Shower pan tile grout problems?

[Lloyd Cimprich]

I have recently had my shower stall gutted and re-done but I am concerned
about the quality of the new tiled shower pan for the following reasons.

1. The cement base was very wet and did not appear to be fully dry when
contractor installed tiles.

2. Shortly after work was complete some areas of the grouting discolored and
some areas broke up.

3. The contractor repaired the grout but now some areas appear to absorb
water whereas others look to repel water.

4. The grout can take more than a whole day to fully dry after being wet
down.

5. The grout is a silver grey color and seems to be being discolored in
random spots after each wet down.

I have not actually used the shower other than to wet it down with clear
water.

Can any one suggest if I have a problem to be concerned about and if so what
might need to be done to correct it.

TIA

[Richard J Kinch]

Lloyd Cimprich writes:

>Can any one suggest if I have a problem to be concerned about and if so
>what might need to be done to correct it.

Hard to tell from your description. The wet concrete should not have been
a problem, though. Can you just say directly what you think is wrong? The
only good fix, if the job is defective, is to chip the whole mess off with
a power hammer (not that big a deal, really) and do it over.

[art james]

Lloyd Cimprich wrote:
>
> I have recently had my shower stall gutted and re-done but I am concerned
> about the quality of the new tiled shower pan for the following reasons.

>
> 1. The cement base was very wet and did not appear to be fully dry when
> contractor installed tiles.

This is normal. Tile set over fresh mortar, especially for shower floors is
a standard practice.

>
> 2. Shortly after work was complete some areas of the grouting discolored and
> some areas broke up.

However, the grouting should have been 24 hours later. Was it done over the
fresh wet mortar as well?

>
> 3. The contractor repaired the grout but now some areas appear to absorb
> water whereas others look to repel water.

How can you tell? The floor is sloped. Or should be. Does water stand on
the floor?

>
> 4. The grout can take more than a whole day to fully dry after being wet
> down.

See last comment. Not enough slope?

>
> 5. The grout is a silver grey color and seems to be being discolored in
> random spots after each wet down.

Common with certain brands of grout. Which did you use? Another
consideration is high salt content in your water. Water which was used in
the mixing fo the mortar, the grout, the sponging, the everyday use. Quit
wetting it everday, and let it dry for a few. Then seal the grout.

>
> I have not actually used the shower other than to wet it down with clear
> water.
>
> Can any one suggest if I have a problem to be concerned about and if so what
> might need to be done to correct it.
>
> TIA

The only tiled shower basin problem you should ever really be concerned with
is a beached and leaking membrane.
http://www.pascospecialty.com/prod04.htm

[Lloyd C]

Can you just say directly what you think is wrong?

I think that the shower floor was not properly installed and I am once
again going to have the shower leak through and ruin the living room
ceiling.

I think this because:

1. Although at my request a drain with weeping holes was installed my
request to slope the sub floor to the drain before installing liner
was ignored.

2. The tiles were installed in such a way as to require very thin
pieces of tile ( < 1/8") one one side of drain. These thin (actually
broken) tile pieces look like a point of future failure.

3. The grouting was faulty from the start requiring the installer to
scrape portions with screwdriver and re-grout.

I was hoping to get some idea as to expected standards for such work
and how best to proceed with contractor/Home Service Club.

Thanks

[Lloyd C]

>
> Common with certain brands of grout. Which did you use? Another
> consideration is high salt content in your water. Water which was used in
> the mixing fo the mortar, the grout, the sponging, the everyday use. Quit
> wetting it everday, and let it dry for a few. Then seal the grout.
>
>

The grout used was Flextile Polymer modified floor tile grout. The
floor was sloped (although the pan liner was not) and there is no
significant pooling/standing water that I can tell. When the tile is
wet most of the grout darkens right away but some spots appear to
repel water. I have left the tile dry for days if not weeks but the
dark spots persist. The tile was not sealed and the contractor was
emphaticly opposed to sealing the grout and so to this point I have
not.

Thanks for your assitance.