Spall & Crack Repair

Spall & Crack Repair – following ICRI Protocol

Over time, concrete will crack and “spall”, at times revealed with small chunks popping off. Concrete is porous, which can allow moisture intrusion. Thermal cycling, periods of exposure to very high or very low temperatures, coupled with moist concrete, can result in cracking and deterioration. Additionally, steel reinforcement within concrete corrodes and rusts, exerting pressure and creating defects in the concrete.

Pro Coat provides an assortment of repair materials and techniques to renovate and repair typical concrete defect for commercial and industrial partners in the Maryland and Delaware area. We employ the best practices & protocols, as specified within ICRI (International Concrete Repair Institute) procedures. After proper testing and identification of defective spots, we remove the weakened & loose concrete typically to a depth of 2 to 3 inches, which exposes reinforcement, steel rebar.

How it’s done:

1. Sandblasting or hand tooling both rebar and exposed concrete surfaces to remove rust, loose particles, and contaminants. The next step is coating steel reinforcement with a corrosion inhibitive coatings, typically a zinc-laden paint product.
2. We patch the opening with an adhesive mortar repair product.
3. If specified, we coat the entire concrete surface with an elastomeric paint material or with a “breathable” coating specially designed for concrete substrates.

Pro Coat also utilizes a migrating corrosion inhibitor which, amazingly, migrates through porous concrete to the target, steel rebar, and inhibits further rusting and corrosion.

Our services not only repair deteriorated concrete to a sound surface, but also ensure an extended life cycle, lasting for many years.

Perdue Agribusiness LLC – Renovation and Coatings

Concrete Silos, Concrete Spalling, Rebar & Concrete Crack Repair and Elastomeric Coating

Completed January 2016 – Chesapeake Virginia

Perdue Agribusiness operates an export grain and soy processing complex in Chesapeake, Virginia, complete with deep water, international export capabilities.  This facility is over 60 years old and  Perdue has made major investments and improvements from top to bottom, including basic infrastructure improvements.  It was recognized that the 22 grain silo cluster, standing 150 feet in height, was in early stages of concrete deterioration—spalling and cracking became a concern and focus to repair.  

Pro Coat developed a work plan and specifications to do the entire spall repair, crack repair, and elastomeric coating.  After “sounding out” the concrete, identifying weak, spalled, and loose concrete, we then demoed &  removed all loose and failing areas.  Following ICRI (International Concrete Repair Institute) guidelines, rectangular saw cuts were made and the concrete was demoed out to the required depth.  Any rebar that needed replacement was installed and all rebar was sandblasted and zinc-coated to prevent future potential corrosion.  A bonding primer was used on fresh demoed concrete and then the final concrete patch was installed and tooled to flush & even with the concrete silo curvature.

An elastomeric coating was applied to the entire surface, minimizing any future moisture intrusion and /or rebar corrosion and deterioration of the tanks.

The project duration was from November 2014 through January 2016.  Perdue and Pro Coat have taken a critical and highly valued asset, protecting its structural integrity for decades to come.