Town/Neighborhood: Calverton
Borough/County: Suffolk County
Construction Type: Residential
Category: Foundation Repair, Foundation Wall Restoration

Problem:

During a basement excavation aimed at increasing ceiling height, the General Contractor inadvertently compromised the foundation’s stability. Multiple sections of the foundation walls completely collapsed, and the remaining walls were structurally unsound, requiring immediate underpinning to prevent further collapse and safeguard the home.

Additionally, we identified a significant vertical structural crack approximately 8 linear feet in length, as well as a deteriorated joint where the foundation wall meets the concrete slab. Both areas exhibited improper waterproofing and were vulnerable to water intrusion and structural degradation.

Solution:

Work Area A: Collapsed Section of the Damaged Beyond Repair Wall (approx. 22 linear feet)

We began by carefully demolishing and disposing of the damaged foundation wall sections. The demolition process was executed in phases with proper shoring in place to prevent the vertical collapse of the 1st and 2nd floors and to stabilize the adjacent concrete walkway.

Once demolition was completed, we installed a new 24-inch deep by 18-inch wide reinforced concrete footing. This footing installation was also phased to maintain constant structural support. On this newly installed footing, we built a waterproof cinder block foundation wall. Due to the lack of exterior access below grade, we utilized a proprietary waterproofing method to ensure a fully sealed exterior surface.

Work Area B: Entire Perimeter Excluding Work Area A (approx. 94 linear feet)

For the remaining perimeter foundation, we excavated to a depth sufficient to install concrete formwork safely. The soil was compacted firmly, and #5 rebar was installed every 15 inches, driven 5 feet into the soil to act as structural piles.

Continuous horizontal reinforcement with #5 rebars were installed throughout the entire length of the footing. A new reinforced concrete footing measuring 24 inches deep by 18 inches wide was formed and poured in phases to prevent undermining the house’s stability. We completed this section using 4,000 PSI concrete to ensure long-term strength.

Subject Area A: Vertical Structural Crack (Approx. 8 Linear Feet)

To address the vertical crack, we chased and ground the area using a diamond blade to eliminate dirt, mildew, and defective materials, exposing the original bare concrete for proper adhesion.

We drilled into the crack where necessary and injected urethane and epoxy formulations to restore the structural integrity and create a watertight seal. After the injection process, we applied a layer of Basecrete waterproofing cement, followed by the installation of reinforced 4.5 oz Basecrete brand fiberglass mesh. A second coat of Basecrete waterproofing cement was applied to complete the repair.

Subject Area B: Joint of the Foundation Wall and Concrete Slab (Approx. 10 Linear Feet)

We ground the joint area using diamond blades to remove old waterproofing paint, mildew, and loose materials, exposing the bare concrete foundation for a clean application.

Next, we installed a 4.5 oz reinforced fiberglass mesh, sandwiched between two layers of Basecrete waterproofing cement to provide a seamless, durable waterproofing barrier that would protect against future water intrusion.

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Conclusion:

This foundation repair project in Calverton, NY, highlights Zavza Seal’s expertise in executing complex structural restorations under challenging conditions. From emergency underpinning of collapsed walls to precise crack injections and advanced waterproofing applications, our team delivered a comprehensive solution that restored both structural integrity and water resistance to the property.

Facing foundation wall cracks, collapses, or water infiltration issues in Suffolk County or throughout New York? Zavza Seal specializes in foundation repair, underpinning, and waterproofing services designed to protect your home for years to come. Contact us today for a free consultation and expert evaluation.