Corroding structural steel is one of the most common drivers of facade and parking structure failure identified in FISP and Local Law 126 inspections. As embedded steel rusts, it expands, a process known as rust jacking, cracking the surrounding masonry and concrete from the inside out and turning a hidden problem into a visible, and often urgent, one.

What Causes Steel Corrosion in Buildings

• Chronic water infiltration through failed sealant, flashing, or waterproofing reaching embedded steel.
• Chloride exposure from de-icing salts in parking structures and coastal environments.
• Failed or missing protective coatings on exposed structural elements.
• Age and deferred maintenance on original steel lintels, shelf angles, and connections.

The Danger of Rust Jacking

• Expanding rust can generate enough pressure to crack brick, stone, and concrete surrounding the steel.
• Cracked masonry above windows and doors is frequently a lintel corrosion problem, not a masonry problem alone.
• Left unaddressed, rust jacking accelerates, eventually compromising the load path the steel was designed to carry.

Our Repair Process

• Removing surrounding masonry or concrete to expose the full extent of corroded steel.
• Cleaning steel back to sound metal and assessing remaining section thickness.
• Repairing or replacing sections that no longer meet structural requirements.
• Applying rust-inhibitive primers and protective coatings before rebuilding.
• Rebuilding the surrounding masonry or concrete correctly so the problem does not recur.

Where We Find Corroding Steel

Lintels, shelf angles, embedded connections, parking structure columns and beams, and facade support steel are the most common locations we address across commercial, residential, and institutional properties throughout the Tri-State area.