding up corrosion. If water gets into the cracks and freezes, it makes the concrete crack further, as frozen water takes up more volume than liquid water. This adds to the cancerous spread too.

What is Concrete Spalling & Common Causes

Remember that concrete is a highly porous and alkaline material. Water can seep through it if it stays unprotected. Also, when acid gets in contact with an alkaline material, it produces water. Having said that, some of the common causes of concrete spalling become easy to understand. These include:

  • Poor-quality concrete that is highly porous
  • Acid rains
  • Concrete structures left bare without a waterproofing layer (like paint) for long
  • Exposure to seawater
  • Water’s freeze-thaw cycle in cracks left unfilled
  • Water seepage
  • Exposure to fire that damages the outer covering of concrete
  • Improper construction
  • Thin concrete cover over the steel reinforcement
  • The use of de-icing salts

Our Concrete Spalling Assessment Process

Here’s what you can expect from our concrete spalling assessment process:

1. Contact Our Team

Get in touch with our team via email ([email protected]) with a brief description of your issue, and we’ll email back to you a free fee proposal tailored to your problem.

2. Site Inspection

If you agree to the fee proposal, we will then organise the site inspection. At the site inspection our expert engineers will investigate the property for concrete spalling.

3. Creation of Report for Concrete Spalling Repair & Treatment

Our expert team will then create a report based on our investigation findings of concrete spalling. Within this report, we will detail the location, description, cause and expert advice for remedial repairs.

Why It’s Important to Treat Concrete Spalling & Scaling

Alongside the obvious loss in aesthetic appeal, concrete spalling decreases the sturdiness of your building. As cracks appear, water will seep into the insides of your property and cause damage to your belongings and electrical systems. You need to take action before concrete spalling begins spreading.

As spalling becomes more severe, chunks of concrete can start falling down and pose safety threats to the building’s occupants. Your property’s value will fall steadily, too, as the damage spreads. So it is best to call Endeavour Engineering to assess the issue. 

What Can Happen if Concrete Spalling Goes Unchecked

Repair costs get higher as more concrete gets compromised. But more importantly, your entire building can collapse as the damage spreads throughout the concrete due to unchecked spalling. 

How to Treat Concrete Spalling in Sydney and Greater New South Wales

Remember that concrete spalling isn’t an issue confined to the surface of a building – it’s a rotting mess inside its walls. We recommend that you get expert engineers to fix the issue in a compliant and long-lasting manner. 

The treatment of concrete spalling may vary from site to site. If the concrete is in a highly acidic environment, an electrochemical treatment can increase the concrete’s alkalinity and reduce the chloride content near the steel. Alternatively, all the damaged concrete can be dug out to clean the steel and coat it with a corrosion-resistant coating before replacing the mortar and covering it with an anti-carbonation coat. A polymer-modified concrete overlay can also be used as a less invasive solution when appropriate.

Arrange a Concrete Scaling & Spalling Assessment Today with Endeavour Engineering

Do you suspect your building is in the initial stages of concrete spalling? Or do you want your old building’s chipping walls assessed thoroughly? No matter what the case is, Endeavour Engineering can help. 

If you want a concrete spalling assessment in Sydney and Greater New South Wales, simply drop us a message through our contact page, email us at [email protected] or call us at (02) 9062 3224. We’ll help you gauge the severity of the problem. You can always book our remedial services to rectify the issue as well.

Frequently Asked Questions

Signs that your building may require concrete cancer repair in Sydney include visible rust stains, paint chipping off, or concrete crumbling into a pitted mess. These are indicators of concrete spalling, which, if left untreated, can lead to concrete cancer. It’s important to address these issues promptly to prevent further deterioration.

The cost of concrete spalling repair in Sydney varies depending on the extent of damage and the size of the affected area. At Endeavour Engineering, we provide a detailed assessment and offer a competitive quote for concrete spalling repair, ensuring effective treatment while being mindful of your budget.

Yes, our team at Endeavour Engineering specialises in both external waterproofing and concrete spalling repair in Sydney. We assess the severity of the damage and offer tailored solutions, including waterproofing design and remedial waterproofing, to protect your property from further water damage.

Our concrete cancer repair Sydney service includes a thorough inspection of the affected area, removal of deteriorated concrete, treatment of the steel reinforcement, and application of corrosion-resistant coatings. We then repair the concrete with durable materials, ensuring long-lasting protection against future spalling.

Hiring a professional waterproofing engineer is crucial for concrete repairs, especially for issues like concrete cancer in Sydney. Our experts not only repair the visible damage but also implement waterproofing design strategies to prevent recurrence, ensuring the longevity and safety of your structure.

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