Why Does Concrete Crack and Spall, and How Can It Be Prevented?

Concrete, the backbone of modern commercial properties, is revered for its strength and durability. Yet, despite its robustness, concrete is not immune to the phenomena of cracking and spalling.

Both cracking and spalling are signs of deterioration and critical concerns for a building’s structural integrity and aesthetics. While both may initially seem minor, they can lead to more severe issues if left unaddressed. This article explores the causes and implications of these common issues, offering insights into preventive measures and repairs.

What are Concrete Cracking and Spalling?

In the lifecycle of concrete structures, two prevalent issues are cracking and spalling, each signaling different underlying problems but often interconnected in their effects on a building’s health.

Concrete Cracking is a common occurrence that can result from several factors. Unlike spalling, cracking refers to forming fissures or lines on the concrete surface, which can vary in depth and length.

Concrete Spalling, on the other hand, goes beyond surface-level deterioration. It involves the breaking off or flaking of concrete surfaces, often exposing the reinforcing steel bars beneath. When this happens, it can lead to accelerated corrosion of the reinforcement and further compromise structural integrity.

Concrete spalling and cracking can arise from various sources:

  • Water Ingress and Freeze-Thaw Cycles – Moisture penetration, followed by freezing and thawing, can cause the concrete to crack and eventually spall.
  • Settlement – Uneven settling of the ground beneath the concrete can create tension, resulting in cracks.
  • Overloading – Exceeding the weight capacity of the concrete can cause cracks due to excessive stress. The toll that much heavier electric vehicles take on parking garage structures has the potential to shorten the lifespan of the concrete.
  • Shrinkage – Concrete requires proper oversight during the curing process, or it can shrink, leading to the formation of cracks.
  • Quality of Materials – The integrity of concrete heavily depends on the quality of its constituent materials. There have been lawsuits because a supplier allegedly omitted a critical chemical additive from their concrete mix. The omission of such additives can compromise the concrete’s resistance to environmental stresses, leading to premature cracking and spalling.
  • Improper Installation – Flaws during construction, like inadequate curing or improper mix proportions, set the stage for future problems.
  • Chemical Damage – Harmful chemicals, like chlorides from de-icing salts, can corrode the reinforcing steel and cause the surrounding concrete to spall.
  • Environmental Factors – 2023 was officially the warmest year on record. Extreme temperatures can reduce concrete strength and increase permeability, contributing to spalling and cracking.
  • Water Ingress – Moisture penetration, often through cracks, leads to deterioration and rusting of reinforcement bars.

Recognizing the signs of both allows for timely intervention and prevention of further damage.

Identifying Signs of Concrete Damage

If spotted in time, recognizing early signs of deterioration can lead to interventions that prevent minor issues from escalating into significant, costly repairs. Here’s what property managers and building owners should look for:

  • Flaking – A clear sign that the concrete surface is deteriorating, potentially exposing the underlying steel reinforcements.
  • Cracks – Thin lines or wide fissures on the concrete surface. Cracks are not just surface-level concerns; they can indicate deeper structural issues.
  • Exposed Reinforcement Bars – When reinforcement bars become visible, it suggests that the concrete has spalled significantly, which could accelerate the corrosion of the steel and compromise structural integrity.

Valcourt’s Approach to Concrete Maintenance: A Case Study

The top level of both parking structures at Park 80 West, approximately 12–15 years post-initial construction, suffered from a deteriorated waterproof coating—a maintenance step recommended every five years.

This neglect led to significant concrete spalls, cracks, and severe water infiltration, necessitating immediate attention before completing the restoration. Valcourt’s comprehensive services for this project included concrete spall and crack repair, traffic-bearing waterproofing membrane repair, and the restriping of parking spaces.

Preventative Measures and Solutions 

Property managers should incorporate routine checks into their maintenance schedules, focusing on areas susceptible to damage, such as exposed surfaces, joints, and areas with known water penetration issues. Inspections should also be more frequent following extreme weather events, which can exacerbate existing vulnerabilities in the concrete.

To mitigate the risks of concrete deterioration, consider implementing the following strategies:

  • Sealing and Waterproofing – Essential for protecting against water infiltration and subsequent corrosion.
  • Pressure Washing and Debris Removal – Keeps surfaces clean and exposes hidden issues.
  • Regular Structural Assessments – Identifies potential problems before they worsen.
  • Proactive Maintenance – Including vigilant monitoring for leaks or structural damage.

Preventative maintenance, followed by early detection and prompt repair actions, can significantly extend the lifespan of a concrete structure and ensure its safety and functionality. Property managers and building owners are encouraged to partner with concrete repair specialists like Valcourt. We can provide expert assessments and waterproofing services and tailor effective repair strategies to address your concrete cracking and spalling issues.

A Proactive Approach to Concrete Maintenance

The integrity of concrete structures significantly depends on regular maintenance and the early detection of potential issues. Property managers can substantially extend the lifespan of their assets by understanding the causes of concrete cracking and spalling and implementing preventative measures. For specialized care and repair, partnering with experienced professionals like Valcourt ensures that commercial properties remain safe, functional, and aesthetically pleasing.

