SPALLED CONCRETE REPAIR
Confirma™ delivers innovative, minimally disruptive, and long-lasting repair solutions to address even the most challenging spalling issues in commercial and industrial projects.
Concrete spalling is the process where the surface layer of concrete becomes damaged and begins to flake, peel or break away. It typically manifests as crumbling or pitted areas and can range in severity from cosmetic damage to significant structural issues. Spalling can begin to compromise the integrity of concrete structures, making timely intervention critical.
Why Concrete Spalling is a Concern
Structural Integrity:
In severe cases, spalling can compromise the structural strength of the concrete, especially if it exposes or damages the reinforcing steel. This can lead to further corrosion and weaken load-bearing components.
Safety Hazard:
Falling concrete poses risks to people and property, particularly in high-traffic areas like parking garages and commercial buildings.
Aesthetic and Functional Issues:
Spalled concrete looks unsightly and can allow water ingress, accelerating further problems and necessitating more extensive repairs if left unaddressed.
Causes of Concrete Spalling
Reinforcement Corrosion:
Water, oxygen and chlorides (often from de-icing salts or seawater) penetrate the concrete, reaching the steel reinforcement.
Corrosion expands the steel, creating internal pressure that causes the concrete to crack and spall.
Freeze-Thaw Cycles:
Water inside the concrete freezes and expands, creating stress that leads to cracking and surface spalling over repeated cycles.
Poor Construction Practices:
Insufficient concrete cover over the reinforcement.
Low-quality concrete mixture or improper curing processes, leading to inadequate concrete thickness and reduced durability.
Chemical Exposure:
Acids, sulphates or other aggressive chemicals degrade the concrete's surface over time.
Overloading or Impact:
Heavy loads or mechanical damage can cause spalling, especially in concrete floor slabs or structures not designed to handle such stresses.
Confirma™’s Approach to Spalling Repair
Confirma™ specialises in innovative, minimally disruptive solutions for commercial-scale concrete repairs, including addressing concrete spalling. Our methods prioritise:
- Restoring structural integrity while preventing further damage.
- Preventing concrete spalling through advanced protective measures.
- Minimising downtime for businesses by avoiding large-scale excavations.
- Using durable repair techniques with a lifespan of 30–50 years, ensuring long-term reliability.
The Confirma™ Repair Process
1. Comprehensive Inspection:
Our team conducts a thorough assessment to identify the extent of the spalling damage and determine its root causes. This includes evaluating the concrete thickness and checking for reinforcement corrosion or other underlying issues.
2. Surface Preparation:
Damaged or loose concrete is carefully removed to expose the sound substrate. Proper surface preparation is essential to ensure the durability and adhesion of repair materials.
3. Reinforcement Treatment:
Corroded steel reinforcement is cleaned, repaired or replaced to prevent further corrosion. Protective coatings may also be applied to enhance durability.
4. Application of Repair Material:
Using high-performance mortars and specialised repair materials, we rebuild the damaged areas. The concrete mixture is optimised for strength and longevity, restoring the concrete to its original form.
5. Waterproofing and Sealing:
To prevent concrete spalling in the future, we apply advanced waterproofing and protective coatings. These layers safeguard the structure against moisture ingress, freeze-thaw cycles and chemical exposure.
Applications of Spalling Repair by Confirma™
Our spalling repair solutions are ideal for:
Multi-Storey Car Parks:
Repairing damage caused by heavy vehicle traffic.
Concrete Floor Slabs:
Addressing wear and tear caused by heavy traffic and environmental exposure.
Stadiums and Arenas:
Repairing concrete in seating areas, walkways and structural supports subjected to high foot traffic and dynamic loads.
Bridges and Overpasses:
Restoring surfaces exposed to weather extremes and heavy loads.
Commercial Building Facades:
Repairing spalled exterior walls to maintain structural and aesthetic integrity.
Industrial Facilities:
Reinforcing structures exposed to harsh chemicals and challenging environments.
Why Choose Confirma™ for Spalling Concrete Repair?
Confirma™ offers tailored solutions to repair concrete spalling and address related structural issues effectively. Here’s why our clients continue to trust us:
Minimised Disruption:
Our minimally invasive techniques ensure reduced downtime and minimal impact on operations.
Long-Lasting Results:
Our repairs are designed to last 30–50 years, providing concrete spalling repair cost-effectively with durable protection.
Expert Knowledge:
Our team’s specialised expertise ensures precise we effectively repair concrete spalling and concrete cancer issues in a way that is tailored to your structure.
Preventive Measures:
We not only repair existing damage but also implement solutions to prevent further corrosion and spalling.
Confirma™ are experts in Concrete Remediation
Concrete Cancer
Basement Leak
Concrete Beam
Concrete Foundation
Structural Strengthening
Structural Injection
Industrial Concrete Repairs
Water Stop Injection
FRP Composite Strengthening
Contact Confirma™ for Expert Concrete Spalling Repair Solutions
If your commercial property is showing any spalling of concrete, Confirma™ can provide the expertise and innovative solutions needed to restore the aesthetic appearance and protect your structure. Experts available on the Gold Coast, Sunshine Coast and Brisbane.
Frequently Asked Questions
How can spalling concrete impact industrial operations?
Spalling concrete can have significant consequences for industrial facilities, including:
- Safety hazards: Uneven or damaged surfaces increase the risk of trips, falls and machinery accidents.
- Structural integrity issues: Prolonged spalling can weaken the overall structure, compromising load-bearing capacity.
- Operational disruptions: Damaged concrete can hinder the movement of machinery and personnel, leading to delays and reduced efficiency.
- Increased maintenance costs: Ignoring spalling can lead to more extensive damage over time, resulting in higher concrete repair costs and potential downtime for complete replacements.
Addressing spalling promptly is essential to maintain safety, efficiency and cost-effectiveness in industrial environments.
What solutions does Confirma™ provide for repairing spalling concrete?
Confirma™ offers comprehensive solutions for how to repair concrete spalling, and have the expertise to meet the unique demands of heavy industries:
Epoxy injection: For deep cracks and severe cement spalling repair, we use an advanced concrete spalling repair epoxy injection technique to restore the concrete’s structural integrity.
Surface repair and overlays: We apply high-performance concrete overlays or resurfacing materials to repair concrete surface damage and provide a durable, smooth finish.
Corrosion protection: Our concrete repair processes include the application of anti-corrosion coatings and treatments to reinforce steel and prevent further deterioration.
Long-term durability: All our concrete spalling repair methods are designed to extend the lifespan of concrete structures, ensuring they withstand the harsh conditions of industrial environments.
By choosing Confirma™, you’re investing in reliable, cost-effective repairs that minimise disruptions and safeguard the integrity of your operations.