Concrete spalling occurs when the surface layer of concrete chips, peels, flakes, or breaks away. This issue affects both the concrete’s appearance and its performance; however, with early identification and the right preventative measures, you can avoid extensive repairs and coating failures.
At Brush Brothers Coatings, our goal is to protect your concrete floors from spalling and extend their lifespan by providing durable, long-lasting floor coatings. If you’re looking for a way to address concrete spalling, keep reading to learn the causes of concrete spalling, how to repair it, the importance of floor coatings, and more.
What Is Concrete Spalling, and What Causes It?
As we said before, spalling occurs when the surface layer of the concrete flakes, chips, crumbles, pits, or breaks away, creating a rough or uneven surface. It can range from minor surface damage to more significant structural deterioration. It commonly occurs on garage floors, warehouses, industrial floors, commercial facilities, parking structures, outdoor concrete, loading docks, and heavy-use areas.
The possible causes of concrete spalling include:
Moisture Intrusion
Moisture intrusion is one of the most common causes of coating and concrete failure. Water can penetrate the pores of concrete floors, getting trapped inside and weakening the concrete over time.
Freeze-Thaw Cycles
Water expands when it freezes. This means that when temperatures fluctuate, the repeated expansion and contraction of the water puts pressure on the concrete, making spalling more likely.
Corrosion of Reinforcing Steel
Some concrete has steel embedded within it for reinforcement. Moisture and salts can corrode the steel, and the rust can expand and push outward against the concrete. This can result in cracking and surface breakage.
Poor Concrete Installation or Finishing
Overwatering concrete during installation, improper finishing techniques, and a lack of proper curing can cause weak surface layer formation, increasing the risk of spalling.
Deicing Salts and Chemical Exposure
Road salts and chemical contaminants can accelerate concrete deterioration, especially in commercial and industrial environments, near entryways, and in areas with lots of vehicle traffic.
Heavy Traffic and Mechanical Wear
Repeated impacts and abrasions from vehicles, machinery, and foot traffic place stress on concrete surfaces, gradually weakening them. This can eventually lead to cracking and spalling.
Why Concrete Spalling Should Not Be Ignored
Concrete spalling is a serious issue that should not be ignored. Even small areas of damage can worsen over time, creating trip hazards and increasing liability risks in commercial environments.
There are also potential structural and financial consequences. If the concrete slab is allowed to continue to weaken and deteriorate, it will need more extensive repairs. Not only is this more costly, but in commercial environments, it will likely mean more downtime, as well.
Spalling can cause coating performance issues, as well. Coatings depend on a strong, sound concrete foundation. Spalling can cause adhesion problems and premature coating failure, which is why it’s so important to address it before installing a coating.
How Concrete Spalling Is Repaired
Fortunately, concrete spalling can be repaired, whether it’s prior to coating application or not.
The first step is surface preparation, which may involve removing loose or damaged concrete, grinding or shot blasting, and creating a stable surface for repairs. Next, it’s time to repair the concrete using patching compounds, mortars, or crack fillers. It’s essential to ensure the surface is uniform and smooth and the repairs are properly bonded.
After that, a protective floor coating can be applied. Epoxy, polyaspartic, and urethane systems can all be used to help shield repaired concrete from moisture, chemicals, and wear.
Why Professional Floor Coating Systems Matter
Professional floor coating systems do more than just improve your concrete floors’ appearance — they provide valuable protection, as well. By improving the durability of your floors, professional coatings can reduce the amount of maintenance they’ll need, which means you’ll save time and money.
Before adding a coating to your concrete floors, it’s important to seek a professional assessment and perform any necessary repairs. Professional repairs address the root causes of spalling rather than just the surface symptoms, ensuring your coating — and the concrete underneath — stand the test of time.
Protect Your Concrete Floors from Spalling with Brush Brothers Coating
At Brush Brothers Coatings, we provide floor coating services for a wide range of applications, from family homes to bustling commercial facilities. If you’ve noticed issues with your concrete floors, contact us today to learn more about how we can repair your concrete and ensure it’s protected for years to come.
