Concrete Spalling & Structural Balcony Repairs in Northern Beaches Strata Buildings

Concrete spalling is one of the most common — and serious — structural issues affecting multi-residential buildingsacross the Northern Beaches of Sydney. Left untreated, it can compromise balcony safety, reduce property value, and lead to costly long-term damage.

At Plan A Builders, we’re experienced in diagnosing and repairing spalled concrete, particularly on older apartment blocks in coastal suburbs like Dee Why, Manly, Narrabeen, and Collaroy. We specialise in structural repairs for balconies — delivering safe, compliant, and long-lasting outcomes for strata and unit owners.

🧱 What Is Concrete Spalling?

Concrete spalling (also known as "concrete cancer") occurs when the steel reinforcement (rebar) inside concrete begins to corrode. As steel rusts, it expands, causing the concrete around it to crack, flake, or even fall away.

Common signs of concrete spalling on balconies include:

• Cracked or flaking concrete

• Rust stains on balcony slabs or soffits

• Loose or crumbling concrete edges

• Exposed steel reinforcement

• Water leakage into units below

This is especially common on Northern Beaches buildings, where sea air accelerates corrosion.

⚠️ Why Spalling Is a Structural Risk

Spalling isn’t just cosmetic. It often indicates deeper structural problems such as:

• Loss of load-bearing capacity in slabs

• Corroded steel reinforcement

• Water penetration weakening internal structure

• Dangerous loose concrete falling from above

These issues can compromise balcony safety and put residents at risk.

🛠️ Our Structural Repair Process

At Plan A Builders, we take a comprehensive approach to concrete spalling and structural balcony repairs:

1. Site Inspection & Engineering ReviewWe assess the full extent of damage and engage structural engineers when needed.

2. Concrete Removal & Rust TreatmentDamaged concrete is carefully removed, and rusted rebar is cleaned or replaced.

3. Structural ReinstatementWe apply structural-grade repair mortars to restore the concrete’s integrity.

4. Waterproofing & FinishingWe install membranes and sealants to prevent future water damage — with options for new tiling, render, or coatings.

5. Compliance Reporting & Council LiaisonIf required, we handle NSW Planning Portal submissions and provide all documentation for strata records.

📍 Common Projects Across the Northern Beaches

We've completed spalling repairs and structural restorations for apartment buildings across:

• Narrabeen

• Dee Why

• Manly

• Freshwater

• Mona Vale

• Palm Beach

• Brookvale

• Queenscliff

Each project is customised depending on the severity of the damage and the building’s age and construction style.

🔍 Do You Need Approval for Structural Repairs?

Yes — in most cases, structural repairs or changes to balcony appearance require:

• A Complying Development Certificate (CDC)

• Or a Development Application (DA) via the NSW Planning Portal

We’ll guide you through this and liaise directly with your certifier or Northern Beaches Council, saving you time and paperwork.

🧱 Case Study: Concrete Spalling Repairs in Collaroy

In 2024, we repaired multiple balconies on a 10-unit complex in Collaroy suffering from severe spalling and water damage. Our team:

• Removed unsafe concrete from all balconies

• Treated rusted reinforcement and rebuilt slab edges

• Applied new waterproofing and compliant balustrades

• Worked alongside a structural engineer and private certifier

• Delivered the project on time and with minimal disruption to residents

The end result: structurally sound, waterproof balconies with full documentation for strata records.

📞 Book a Balcony Condition Assessment

If you're a strata manager or unit owner concerned about concrete spalling, don’t wait until the damage becomes dangerous or expensive.

📲 Call Craig Chamberlin on 0429 030 851📧 craig@planabuilders.com.au🌐 www.planabuilders.com.au

Plan A Builders – Experts in concrete spalling and structural balcony repairs for Northern Beaches strata buildings.