Concrete cancer is one of the most destructive—and preventable—threats to Australia’s built environment. Left unchecked, it compromises structural integrity, endangers public safety, and drains asset value. But when addressed by a specialist contractor with the right systems, expertise, and values, concrete cancer repair doesn’t just fix a problem—it extends the life of your asset for decades.
At Perfect Remediation and Refurbishment, we’ve spent over 12 years mastering the science and craft of concrete cancer repair across commercial towers, industrial plants, heritage landmarks, and critical infrastructure throughout NSW and beyond.
Our motto—“Extending the life of your assets”—isn’t marketing fluff. It’s a promise backed by ISO-certified processes, Tier 1 project experience, and a team that believes “our best should never come at the cost of our integrity.” (Our Approach )
In this detailed guide, we’ll walk you through our 7-step concrete cancer repair methodology—from initial diagnosis to final certification—showcasing how we deliver safe, compliant, and durable outcomes on every project, big or small.
Why Concrete Cancer Repair Demands a Specialist Approach
Before diving into the process, it’s vital to understand why generic “concrete patching” won’t cut it.
Concrete cancer is not surface-level damage. It’s a progressive electrochemical decay caused when:
- Water and oxygen penetrate cracks or porous concrete
- Embedded steel reinforcement (rebar) begins to rust
- Rust expands up to 7x its original volume, cracking the concrete from within
- More cracks = more moisture = accelerated corrosion
This cycle can’t be stopped with a quick render or paint job. Effective concrete cancer repair requires:
- Accurate diagnosis of corrosion extent
- Full removal of unsound material
- Rebar treatment or replacement
- Structural-grade repair mortars
- Protective waterproofing systems
- Compliance with Australian Standards (AS 3600, AS 5100)
At Perfect Remediation, we don’t just treat symptoms—we eliminate root causes. And we do it with zero compromise on safety, quality, or sustainability.
Step 1: Comprehensive Site Assessment & Diagnostics
Goal: Accurately map the extent and severity of concrete cancer.
We never guess. We measure, test, and document.
Our diagnostic toolkit includes:
- Half-Cell Potential Testing (per ASTM C876): Identifies active corrosion zones by measuring electrical potential of rebar. Readings below -350mV signal high risk.
- Cover Meter Surveys: Determines concrete cover depth over rebar—critical for assessing vulnerability.
- Ultrasonic Pulse Velocity (UPV): Detects internal delamination and voids before spalling occurs.
- Visual & Moisture Inspections: Rust stains, hollow sounds, and damp patches are documented with geo-tagged photos.
Real Example: At a residential property in Kingsford, UPV testing revealed hidden delamination beneath seemingly intact balcony soffits—preventing a potential collapse. (Project: Carbon Fibre Balcony Repairs )
This data feeds into a Remediation Method Statement (RMS)—approved by engineers and aligned with client risk profiles.
Step 2: Safety Setup & Containment
Goal: Protect people, property, and the environment.
Concrete cancer repair generates dust, debris, and falling hazards—especially in occupied buildings. Our OH&S-first approach includes:
- Edge protection and debris netting (AS 4546 compliant)
- Dust suppression systems (wet cutting, HEPA vacuums)
- Silica control measures under new Australian legislation (Read our silica guide )
- Site induction and signage for all personnel
As an AS/NZS 4801-certified company, safety isn’t optional—it’s engineered into every workflow. (Certifications )
“We believe a happy, safe workforce delivers better outcomes.”
— Outstanding Employer of Choice Award
Step 3: Precision Removal of Unsound Concrete
Goal: Eliminate all deteriorated material without damaging sound structure.
This is where equipment quality matters. We use only trusted, low-vibration tools:
- Hilti and Brokk robotic demolition units
- Husqvarna wall saws and grinders
- Tyrolit diamond blades for clean cuts
Our operators are trained to:
- Stop 10–15mm short of rebar to avoid nicking steel
- Remove concrete in layers to preserve structural geometry
- Segregate waste for recycling
With three full-service workshops and mobile technicians on call 25/8, downtime is “almost irrelevant” in our vocabulary. (Our Equipment Standards )
All removed material is tracked via digital reporting, supporting our 60%+ waste recycling target. (Environmental Commitment )
Step 4: Rebar Treatment & Reinforcement
Goal: Restore or enhance the steel’s corrosion resistance.
Exposed rebar is never left untreated. Our process:
- Mechanical Cleaning: Abrasive blasting to SA 2.5 (near-white metal) standard using Tyrolit or Hilti systems.
- Corrosion Inhibitor Application: Penetrating sealers that neutralise chlorides and slow future oxidation.
- Anti-Rust Primer: Epoxy-based coatings for long-term protection.
In severe cases, we supplement or replace rebar using advanced systems:
- Carbon Fibre Reinforcement: Lightweight, non-corrosive wraps that add tensile strength without increasing dead load. Ideal for balconies and heritage structures. (Service: Cathodic Protection & Carbon Fibre )
- Stainless Steel Rebar: For high-risk zones like coastal or chemical environments
Case Study: At Kingsford, carbon fibre laminates restored structural capacity to cancer-ridden balconies—without demolition. (View Project )
Step 5: Structural Repair & Re-profiling
Goal: Restore geometry, strength, and durability with high-performance materials.
We never use generic bag mixes. Every repair mortar is selected for:
- Shrinkage compensation (to prevent new cracks)
- High early strength (for rapid return-to-service)
- Compatibility with parent concrete
Common systems we deploy:
- Polymer-modified cementitious mortars (for vertical/overhead repairs)
- Flowable micro-concrete (for deep voids)
- Shotcrete stabilisation (for large-scale or complex geometries) (Shotcrete Guide )
Application is done in layers, with proper curing and moisture control—ensuring bond strength exceeds 2.0 MPa (per AS 3600).
