At Zavza Seal LLC, we specialize in delivering structural repairs, foundation restoration, and waterproofing solutions for commercial and residential properties throughout Long Island. This case study highlights a complex project our team completed in South Setauket, NY, where we repaired multiple structural cracks and replaced damaged steel plates in a tunnel ceiling to restore the property’s stability and prevent future water damage.
This project demonstrates our expertise in advanced concrete repair techniques and our commitment to long-term, high-quality results.
The Problem: Multiple Structural Cracks and Damaged Tunnel Ceiling
The property owner contacted Zavza Seal LLC after discovering numerous vertical structural cracks and a compromised tunnel concrete ceiling with corroded steel plates.
The identified issues included:
- Multiple vertical cracks of varying lengths in foundation walls
- A hairline crack allowing water seepage
- Damaged steel plates in the tunnel ceiling compromising structural integrity
- Water infiltration through cracks and ceiling gaps
The client required a contractor who could resolve all issues in a single, comprehensive repair plan to restore structural strength, waterproof the affected areas, and ensure long-term performance.
The Solution: Professional Concrete and Steel Repair by Zavza Seal LLC
Our team performed a full site assessment and developed a detailed scope of work to address each issue. The solution combined advanced structural reinforcement, epoxy injection, waterproofing, and steel replacement.
Repairing the Hairline Crack
We began by addressing a hairline crack approximately 5 linear feet long.
- We used diamond blades to grind both sides of the crack to expose bare concrete.
- A layer of 7,000 PSI waterproofing cement was applied, extending two inches on each side of the crack.
- We embedded 4.5 oz reinforced fiberglass mesh into the wet cement to add strength.
- A second layer of waterproofing cement was applied to complete the repair.
Repairing Multiple Vertical Structural Cracks
We repaired several vertical cracks ranging from 5 to 12 linear feet in length. For each crack, we followed a robust process:
- We cut into the concrete to create deep perpendicular slots every 12 inches along the entire crack.
- The slots were filled with structural epoxy for reinforcement.
- Non-corrosive carbon stitches were installed into the epoxy-filled slots to provide additional structural strength, with each stitch rated to support up to 6,500 pounds.
- Using diamond bits, we drilled injection ports every six inches along the cracks.
- We injected a combination of epoxy and urethane formulations to strengthen and waterproof the cracks internally.
- A layer of 7,000 PSI waterproofing cement was applied over the entire repaired area, extending two inches on each side.
- Reinforced fiberglass mesh was embedded into the wet cement for durability.
- We applied a final layer of waterproofing cement, followed by construction adhesives and sealants as needed.
Replacing Damaged Tunnel Ceiling Steel Plates
The tunnel ceiling required the replacement of two damaged support steel plates measuring approximately seven linear feet across.
- We installed temporary shoring using hydraulic jacks and adjustable steel posts to hold the concrete ceiling securely in place during the repair.
- Using diamond blades, we cut into the concrete around the steel plates and removed the corroded plates with carbide blades.
- The area was waterproofed by sandwiching reinforced fiberglass mesh between two layers of Basecrete waterproofing cement, extending at least three inches beyond the edges.
- Waterproofing adhesives and sealants were applied to ensure complete moisture protection.
- We fabricated and installed two new steel plates, securely anchored to the substrate core with structural epoxy and galvanized structural steel bolts.
- Once the plates were set, we removed the temporary shoring to complete the repair.
The Result: Restored Strength and Waterproofing
The client was extremely satisfied with the comprehensive repairs. The foundation walls were fully stabilized, the cracks were waterproofed and reinforced, and the tunnel ceiling regained its structural integrity with new steel plates securely installed.
By addressing both structural and waterproofing needs, our team delivered a solution that improved the property’s safety, durability, and value. This project is a testament to our ability to handle complex repair challenges with precision and expertise.
Why Choose Zavza Seal LLC?
This South Setauket, NY project exemplifies the Zavza Seal difference:
- Expertise in advanced structural reinforcement and crack repair
- Use of premium materials like 7,000 PSI cement and carbon stitches
- Professional workmanship backed by proven techniques
- Commitment to customer satisfaction and long-term results
For foundation repair, waterproofing, and structural restoration across Long Island, Zavza Seal LLC is the trusted choice for homeowners and commercial property managers alike.
Contact Us
If you notice cracks, water seepage, or structural weaknesses in your property, contact Zavza Seal LLC for a professional inspection and repair plan.
📞 Call us at (631) 980-1800
🌐 Visit us online at www.zavzaseal.com to schedule your consultation.
We proudly serve clients in South Setauket, NY, and throughout Long Island with expert structural and waterproofing services you can count on.