Concrete spalling, or concrete degradation also known as concrete cancer, is a common issue affecting many buildings, especially those standing for a long time. Concrete cancer occurs when the surface of the concrete begins to flake or peel away, exposing the underlying structure. This issue not only looks unsightly, but it can also lead to serious problems if left unaddressed. For example, if the degradation is severe enough, it can compromise the structural integrity of the building, which can be dangerous for occupants. It’s essential to address concrete spalling promptly to prevent further damage to the building and ensure its longevity.
Concrete spalling is a common issue that occurs when the outermost layer of concrete begins to flake, peel, or chip away, exposing the underlying layers. A combination of factors such as freeze-thaw cycles, exposure to chemicals and salts, and age typically causes concrete deterioration. When the concrete absorbs moisture, it expands and contracts as temperatures fluctuate, which can cause stress and cracking. This can lead to the development of spalls or cracks on the concrete surface. These cracks can be unsightly and may pose safety hazards to building occupants.
Building owners should be aware of several signs of concrete degradation. These signs may include a flaking or chipping of the concrete surface, cracks or holes in the concrete, and rust stains on the surface. Concrete deterioration can also result in reduced structural integrity, which may cause the building to become unstable or unsafe for occupancy. Therefore, it is essential to address concrete degradation promptly to prevent further damage and ensure the safety and longevity of the building.
With over 18 years of experience, MJ Engineering Projects has established a strong reputation for delivering safe, durable and compliant concrete spalling repair solutions. Our engineers specialise in identifying the causes of spalling, such as water ingress, corrosion of reinforcement and structural deterioration, and providing tailored strategies to restore both safety and longevity.
Our process follows a clear and proven pathway. We begin with a detailed site inspection to assess the extent of damage, then develop a comprehensive repair plan specifying methodologies, materials and compliance requirements. Once the scope is confirmed, we manage the tender process to engage qualified contractors and oversee the works from start to finish. With ongoing quality assurance and compliance checks, we ensure repairs are completed to the highest standard and protect long-term building performance.
A professional engineer will typically conduct a visual inspection and use specialised tools to check non-conformances and diagnosis the issue.
When it comes to waterproofing repairs, there are several options available. If the damage to the waterproofing system is not too severe, it may be possible to repair the existing system. This is often the most cost-effective approach, as it involves our waterproofing consultants fixing the current system rather than replacing it entirely. Repairs include patching cracks or holes, sealing gaps, and re-applying waterproofing products.
A full system replacement may be necessary if the existing waterproofing system is beyond repair or if a partial replacement would not be effective. While this can be costly, ensuring the building is adequately protected from water intrusion is often necessary.
Concrete spalling in commercial buildings can quickly impact safety, appearance and asset value if left untreated. At MJ Engineering Projects, we undertake detailed inspections to determine the causes, such as reinforcement corrosion or water ingress. From these findings, we prepare tailored repair specifications designed to meet NCC requirements and relevant Australian Standards, ensuring durability and compliance.
Our team manages every stage of the process, including documentation, tendering, contractor supervision and quality assurance checks. By coordinating with owners, consultants and contractors, we ensure works are delivered efficiently, safely and in line with industry best practice. This structured approach restores structural integrity, safeguards occupants and extends the lifespan of commercial assets.
In residential buildings, spalling often shows as cracks, surface delamination or rust staining, which can signal deeper structural issues. Our engineers assess the affected areas to identify root causes and develop repair plans that comply with both NCC requirements and Australian Standards. These plans are tailored to suit the needs of strata managers and owners’ corporations.
We oversee the full repair process, from specifications and tendering through to site supervision and quality control. By maintaining transparent communication with residents, strata committees and contractors, we deliver a smooth, efficient program. This ensures residential properties remain safe, compliant and durable, while protecting long-term building performance and value.
With more than eighteen years of proven experience in remedial engineering, our firm has built a strong reputation for delivering reliable and long-lasting results. As registered design practitioners, we specialise in repairing building defects across a wide range of projects, from heritage façades that require delicate restoration to modern high-rise towers that demand technical precision.
Our structured project management approach, combined with thorough quality control processes, ensures every repair is handled with efficiency and care. We focus on minimising disruption, controlling costs and tailoring repair strategies to meet the unique requirements of each client.
This commitment to detail and excellence enables us to consistently provide durable, value-driven solutions that stand the test of time.
