Common Structural Defects Found During Building Safety Assessments
A Building Safety Assessment under the Building Safety Act 2022 requires a thorough review of a building’s structure to ensure it remains safe for residents. For high-rise residential buildings (HRBs), those over 18 metres or seven storeys with at least two residential units, the Principal Accountable Person (PAP) must provide a Structural Report as part of the Safety Case.
During these inspections, structural engineers often discover issues that, if left unmanaged, could affect stability, safety or long-term durability. Understanding the most common defects helps owners and managers act early, avoiding costly emergency works and ensuring compliance with the Building Safety Regulator (BSR).
- Concrete Spalling and Reinforcement Corrosion
Spalling occurs when concrete cracks or flakes due to moisture penetration and corrosion of the steel reinforcement inside. Over time, rusting steel expands, causing the concrete cover to break away and reducing the load-bearing capacity of beams, columns and slabs.
High-rise towers built from reinforced concrete, particularly those from the mid-20th century, are vulnerable if waterproofing or maintenance has been neglected.
- Balconies and Projecting Slabs Deterioration
Cantilevered balconies and projecting concrete slabs are highly exposed to the weather. Over time, water ingress can corrode the reinforcement, weaken connections and cause cracking or localised failure. Balconies may also suffer from thermal movement and poor original detailing, making them a frequent concern during safety assessments.
- Large Panel System (LPS) Weaknesses
Some 1960s–1970s tower blocks were built using Large Panel Systems, precast concrete panels tied together on site. Historic failures such as Ronan Point showed that poor joint connections can lead to disproportionate collapse after a local failure or explosion. Modern assessments check panel connections, anchors and diaphragm action to confirm robustness.
- Steel Frame Corrosion
Exposed or poorly protected steel frames can suffer from rusting, especially where water ingress has occurred. Corroded members lose section thickness, reducing strength and potentially compromising fire protection coatings.
- Differential Settlement or Foundation Movement
Older high-rises built on variable ground can experience settlement, leading to cracks in walls, uneven floors and in some cases, structural instability. While minor settlement is common, ongoing or uneven movement can threaten the building’s load path and needs investigation.
Why These Defects Matter
Each of these issues can reduce a building’s structural robustness, the ability to withstand fire, accidental impact or local failure without progressive collapse. The Building Safety Act requires PAPs to show that such risks are identified and managed. Early detection through a professional structural inspection and risk assessment saves cost, improves safety and satisfies the BSR’s “suitable and sufficient” standard.
How We Can Help
At Structures Made Easy, our chartered structural engineers carry out detailed Building Safety Assessments and produce BSR-ready structural reports. We identify critical defects early, explain the level of risk, and recommend practical remediation or monitoring, helping you stay compliant and keep residents safe.
- Competence/chartered sign-off.
- Proven HRB experience.
- Fast turnaround.
- Portfolio pricing.
- BSR-ready reporting format.
Why choose us?
With over 3000 successfully completed projects to date, we have consistently proven ourselves to be a leader in the industry. From design cross check procedures to quality control measures, we will ensure your project is completed to your exact specifications.
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STEP 1
Get a quote. Refer to enquiry form or email or speak to engineer
STEP 2
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