Concrete spalling repair
BCS delivers expert concrete and asset repair, protection, and strengthening solutions using advanced technology, premium materials, and industry-leading expertise.
Industry-leading concrete spalling repair solutions for large commercial structures
BCS excels in expert concrete spalling repair for large structures, bridges, and buildings, using advanced techniques and high-performance materials to restore integrity, prevent deterioration, and ensure long-term structural reliability.
Two decades of excellence in concrete spalling solutions
With over 20 years of experience in concrete spalling repairs, we blend top-quality products, industry-leading techniques, and our commitment to providing exceptional service to restore structural integrity.
Our concrete spalling repair solutions
Unlike concrete cracks, which are often caused by stress or pressure and are addressed through sealing or filling, spalling primarily results from the deterioration of the concrete's core caused by moisture infiltration and the corrosion of the steel reinforcement. Spalling focuses on repairing the loss of surface material and restoring the integrity of the underlying structure.
With a wide range of standard and custom solutions available, our expert team applies advanced injection systems, sealants and waterproof barriers such as:
Epoxy injection
Epoxy injection is ideal for bonding structural cracks, achieving a permanent, high-strength solution that restores the integrity and stability of compromised structures. This approach ensures long-lasting results that prevent further damage, saving you from costly repairs down the line.
Polyurethane (PU) injection
Used to seal cracks with water ingress, PU injection expands to form a flexible, tight seal, effectively preventing moisture damage in areas like foundations, basements, and walls.
Surface sealing and stitching
Surface sealing applies protective coatings to prevent further damage, while stitching reinforces cracked or fractured areas with steel bars, enhancing strength and extending the structure’s lifespan.
Crack routing and sealing
This process involves widening and cleaning cracks before applying a high-quality sealant, stopping dirt, water, and contaminants from entering and preserving the structure’s integrity
Causes of concrete
spalling (concrete cancer)
Concrete spalling, often referred to as concrete cancer, is a common issue that occurs when the concrete surface flakes, chips, or deteriorates due to underlying structural problems. This damage is often caused by the corrosion of steel reinforcement bars within the concrete. Over time, the corrosion expands, causing the concrete to crack and eventually fall off, leading to surface degradation and potential structural weakness. Below are some of the most common factors that lead to concrete spalling:
Corrosion of reinforcement
When water or moisture infiltrates the concrete, it can reach the steel reinforcement inside. As the steel corrodes, it expands, causing the concrete to crack and fall off.
Water infiltration
Moisture that enters through cracks or porous surfaces can lead to rusting of reinforcement, exacerbating spalling damage.
Poor concrete mix or workmanship
An improper mix or poor workmanship can result in weak, porous concrete, which is more susceptible to moisture damage and corrosion.
Exposure to harsh environments
Concrete exposed to extreme weather conditions, chemicals, or saltwater (especially in coastal areas) is at higher risk of spalling, as these elements accelerate the corrosion process.
Our concrete spalling repair process
Custom solutions & expert methodology
We provide custom solutions and use trialled and tested approaches to ensure every project receives the most effective repair or protection strategy. We develop these approaches by assessing site conditions and structural integrity to deliver a solution that meets the structural and environmental demands.
Precision application & quality assurance
Our advanced team employs industry-leading equipment, premium materials, and strict quality control to ensure durability, safety, and compliance. We adapt to changing conditions, ensuring seamless execution and maintaining project integrity.
Comprehensive monitoring & reporting
Safety, transparency, and accountability are central to our approach. We uphold strict compliance with Australian and international standards, backed by detailed reporting and continuous assessments. Our thorough inspection and monitoring processes ensure long-term performance, giving you confidence in the solution.
Compliant, safe, and effective concrete spalling solutions
At BCS, we take our work seriously, ensuring strict adherence to QBCC regulations, using the correct and safe equipment, maintaining up-to-date safety training, and implementing site-specific risk and environmental management plans on every project.
Why choose
Building Chemical Supplies
Expertise in injection, repair, and protection (IRP)
With over 20 years of experience in concrete restoration, we apply advanced injection, repair, and protection techniques to guarantee lasting structural repairs for structures experiencing concrete spalling.
Advanced equipment and skilled applicators
Our skilled team and advanced equipment work together to deliver efficient, precise, and effective solutions on every project.
Integrity and transparency
We are committed to honesty and transparency, providing realistic solutions and maintaining clear communication throughout the repair process.
High-quality concrete spalling repairs
Our concrete spalling repair services address corrosion and material loss, restoring the strength and durability of your structures for long-term performance.
Our projects
Our relationships with repeat customers such as Acciona, QLD Rail, Transurban, CPB, Rio Tinto, Sydney Trains and more have allowed us to repeatedly provide successful solutions on projects such as:
Combat concrete spalling with Building Chemical Supplies
Whether you're facing concrete spalling, water infiltration, or long-term durability issues, our expert team delivers effective solutions to restore and protect your concrete structures.
Contact us today to discuss how we can restore your structural integrity with concrete cancer repairs.