Example: At Sofitel Sydney Wentworth, we repaired lobby columns and slabs using precision re-profiling—blending seamlessly with original finishes. (Project Details )
Step 6: Waterproofing & Protective Coatings
Goal: Seal the repair and prevent recurrence.
This is the most critical step—and the one most contractors skip.
At Perfect Remediation, every concrete cancer repair includes a tailored protective system:
| Balconies / Roofs | Liquid-applied elastomeric membrane + drainage enhancement |
| Car Parks | Cementitious crystalline waterproofing + anti-carbonation coating |
| Coastal Zones | Marine-grade epoxy + UV-resistant topcoat |
| Industrial Floors | Chemical-resistant polyurethane system |
We apply concrete protective coatings that resist:
- Chlorides and carbonation
- UV degradation
- Abrasion and impact
“Concrete surfaces can experience a lot of wear and tear… protective coatings are essential.”
— Concrete Protective Coatings Blog
At Palm Beach, marine-grade coatings now shield repaired columns from salt-laden air. (Project: Concrete Repairs Palm Beach )
Step 7: Quality Assurance, Documentation & Handover
Goal: Deliver certified, warrantied, and fully compliant outcomes.
We don’t just walk away. We verify, document, and guarantee:
- Post-repair testing: Adhesion pull-tests, moisture scans, visual QA
- Digital reporting: Time-stamped photos, material batch numbers, technician logs
- Compliance certificates: Aligned with ISO 9001 (Quality) and ISO 14001 (Environmental) standards (Certifications )
- Warranty: Typically 5–10 years on materials and workmanship
Clients receive a Project Completion Dossier—ideal for strata records, insurance, or future audits.
Real-World Applications: Concrete Cancer Repair in Action
Artarmon – SBS Studios Car Park
Challenge: Widespread spalling across 5 levels due to decades of water ingress.
Solution: Phased remediation with dust containment, rebar replacement, and protective coatings.
Outcome: 25+ years of extended service life with minimal tenant disruption.
View Full Project
Kingsford Residential Balconies
Challenge: Advanced concrete cancer threatening structural integrity.
Solution: Carbon fibre strengthening + marine-grade waterproofing.
Outcome: Full safety restored—no demolition required.
Project Details
Albright & Wilson Chemical Plant (Wetherill Park)
Challenge: Acid exposure accelerating rebar corrosion in bund walls.
Solution: Chemical-resistant repair mortars + epoxy lining system.
Outcome: Compliance with hazardous materials regulations.
Industrial Remediation Project
These projects reflect our ability to adapt our 7-step process to any sector—commercial, industrial, residential, or heritage. (Explore Sectors )
Why Our Approach Delivers Superior Results
Technical Excellence
- Team includes engineers, PMs, estimators, and certified applicators
- Experience on Westpac Kent Street, Town Hall Station, Muswellbrook Water Plant
- Use of Tier 1 equipment: Volvo, Brokk, Hilti, Husqvarna (Our Approach )
Safety & Compliance
- AS/NZS 4801 certified
- Full licences and insurance (Licences & Insurance )
- Strict adherence to silica and WHS laws
Sustainability Leadership
- 60%+ waste recycling rate
- Winner: Excellence in Sustainability (NSWBC)
- Low-emission equipment and processes (Sustainability Commitment )
Client-Centric Flexibility
- 12-hour response in Sydney
- Phased works for occupied buildings
- Transparent pricing and communication (FAQ )
“As PMs ourselves, we understand the pain of being let down… We’re committed to responsible, flexible personnel.”
— Our Team Ethos
FAQs: Your Concrete Cancer Repair Questions Answered
Q: How long does concrete cancer repair take?
A: A single balcony: 3–5 days. A multi-level car park: 6–12 weeks. We provide rapid mobilisation—within 12 hours in Sydney.
Q: Can you work in occupied buildings?
A: Yes. We specialise in low-disruption, after-hours, and phased works with full containment.
Q: Do you offer warranties?
A: Yes—typically 5–10 years, depending on the system and environment.
Q: Is concrete cancer repair covered by insurance?
A: Usually not for gradual deterioration. But a professional repair report can support future claims or compliance.
Q: How much does it cost?
A: Costs vary by scope, access, and materials. We provide transparent, no-obligation quotes. (Contact Us )
Prevention: How to Avoid Future Concrete Cancer
While repair is essential, prevention is smarter:
- Annual inspections of high-risk areas (balconies, car parks, façades)
- Prompt crack sealing with flexible sealants
- Reapply protective coatings every 5–10 years
- Ensure proper drainage away from concrete surfaces
- Engage early contractor involvement (ECI) in new builds (ECI Service )
“We go above, go beyond, do more, and be better.”
— Our Commitment
Final Thoughts: Trust the Specialists
Concrete cancer repair is not a commodity service. It’s a precision engineering discipline that demands:
- Technical expertise
- Certified processes
- Quality equipment
- Ethical integrity
At Perfect Remediation and Refurbishment, we bring all four—plus 12+ years of Tier 1 experience—to every project.
Whether you’re managing a Sydney apartment block, a NSW council bridge, or an industrial facility in Wetherill Park, our 7-step methodology ensures your asset is restored, protected, and future-proofed.
Need a professional concrete cancer repair assessment?
Contact us today for a transparent quote and expert advice.
Email: info@perfectremediation.com.au
Phone: 02 7912 3054 | 1300 737 332
Services: Concrete Repairs & Remediation
Perfect Remediation and Refurbishment acknowledges the Aboriginal and Torres Strait Isander people as Traditional Custodians of the country on which we live and work. We pay our respects to the Traditional Custodians and Elders past, present and future, and honour their connection to the land and ongoing contribution to society.