Concrete spalling — often referred to as concrete cancer — occurs when embedded steel reinforcement corrodes. As the steel rusts, it expands up to seven times its original volume, cracking the surrounding concrete and accelerating deterioration. Left untreated, it can compromise the safety, structural integrity, and waterproofing of the building.
How We Diagnose & Repair
- Condition Assessment
- Visual inspection to identify cracking, rust staining, and delamination.
- Tap testing, cover meter readings, and carbonation depth checks.
- If necessary, chloride testing to determine salt contamination levels.
- Breakout & Removal
- Carefully break out all loose and contaminated concrete to expose clean, solid material.
- Extend removal to sound concrete to prevent future propagation.
- Steel Reinforcement Treatment
- Mechanically clean exposed rebar to bright metal finish (Sa 2½ standard).
- Apply high-performance anti-corrosion primers or zinc-rich coatings to inhibit further rusting.
- Structural Restoration
- Where reinforcement is severely corroded, cut out and replace with new steel bars lapped into existing reinforcement.
- Reinstate concrete with proprietary high-build repair mortars designed for structural applications, matching the strength and modulus of existing concrete.
- Protective Finishes
- Apply anti-carbonation coatings or waterproof membranes to prevent moisture and CO₂ ingress.
- Integrate with existing façade waterproofing to ensure continuity of protection.
Where We Repair Concrete Spalling
- Balcony Edges & Slabs – High exposure to rain and salts.
- Façades & Parapets – Frequent carbonation and wind-driven rain exposure.
- Roof Slabs & Podiums – Thermal cycling and ponding water.
- Basement Walls & Soffits – Chloride-rich groundwater intrusion.
- Structural Beams & Columns – Load-bearing elements where failure is not an option.
Why Our Method is Different
- Engineering-Driven Approach: All repairs designed in consultation with structural engineers.
- Long-Term Protection: Not just patching — we stop the root cause of corrosion.
- Compliance Guaranteed: Works delivered in accordance with AS 3600 (Concrete Structures) and manufacturers’ specifications for warranty validity.
A proper concrete cancer repair isn’t just about filling holes — it’s about arresting the corrosion process entirely and restoring the structure to full load-bearing capacity. With Atomic Projects, you get repairs that last, not just cosmetic fixes that hide the problem until it comes back worse.
If you’re ready to get started, we're ready to help.
Take the next step and let’s build something that lasts.
📞 Call Us: 0410 515 509
✉️ Email Us: hello@atomicprojects.com.au
— Ben Tran, General Manager, Atomic Projects
