Older homes often develop structural problems as wood framing ages. In this Floral Park, NY project, the homeowner became concerned about a large central wood beam that showed signs of deterioration and cracking.
After a detailed inspection, Zavza Seal developed a solution to restore the damaged beam and provide additional structural support for long-term stability.
Problem
The home’s central wood beam had visible cracks along both sides and the bottom. Over time, aging, moisture exposure, and normal structural movement had weakened the beam.
The homeowner was concerned that the cracks could continue to grow and affect the beam’s ability to support the structure properly. In addition, the existing support system needed strengthening to help distribute the load more effectively.
Without repairs, the beam could continue to deteriorate, leading to larger structural issues in the future.
Solution
Our team designed a complete structural reinforcement plan that addressed both the damaged beam and the support system beneath it.
Restoring the Damaged Wood Beam
The first step was to repair and strengthen the existing wood beam.
We treated the deteriorated and cracked sections using a GreenGuard-certified wood restoration product designed to penetrate damaged wood, restore strength, and seal the surface against future moisture exposure. This process helped reinforce weakened areas while preventing the existing cracks from expanding further.
Installing Structural Steel Plates
To further strengthen the beam, we installed heavy-duty steel plates on both sides of the wood beam.
Before installation, electrical conduits attached to the beam were carefully detached and moved out of the work area. We then secured custom hot-rolled steel plates to each side of the beam, creating a sandwich-style reinforcement system.
The plates were fastened using galvanized threaded bolts and structural epoxy, creating a strong connection between the steel and wood. This reinforcement significantly increased the beam’s structural capacity and long-term durability.
Installing New Concrete-Filled Steel Columns
To provide additional support, we installed new concrete-filled steel columns beneath the beam.
Each column location required careful preparation. Temporary supports were installed to safely carry the structural load while the work was performed. Our team then cut and removed sections of the concrete floor and excavated for new reinforced footings.
Each footing was constructed with compacted soil, a steel base plate, a reinforced rebar cage, and high-strength 4,000 PSI concrete mixed with fiber reinforcement for added durability.
Once the footings had cured, the new steel columns were installed and secured in place. The columns were factory-primed with rust-inhibiting paint to help protect them from corrosion and ensure long-term performance.
After installation, all temporary supports were removed and the structure was carefully checked to confirm proper load transfer.
Result
After the project was completed, the central beam was significantly stronger and better protected against future deterioration. The repaired wood sections were stabilized, and the steel plate reinforcement added substantial structural support along the length of the beam.
The newly installed concrete-filled steel columns and reinforced footings now help distribute the weight of the structure more effectively. The homeowner gained peace of mind knowing that the home’s support system has been strengthened and built to provide reliable performance for years to come.
Why This Solution Works
This repair combined wood restoration, steel reinforcement, and new structural supports into one complete system. By addressing both the damaged beam and the load-bearing supports beneath it, the project provided a long-term solution rather than a temporary fix.
The combination of restored wood, structural steel plates, reinforced footings, and concrete-filled steel columns helps protect the home’s structural integrity while reducing the risk of future movement and damage.