How to level garage door opening to external paver height?

Question

Looking to replace roller garage door with a timber frame cladded in ekodeck to our pool area.  However the existing exterior paver height is currently higher than then garage floor level.

Given that the timber frame bottom plate would need to higher than the exterior level (for water protection) I'll need to raise the existing concrete base level to at least paver level.

What is the recommended way to create a new solid base level to which I could then attach any timber bottom plate for the frame.

JacobZ · Answer

Don't hesitate to reach out if you have any questions along the way @Darran99.

I am more than happy to help.

Jacob

Darran99 · Answer

Liking the idea of the SikaQuick Repair Mortar. Link reads as most appropriate as within the max depth of 75mm (only 60mm).  Thanks for reminder of the pine framing to keep mortar on place whilst setting. Should be an easy preparation step to the framework construction.

JacobZ · Answer

Hi @Darran99,

Welcome to the Bunnings Workshop community, it is fantastic to have you with us.

I'd say the best thing you can use is a repair mortar such as this SikaQuick 2500 (au) Rapid Hardening Repair Mortar, but considering it is relatively thick, you should be able to get away with using a standard concrete mix.

You'll want to start by giving the existing concrete a good clean to ensure there is no dirt or contaminants. I'd suggest giving it a good scrub with some warm soapy water and a Long Handle Scrub Brush to remove any dirt or contaminants, then allowing it to fully dry.

You can then apply BondCrete, mixed 4-parts water to 1-part Bondcrete, which is a bonding coat mix, and then brush it onto the concrete.

If you'd like to go a bit extra to ensure everything is good and strong, you could then drill some holes in the concrete and install some short lengths of Reinforcing Dowel, and tie them to a length of reinforcing bar or trench mesh depending on how wide you are planning on building this up. This would mechanically tie the new concrete or mortar to the old and reinforce it, which is not 100% necessary, but certainly worth considering.

You should then build a basic form on the back edge of the concrete, using something like pine framing, and attach it to the concrete with masonry anchors. This is there to ensure the concrete or mortar stay in place.

I'd then suggest you place some joint filler foam on the back edge of the pavers. This will allow for slight expansion and contraction without damaging or shifting the pavers.

You can then use your concrete or mortar to fill the void between the pavers and your form, and smooth it out using a trowel.

When it comes time to attach the bottom plate to the slab, I'd suggest you use anchors that are long enough to penetrate through the new concrete or mortar and penetrate into the existing slab below.

Let me know what you think and if you have further questions, please don't hesitate to ask.

Jacob