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Concrete spalling repairs are quite a common fault on buildings that have started to age, especially structures that use concrete as an aesthetic element. Delamination occurs rather easily when multiple factors are encountered. Rust – a killer for many buildings, a structural concrete column will use steel reinforcement. When this settles, whilst the concrete is setting, the steel can rest close to the surface. Once the final concrete skim is placed upon it which is porous, the steel is still partially open to the elements, opening it up to rust. As the rust eats its way into the steel, the steel tends to swell which in turn can pop off the concrete layer as in the photos below.

Delamination itself is quite common even in cases where there is no internal or external rust – perhaps in an area where vibration abounds or high traffic areas like warehouse pillars where steel sack trucks, pallet lifts and forklift operate. Concrete that is ageing, tends to lose its bond with the under layer making it a prime subject for delamination. A mere tap will cause the entire layer to break off, leaving an unsightly void.

Concrete spalling repairs work well when carried out properly. A series of deep scores are made into the base material, to provide a decent bond for the new concrete final layer. Shuttering is formed around or across the area being repaired. The shuttering is designed in such a way that concrete, or resin (Depending on the application) can be poured in which when hardened, forms a brand new skin. Once this new skin has hardened, the shuttering is removed and the wall or area being subjected to concrete spalling repairs is as good as new. These repairs could also be used on properties built during wartime, as the concrete available at the time was often sub standard due to shortages.

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