About Spall Repair and Surface Patching
Concrete spalling occurs when the surface layer separates and breaks away, often from freeze-thaw damage, corrosion of embedded steel, or poor original construction. Commercial properties with spalling concrete face safety concerns, appearance problems, and accelerating deterioration.
Spall repair involves removing unsound concrete, preparing the substrate, and applying repair materials that bond to the remaining concrete and restore the surface. Repair materials must be compatible with the original concrete and suitable for the specific conditions.
Surface patching addresses localized damage from impacts, abrasion, or chemical attack. The patches must achieve adequate bond, match original concrete appearance as closely as possible, and perform under expected traffic and conditions.
Commercial spall repair often requires phased work to maintain operations, particularly for parking structures and active industrial facilities. We develop repair programs that address safety priorities while minimizing disruption to property operations.
What’s Included
- Damage assessment and cause identification
- Unsound concrete removal
- Reinforcing steel cleaning and coating
- Bonding agent application
- Repair mortar or concrete placement
- Finish to match surroundings
- Curing and protection
- Root cause recommendations
Frequently Asked Questions
What causes concrete spalling?
Common causes include freeze-thaw damage to non-air-entrained concrete, corrosion of reinforcing steel, impact damage, poor original placement, and chemical attack. Identifying the cause is important for selecting effective repairs and preventing recurrence.
Can spall repairs match the original concrete appearance?
Repair materials can be colored to approximate original concrete, but perfect matches are difficult, especially on aged concrete. We work to minimize visual contrast, but repairs are typically visible on close inspection.
How long do spall repairs last?
Quality repairs on sound substrate last 10-20 years or more. Longevity depends on addressing root causes. Repairs over actively corroding steel or unsound concrete will fail prematurely.
When should spalling be repaired versus replaced?
Isolated spalls on sound concrete are good repair candidates. Widespread spalling, active corrosion, or structural concerns may warrant replacement. We assess conditions and recommend the most cost-effective approach.
How do you address reinforcing steel corrosion?
When spalling exposes corroded reinforcing, we clean the steel to remove corrosion, apply protective coatings, and replace concrete with appropriate repair materials. This process stops active corrosion and restores protection.