Every building construction includes typical planning and designing to ensure its overall durability and longevity. Unfortunately, even the most carefully curated construction can also lead to a commonly occurring challenge known as concrete spalling. It is crucial to take this into consideration to avoid creating costly issues on the concrete surfaces. If you’re not aware of this condition, read this article. This is about what concrete spalling is, its causes, and preventative tips.
What is Spalling Concrete?
Concrete spalling is a common condition that occurs when the surfaces are about to crack, chip, or break off. It’s not a natural occurrence; this is due to underlying structural issues. This phenomenon is characterised by the disintegration of concrete surfaces, leading to significant damage if you fail to provide proper maintenance and repair.
Concrete spalling is a big example of compromising the structural integrity when you build with concrete. It may be up to 150 mm or more in diameter and at least 25 mm in depth.
Why Is It Important to Fix It?
Early identification of concrete spalling prevents the occurrence of many serious concerns. Here are the reasons:
Structural Integrity: Spalling has the potential to weaken the concrete surface, which compromises its overall structural integrity. When the outer layer of concrete peels away, it exposes rebar to moisture and other contaminants, leading to cracks and corrosion. It further causes potential damage to the structure.
Reliability: Concrete spalling accelerates the deterioration process, resulting in more significant damages from environmental factors like acid rain, freeze-thaw cycles, and de-icing salts. Ultimately, you may want to avoid compromising the overall lifespan of the structure.
Safety Hazards: Spalling creates sharp edges and loose pieces of concrete, which are hazardous to vehicles and people using it. Such falling debris can cause serious problems, like uneven surfaces and injuries.
Aesthetic Appeal: Imagine a structure with uneven concrete surfaces visible cracks. Undoubtedly, it creates a negative impact on the overall property value and aesthetic appeal of the building.
Causes of Spalling Concrete
These are the primary causes of spalling concrete:
- Reinforcement corrosion is a significant reason, resulting in water and oxygen penetration inside the concrete surface. It weakens the rebar and allows rust to expand throughout the concrete, causing it to spall and crack.
- A poor concrete mix design with an excessive range of water-cement ratio or insufficient cement content can also create concrete spalling.
- The alkali-silica reaction in the cement causes expansion and cracking in the concrete.
- Improperly constructed joints are also a significant factor behind joint spalls.
- Pouring low-quality concrete over the reinforcing steel causes spalling.
Step-by-Step Guide to Fix Spalling Concrete
Below are the steps involved in repairing the spalling concrete. Hiring a professional concrete contractor is advisable to execute this process efficiently.
Assess the Damage: Identify the size and depth of the damaged area to plan for the solution accordingly. You can determine it through the signs of cracks, corrosion, or other issues that may contribute to discovering the appropriate underlying causes.
Prepare the Area: Clean the existing loose concrete using a hammer, chisel, or other suitable tools to thoroughly remove the dust, debris, and other contaminants. Using handy tools like a wire brush or power washer is recommended.
Apply Bonding Agent: Once the surfaces are cleaned, apply the bonding agent according to the manufacturer’s instructions. Ensure the newly poured concrete is adhered to the surface properly.
Fill the Spalled Area: It is paramount to choose the right mortar or concrete mix for your specific application. To ensure a smooth and uniform finish, proper compaction and consolidation are key.
Cure the Repair: Allow the repaired area to cure completely. You can use either a curing compound or plastic sheeting to cover the specific area, preventing rapid drying and further damage.
Tools and Materials Needed
These are the tools and materials you will need while handling spalling concrete:
- Safety gear like gloves, dust masks, and safety glasses.
- Chisel and hammer to remove the loose concrete.
- Wire brush or power washer to clean the surface thoroughly.
- Mixing bucket and trowel for proper mixing and applying of repair materials over the surface.
- Putty knife for smooth repairs.
- Plastic sheet for curing the repaired area.
- Measuring tape to measure the area to be repaired.
- Repair mortar or concrete mix suitable for the specific application.
- Bonding agent to create adhesion between old and new concrete.
Common Mistakes to Avoid
Some common mistakes that may occur during the concrete spalling. Being aware of these points will help you avoid problems:
- Inadequate removal of loose concrete may weaken the bond between new and old concrete, causing the repair to fail prematurely.
- Choosing inappropriate repair material will not fit specific applications properly; it may lead to various damages.
- Inadequate curing can significantly reduce the repaired concrete’s strength and durability.
- Determining the underlying causes of concrete spalling will likely lead to recurring problems.
- Severe or complex spalling issues require professional guidance to prevent further costly mistakes to the structure.
Preventive Maintenance Tips
By following the given tips, provide assistance preventing concrete spalling. Let’s have a look at them:
- Conduct a regular inspection to identify early signs of spalling, like surface flaking, discoloration, or small cracks. It helps prevent further damage and can repair it easily.
- Pay close attention to the areas that are highly exposed to harsh weather conditions like chemical spills or de-icing salts.
- Most importantly, using high-quality concrete mix can ensure the structure’s strength and durability.
- A proper curing of concrete is a way to achieve its maximum strength.
- You can use sealants or protective coatings to prevent chemical attack and moisture penetration.
Closure Lines
Concrete spalling is a common cause, yet it can be avoided easily. By using quality concrete mix and proper care, you can prevent the surfaces from severe damage and ensure the longevity of the structure. In this article, you have been provided with the causes and tips to prevent the spalls. Make use of this information in the right way to ensure the strength and durability of the structure.