Concrete and masonry are among the most durable building materials available — when they are properly designed, mixed, placed, and cured. When any of these steps goes wrong, the resulting defects can compromise the structural integrity of foundations, walls, floors, and parking structures. In Nebraska, where the climate subjects these materials to severe freeze-thaw cycling, temperature extremes, and moisture exposure, the margin for error is particularly thin.

Types of Concrete Defects

Cracking

Concrete cracks. This is not controversial — some degree of cracking is inherent in the material. The question in a construction defect analysis is whether the cracking exceeds what is acceptable and whether it affects the structural performance or serviceability of the element.

Plastic shrinkage cracks occur while the concrete is still curing, typically due to rapid moisture loss at the surface. They are generally cosmetic. Drying shrinkage cracks develop over time as concrete loses moisture and contracts. Control joints are designed to manage this cracking by creating predetermined weak points. When control joints are improperly spaced or omitted, drying shrinkage cracks appear in random, uncontrolled patterns.

Structural cracks are the most serious. These result from loading that exceeds the element's capacity, settlement of supporting soils, or inadequate reinforcement. Horizontal cracks in basement walls often indicate lateral soil pressure exceeding the wall's design, while diagonal cracks from corners of openings suggest stress concentration at those points. For more, see Foundation Defects in Nebraska New Construction.

Spalling

Spalling — the flaking, chipping, or delamination of concrete surfaces — results from several mechanisms. The most common in Nebraska is freeze-thaw damage. When water penetrates concrete and freezes, it expands approximately nine percent in volume. Repeated freeze-thaw cycles progressively break down the concrete surface.

Proper air entrainment in the concrete mix creates microscopic voids that accommodate this expansion. When air entrainment is inadequate — due to improper mix design, over-vibration during placement, or the use of deicing chemicals on surfaces not designed to resist them — spalling is the predictable consequence.

Spalling can also result from corrosion of embedded reinforcing steel. As steel rusts, it expands, creating internal pressure that fractures the surrounding concrete. This is particularly common in parking structures, bridge decks, and any concrete element exposed to moisture and chlorides.

Scaling

Scaling is the loss of the surface mortar layer, exposing the coarse aggregate beneath. It is closely related to freeze-thaw damage and is especially common on flatwork — sidewalks, driveways, and garage floors — that was finished improperly or exposed to deicing chemicals before achieving adequate strength.

Honeycombing

Honeycombing occurs when concrete is not adequately consolidated during placement, leaving voids where paste did not fully surround the aggregate. The resulting rough, porous surface is both structurally weaker than properly placed concrete and more permeable to moisture, accelerating other deterioration mechanisms.

Common Masonry Defects

Masonry construction — brick, block, and stone — involves its own set of potential defects.

Mortar joint failures. Improperly mixed mortar, inadequate tooling of joints, or the use of mortar that is not compatible with the masonry units can lead to premature joint deterioration. Once mortar joints fail, water enters the wall system, and the damage accelerates.

Efflorescence and staining. The white, crystalline deposits that appear on masonry surfaces indicate water moving through the wall and dissolving soluble salts. While efflorescence itself is primarily cosmetic, it signals a moisture management problem that may cause more serious damage over time.

Brick veneer tie failures. In Nebraska's common cavity wall construction, brick veneer is connected to the structural backup wall with metal ties. Improperly installed, missing, or corroded ties can lead to bulging or collapse of the veneer — a serious safety hazard.

Inadequate weep systems. Cavity walls require weep holes at the base to drain moisture that enters the cavity. Missing or blocked weeps trap water, promoting deterioration of the backup wall, insulation, and structural framing.

Evaluating Concrete and Masonry Defects

Determining whether a concrete or masonry condition constitutes a construction defect — as opposed to normal aging or owner-caused damage — requires expert analysis. Common evaluation methods include visual inspection and crack mapping to document the extent and pattern of distress, core sampling to test compressive strength and air content of in-place concrete, petrographic analysis to examine the concrete microstructure and identify mix design problems, cover meter surveys to determine the depth and spacing of reinforcing steel, and moisture testing to evaluate the permeability of the material.

Industry standards from organizations like the American Concrete Institute (ACI) and The Masonry Society (TMS) provide benchmarks for evaluating whether concrete and masonry conditions meet acceptable quality levels.

Nebraska Climate Considerations

Nebraska's climate is particularly harsh on concrete and masonry. The state experiences over 100 freeze-thaw cycles per year in many locations, with temperature swings that can exceed 50 degrees in a single day during transitional seasons. These conditions demand strict adherence to proper mix design, air entrainment, curing practices, and protective coatings — and they reveal the consequences of shortcuts more quickly than milder climates.

Claims arising from concrete and masonry defects are subject to Nebraska's standard construction defect framework, including the four-year statute of limitations from discovery and ten-year statute of repose under Neb. Rev. Stat. Section 25-223. Because deterioration is often progressive, early documentation of conditions is essential — both for preserving the evidence and for establishing the timeline of the claim.

Concrete and masonry defects are often expensive to repair, particularly in structural applications. Understanding the cause, scope, and appropriate remedy requires qualified expert analysis and forms the foundation of any successful claim.