Ohio State University (OSU), renowned for its athletic prowess, particularly in baseball, football, and basketball, is committed to maintaining top-notch sports facilities. When administrators observed issues plaguing the indoor track at Ohio State University's French Field House due to sub-surface erosion, they recognized the urgency of addressing the problem. The indoor track, covering over 2000 square feet and constructed in 1956, had faced recurring resurfacing due to its deteriorating subsurface, compounded by its initial placement on uncompacted soil. These challenges necessitated a comprehensive solution.
One option considered was a complete excavation and replacement of the track, with an estimated cost exceeding $1 million. Seeking an alternative, OSU organized a Lunch and Learn event to connect with local engineers, where they encountered Joe Work, the owner of Mr. Level, a Cleveland-based concrete lifting company. Mr. Level's approach involved using a chemical grout made from polyurethane, known as polyjacking or deep-soil injection, and offered a unique lifetime guarantee backed by insurance. This floor leveling alternative proved to be a cost-effective way to permanently repair the track without the hefty price tag of excavation.
In collaboration with OSU, Joe Work and his team at Mr. Level engaged NCFI Geotechnical's Polyurethane Division, a trusted material supplier. Together, they devised a plan to meet the stringent requirements set by the National Collegiate Athletic Association (NCAA) for a safe and perfectly level track surface. The selected floor leveling approach involved using advanced polymer polyjacking systems, specifically Terrathane 24-010 and Strata-Fill 24-039, with laser level monitoring to ensure a precise and even surface.
While other methods like mudjacking offer quick fixes, Joe Work explained why polyjacking is a superior, long-term solution. Mudjacking may provide short-term relief but necessitates ongoing maintenance due to subsurface shifting and erosion. In contrast, polyjacking employs highly durable polyurethane compounds, offering a permanent leveling solution that doesn't require repeated applications.
The deep-soil injection process began in early May 2023, led by a dedicated team comprising staff from both Mr. Level and NCFI. This efficient crew, including pumpers, helpers, and a supervisor, completed the polyjacking work in just five days. NCFI Geotechnical provided the essential polyjacking systems, while a supervisor oversaw the process. The project's high profile required coordination and precision to ensure its success.
To stabilize the track without excavation, the team employed a multi-step deep-soil injection leveling process. Mapping the area with 5-foot grid patterns, Mr. Level's team drilled 2-inch holes into the subsurface at depths of three, six, and nine feet. Three hollow ⅝ inch rods corresponded to the appropriate depth, with Terrathane 24-010 initially filling the three-foot deep holes, followed by Strata-Fill 24-039 at six and nine-foot depths. The process demanded precision to prevent over-lifting issues, and laser levels were employed to monitor the track's lift. Personal protective equipment like gloves, boots, and eye protection were used as necessary, making the process efficient and safe. The track was ready for use in under a week.
OSU was delighted with the results achieved by Mr. Level and NCFI. They not only saved approximately $900k by avoiding full excavation but also ensured compliance with NCAA standards. Furthermore, Mr. Level's polyjacking services come with a unique lifetime guarantee backed by insurance, setting them apart from others in the industry. Joe Work and NCFI aim to spread awareness about the benefits of this method, making it a popular choice across various industries. Their commitment to quality and customer satisfaction is driving them to lead the way in solving floor leveling problems for the long term.