Problem:

The homeowner in Bethpage, NY contacted Zavza Seal after noticing worsening foundation cracks and signs of structural movement along the foundation wall and footing. Several cracks indicated shifting and loss of support below grade, raising concerns about the long term stability of the home.

A full inspection revealed that portions of the foundation footing were compromised and no longer providing adequate support. Some cracks were under tensile stress while others showed signs of lateral and vertical movement. Without proper stabilization, these conditions could continue to worsen, leading to additional structural damage, water intrusion, and costly future repairs.

Because of the severity of the movement, standard surface repairs alone were not sufficient. The foundation required both structural crack repair and deep foundation stabilization using helical piles.

Solution:

Zavza Seal implemented a comprehensive structural repair plan designed to stabilize the foundation, restore load bearing capacity, and protect the foundation wall and footing from future damage.

Foundation Wall and Footing Excavation

• Excavated the affected areas to expose the entire foundation wall below grade down to the bottom of the footings at all cracked sections and helical pile locations.
  
• Thoroughly cleaned and wire brushed the exposed foundation wall and footings.
  
• Inspected the footings to identify areas requiring structural repair.
  

Structural Crack Repair Methods

Based on the type and direction of force acting on each crack, Zavza Seal used the appropriate reinforcement method to restore structural integrity.

Steel Anchor Reinforcement

• Steel brushed each crack to ensure proper bonding.
  
• Installed hot dip galvanized steel anchors every 12 inches to restore tensile strength, reestablish compression, and prevent further expansion.
  
• Filled cavities with structural mortar.
  
• Applied a layer of 6,000 PSI waterproofing cement.
  
• Embedded 4.5 oz reinforced fiberglass mesh into the cement.
  
• Applied a second layer of 6,000 PSI waterproofing cement to complete the repair.
  

Carbon Fiber Reinforcement

• Chased and ground cracks along their full length to remove damaged and foreign materials.
  
• Cut deep perpendicular slots into the concrete core every 12 inches using diamond blades.
  
• Installed carbon fiber stitches embedded in structural epoxy to add high tensile strength.
  
• Applied a layer of 6,000 PSI waterproofing cement.
  
• Installed 4.5 oz reinforced fiberglass mesh.
  
• Applied a second layer of 6,000 PSI waterproofing cement for full encapsulation.
  

Helical Pile Installation

• Installed seventeen helical piles to a minimum ultimate capacity of 15 tons.
  
• Terminated each pile with a galvanized steel bracket.
  
• Secured the steel brackets directly to the foundation footing.
  
• Attempted controlled lifting of the broken footing to reduce gaps and close cracks where possible, with movement dependent on site conditions.
  
• Backfilled all excavated areas to the original grade, sloped away from the foundation.
  
• Compacted the soil to complete the installation.
  

Result:

The foundation was successfully stabilized and reinforced, significantly reducing the risk of further movement. The combined use of helical piles, steel anchors, and carbon fiber reinforcement restored structural integrity and extended the life of the foundation.

The homeowner now has a secure and stabilized foundation system designed to withstand future soil movement and structural loads. This Bethpage property is now protected with a long term structural solution backed by proven engineering methods.