The Problem:

The homeowner in Commack, NY contacted Zavza Seal after noticing visible deterioration around a garage lally column and cracking throughout the concrete garage floor. The existing steel column showed signs of structural failure, raising concerns about proper load support from above. In addition, sections of the garage slab were cracked, spalling, and weakened due to age, moisture exposure, and prior stress.

Without proper repair, the compromised lally column could have led to uneven load distribution, sagging, or further structural damage. The cracked garage floor also presented long term durability issues and potential moisture intrusion through the slab.

Our team was asked to evaluate the structural integrity of the garage and provide a permanent solution that addressed both the vertical support system and the damaged concrete floor.

The Solution:

Zavza Seal developed a comprehensive repair plan focused on restoring structural stability and reinforcing the garage floor using high strength materials and proven installation methods.

Garage Lally Column Replacement:

To ensure safety and precision, our team followed a step by step structural process:

• Installed temporary structural supports to safely carry the load during replacement
• Cut the existing concrete slab using diamond blades
• Removed and properly disposed of the damaged lally column
• Excavated the area to create space for a new reinforced footing
• Constructed a 16 inch by 16 inch by 16 inch footing on well compacted soil
• Installed a steel base plate within the footing
• Added a #4 rebar cage to enhance footing strength
• Poured fiber reinforced concrete to increase PSI and durability
• Leveled the new concrete flush with the existing garage slab
• Allowed proper curing time before returning to install the new 4 inch diameter concrete filled steel column
• Installed the new steel column and removed all temporary supports
• Cleaned the work area and left the garage broom clean

This process ensured the new column was properly supported from the ground up and capable of carrying long term structural loads.

Garage Floor Concrete Repair and Waterproofing:

After completing the column installation, our team addressed the damaged garage floor:

• Scarified deteriorated concrete to remove loose and compromised material
• Repaired damaged sections using 6,500 PSI mortar for strength and bonding
• Applied two coats of 6,000 PSI waterproofing cement for added durability and moisture resistance

For structural cracks, we used the appropriate repair method based on crack depth and width:

Method 1 Structural Stitching:

• Cut deep slots perpendicular across the crack every 12 inches
• Filled slots with structural epoxy
• Installed non corrosive carbon fiber stitches capable of handling up to 6,500 pounds each
• Applied a final coat of 6,000 PSI waterproofing cement

Method 2 Epoxy Injection:

• Injected structural epoxy deep into the crack cavity
• Finished with a 6,000 PSI waterproofing cement coating

These repairs restored the slab’s integrity while helping prevent future cracking and moisture intrusion.

The Result:

The garage in Commack, NY now has a fully supported structural column installed on a reinforced footing, along with a restored and waterproofed concrete floor. The repairs improved load transfer, strengthened the slab, and extended the lifespan of the garage structure.

Most importantly, the homeowner gained peace of mind knowing their garage is structurally sound, safe, and built to withstand long term use.

Why This Matters?

Lally column failures and concrete floor cracks are common in older garages across Long Island. Addressing these issues early with professional structural repair helps prevent costly damage, improves safety, and protects property value.

Zavza Seal specializes in permanent structural and concrete solutions designed for real world conditions in New York homes.