Structural
RepairSPALLED · CORRODED · LOAD-RESTORING
A concrete rebuild system for sections damaged by spalling, corrosion or impact. Loose, carbonated concrete is cut back, exposed reinforcement is cleaned and protected, and the profile is rebuilt with high-strength polymer-modified repair mortars — restoring the original section, cover and load capacity.
What is Structural Repair?
Structural repair is the rebuilding of concrete that has lost section through spalling, reinforcement corrosion, impact or deterioration. Unsound, carbonated concrete is cut back to a solid base, corroded steel is cleaned and treated with an anti-corrosion coat, and the missing profile is rebuilt with high-strength, polymer-modified repair mortars bonded to the parent concrete. The result restores the original section, the cover protecting the steel and the load-carrying capacity of the member. It is delivered as a POLYZEN Applied System, surveyed and installed by trained applicators.
How the Repair Is Built
A damaged section is rebuilt from the steel outward — cut back, the reinforcement protected, then the profile restored in bonded high-strength mortar. Tap any stage to see its role.
Cure & Protective Finish
The rebuilt section is cured and, where exposure demands, finished with a protective or anti-carbonation coating to slow future deterioration and match the surrounding surface. System values: Per TDS.
Delivered as a POLYZEN Applied System
This repair is delivered as a POLYZEN Applied System — surveyed, specified and installed turnkey by trained applicators using high-strength repair mortars, anti-corrosion rebar treatment and bonding agents. The mortar grade, build and protection strategy are selected per member, exposure and structural assessment.
Repair the Cause, Not Just the Surface
Most concrete damage starts at the steel — corrosion expands the rebar and bursts the cover. Skimming over it traps the problem and it returns. POLYZEN's method removes all unsound concrete, treats the reinforcement at the source, then rebuilds with a bonded high-strength mortar so the section and its protective cover are genuinely restored. Mortar grade and protection are matched to each member. Performance is confirmed on the product TDS.
Mortar grade, build thickness, rebar treatment and protective finish are specified per member, exposure and structural assessment. Where load capacity is in question, a structural engineer's input is recommended. POLYZEN confirms finished values on the product TDS and does not publish fabricated figures.
The Application Process
Inspect & Assess
Identify the cause and extent of damage, then define repair scope, mortar grade and protection strategy.
Cut Back & Clean
Break out unsound concrete to a solid base, expose and clean corroded reinforcement to bright steel.
Treat & Rebuild
Anti-corrosion coat and bonding bridge, then rebuild the profile in high-strength repair mortar.
Finish & Handover
Cure, protective coat where needed, final inspection and written warranty.
System Specifications
| Property | Detail |
|---|---|
| System Type | Structural Concrete Repair (Section Rebuild) |
| Delivery | POLYZEN Applied System (turnkey) |
| Method | Cut-back · rebar treatment · mortar rebuild |
| Repair Material | High-strength polymer-modified repair mortar |
| Rebar Protection | Anti-corrosion coat + bonding bridge |
| Application | Beams · Columns · Slabs · Soffits · Facades |
| Outcome | Section · cover · load capacity restored |
| Coverage / Values | Per Product TDS |
Ideal Applications
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Applied & Warranted
Every POLYZEN structural repair is carried out by trained applicators and handed over after a final inspection and a written system warranty. Warranty terms are confirmed per member, exposure and structural assessment.
Frequently Asked Questions
Related Grouting & Repair Systems
Rebuild Every Damaged Section.
Get a site survey, damage assessment and quote for structural concrete repair.