Concrete corrosion, also known as concrete cancer, is a major structural challenge facing buildings and infrastructure in Australia. The importance of addressing this issue cannot be understated, as it leads to rapid deterioration, safety concerns and exorbitant repairs. Here at SiGeo Concrete, we offer comprehensive concrete cancer and corrosion investigation services by combining advanced non-invasive testing with expert insights. Our team has the skill and experience to assess, diagnose and monitor corrosion activity. Our goal is to prevent small issues from becoming structural failures while helping property owners make informed, cost-effective decisions.
What is Concrete Cancer?
Concrete cancer, also known as corrosion, occurs when the steel reinforcement (rebar) embedded within concrete experiences corrosion caused by moisture, carbonation, environmental exposure or chlorides. The corrosion inevitably leads to the expansion of the rebar, resulting in cracking, delamination and a complete breakdown of the concrete structure. Contact SiGeo Concrete to assess whether your building is degrading due to concrete cancer.
Corrosion Testing in Concrete Structures
Purpose
The first and most important step during the concrete cancer repair process is effective diagnosis. The primary purpose of this corrosion testing is to detect corrosion activity and understand the environmental or chemical conditions that are causing the rebar to deteriorate. This is especially important in coastal, industrial or high-humidity environments where chloride ingress or carbonation is common.
Methods and Technology
Our concrete cancer repair methods are non-destructive and minimally invasive, so that corrosion can be detected without any visible damage to the building. This includes:
- Half-cell potential testing: This ASTM C876-compliant method identifies zones of active corrosion by measuring electrical potentials across the concrete surface.
- Carbonation testing: Using phenolphthalein indicators, we identify the depth to which the concrete’s alkalinity has been compromised—an essential factor in rebar corrosion.
- Chloride ion profiling: We sample core materials and perform laboratory chloride content analysis to assess salt contamination.
- Surface electrical resistivity: High-resistivity zones indicate low ionic mobility and durability, while low resistivity can signal conditions favourable to corrosion.
- Cover depth measurements: We ensure rebar is properly embedded and protected, as shallow cover is a leading cause of corrosion.
Benefits
- Early detection significantly reduces the cost of concrete cancer repairs
- Enables asset managers to implement proactive protection strategies such as surface coatings, cathodic protection or sealants.
- Provides detailed data to inform remediation planning and extend asset service life.
Corrosion Risk Evaluation and Severity Assessment
Purpose
Understanding the relationship between concrete and corrosion involves gaining a clear and technically sound understanding of the severity of the corrosion and its highest-risk areas, enabling us to provide efficient and long-lasting concrete cancer repairs. This detailed assessment takes into account the severity of environmental exposure to the structure, material properties and the extent of damage detected through testing.
Methods and Technology
- Linear Polarisation Resistance (LPR): Measures corrosion rates directly, helping estimate the lifespan of reinforcement.
- Mapping of corrosion potential fields: This helps visualise the spatial distribution of corrosion activity across a slab or structure.
- Environmental monitoring: Ambient temperature, relative humidity and presence of aggressive agents are recorded for correlation with corrosion progression.
- Moisture content testing: Wet concrete promotes ionic movement, and high moisture content accelerates corrosion. That’s why understanding the relationships between concrete and corrosion is key.
Benefits
- Accurate risk profiling across the entire structure.
- Enables targeted repair, rather than full-scale replacement.
- Supports budgeting and lifecycle cost planning.
- Ultrasonic Diagnosis of Delamination and Risk of Spalling
Ultrasonic Diagnosis of Delamination and Risk of Spalling
Purpose
Concrete delamination is the term used to refer to layers of concrete separating internally and surface spalling, which are among the most visible symptoms of concrete cancer. Ultrasonic testing is a non-destructive and highly accurate way to locate these defects before they become major hazards.
Methods and Technology
- Ultrasonic Pulse Velocity (UPV): Determines internal consistency and detects voids, honeycombing and weak zones in concrete.
- Tomographic imaging: Creates layered 3D maps of concrete elements to visualise internal damage or disbondment between concrete and rebar.
- Impact echo and acoustic resonance: Complementary methods used to verify ultrasonic data and identify laminar cracking.
Benefits
- Prevents sudden spalling, which is dangerous in high-traffic or overhead structures.
- Improves repair accuracy by pinpointing exact defect locations.
- Saves money by avoiding unnecessary demolition or exploratory core drilling.
- Structural Health Monitoring with Corrosion Monitoring
Contact SiGeo Concrete for a detailed chat about concrete corrosion maintenance in Victoria.
Structural Health Monitoring with Corrosion Monitoring
Purpose
Corrosion in reinforced concrete is a progressive issue that requires continuous and regular structural health monitoring. This is essential for large structures like bridges, tunnels and commercial buildings. Structural health monitoring enables project managers to track corrosion in real time and take timely action.
Methods and Technology
- Embedded corrosion sensors: Installed in new construction or retrofitted into existing structures, these sensors measure parameters such as corrosion current, pH and chloride concentration.
- Wireless monitoring systems: Remote data collection enables ongoing oversight without the need for physical site inspections.
- Digital dashboards: Visualise data trends over time, alert engineers when thresholds are exceeded and integrate with Building Management Systems (BMS) or asset planning platforms.
Benefits
- Enables condition-based maintenance, saving on unnecessary repairs.
- Minimises unexpected downtime or asset failure.
- Supports certification and compliance reporting with accurate, time-stamped records.
Real-World Applications
SiGeo Concrete is proud to serve a wide range of clients across Victoria, including:
- High-rise buildings: Diagnosing and repairing façade spalling or balcony cancer.
- Infrastructure assets: Monitoring corrosion in overpasses, culverts and tunnels.
- Industrial sites: Assessing floor slabs, tanks and silos for chloride damage.
- Strata and property managers: Providing actionable defect reports for insurance claims or owner planning.
The Importance of Addressing Concrete Cancer
Concrete cancer is more than just an aesthetic problem. Over time, it weakens structural elements, negatively impacts safety and renders entire buildings to become non-compliant with Australian Standards such as AS 3600. Cracked or spalling concrete may also allow water to penetrate deeper into the structure, accelerating corrosion in what is truly a vicious cycle.
Early detection and expert diagnosis are the key to breaking that cycle. At SiGeo, our structural engineers and certified technicians have years of experience delivering reliable results with minimal disruption to operations or occupancy.
Trusted Partner For Long-Term Structural Reliability
SiGeo is an industry leader in concrete testing, NDT (non-destructive testing) and subsurface investigation services across Victoria. Our corrosion and concrete cancer assessments are guided by compliance with:
- ASTM C876 (Half-cell potential)
- ASTM C876-22 (Chloride and carbonation testing)
- EN 1504-9 (Protection and repair of concrete structures)
- AS 5100 (Bridge design) and AS 3600 (Concrete structures)
Our comprehensive range of services includes diagnostic surveys, ongoing monitoring as well as consulting for repair planning. We provide a complete suite of services designed to help you understand, manage and mitigate corrosion risk. Contact us today for a deeper understanding of our advanced equipment and industry certifications.
Advanced Treatment of Corrosion In Reinforced Concrete
Looking for the answer to the question, ‘What is concrete cancer?’ With proactive corrosion monitoring and analysis, SiGeo Concrete enables you to address the symptoms and improve the structural integrity of a commercial building, heritage site or large-scale infrastructural asset. Contact us today for world-class concrete treatment and maintenance in Victoria.