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Concrete Spalling / Concrete Cancer Repairs
Specialist remediation of deteriorated concrete caused by steel reinforcement corrosion, restoring structural integrity and preventing further damage.

Concrete spalling — often called concrete cancer — is one of the most serious structural defects in mid- to high-rise buildings. It occurs when moisture penetrates the concrete, causing the embedded steel reinforcement (rebar) to corrode. As steel rusts, it expands up to seven times its original volume, exerting immense pressure on the surrounding concrete. This leads to cracking, delamination, and eventual failure of the structure if left untreated.

Our approach is designed to not just patch the visible damage, but address the root cause to deliver a repair that lasts.

Step-by-Step Process

  1. Assessment & Mapping:
    • We conduct a detailed visual inspection, sounding tests, and in some cases, covermeter scanning to locate reinforcement and assess the full extent of corrosion.
    • Defects are mapped to create a repair schedule that ensures no damaged area is overlooked.
  2. Break-Out of Damaged Concrete:
    • Using dust-controlled demolition tools, we remove all loose and delaminated concrete, cutting back to sound substrate.
    • The exposed rebar is revealed for full inspection.
  3. Steel Reinforcement Treatment:
    • Corroded rebar is cleaned to bright metal using mechanical wire brushing or abrasive blasting.
    • A high-performance anti-corrosion coating is applied to protect against future rusting.
  4. Reinstatement with Repair Mortar:
    • Structural-grade polymer-modified repair mortars are used to rebuild the section to its original profile.
    • Mortar is carefully compacted around the rebar to ensure complete encapsulation.
  5. Finishing & Protection:
    • Repaired areas are finished flush with the existing surface.
    • Where required, the area is treated with a protective coating or waterproof membrane to prevent moisture ingress.

Why Our System Works Long-Term

  • Root-Cause Elimination: We prevent recurrence by cutting off the moisture pathway and isolating steel from oxygen and water.
  • High-Performance Materials: We use only structural repair mortars with shrinkage control, chloride resistance, and thermal compatibility.
  • Integrated Protection: Repairs are often combined with façade waterproofing, joint remediation, or balcony upgrades to protect the structure holistically.

Concrete spalling is not just an aesthetic problem — it can lead to partial structural collapse, falling debris hazards, and rapid value depreciation of the property. Our methodology is designed for mid- to high-rise, live-occupancy projects where safety, minimal disruption, and compliance with Australian Standards (AS 3600) are paramount.

If you want, I can now prepare Sealant & Joint Remediation in the exact same format so we can finish the first half of the Remedial Building category in one go. That way, we’ll have a clean, uniform set for the website.

Alright — here’s Sealant & Joint Remediation in the same $1B-status, full-blog format as Concrete Spalling.