CRACK DETECTED — REF: SLB-2026-047
FORENSIC CONCRETE CONSULTING

Every crackis telling yousomething.

Spalling, carbonation, alkali-silica reaction — diagnosed in parking decks, bridge abutments, and post-tensioned slabs before they become six-figure failures.

340+
Structures Assessed
18 yrs
Field Experience
$47M
Failures Prevented
SCROLL
SpallingCarbonation DepthChloride IngressAlkali-Silica ReactionDelaminationCorrosion MappingPetrographic AnalysisPost-Tension FailureFreeze-Thaw CyclingReactive AggregateCore Sample ReviewNon-Destructive TestingSpallingCarbonation DepthChloride IngressAlkali-Silica ReactionDelaminationCorrosion MappingPetrographic AnalysisPost-Tension FailureFreeze-Thaw CyclingReactive AggregateCore Sample ReviewNon-Destructive Testing
01
SEVERITY: LOW
DISTRESS TYPE 01 — SURFACE

Spalling & Delamination

Surface concrete breaks away in flakes or sheets. Appears cosmetic at first — a maintenance crew patches it, the patch fails, the cycle repeats. What's actually happening is that freeze-thaw cycling or corrosion pressure has fractured the bond between the cover concrete and the substrate.

Close-up of concrete surface showing spalling and delamination with exposed aggregate and rust staining
FIG 1.1 — Surface spalling with rebar exposure. Chloride-induced corrosion pressure.
INTERVENTION — SURFACE DISTRESS

Cover Depth Mapping & Repair Specification

Half-cell potential mapping locates active corrosion cells before visual symptoms appear. Covermeter survey quantifies the extent. A proper repair specification — not a patch schedule — addresses the root cause.

  • Half-cell potential survey to map active corrosion zones
  • Covermeter scan to verify cover depth against design
  • Chloride profile testing at 3 depths per ASTM C1152
  • Repair specification with material selection and surface prep requirements
Cost multiple of repair vs. replacement
3–5×
02
SEVERITY: MODERATE
DISTRESS TYPE 02 — CHEMICAL

Carbonation & Chloride Penetration

Carbonation neutralizes the alkaline environment that passivates rebar. When the carbonation front reaches the steel, corrosion initiates without any external chloride source. In parking structures, road salt accelerates chloride penetration simultaneously — a compound attack most inspections miss.

Concrete core sample cross-section showing carbonation depth measurement with phenolphthalein indicator spray
FIG 2.1 — Phenolphthalein indicator test on core. Colorless zone = carbonated concrete.
INTERVENTION — CHEMICAL ATTACK

Petrographic Analysis & Carbonation Profiling

A 50mm core tells you everything the surface doesn't. Thin-section petrography under polarized light reveals carbonation depth, pore structure, paste quality, and aggregate reactivity — the complete chemical biography of your concrete.

  • Phenolphthalein carbonation depth measurement per BS EN 14630
  • Chloride profile analysis at 10mm depth intervals
  • Thin-section petrographic examination under polarized light
  • Remaining service life estimation with intervention thresholds
Carbonation depth triggering immediate action
28mm
03
SEVERITY: CRITICAL
DISTRESS TYPE 03 — STRUCTURAL

Alkali-Silica Reaction

ASR is the slow-motion catastrophe. Reactive silica in aggregate reacts with alkalis in cement paste to form an expansive gel. Over years, the internal pressure exceeds concrete tensile strength — map cracking appears, cracks widen, structural elements lose stiffness. By the time you see it clearly, the damage is already deep.

Concrete bridge abutment showing characteristic map cracking pattern caused by alkali-silica reaction with gel exudate
FIG 3.1 — Map cracking with silica gel exudate. ASR confirmed by petrographic thin section.
INTERVENTION — ASR DIAGNOSIS

Petrographic Confirmation & Expansion Monitoring

ASR cannot be reversed, but its progression can be managed. Definitive diagnosis requires petrographic thin-section examination — not just visual inspection. Once confirmed, a monitoring program tracks expansion rate and informs the structural engineer's load capacity assessment.

  • Petrographic thin-section examination per ASTM C856
  • Uranyl acetate fluorescence test for gel identification
  • Stainless steel pin installation for expansion monitoring
  • Structural assessment in collaboration with engineer-of-record
Expansion threshold triggering structural review
0.04%
CASE FILES

What happens
when you wait.

Three real structures. Three different failure modes. One common thread — early diagnosis would have changed everything.

Concrete parking deck showing surface deterioration and cracking patterns
CSE-2024-031
MODERATE

Multi-Level Parking Structure

Houston, TX22 years old
$1.2M
COST PREVENTED
SYMPTOM

Efflorescence and hairline cracking on Level 3 deck

🔬 FINDING

Chloride-induced corrosion of top mat rebar. Cover depth 18mm vs. specified 38mm.

INTERVENTION

Cathodic protection system + selective patch repair + waterproof membrane overlay

Avoided full deck replacement
Bridge abutment concrete surface showing map cracking and orange-brown staining from ASR
CSE-2023-019
CRITICAL

Bridge Abutment

Nashville, TN34 years old
$3.8M
COST PREVENTED
SYMPTOM

Visible cracking with orange-brown staining, map cracking pattern

🔬 FINDING

Advanced alkali-silica reaction confirmed by petrographic thin section. Expansion gel in cracks.

INTERVENTION

Topical silane treatment, crack injection, structural monitoring program installed

Structure rehabilitated — closure avoided
Post-tensioned slab showing tendon pocket cracking and water infiltration at anchorage zones
CSE-2025-008
CRITICAL

Post-Tensioned Transfer Slab

Chicago, IL11 years old
$8.4M
COST PREVENTED
SYMPTOM

Tendon pocket cracking; water infiltration at anchorage zones

🔬 FINDING

Grout voids in 6 of 24 tendon ducts. Carbonation front at 28mm — within cover of corroding anchors.

INTERVENTION

Emergency tendon bypass + re-grouting + carbonation-neutralizing treatment

Prevented partial collapse scenario
FREE RESOURCE

Concrete Distress Field Guide

24 pages. 14 distress types. Field photos, severity indicators, and when to call a specialist. Used by facility managers across 12 states.

START HERE

Get a
Diagnosis.

Tell us what you're seeing. We'll review your intake personally and respond within one business day with preliminary observations and a path forward. No pricing, no commitment — just a clear-eyed assessment of what your structure is telling you.

THIS CONSULT IS FOR
🏗
Facility Managers
Staring at a loading dock that isn't getting better on its own
📐
Structural Engineers
Who need a second opinion on a core sample or mix design
🔨
General Contractors
Two weeks from a pour who just found reactive aggregate
Drop photos here or click to browseJPG, PNG, HEIC up to 20MB
No commitment. We'll review and respond within 1 business day.
CREDENTIALS & STANDARDS
ASTM C856ACI 318BS EN 14630ICRI CertifiedASCE MemberICC Special Inspector