Foundation Repair & Rebar Reinforcement
Crack Sealing, Spall Patching & Wall Dowels in Toronto & the GTA
At Tornado Concrete, we restore flaking, cracked, or settling foundation walls using rebar doweling, structural grout injection, and spall patching. Our engineered solutions comply with the Ontario Building Code, ensuring long-lasting structural integrity and differential settlement repair.
Whether you have vertical cracks, horizontal bowing, or concrete delamination, our certified crew installs corrosion-resistant dowels, injects high-strength epoxy, and patches spalled areas to prevent water ingress and future deterioration.
6-Step Foundation Repair Process
- 1. Visual Inspection & Crack Mapping
- 2. Surface Prep & Concrete Cleaning
- 3. Rebar Dowel Drilling & Epoxy Anchoring
- 4. Epoxy/Polyurethane Crack Injection
- 5. Spall Repair & Structural Grout Application
- 6. Final Inspection & Protective Coating
Detailed Repair Steps
Step 1: Visual Inspection & Crack Mapping
We perform a thorough survey, document crack patterns, spalled areas, and assess wall bowing to tailor a precise repair plan.
Step 2: Surface Prep & Cleaning
Loose concrete, rust, and debris are removed via wire brushing or water blasting to expose sound substrate for optimal bonding.
Step 3: Rebar Dowel Drilling & Epoxy Anchoring
We drill holes into existing concrete, install galvanized rebar dowels, and secure them with high-strength epoxy to tie in new repair sections.
Step 4: Crack Injection
Cracks are injected with structural-grade epoxy or polyurethane to seal moisture pathways and restore concrete continuity.
Step 5: Spall Repair & Grout Application
We fill voids and spalls with polymer-modified repair mortar or non-shrink grout, matching texture and ensuring a smooth, protective surface.
Step 6: Final Inspection & Coating
After curing, we conduct a final structural inspection, then apply a breathable masonry coating to protect against moisture and UV exposure.
Premium Materials & Specialized Equipment
- Corrosion-Resistant Galvanized Rebar Dowels
- Structural Epoxy & Polyurethane Injection Resins
- Polymer-Modified Spall Repair Mortar
- Carbon Fiber Reinforcement Straps
- High-Pressure Water Blasting Units
- Hydraulic Rebar Anchoring Tools
Pricing, Timeline & Warranty
Foundation repair costs range from $100–$200 per linear foot for crack injection up to$300–$500 per linear foot for full spall and rebar dowel repairs. Typical durations:
- Crack sealing only: 1–2 days
- Spall repair & dowel anchoring: 3–5 days
- Full wall reinforcement: 5–7 days
All work is backed by a 5-year workmanship warranty and manufacturer warranty on materials.
Frequently Asked Questions
What is rebar doweling?
Rebar doweling involves drilling holes into existing concrete, inserting steel dowels, and securing them with epoxy to tie new repair material to the original structure.
Can we patch only the surface?
For minor spalls and surface cracks, patching with polymer-modified mortar is sufficient, provided the underlying concrete is sound and properly cleaned.
How long before I can paint or seal?
Most repair mortars and epoxies cure within 24–48 hours. After that, you can apply paints, sealants, or coatings as desired.
Do I need a permit?
Minor interior crack repairs generally do not require a permit. However, any work involving structural anchors or exterior excavation may need a City of Toronto building permit and engineer-approved drawings.