Restoring In-Slab Air Ducts After Severe Ground Water Damage - Lake Zurich, Illinois – Spring/Summer 2025
When a homeowner in Lake Zurich, Illinois, noticed water inside their air ducts and severe rusting around the registers, they reached out to Trenchless Innovations for help. What followed was a step-by-step process to identify the source of the problem, eliminate it, and fully restore the damaged in-slab air duct system.
Hidden Issues Revealed by Camera Inspection
A video inspection gave us a clear look inside the in-slab ducts and allowed us to take precise measurements for restoration. What we uncovered was severe:
- Significant amounts of standing water inside the air ducts
- Advanced rust and corrosion around the register areas
- A clear indication that groundwater intrusion was compromising the entire duct system
Identifying and Solving the Water Intrusion
To prevent future water from entering the ductwork, the exterior grading and drainage around the home needed to be addressed. The following recommendations were made:
- Extend downspouts at least 5 feet away from the foundation
- Keep gutters clear of debris to prevent overflow
- Create a swale (a shallow channel) to direct water away from the home
However, due to the severity of the groundwater intrusion, additional action was necessary.
The Solution: Install a Sump Pit and Pump System
This sump system was designed to create a new low point in the home, allowing water to collect in the pit and be pumped out—before it could reach the air ducts.
Immediate results: As soon as the sump pump was plugged in, water began flowing from the discharge pipe, effectively relieving water pressure that had been building under the home.
Step One: Water Problem Resolved
With the sump system in place and drainage improvements made, the home was finally protected against future groundwater infiltration.
Step Two: Air Duct Restoration Completed
With the water issue resolved, the team scheduled a three-step air duct restoration project to repair and encapsulate the in-slab duct system:
1. Duct Cleaning & Mortar Coating
- Removed all debris, sand, and stone that had entered the ducts
- Applied a special mortar coating to reinforce and restore the structural integrity of the rusted metal ducts
2. Spray Lining – First Coat
- Applied a specialized spray lining to encapsulate the entire duct system
- Used live video feed to ensure full and even coverage
3. Final Spray Lining – Second Coat
- A second coat of lining was applied for extra durability and long-term protection
- Again, camera inspection ensured complete restoration
Restored, Protected, and Good As New
Thanks to a thorough inspection process, professional waterproofing recommendations, and state-of-the-art restoration methods, the homeowner in Lake Zurich can now enjoy clean, dry, and safe in-slab air ducts.
This case is a prime example of how early detection and a comprehensive restoration plan can fully resolve even the most severe in-slab duct issues caused by groundwater intrusion.