Our engineers bring extensive expertise in remedial engineering, supported by years of specialised experience and a detailed understanding of industry standards. We take pride in delivering tailored remediation strategies that address both visible and hidden defects across a wide range of building types.
By staying informed of changing regulations and compliance requirements, our team ensures every project achieves technical excellence and long-term durability. We also place a strong emphasis on sustainability, applying environmentally responsible practices and innovative methods wherever possible.
From diagnosing complex issues to implementing cost-effective repair programs, we are committed to providing clients with outcomes that are reliable, compliant and built for the future.
We have successfully completed inspections and remedial work on more than one thousand residential, commercial and industrial buildings across Sydney. This extensive experience allows us to identify and resolve issues with accuracy, from water ingress and façade deterioration to concrete spalling and structural concerns.
Each project benefits from a customised repair strategy designed to achieve durability, compliance and lasting performance. Our large and diverse portfolio equips us to anticipate challenges, optimise resources and streamline delivery to minimise site disruption.
With this proven track record, we are confident in managing projects of any scale or complexity, delivering solutions that are efficient, cost-effective and built to endure.
Is your building showing signs of concrete spalling? Don’t wait until those minor cracks become a major threat. MJ Engineering Projects is your go-to expert for diagnosing the root causes of concrete spalling and developing a robust remedial plan to restore your building’s safety and integrity.
With over 18 years of experience, we understand better than anyone what the complexities of concrete spalling mean for you. We tailor our inspections and recommendations to your building’s specific needs and prioritise speedy assessments. Our exceptional project management will ensure fast, effective results. Partner with MJ Engineering Projects for peace of mind and lasting solutions. Fill out the contact form below for a consultation today.
Client: Owners Corporation
Remedial works at Milsons Point have stopped persistent water ingress, repaired concrete damage and delivered a modern balcony enclosure that satisfies the Design and...
Client: Owners Corporation
MJ Engineering Projects served as superintendent and adviser on extensive remedial works at a three-storey, eight-block complex containing 52 units in Lane Cove. Constructed...
Client: Owners Corporation
MJ Engineering Projects served as superintendent and adviser on remedial works for an eight-storey, fifty-unit apartment building in Wollstonecraft. The concrete-frame, brick-infill structure suffered...
MJ Engineering Projects conducts window and door rectification to ensure functionality, water tightness and compliance with BCA.
MJ Engineering Projects conducts waterproofing repairs to find and rectify the sources of water penetration into the building.
MJ Engineering Projects conducts a tender process with several specialised remedial contractors to ensure the best fit for the job.
MJ Engineering Projects provides an in-depth specification to ensure remedial rectification works are completed in a methodical manner.
MJ Engineering Projects acts on behalf of the client for all Remedial Building Services to ensure the contractor completes a smooth rectification process.
MJ Engineering Projects conducts an inspection of your assets and provides a maintenance regime plan to optimise cost savings.
MJ Engineering Projects conducts floor topping investigations and repairs to prevent and rectify corrosion to the internal concrete slab.
MJ Engineering Projects conduct inspection reports that highlight building defects and recommend rectification methods.
MJ Engineering Projects conducts facade rejuvenation to ensure optimal performance and appearance of the building.
MJ Engineering Projects specialises in delivering thorough and litigation-compliant expert witness reports for construction claims, tailored for building dispute resolution cases.
MJ Engineering Projects conducts diagnostic investigations prior to remedial works to search for any potential building deficiencies.
MJ Engineering Projects provides expert design practitioner services, specialising in regulated designs and technical specifications for Class 2, 3, and 9c buildings.
MJ Engineering Projects conducts rectification of existing cladding that is both unsafe and non-compliant with the BCA.
MJ Engineering Projects conducts ballustrade rectification to ensure compliance to the BCA and safety to the public and building occupants.
MJ Engineering Projects specialises in expert balcony repairs, ensuring safety, compliance, and long-lasting solutions tailored to your property needs.
Key Concerns and Frequently Asked Questions About Concrete Spalling Repairs in Australia
Everything you need to know about MJ Engineering Projects. Can’t find the answer you’re looking for?
Chat With Our Team Now.
Remedial concrete spalling repairs are an essential aspect of building maintenance and repair. Concrete deterioration occurs when the surface of concrete deteriorates or flakes due to exposure to the elements, such as freeze-thaw cycles, chemical exposure, or excessive moisture. It is a common issue in any building with concrete elements, such as balconies, stairs, or walls.
