Concrete Spall Repair

Expert Solutions to Strengthen Structures and Improve Safety

Epoxy Design Systems proudly offers spalling concrete repair and restoration services to the United States and international clients for industrial, commercial, marine and petrochemical structures.

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Epoxy Design Systems are the leading experts in spalling concrete repair and restoration over the last four decades. Focused on industrial and commercial structures, we proudly service beyond the Greater Houston area with both national and international clients. We make it our priority to provide efficient work with industry-leading customer service. Contact us today for a consultation.

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What is Spalling Concrete?

A concrete spall is a damaged, fractured section of concrete that varies in size and depth. Properly identifying the cause is crucial to choosing the right repair method. Repairing spalls maintains the concrete’s durability, prevents steel reinforcement corrosion, and preserves structural strength for longer service life.

The repair process involves removing loose section, preparing the surface by roughening and square-cutting edges, and cleaning exposed steel of corrosion. Protective measures includes applying corrosion inhibitors, bonding agents, and proper curing techniques ensure a durable and lasting repair. Additionally, crack injection can be utilized to seal and reinforce any associated cracks, further enhancing the concrete's integrity.

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Examples of Spalling Concrete Repair Needs

exposed rebar under a freeway in need of spall repair

Additional Considerations for Spalling Concrete:

Use a hammer to sound surrounding concrete at spalls for delamination’s and to ensure full, complete concrete repairs.
Identify root causes of structural spalls to prevent recurring repair fractures.
Use a cementitious hybrid epoxy resin bonder based upon requirements and conditions.
The repair mortar physical properties must be compatible with the concrete element and have structural properties which most nearly replicate the original concrete design and structural integrity.

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Our Concrete Spall Repair Process

At Epoxy Design Systems, every spall repair begins with a thorough structural assessment to identify the cause and full extent of the damage. From there, our restoration process follows a proven, step-by-step approach to ensure a durable and long-lasting repair:

Assessment & Root Cause Identification — Inspect and sound the surrounding concrete with a hammer to detect delamination and determine the true scope of damage
Concrete Removal — Remove all loose, deteriorated, and unsound concrete from the affected area
Surface Preparation — Square-cut edges and roughen the substrate to the appropriate concrete surface profile (CSP) for maximum bond strength
Steel Treatment — Clean exposed reinforcing steel of all corrosion and apply a corrosion inhibitor to halt further deterioration
Bonding Agent Application — Apply a cementitious or epoxy-based bonding agent suited to the conditions and repair requirements
Repair Mortar Installation — Place a repair mortar with physical and structural properties compatible with the original concrete design
Crack Injection (if required) — Inject epoxy or polyurethane into associated cracks to seal and reinforce the surrounding concrete
Curing — Apply proper curing techniques to ensure full strength development and a durable, lasting repair

Worker inspecting exposed rebar in a spalled concrete beam ceiling prior to repair

FAQs for Spall Repair

What causes concrete spalling?

Concrete spalling is commonly caused by corrosion of embedded steel reinforcement, freeze-thaw cycles, chloride intrusion from de-icing salts or seawater, improper curing during original construction, and long-term moisture exposure. Identifying the root cause is a critical first step in any concrete spall restoration project — without it, repairs are likely to fail prematurely.

How do I know if my structure needs spall repair services?

Signs that you need professional spall repair services include visible flaking or chipping of the concrete surface, exposed or rusting rebar, hollow sounds when the surface is tapped with a hammer (known as delamination), cracking, and structural weakening. Early detection and repair prevent costly structural failure down the line.

Can spalled concrete be repaired rather than replaced?

In most cases, yes. Professional spalling restoration services can fully restore structural integrity without full demolition and replacement. The key factors are the depth and extent of the spall, the condition of the reinforcing steel, and whether the root cause has been addressed. Epoxy Design Systems evaluates each structure individually to recommend the most effective and cost-efficient solution.

Do you offer spall repair services in Houston?

Yes. Epoxy Design Systems provides spall repair services in Houston and throughout the United States for industrial, commercial, marine, and petrochemical structures. We also serve international clients. Contact us to discuss your project and arrange a site assessment.

What types of structures do you perform concrete spall restoration on?

We perform concrete spall restoration on a wide range of structures including parking garages, bridges, marine structures, industrial facilities, petrochemical plants, commercial buildings, and more. Any concrete structure with deteriorating or fractured sections can benefit from our spalling restoration services.

How long does a spall repair last?

When performed correctly — with proper surface preparation, compatible repair materials, corrosion treatment, and appropriate curing — a professional spall repair can last decades. Using a repair mortar that closely replicates the original concrete's physical and structural properties is essential to long-term durability.

Explore Our Other Services

In addition to Spalling Concrete Repair, Epoxy Design Systems offers a range of services to protect and strengthen your infrastructure. Explore our other specialized solutions below.

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