{"id":215112,"date":"2026-07-24T10:27:49","date_gmt":"2026-07-24T14:27:49","guid":{"rendered":"https:\/\/www.constructionspecifier.com\/?p=215112"},"modified":"2026-07-28T10:28:16","modified_gmt":"2026-07-28T14:28:16","slug":"the-dark-side-of-the-moon-dangers-of-concealed-spalls","status":"publish","type":"post","link":"https:\/\/www.constructionspecifier.com\/the-dark-side-of-the-moon-dangers-of-concealed-spalls\/","title":{"rendered":"The dark side of the moon: Dangers of concealed spalls"},"content":{"rendered":"<p>As discussed in the article \u201c<a href=\"https:\/\/www.constructionspecifier.com\/bad-moon-rising\/\">Failures: Bad Moon Rising<\/a>\u201d in the August 2024 issue of <em>The Construction Specifier<\/em>, a common failure of stone masonry veneer is the formation of \u201chalf-moon\u201d spalls at kerf cuts that receive the lateral anchorage of the stone panel. When this failure occurs on the panel\u2019s exposed face, it is readily identified and repaired, mitigating the loss of lateral support and the associated hazard of falling material. However, depending on panel geometry and anchor placement, similar spalls may occur on the concealed rear face with little or no visible evidence. This hidden damage can result in a loss of lateral support for the stone panel, which can become dislodged from the wall. Two recent projects illustrate this.<\/p>\n<p>The first project is an institutional building in a high-seismic-risk area. Limestone masonry units on the facade are anchored to the structure with stainless-steel strap anchors set into kerf cuts. A recent repair project addressed several units that had developed incipient half-moon spalls on the exposed face (Figure 1). Removal of the damaged units provided access to the veneer cavity and adjacent panels, revealing significant cracks and spalls on the concealed back faces of multiple units (Figure 2). The repair scope was subsequently expanded to include the replacement of numerous cracked panels.<\/p>\n<figure id=\"attachment_215114\" aria-describedby=\"caption-attachment-215114\" style=\"width: 800px\" class=\"wp-caption aligncenter\"><a href=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-1-2.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-215114\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-1-2.jpg\" alt=\"\" width=\"800\" height=\"533\" srcset=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-1-2.jpg 800w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-1-2-300x200.jpg 300w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-1-2-500x333.jpg 500w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-1-2-768x512.jpg 768w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><\/a><figcaption id=\"caption-attachment-215114\" class=\"wp-caption-text\"><strong>Figure 1:<\/strong> Incipient spalls on the exposed face were identified visually, and the units were marked out for replacement.<\/figcaption><\/figure>\n<figure id=\"attachment_215115\" aria-describedby=\"caption-attachment-215115\" style=\"width: 800px\" class=\"wp-caption aligncenter\"><a href=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-2-2.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-215115\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-2-2.jpg\" alt=\"\" width=\"800\" height=\"533\" srcset=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-2-2.jpg 800w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-2-2-300x200.jpg 300w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-2-2-500x333.jpg 500w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-2-2-768x512.jpg 768w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><\/a><figcaption id=\"caption-attachment-215115\" class=\"wp-caption-text\"><strong>Figure 2:<\/strong> After removal of the units with damage on the exposed face, adjacent units were visible within the wall cavity, and numerous cracks and spalls were discovered on the back face (arrow).<\/figcaption><\/figure>\n<p>The second project involves a historic structure clad with large marble panels, only 40 mm (1.5 in.) thick but exceeding 1 m<sup>2<\/sup> (12 sf) in area. Aside from intermittent surface corrosion staining, the cladding appeared intact. During mortar removal in preparation for repointing, two panels were destabilized and fell to the ground. Investigation revealed that the original lateral anchorage consisted of 20 mm (0.75 in.) diameter steel pins engaging the panels\u2019 top back edges. Corrosion of these anchors had created half-moon spalls on the back face of many panels, compromising their lateral support (Figure 3). Until the panels fell, corrosion staining was the only visible indication of failure. The repair scope was expanded to include shoring followed by remedial pinning of the entire wall.<\/p>\n<figure id=\"attachment_215116\" aria-describedby=\"caption-attachment-215116\" style=\"width: 800px\" class=\"wp-caption aligncenter\"><a href=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-3-1.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-215116\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-3-1.jpg\" alt=\"\" width=\"800\" height=\"533\" srcset=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-3-1.jpg 800w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-3-1-300x200.jpg 300w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-3-1-500x333.jpg 500w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/07\/Figure-3-1-768x512.jpg 768w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><\/a><figcaption id=\"caption-attachment-215116\" class=\"wp-caption-text\">Figure 3: Removal of a few representative marble cladding panels revealed that many panels had spalled on the reverse face at the locations of pin anchors (circle).<\/figcaption><\/figure>\n<p>When assessing a facade incorporating metal lateral anchorage, a visual survey alone will not identify reverse-face spalls. Depending on the assembly, additional investigation may include metal detectors to locate anchors, hammer sounding to identify delaminated or loose panels, ground-penetrating radar to detect voids, removal of joint materials to inspect panel edges, borescopes to view concealed cavities, or selective panel removal to observe concealed conditions. If the investigation is conducted during the preparation of construction documents and before starting repairs, the scope of required work can be better understood.<\/p>\n<h2>Author<\/h2>\n<p><a href=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/05\/Itle_Headshot-e1779991019207.gif\"><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-214565 size-thumbnail\" src=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/05\/Itle_Headshot-e1779991019207-150x150.gif\" alt=\"\" width=\"150\" height=\"150\" srcset=\"https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/05\/Itle_Headshot-e1779991019207-150x150.gif 150w, https:\/\/www.constructionspecifier.com\/wp-content\/uploads\/2026\/05\/Itle_Headshot-e1779991019207-300x300.gif 300w\" sizes=\"auto, (max-width: 150px) 100vw, 150px\" \/><\/a><\/p>\n<p>Kenneth Itle, AIA, is an architect and associate principal with Wiss, Janney, Elstner Associates, Inc. (WJE) in Northbrook, Ill., specializing in historic preservation. He can be reached at kitle@wje.com.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>When assessing a facade incorporating metal lateral anchorage, a visual survey alone will not identify reverse-face spalls. Find out how to conduct a thorough investigation.<\/p>\n","protected":false},"author":35591,"featured_media":215114,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[9,24],"tags":[80],"class_list":["post-215112","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-columns","category-failures","tag-failures-2","entry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.8 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>The dark side of the moon: Dangers of concealed spalls - The Construction Specifier<\/title>\n<meta name=\"description\" content=\"See how hidden spall damage can result in a loss of lateral support for the stone panel, which can become dislodged from the wall.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" 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