Concrete Spalling

Concrete spalling is a significant issue in construction, involving the breaking or flaking of the concrete surface, which can expose inner aggregates and compromise structural integrity. Understanding its causes is key to effective prevention and repair.

Causes of Concrete Spalling

1. Freeze-Thaw Cycles: Water infiltrates concrete, freezes, expands, and causes surface flaking over time.
2. De-icing Salts: Lower the freezing point of water, intensifying freeze-thaw damage.
3. Improper Pouring/Finishing: Poor techniques create weak surface layers susceptible to spalling.
4. Corrosion of Embedded Metals: Moisture and chlorides cause steel reinforcement to corrode, expand, and lead to spalling.

Preventative Measures

1. Proper Mix Design: Use air-entrained concrete, high-quality aggregates, and suitable water-cement ratios.
2. Effective Curing: Maintain moisture and temperature to strengthen the surface.
3. Surface Protection: Apply sealants to guard against moisture and salts.
4. Reinforcement Protection: Use corrosion inhibitors or protective coatings on steel.

Repair Methods

1. Surface Patching: Remove damaged concrete, apply repair mortars, and ensure proper bonding.
2. Corrosion Treatment: Treat corroded steel before repairing concrete.

Prevention and Protection

1. SpecShield / All Shield: Penetrates and seals concrete, protecting against moisture and salts.
2. Curing and Sealing Products: Maintain moisture during curing and add a protective layer.

Repair Products

1. RepCon V/O: High-performance mortar for vertical/overhead repairs.
2. RepCon 928: Versatile repair mortar for various applications.
3. Duo Patch: Dual-component compound for durable repairs.
4. OverCrete: Overlay system for resurfacing and repairing concrete.

Additional Information on Concrete Spalling

1. Causes: Freeze-thaw cycles, de-icing salts, improper finishing, and metal corrosion.
2. Prevention: Use proper mix design, effective curing, sealants, and protect steel reinforcement.
3. Repair: Spalled concrete can be repaired using patching techniques and quality mortars.
4. Best Products: SpecShield, All Shield, and curing/sealing products.
5. Freeze-Thaw Impact: Causes internal stress by expanding trapped water, leading to spalling.
6. De-icing Salts: Accelerate spalling by increasing freeze-thaw cycles and metal corrosion.
7. Air Entrainment: Helps concrete withstand freeze-thaw cycles.
8. SpecChem Repair Products: Include RepCon V/O, RepCon 928, Duo Patch, and OverCrete.

Learn more about concrete spalling here.