Spall Repair

Spalling—the breaking away of concrete surface layers—occurs when embedded rebar corrodes and expands, freeze-thaw cycles damage surface concrete, deicing salts penetrate and cause deterioration, or poor initial construction leads to delamination. Left unaddressed, spalling accelerates and compromises structural integrity. Our spall repair services restore damaged concrete through systematic material removal, rebar treatment, and application of high-strength repair mortars that bond to existing concrete and withstand the same loads and environmental conditions. We handle spall repairs in parking structures, loading docks, exterior walkways, columns, and any concrete subject to harsh conditions. The spall repair process begins with identifying all deteriorated concrete through visual inspection, sounding tests, and sometimes ground-penetrating radar. We saw-cut around damaged areas to create clean boundaries, then remove all unsound concrete to expose underlying rebar. Corroded rebar is cleaned, treated with anti-corrosion coating, and supplemented if section loss is significant. The repair cavity is prepared to ensure proper bonding, then filled with polymer-modified repair mortar or epoxy-based repair concrete that matches or exceeds the strength of surrounding concrete. Proper surface finishing ensures repairs blend seamlessly with existing concrete.