Concrete Ceiling/Rusty Rebar W/pics

Sir Mixalot

I'm re-doing a popcorn ceiling @ an oceanfront hotel. The ceiling is concrete, and a big chuck of it has fallen out. It was just a crack, but it sounded hollow when i was scrapping around it. So I started picking @ it and it was loose. When I pulled out the loose peices, I could see that the rebar was rusted. Do any of you know what the best way to repair this would be? I will be priming and respraying popcorn over the entire ceiling after it is repaired. Thanks. Paul

neolitic

That isn't just cosmetic.
This is something that
should be passed up the
food chain for someone
to evaluate the cause.
Just my thoughts.
Good luck.

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billy d

Hi paul this happened a lot to concrete structures built in the 60s +70s in the UK,got so bad that they even gave it a name "Concrete cancer".The original thought was some sort of chemical reaction going on.They discovered it was inadequate spaces on the rebar not keeping the bar a min of 30mm (ie1and 1/4")away from the edge of the concrete moisture coursing the steel to rust.I never seen any major repair work going on so they must have found an answer to it.Sorry but what it was I don`t know maybe another Brit on the site know`s,Sorry mate.

neolitic

Mixalot,
Thing is when the iron rusts
it expands, that is what popped
the topping to begin with.
Unless that problem is cured
it'll just keep expanding and.....

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billy d

Neolitic I can see where your coming from but the only way to stop oxidizing steel is to gun it out.I didn`t try to give an answer and I dont`t think you did.This could just be a cracking bar from over the wall that some body forgot to tie and got pushed out of place.Might be, could be,we don`t know and I agree with you 100%.It`s not our place to try and give this guy an answer.there are people out there getting paid good money to come up with the answer`s let them do it.