What Causes Spalling
Water that penetrates the top layer of concrete, freezes, and expands lifts small flakes and pop-outs. Road salt tracked in from winter driving accelerates the process.
Surface Spalling vs Deep Deterioration
Surface scaling — losing the top 1/8 to 1/4 inch — is repairable. Deep spalling where aggregate is loose or the slab crumbles under a hammer means the concrete itself has failed and coating won't fix it.
How We Resurface a Spalled Floor
- Diamond-grind the entire surface flat
- Patch pop-outs with a fast-set polymer mortar
- Feather-fill low areas so the coating sits level
- Install a flake or full-broadcast system to hide texture variation
When Replacement Is Better
If more than roughly 25% of the slab has active spalling or the concrete flakes off with hand pressure, resurfacing puts good money over a failing substrate. Replacement is the honest answer.