Spalling

Spalling is primarily a result from the corrosion of the reinforcing steel and/or embedded objects such as clips,

chairs, anchors, etc. When the steel corrodes, the rust expands to 10 times the original volume, creating internal

tension forces in the concrete . Concrete is unable to handle the tension forces, and the pieces between the

corroded steel and the nearest surface will break off, called "spalling" (PCA 2001, p. 12).

Even just a small spall can indicate a much larger issue for two main reasons. First, a small spall can expose the

steel, leaving it ultra-vulnerable to more corrosive elements. This can been seen in Figure 10. If the steel

corrodes more, there will be more spalling, as seen in Figure 11. Second, a spall in one area may be the first

piece of a larger issue beneath the surface. It is likely that other rebar in the immediate area has also been

affected by the corrosive effects and will begin to spall soon. Small spalls are relatively simple and inexpensive

to fix, and repairing these early on can help to avoid large spalling areas.

A large spall area in a slab may indicate immediate danger to a structure. If enough concrete has spalled off of

the bottom, exposing the reinforcing grid, then the concrete and steel are no longer working together to handle

the compressive and tension forces. Essentially, when the concrete reaches its tensile limit, it will fail. The steel

is not engaged by the concrete to take the excess tensile forces, and is only acting as a cage to hold up the

concrete. At this stage, repairs may be enormously expensive. Figure 12 shows a whole building spalling failure.

Spalling of Concrete Causes, Prevention & Repair

Spalling of Concrete slab due to corrosion

The word Spall in engineering, describes the chips or fragments of a material that is broken off a bigger
object. The process of spalling also known as spallation is the surface failure that occurs when a material
such as concrete, brick, or limestone is subjected to excess moisture, corrosion, weathering, and much
more. Concrete spalling commonly known as (concrete cancer) is an eye-sore and has the potential to be an
extreme hazard. Left untreated and exposed to the elements will cause extensive structural damage and
may cause it to break away from the faade, potentially injuring the public and damaging property.
Spalling, at a low level, is mainly a cosmetic problem but it can lead to structural damage if not dealt with
immediately. If left untreated, damage can occur to the reinforcing bars within the concrete. Also, large
enough fragments could fall off which could lead to serious consequences.

Spalling of a Brick Wall

crumble. Causes of excess moisture may include consistent, heavy rainfall coming into contact with
outdoor brick, or dark, damp areas such as basements in which the humidity and also salt will affect the
walls.

Spalling of Concrete in Detail

A common but not well understood problem with older concrete structures is spalling. Concrete spalling is
usually caused by corrosion of the steel reinforcement bars embedded in the concrete matrix, but can be
caused by other ferrous elements either fully or partially embedded inthe structure. Steel frame window
systems, handrails, structural I-beams, metal pipes and conduits are among the most common of the
damage causing building components. Corrosion of the reinforcement steel however, is by far the most
common cause of spalling and splitting in older concrete structures. Steel reinforcement bar (rebar) is used
in concrete to provide strength to a material that is extremely high in compressive strength but has very
limited flexural or tensile strength. One of the principles of reinforced concrete is that the high alkaline
content of the concrete passivates and protects the

Mechanism of Spalling of Concrete slab due to corrosion

embedded steel from corrosion. One of the main components of this corrosion protection is provided by
the amount of concrete cover protecting the steel. As a general rule of thumb one inch of cover is required
to protect the steel rebar, in other words, no rebar should be nearer than one inch of the concrete surface.
Another important factor for the protection rebar is to make sure that the concrete is properly consolidated
during installation.

Besides environmental factors, poor installation also induces spall to form in concrete or limestone such as
through structural overloading of the stone or not taking care to have the proper mixture of ingredients
while pouring the concrete.

Good consolidation is achieved by installing concrete that is the proper consistency, and by vibration of the
wet concrete before it begins to set. Concrete that is too stiff (has too little water) is often not consolidated
properly which allows air bubbles and voids to be left in the finished matrix. If these voids (commonly
known as rock pockets) are large enough or extend all the way through the wall structure, water can easily
penetrate the finished wall and/or contact the rebar and cause corrosion.
 Mechanism of Spalling due to moisture penetration

Repair of Spalled Concrete Slab

Remove the concrete at the spalled areas to expose the corroded steel bars.

Scrape and clean the exposed steel bars and use a wire brush to remove the rust.

Apply two coats of anti-rust paint to the steel bars.

Before patching the area, apply a bonding agent to the affected surface to ensure proper adhesion.

Patch up the hacked area using polymer modified cement mortar.