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PolyLevel Installation Project: Front Porch Concrete Steps Location: Nolensville, TN

Challenge:

 

Jane of Nolensville, TN called us to set up an appointment after she noticed that the front porch concrete steps were separating from the rest of her house. Upon inspection, our specialist noted that although the stairs were still connected to the porch at the bottom, they were over an inch away already at the top and bending farther outwards by the day.

 

Jane wanted us to find a solution which would not only leave a seamless cosmetic repair but would also reduce the trip hazard and make the stairs safer for her and her family to use.

Solution:

 

After examining the situation and considering the options, our specialist decided that our PolyLevel product would be the best solution to fix the stairs. PolyLevel is a powerful concrete lifting solution that is injected into concrete in a liquid form then expands to a foam-like substance within seconds to lift concrete back to its original state. PolyLevel is also manufactured from recycled materials making it environmentally friendly.

 

The specialist called for about 18 pounds of PolyLevel for this project. After lifting the stairs, any cracks in the concrete all the way down the sidewalk were to be filled in with NexusPro Joint Sealant, which not only provides a sleek look, but also seals cracks from exposure to water and other elements which could damage the concrete or affect the soil underneath.

 

The crew faced adversity immediately as the solid concrete steps were too heavy for PolyLevel alone to lift. They decided that considering the weight of the steps, it would be much easier to get the PolyLevel where it needed to go if they jacked up the steps manually.

 

The new plan called for an angle iron bolted to each side of the steps. The crew then took jacks, placed them under the angle iron, and jacked the steps up to their original state by hand. Lifting the steps manually then opened up a huge gap underneath where PolyLevel could be injected until it held the stairs where they needed to be.

 

After the steps had been jacked up to the desired height, the crew drilled several dime sized holes in the bottom step and sidewalk in front of the steps to be used for PolyLevel injection.

 

They hit their second speed bump when they started injecting, as the PolyLevel still wasn’t getting where it needed to be to hold the steps in place. After some investigation, the crew realized that this was because the concrete extended about 2 feet into the ground, and had a hollow center filled with gravel. This meant that the holes drilled wouldn’t be deep enough to get the PolyLevel below the slab and lift it up, they were just injecting into the gravel filled void inside the steps.

 

It took some brain storming, but eventually our guys came up with a solution that would work. They had to drill a slightly bigger hole with a longer drill that could extend past the 2 feet of concrete, then stuff the hole with a red rubber tube that would extend through the void and come out on the other side underneath the steps.

 

The PolyLevel, when injected through the tube, would then be able to travel through the steps and come out on the other side, having the desired lifting effect. Finally, something went the crew’s way as this idea worked perfectly. After several injections in different spots, the jacks were removed and sure enough the stairs stayed put!

 

All that was left was for the crew to seal up any cracks and port holes using Nexus Pro Joint Sealant and crack filler. After all the setbacks, about 58 pounds of PolyLevel was needed compared to the 18 quoted by the specialist.

 

The determination and resourcefulness of our production crew assured that no obstacle would be too big for them to complete the job. That’s what we call redefining the industry!

 

 

Project Summary Specialist: Mike Lattero Team Leader: Joe Alletto Materials Used: PolyLevel (approx. 58 lbs.), NexusPro Joint Sealant