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Concrete Spalling Repairs Service Sydney
At Concrete Cancer Repairs Sydney, we specialise in professional concrete spalling repairs in Sydney, delivering accurate diagnosis, targeted treatment, and dependable long-term repair solutions. Our team uses proven remediation methods to locate damage, treat underlying causes, and restore structural strength, durability, and visual appearance.
From surface flaking and rust staining to exposed steel reinforcement and structural deterioration, we offer reliable and cost-efficient solutions designed to stop concrete spalling from progressing and protect your property. Our goal is to return your concrete surfaces to a secure, long-lasting, and visually appealing condition while maintaining high-quality workmanship and exceptional service throughout Sydney.

FREE QUOTE CALL OR TEXT 0424 408 330
We’ll Beat All Quotes By Up To 10%*, No Call Out Fee Conditions apply*
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QUOTE
We’ll Beat ALL Quotes By Up To 10%
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Concrete Spalling Repair Service
Concrete Spalling Repair Service
Why Choose Concrete Cancer Repairs Sydney’s Team To Repair Your Concrete Spalling & Concrete Cancer?
At Concrete Cancer Repairs Sydney, we specialise in both concrete spalling repairs and concrete cancer remediation, delivering high-quality workmanship backed by advanced techniques and decades of expertise. Here’s why homeowners, strata managers, and commercial clients trust our team:
Dust-Free Concrete Repair Technology:
We utilise premium dust-control and HEPA extraction systems to keep your environment clean and safe throughout the spalling repair process. This reduces airborne debris, minimises mess, and protects surrounding surfaces while we work.
Over 35 Years Of Experience:
With more than 35 years of hands-on experience in concrete spalling repair throughout Sydney, our experts understand exactly how to diagnose issues correctly and restore structural strength efficiently.
Fully Licensed And Insured:
Concrete Cancer Repairs Sydney holds all required licensing and insurance for small-scale residential remediation through to complex structural concrete cancer projects. Every repair is carried out safely, professionally, and in accordance with relevant Australian standards.
Modern & High-Performance Equipment:
We provide premium spalling repair services without inflated costs. If you receive a comparable written quote, we’ll beat it by up to 10%*, ensuring exceptional value for long-lasting workmanship.
Competitive Pricing & Quote-Beat Promise:
We pride ourselves on offering great value. If you receive a written quote from another provider, we’ll beat it by up to 10%*, ensuring you get premium workmanship at an affordable price.
Complete Concrete Repair Solutions:
We provide fully integrated services—from detailed inspections and moisture testing to steel treatment, concrete patching, waterproofing, and surface restoration. Whatever the level of deterioration, we manage the entire process from start to finish.
Long-Term Warranty Options:
We believe professional concrete repairs should stand the test of time. Depending on the chosen system, we offer long-term warranties ranging from 7 to 30 years, giving you complete peace of mind.
Commitment To Customer Satisfaction:
We take pride in providing clear communication, reliable scheduling, and responsive support. Every project is carried out with the goal of exceeding your expectations and ensuring complete satisfaction.
Premium & Compliant Materials:
All products and repair systems we use comply with strict Australian requirements, ensuring durability, performance, and long-term protection against moisture intrusion and corrosion.
Tailored Repair Methods:
Concrete spalling and concrete cancer vary significantly from site to site. That’s why our repair recommendations are based on a detailed assessment for your property, ensuring you receive the most effective, efficient, and long-lasting remediation strategy for your specific issue.
What Is Concrete Spalling And How Do We Repair It?
Concrete spalling occurs when the reinforcing steel inside the slab begins to corrode. As the steel rusts, it expands, forcing the concrete to crack, flake and break away. These openings then allow more moisture and air to reach the reinforcement, accelerating the deterioration and weakening the structure over time.
How We Repair Concrete Spalling
STEP 1: Complimentary Inspection & Estimate
We begin by inspecting your property and identifying the affected areas. After this assessment, you’ll receive a free, no-obligation quote outlining the recommended repairs and treatment plan.
STEP 2: Comprehensive Condition Assessment
Our team performs a detailed evaluation to determine the cause of the spalling, the extent of the damage, and the most suitable remediation method based on your situation.
STEP 3: Cutting Out The Damaged Areas
All unstable concrete is carefully cut out and edges are shaped neatly to create a clean work area and prepare the surface for restoration.
STEP 4: Low-Dust Concrete Removal
Using specialised jackhammers and dust-control techniques, we remove the weakened concrete surrounding the corroded steel while keeping dust exposure to a minimum.
STEP 5: Rust & Corrosion Removal
Once reinforcement is fully exposed, we mechanically remove rust using wire brush attachments and mechanical grinding, ensuring the steel is ready for treatment.
STEP 6: Professional Surface Preparation
The remaining concrete and exposed steel are thoroughly cleaned to ensure maximum adhesion for protective primers and anti-corrosion coatings.
STEP 7: Applying Primers & Anti-Corrosion Treatments
We apply premium epoxy primers and corrosion-resistant coatings to help stop rust from returning and prevent further spalling.
STEP 8: Reinforcement Repairs or Replacement
If the reinforcing steel is damaged, we replace sections or install additional reinforcement to restore the structural integrity of your concrete.
STEP 9: Waterproof Barrier Application
A moisture-resistant barrier is applied to guard against future water penetration and provide long-term protection.
STEP 10: Rebuilding The Concrete Section
New concrete is reinstated to the correct depth, finished cleanly, and allowed to cure—bringing your structure back to full strength and restoring its original appearance.
Major Factors That Contribute To Concrete Spalling & Concrete Cancer
A variety of conditions can significantly increase the likelihood of concrete spalling and reinforcement corrosion—both of which can lead to serious structural deterioration.
Magnesite Flooring:
Many buildings constructed between the 1920s and late 1990s contain magnesite flooring. Although widely used historically, magnesite absorbs and retains moisture, which can accelerate corrosion of the steel reinforcement underneath. If magnesite is present, professional removal is strongly recommended to prevent future structural issues and minimise the risk of concrete spalling.
Proximity To The Coast:
Structures located along coastal suburbs are exposed to intense environmental conditions. Salt-laden ocean air penetrates concrete and causes the reinforcing steel to corrode more quickly, leading to visible spalling and internal deterioration.
Water Penetration:
Cracks, damaged joints, or worn surfaces can allow water to infiltrate concrete. Moisture also naturally moves through concrete’s pores. Once water reaches the steel reinforcement, rust develops and concrete begins to break away.
High Salt Exposure:
Coastal buildings are particularly vulnerable due to constant airborne salt. Salts accelerate corrosion significantly, compromising both reinforcement and the surrounding concrete cover.
Carbonation:
Over time, concrete reacts with carbon dioxide in the atmosphere, reducing its natural alkalinity. Lower alkalinity means less protection for embedded steel, increasing the likelihood of concrete spalling and internal corrosion.
Age and Environmental Conditions:
Older buildings have endured decades of rain, humidity, pollution, vibrations, and natural wear. These conditions eventually weaken the concrete, exposing the reinforcing steel and creating ideal conditions for spalling to occur.
Insufficient Concrete Cover Over Reinforcement:
If reinforcement bars are installed too close to the concrete surface, they are more easily reached by moisture, oxygen, and chlorides. This shallow cover significantly increases the speed at which the steel corrodes.
Substandard Construction Techniques:
Poor material quality, incorrect mix proportions, inadequate reinforcement placement, or failing to properly prepare steel during construction can greatly reduce the durability of concrete and lead to premature spalling.
Poor or Failing Waterproofing:
When waterproofing membranes, coatings, or drainage systems fail, moisture enters concrete and rapidly accelerates reinforcement corrosion. Effective waterproofing is critical to prevent spalling and internal decay.
Structural Movement and Cracking:
Movement in foundations, heavy loads, and temperature fluctuations all cause cracking. Cracks act as direct access points for water, escalating rust formation and causing concrete layers to detach.
Use of Incompatible Metals:
When different metals are combined within the concrete, electrochemical reactions can occur. These reactions speed up deterioration and increase the risk of spalling and concrete cancer forming over time.