For expert concrete maintenance and repair services, contact Valcourt to help ensure your property remains in prime condition.

 

Parking Garage Maintenance: What to Do to Prevent High-Cost Structural Repairs?

Parking garages face unique challenges due to their constant exposure to vehicular traffic, environmental elements, and heavy loads. As a result, they require diligent, routine attention for basic upkeep like cleaning, lighting, and proactive structural care. This preventative maintenance, as well as responsive repairs, are essential for ensuring safety, preserving profitability, and maintaining property value.

Investing in routine parking garage maintenance also ensures smaller issues are resolved before they become larger —and much more costly— structural repairs. Especially noteworthy is the increased adoption of electric vehicles (EVs), often 30% heavier than traditional gas-powered cars, adding an extra layer of stress to parking structures.

A recent assessment of four parking garages in Asheville, NC, found they needed over $11 million in repairs, and continued deferred maintenance could lead to structure collapse. This article contrasts regular maintenance costs with extensive repairs due to neglect, underscoring the importance of proactive care for parking structures.

Parking Garage Essential Maintenance Practices

Parking garage maintenance should be a top priority. Here are some best practices for knowing where and what to look for and the action needed to maintain the facility and avoid the high costs of more extensive repairs.

 

  1. Monitoring for Leaks, Spills, and Damage: Vigilantly checking for any signs of leaks, spills, or structural damage and addressing these issues promptly to prevent minor problems from escalating into significant concerns.
  2. Structural Assessments: Regular structural assessments identify potential issues before they escalate into major problems.
  3. Sealing and Waterproofing: Applying sealants protects against water infiltration, which can lead to corrosion and concrete deterioration.
  4. Pressure Washing and Debris Removal: Regular cleaning and debris removal prevent the accumulation of materials that can hide potential issues. Keeping garages clean and pressure washed every 6-12 months helps expose underlying issues that, if unaddressed, could escalate into significant damages.
  5. Lighting Maintenance: Ensuring proper lighting is crucial for safety and helps identify potential issues needing attention.
  6. Entrance and Exit Gate Maintenance: Regular checks and repairs of gates help promote smooth traffic flow and security.
  7. Booth Maintenance: Confirm that the attendant booths are in good condition and functional.
  8. Elevator and Stair Maintenance: Maintenance of elevators and stairs is crucial for safety and accessibility, preventing breakdowns and potential accidents.

The repercussions of disregarding these standard practices can be dire for your building’s tenants, employees, and visitors.

Case Study: The Tragic Collapse of a Manhattan Parking Garage

In April 2023, Lower Manhattan witnessed a catastrophic collapse of a four-story parking garage on Ann Street. This tragic incident, resulting in one fatality and multiple injuries, highlighted the disastrous consequences of neglecting parking garage maintenance.

The building, dating back to 1925, had a history of structural issues, including cracked and spalling concrete. This failure underscored the risks of deferred maintenance, particularly in structures constantly exposed to elements like water and road salts, which can accelerate concrete deterioration.

This case is a stark reminder of the importance of regular, comprehensive structural assessments to prevent such disasters. It emphasizes the need for property owners to prioritize the safety and integrity of their parking facilities, ensuring compliance with inspection laws to safeguard against potential structural failures.

A1 Orange’s Comprehensive Maintenance Solutions

A1 Orange offers specialized maintenance services tailored for parking garages with a consistent maintenance plan designed to address all aspects impacting the life cycle of the garage. Our approach enhances the parking garage’s structural health, aesthetic appeal, and safety to ensure you get the most out of your investment.

  1. Leak Investigation & Repair: Expertise in swiftly identifying and addressing water infiltration, preventing extensive damage, and preserving building value.
  2. Pressure Washing: We effectively remove tough stains and spills commonly found in parking garages, utilizing eco-friendly methods and specialized techniques for various surfaces.
  3. Waterproofing: Diverse waterproofing services, from traffic coatings to membranes, are crucial for long-term protection against moisture and chemical intrusion.
  4. Concrete Strengthening: Enhancing structural longevity through advanced strengthening systems, adapting to changing loads and building standards.
  5. Stairwell Handrail Repair & Replacement: Ensuring safety and compliance with changing codes through expert handrail services.
  6. Traffic Coatings: Specialized coatings protect and extend the life of high-traffic areas, offering resistance against environmental and mechanical stress.
  7. Concrete Repair and Restoration: We offer comprehensive services for structural integrity restoration, addressing everything from expansion joint replacement to decorative coatings.
  8. Emergency Leak Repair: Rapid response to leakage issues caused by various factors, ensuring a safe and functional environment.
  9. Plaza Deck Repair and Maintenance: Specialized in managing the unique challenges of plaza decks, from waterproofing to finish replacements, emphasizing the minimal impact on occupants and guests.
  10. Post-Tension Repair: We provide advanced post-tensioning techniques to help address critical issues such as tendon oxidation due to water infiltration.

