Project Overview
A homeowner in Huntington, NY contacted Zavza Seal after noticing large structural cracks in a retaining wall located next to the garage. The cracks had grown over time and raised concerns about the stability of the wall. Because retaining walls are constantly exposed to soil pressure, water, and seasonal movement, structural cracking can become a serious issue if left untreated.
After a detailed inspection, our team developed a repair plan designed not only to seal the cracks but also to restore the wall’s structural integrity and help prevent future movement.
The Problem
The retaining wall had a major structural crack measuring approximately 92 inches in length, along with a secondary corner crack measuring approximately 28 inches. The cracks showed signs of movement and had weakened the wall’s ability to resist pressure from the surrounding soil.
The homeowner was concerned that the damage would continue to worsen and eventually require complete wall replacement. In addition to the visible cracking, the wall was showing signs of stress near the garage where additional support was needed.
Without proper repair, water infiltration and continued expansion could have caused further structural deterioration.
Our Solution
The Zavza Seal team began by preparing the damaged areas to ensure the repair materials could properly bond to the concrete.
Using diamond blades, we carefully opened and chased each crack to create a clean repair cavity. The concrete surrounding the cracks was then ground several inches in all directions to remove loose material and expose solid concrete.
To restore structural strength, we cut deep slots perpendicular to the cracks at regular intervals. These slots were filled with structural epoxy and reinforced with non-corrosive carbon fiber stitches. Each stitch is capable of providing substantial reinforcement and can resist thousands of pounds of force, helping restore tensile strength and prevent future crack expansion.
Once the structural repairs were completed, we applied a layer of high-strength 6,000 PSI waterproofing cement over the repaired areas. Reinforced fiber mesh was embedded into the first coat while still wet, creating additional strength and durability. A second coat of waterproofing cement was then applied to fully encapsulate the repair system.
Additional Structural Support
Because the retaining wall was located adjacent to the garage and carrying significant loads, additional reinforcement was recommended.
Our team excavated selected areas around the wall and installed steel support components designed to improve long-term stability. We drilled through the concrete and embedded a 10-foot steel channel into the wall structure. The channel was connected to steel plates and anchored with steel rods extending into stable ground.
This support system helps transfer pressure away from the damaged section of wall and provides additional resistance against future movement.
The Result
The retaining wall was successfully stabilized, reinforced, and waterproofed. The structural cracks were repaired using a combination of epoxy injection, carbon fiber stitching, and high-strength cementitious coatings. The additional steel support system provided another layer of protection and long-term structural stability.
The homeowner now has confidence that the retaining wall is secure and capable of withstanding the pressures that originally caused the damage.
Why Carbon Fiber Stitching Works
Carbon fiber stitching has become one of the most effective methods for repairing structural concrete cracks. Unlike surface patching alone, stitching reconnects separated sections of concrete and helps restore the wall’s ability to resist movement and loading forces.
When combined with structural epoxy and waterproofing materials, this system creates a durable repair that addresses both the cause and the symptoms of structural cracking.