duraceramic grout cracking

sm1996

16 years ago

Have noticed similar posts on people who have a duraceramic floor and the grout is cracking. I too have a duraceramic floor with a recurring grout problem. The grout cracked within the first 5 months of the initial installation. The flooring contractor attempted to correct the problem by applying skimcoat of new grout over the old grout. The cracks in the old grout showed up in the "new" grout within a year or the skimcoat merely flaked flaked off. Has happened three times now. I was told by the flooring contractor that the problem must have resulted from using too much water when the grout was initally installed. They came out and removed a small section of grout around a tile--instead of being flexible like it is supposed to be, it is is hard as a rock. The floor (around 7500 sq. ft.) was laid down on various substrates: subflooring installed by the contractor, steps, and a concrete pad. Experiencing cracks on all parts. No tiles are loose, so it does not appear to be a problem with the subflooring or the adhesive.

The Congoleum rep wants to "open up" the cracks with a knife and shove new grout in the cracks and on top with another skimcoat. He seemed to indicate that they never have problems with grout cracking, but in reading other posts I find I am not alone. I do not think the rep's solution is going to solve the problem. I think the cracks are going to come right back and that the entire floor needs to have the old grout removed and new grout put down. Love the floor...hate the grout! Does anyone with knowledge on this product have any suggestions or know how other flooring contractors have attempted to correct similar problems? Thanks!

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Comments (8)

floorguy
16 years ago
An inspection by an unbiased certified inspector/consultant, would help your situation. The congo rep is there to protect his companies interest. The grout is not suppose to get "rock hard" Too much water in the clean up, does not effect the congo acrylic grout, like it would if it was portland cement mortar. If this is over a wood substrate, there my be structural movement(normal shrink & swell of wood) coming into play. Only your own hired inspection, is going to cut to the truth and come to a conclusion, with a correction avenue.

Are you sure the flooring company didn't cheap out, and use cement grout, instead of Congo's high priced acrylic grout?? Hard as a rock... Cracking?????? Sounds like cement mortar to me.
sm1996
Original Author
16 years ago
It is the high-priced acrylic grout, still have a tub of extra grout sitting in the closet! The problem is that it was over multiple substrates: wood subflooring installed by the contractor (abour 4' x 4' marked with a grid and supposedly the stuff to be used under the floor), a cement pad, and composite wood stairs. There is cracks on all three areas. And it is not limited to one particular spot, it is a universal problem for the entire installation.

How do I find an unbiased certified inspector/consultant?

Thanks for your help!
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floorguy
16 years ago
Here are a couple of places

http://www.fitscertified.org/inspector_directory_map.php

http://www.inspectortrainingservices.biz/InspectorRegistry.html
glennsfc
16 years ago
Is it the grout specified and sold by Congoleum? If it is not, then that is your problem...and that of the company that sold and installed the job
floorguy
16 years ago
She did say they have been back several times. This left over bucket may be the right stuff, but what they are trying to cover, that is the base that is actually cracking, may not be the right stuff.
glennsfc
16 years ago
You're right...it may not have been the right stuff initially.
sm1996
Original Author
16 years ago
Thanks for the additional posts. The grout used in the original installation and the "patch" jobs was the Congoleum Duraceramic premixed grout.

A family member suggested that maybe humidity was a problem. We live in an older house (about 90 years old), but the flooring is installed in a newer addition. Plus, we have a humidifier installed on the furnace system.
Any thoughts?

Has anyone had problems with the grout cracking that was successfully corrected and how? I'm worried that the original grout might just continue to crack and crumble under a new layer of grout as suggested by the Congoleum rep.

Need to check out the flooring inspector directories suggested to see if any are close or have experience with this product?
airforceguy
16 years ago
Howdy!! ya ours has cracked in a few places and yes they used the proper grout (I have 3 tubs of it) The installer said one can just grout over top, and that should fix it!! He hasn't done that, but will be contacting the store asap and they have been excellent to deal with. Will update ya all when they come and repair it.

duraceramic grout cracking

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duraceramic grout cracking

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