How Our Melbourne Team Removed Outdated Stucco Using Grinders and Dust Control Methods

Old stucco can be more than just an eyesore, it can cause serious moisture damage, cracking, and hidden structural problems. That’s exactly what one homeowner in Melbourne, FL was dealing with. Their outdated stucco siding was trapping moisture against the wood framing and showing signs of mold beneath the surface. Our team stepped in with a clear plan for stucco removal, using industrial grinders and professional-grade dust control to do it safely and efficiently.

​If you’re dealing with cracking walls, peeling paint, or bubbling surfaces, this breakdown of our real project might help you figure out your next step.

Why Stucco Removal Is Sometimes the Only Option

Stucco is durable, but not forever. Over time, Melbourne’s humid weather can cause moisture to get trapped behind the layers. If your exterior walls show any of these signs, removal might be essential:

• Cracking or chipping across the surface
• Dark spots, bubbling, or signs of mold
• Soft or hollow-sounding spots when tapped
• Warped or rotting wood framing underneath
  
  

In this project near Wickham Park in Melbourne, our team found that the original stucco siding was applied incorrectly over wood batten without the proper moisture barrier. The result? Trapped water, cracking cement, and early signs of rot.

When patching won’t address the underlying issues, removing stucco completely becomes the only responsible step.

Our Step-by-Step Process for Removing Stucco in Melbourne

Stucco removal is a messy job, especially when it’s over wood or brick. But with the right tools and dust control setup, it can be done cleanly and safely.
​
Here’s how our Melbourne team handled it:
​

1. Prepping the Site

• We sealed off windows and doors with plastic wrap.
• Nearby landscaping was covered.
• Negative air pressure machines were installed to control dust in real-time.
  ​

2. Grinder-Based Removal

We used high-powered grinders with diamond blades to break through all the stucco layers, down to the original building surface. Grinding helps avoid uncontrolled chipping, which can damage the structure or send dust flying.
​

3. Dust Control

We connected each grinder to HEPA vacuums. This significantly reduced airborne particles, protecting our crew and the homeowners. It also helped us contain mess across the work area, especially important near homes in Lake Washington or Palm Bay Rd areas where dense residential spacing increases risk.
​

4. Inspecting for Damage

Once the stucco was gone, we examined the wood framing and installed temporary sheathing over compromised areas. In this project, we found early mold growth and minor rot behind the southern wall, something that would have been missed without full removal.
​

What Comes After Stucco Removal? Replacing It Right

The next step after stucco removal is choosing the right replacement material. In Melbourne, many homeowners are now switching from traditional stucco to options like:
​

• Fiber cement siding: Durable and low-maintenance
• Vinyl siding: Affordable and water-resistant
• Board and batten: Aesthetic upgrade for beachside homes
• Brick veneer: Long-lasting and classic
  
  

In our project, the homeowner chose fiber cement siding, which resists moisture and heat better than traditional stucco. We made sure to install it with a proper barrier, addressing previous mistakes like poor sealing and lack of airflow.

What Factors Affect the Cost of Stucco Removal?

The cost of stucco removal varies depending on several factors:
​

• Size of the project
• Condition of the existing walls
• What’s underneath the stucco (wood vs. brick)
• Waste disposal needs
• Labor and safety requirements (like dust control)
  
  

In Melbourne, most stucco removal projects range between $8 to $16 per square foot. That includes removal, inspection, basic repairs, and waste haul-off.

Tips:

• Always account for unexpected underlying issues.
• Don’t forget to factor in the cost of new siding or painting.
• Get quotes from a licensed contractor familiar with Melbourne’s coastal weather risks.
  
  

Is Dust Really That Big of a Deal?

Yes, especially during stucco removal. Fine particles can spread fast, linger in the air, and settle inside vents or windows. Without dust control:
​

• You’ll risk health issues from inhaling silica
• Clean-up takes twice as long
• The value of your property can drop if you damage interior surfaces
  
  

Our team uses commercial-grade vacuums, physical barriers, and negative air machines to trap and filter dust before it spreads. This step alone can create a huge difference in safety and job satisfaction.

Choosing the Right Contractor for Your Melbourne Stucco Removal

Not all removal jobs are the same. Choose a contractor who:
​

• Has experience removing stucco over wood and brick
• Uses grinders with proper dust control
• Can inspect and address underlying issues
• Is licensed and insured in Florida
• Offers help with installation of new siding
  
  

Also, check if they work in your area, whether you’re near Eau Gallie, Sarno Rd, or Crane Creek. Hyper-local knowledge helps avoid mistakes and increases overall project success.

Protect Your Melbourne Home with Proper Stucco Removal

Removing old stucco isn’t just about giving your home a fresh look, it’s about protecting your structure, preventing future moisture damage, and choosing a better replacement for your Florida climate.
​
If your home in Melbourne is showing signs of cracking, mold, or stucco failure, don’t wait for bigger problems. Our team at Melbourne Stucco Repair Pros is ready to assess, remove, and rebuild with safety and value in mind.

Contact us today to schedule an inspection or check out our related blog posts on siding options and moisture control.
​

Frequently Asked Questions

How long does stucco removal take for an average home in Melbourne FL?
The stucco removal process usually takes 3 to 7 days, depending on the size of the home, thickness of the stucco, and the amount of underlying damage. Weather and access can also affect the timeline.
​
Is stucco removal necessary before installing new siding like fiber cement?
Yes. If your current stucco siding is damaged or trapping moisture, it must be removed before installing new siding such as fiber cement. Leaving compromised materials in place can cause rot, mold, and structural issues down the line.

How much does stucco removal cost in Melbourne FL?
Prices typically range from $9 to $14 per square foot, depending on the scope of the project, the condition of the underlying framing, and the type of replacement siding chosen. A professional contractor can give a more accurate quote after a site visit.

Can I remove stucco myself?
DIY stucco removal is not advisable. It requires heavy equipment, safety gear, and knowledge of dust-control methods. Without proper tools and experience, it’s easy to damage the wood, walls, and windows, or miss hidden issues like mold or framing damage.

What siding is best to install after stucco removal?
Fiber cement siding is a popular choice in Melbourne FL because it’s durable, moisture-resistant, and performs well in Florida’s coastal climate. It offers a modern look and avoids the cracking problems that come with traditional stucco.