The Problem
A property owner in Bay Shore, NY needed a level surface for the installation of steel plates along a 100-foot-long by 10-foot-wide concrete slab.
The challenge was that the existing concrete slab was uneven, sloped, and had multiple elevation changes throughout the area. Because of these inconsistencies, installing the steel plates directly on the existing surface would not provide the level support required.
In addition to the uneven surface, there were cracks and damaged sections within the existing concrete that needed to be addressed before any new work could be performed.
The owner needed a long-term solution that would create a smooth, level surface while maintaining strength, durability, and safety.
Our Solution
After evaluating the site, our team determined that the best solution was to install a new reinforced concrete overlay on top of the existing slab.
To ensure the new surface remained strong and consistent throughout the entire area, the new concrete would be placed at least one inch above the highest point of the existing slab. This approach allowed us to create a uniform elevation and provide the level surface needed for the future steel plate installation.
Before placing the new concrete, our team thoroughly prepared the existing slab.
We began by vacuuming and power washing the area to remove dirt, debris, and loose materials. Next, we inspected the slab for cracks and damaged sections. Any cracks were opened using diamond blades to remove deteriorated material and expose sound concrete beneath.
To strengthen the connection between the old and new concrete, we installed a matrix of steel anchors throughout the slab. A bonding agent was then applied across the entire surface to improve adhesion.
For additional reinforcement, we installed steel wire mesh and secured it to the anchors using steel wire ties.
Our scope of work included:
- Thorough cleaning and surface preparation
- Crack inspection and repair preparation
- Power washing the existing slab
- Installation of L-shaped concrete formwork
- Installation of steel anchors throughout the slab
- Application of a concrete bonding agent
- Installation of reinforcing steel wire mesh
- Placement of 4,000 PSI concrete
- Level finishing of the new surface
- Removal of formwork after curing
- Feathering edges into the existing slab to eliminate tripping hazards
In areas where a smooth transition was needed, we used specialized repair materials and reinforced fiber mesh to help create durable feathered edges that blended seamlessly with the surrounding concrete.
The Result
The project successfully transformed an uneven and sloped concrete slab into a level, reinforced surface ready for the owner’s future steel plate installation.
The new concrete overlay provided consistent elevation throughout the entire area while improving both safety and durability. By feathering the edges into the existing slab, our team eliminated potential trip hazards and created a smooth transition between old and new surfaces.
The property owner now has a strong, level concrete foundation designed to support long-term use and future improvements.
Why Surface Preparation Matters for Concrete Overlays?
Concrete overlays perform best when they are installed over a properly prepared surface. Cleaning, crack preparation, mechanical bonding, and reinforcement all play important roles in helping the new concrete bond to the existing slab.
Without proper preparation, overlays can be more susceptible to cracking, separation, or premature failure. Reinforcement and bonding systems help improve durability and extend the life of the finished concrete surface.
Need Concrete Slab Leveling in Bay Shore, NY?
If you have an uneven concrete slab, settling concrete, or a surface that needs to be leveled for future construction, Zavza Seal can provide professional concrete overlay and slab restoration solutions that deliver long-lasting performance.