Addressing concrete degradation promptly is crucial to prevent further damage to the building and ensure the safety of its occupants. Remedial concrete spalling repairs involve removing the damaged concrete, preparing the surface, and applying a repair system. The repair system used can vary from traditional cement-based systems to advanced polymer-modified systems, depending on the extent of the damage and the desired outcome.
The process of remedial concrete spalling repairs begins with the identification of the extent of the damage. A remedial engineer will inspect the concrete surface to determine the deterioration’s root cause and assess the damage’s extent. Once the extent of the damage is known, the engineer will develop a remedial plan that outlines the best repair system to use.
The remedial plan will then be implemented by trained professionals who will remove the damaged concrete, prepare the surface by cleaning and roughening it, and apply the repair system. The repair system will depend on various factors, including the type of concrete, the extent of the damage, and the desired outcome. A high-quality repair system is essential for long-lasting results.
Professional assistance is crucial in addressing concrete spalling issues, requiring specialised knowledge and expertise. At MJ Engineering Projects, we are committed to delivering cost-effective and practical solutions to our clients. Here’s how we can help with concrete deterioration repairs:
Experience and Expertise: Our team of experienced professionals has extensive experience in conducting concrete deterioration repairs. We have a proven track record of successfully addressing concrete deterioration issues promptly and effectively.
Advanced Repair Systems: We use advanced repair systems that provide long-lasting results. These systems are designed to restore the structural integrity of the concrete and protect it from further damage. We carefully choose the appropriate repair system based on the type and severity of the concrete spalling issue.
Tailored Solutions: We take a tailored approach to concrete spalling repairs, working closely with our clients to develop custom solutions that meet their specific needs. We consider various factors, such as the location and extent of the damage, to develop a comprehensive repair plan.
Comprehensive Diagnostic Process: Our team utilises a comprehensive diagnostic process to identify the root cause of concrete spalling issues. We conduct a thorough inspection of the concrete to determine the extent of the damage and develop a tailored repair plan that addresses the underlying issue.
Ongoing Support and Guidance: We provide ongoing support and guidance throughout the implementation of concrete deterioration repair solutions. Our team works closely with our clients to ensure the successful implementation of our solutions.
By engaging our services for concrete spalling repairs, our clients can rest assured that their building’s structural integrity is restored and protected from further damage. Our experience, advanced repair systems, tailored solutions, comprehensive diagnostic process, and ongoing support and guidance set us apart from other service providers in addressing concrete spalling issues.
Concrete spalling is a common issue in buildings that can lead to significant damage and safety hazards if left untreated. It’s crucial to address concrete deterioration promptly to prevent further damage and ensure the longevity of the building. Engaging the services of a reputable provider of concrete spalling repairs can ensure effective and long-lasting solutions.
We are committed to delivering cost-effective and practical solutions for concrete deterioration repairs at MJ Engineering Projects. Our comprehensive diagnostic process and tailored solutions have helped our clients identify and address building issues promptly and effectively.
We utilise the latest technology and equipment to provide accurate and reliable diagnoses and offer tailored solutions to meet each client’s needs. Don’t hesitate to contact a reputable engineering firm to learn more about their concrete spalling repair services and how they can help improve the longevity and value of your building.
The duration of a concrete spalling repair project depends on several factors, including the severity of the spalling, the size of the affected area and the chosen repair method. Minor repairs may be completed within a day or two, while more extensive cases could take several days or weeks. During your consultation with us, we’ll provide a more accurate timeline based on your specific situation.
Ideally, concrete degradation repairs are best performed in dry, moderate weather conditions. Extreme temperatures, rain or snow, can affect the curing process and the overall effectiveness of the repair materials.
However, certain urgent repairs may need to be carried out in less optimal conditions. Our team can assess your situation and advise on the best course of action, including temporary weather protection measures if needed.
The frequency of concrete spalling inspections depends on factors like the building’s age, location and exposure to environmental elements. As a general rule of thumb, it’s recommended to schedule inspections every 5-10 years.
For buildings in coastal areas or those subjected to harsh weather conditions, more frequent inspections may be necessary. If you notice any signs of potential spalling, it’s essential to get a professional assessment as soon as possible.
MJ Engineering Projects is a remedial-engineering leader, complemented by in-house structural and civil engineering expertise.
MJ ENGINEERING PROJECTS PTY LTD, 2025. All Rights Reserved. (ACN 123 818 511) (ABN 34 123 818 511)