As we’ve explored the critical aspects of parking garage maintenance, it’s evident that routine care and expert intervention are pivotal for staying ahead of wear and tear.

Regular Maintenance, The Key to Parking Garage Longevity

Regular and proactive maintenance of parking garages is crucial to avoid high-cost structural repairs. By adhering to standard maintenance practices and utilizing the specialized services offered by A1 Orange, property managers can safeguard their investments and ensure the safety and longevity of their parking structures. 

Consistent care and attention to detail in parking garage maintenance can significantly extend the structure’s longevity, enhance its functionality, and maintain its aesthetic appeal. This approach minimizes the likelihood of costly repairs and ensures a safer environment for users, contributing to the overall value and appeal of the property.

Contact A1 Orange today for a comprehensive maintenance plan tailored to your parking garage’s needs that will help protect your valuable asset for years.

two men inspecting commercial building facade preventative maintenance

 

Types of Stadium Concrete Repairs and How They Impact Structural Integrity

A stadium is a tiered structure for people to observe an event. Without proper stadium concrete repairs and maintenance, the safety of observers is at risk and therefore cannot be overlooked or ignored. Even flashing on roofs or other items can lead to premature wear and tear. Maintaining and repairing stadium concrete will enhance the structure’s appearance, overall structural integrity, and the safety of patrons. 

A 2022 article on TileLetter.com says that the new home of the Los Angeles Rams and Chargers is the “first open-air, indoor-outdoor stadium constructed with more than 70,000 seats, including 260 luxury suites, with expansion capabilities that will accommodate up to 100,000 guests.” SoFi Stadium is an indoor and outdoor facility that needs routine and preventative stadium concrete repairs to maintain the life and longevity of the structure

Early detection of problems saves money and prevents the need for a complete replacement. Below are some of the most common implemented maintenance tips for stadium repairs.

Replacement of Spalling Concrete

Concrete is constantly exposed to the weather and free-thaw cycles. These cycles decrease the structural longevity of concrete. It creates spalling, which can indicate more serious issues. The damaged concrete needs to be removed immediately and replaced with new concrete. Applying sealers and waterproofing membranes will increase the life of the product. This is a stadium waterproofing solution that is requisite to the longevity of the stadium. 

Rebar Coatings to Reduce Damage

The wet and dry cycle of the environment will eventually cause corrosion of steel rebar. When corrosion occurs, it reduces the bond strength of the concrete and rebar, leading to significant problems. Applying rebar protective coatings helps fend off corrosion. The use of corrosion inhibitors provides a protective layer that is a physical and chemical barrier between steel rebar and the environment. This stadium concrete repair is one of the most effective and efficient solutions to reduce damage.

New Sealants to Waterproof Exposed Surfaces

Waterproofing sealants and materials help stadiums and structures last longer by minimizing water absorption and freeze-thaw damage. The waterproofing sealant must withstand all types of weather. Ensure all gaps, fractures, and exposed surfaces are sealed and waterproofed. This stadium waterproofing solution creates protection and a barrier between the stadium and water infiltration. 

Specialty Membranes for High-Risk Areas

Specialty waterproofing membranes for stadium concrete repairs will increase the structure’s functionality, especially in high-risk areas such as the restrooms. Concrete is naturally very porous, allowing acidic liquids such as urine to penetrate and absorb. This leads to several issues, including corrosion, odors, and concrete damage. With various types of membranes available, ensure the correct specialty waterproofing membranes are applied to avoid these issues. 

Below-Grade Drainage and Waterproofing

Below-grade systems are essentially below ground, allowing for even more moisture infiltration as it seeps in from the soil and into any exposed cracks or pores. If not waterproofed and drained correctly, multiple issues will arise, including the presence of mold and mildew. Below-grade drainage and waterproofing is a stadium concrete repair vital to the stability of the stadium structure and the stadium waterproofing solutions

Expansion Joint Repairs

By design, expansion joints in a stadium absorb and release the stress created by natural expansion and contraction. Extensive cracks can spread throughout your stadium if joints are missing or damaged, causing substantial damage such as buckled concrete. Expanding joints should be inspected and repaired immediately if damaged and never ignored to prevent further damage and safety hazards. 

Handrail Repairs

Constant use and weather conditions create considerable wear and tear on outdoor railings, jeopardizing the structure’s stability. The presence of cracks in the concrete supporting the handrail structure indicates corrosion and therefore requires stadium waterproofing solutions and repair to any damaged railing. Handrail repair or replacement is imminent to avoid safety hazards.  

Enhance Stadium Concrete Longevity and Strength by Partnering with The JOBS Group

Following the tips for preventative stadium concrete repairs will prolong the structure’s lifespan. Inspecting regularly and acting fast saves money and prevents significant complications. Enhance your stadium longevity and strength by partnering with The A1orange Group today!