Rust-Coloured Stains:
Brown or reddish streaks running down walls, balconies, or ceilings typically indicate corrosion of embedded reinforcement steel inside the concrete.
Surface Wear or Erosion:
Concrete that appears flaky, porous, or weathered allows moisture to enter and accelerate deterioration, ultimately leading to surface failure and structural spalling.
Cracks of Any Size:
Whether hairline or severe, cracks signal movement within the structure or expanding corroded reinforcement pushing outward from inside the concrete.
Persistent Moisture or Water Staining:
Standing water, damp patches, or surface discolouration usually point to water ingress—one of the most common causes of concrete spalling in Sydney.
Failing Expansion Joints:
When expansion joints lose flexibility or deteriorate, concrete becomes more vulnerable to cracking and surface separation.
Insufficient Concrete Cover Over Steel:
If reinforcement is too close to the surface, moisture and oxygen can reach it easily, quickly causing rust and structural spalling.
Corroded Metal Hardware:
Rusting brackets, tie-downs, bolts, or embedded steel components signal active corrosion and may contribute to larger structural problems.
Paint Bubbling, Blistering, Or Peeling:
Frequently visible on soffits, beams, and ceilings, this often indicates moisture trapped behind the surface and early-stage spalling beneath the paint layer.
Areas That Sound Hollow When Tapped:
A hollow or “drummy” sound suggests the concrete has separated internally, usually due to delamination or rust-induced expansion.
Visible Reinforcement Steel:
When concrete flakes away enough to expose rusty steel reinforcement, the problem has advanced significantly and requires urgent professional repair.
Add-On Services For A Complete Solution For Your Project
Alongside concrete spalling repairs, Concrete Cancer Repairs Sydney offers a full suite of related services to prepare your floors for their next stage. These include:
– Floor Levelling
– Flooring Removal
– Concrete Grinding
– Magnesite Removal
– Concrete Crack Repairs
– Concrete Cancer Repairs
– Concrete Spalling Repairs
– Free Concrete Cancer Inspections
– Waterproofing Membrane Removal
– Waterproofing Membrane Installation
– Supply & Installation Of A New Flooring System
This makes us a one-stop solution for floor preparation services across Sydney.

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We Will Beat All Quotes By Up To 10%*
No Call Out Fee Conditions apply*
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