Tiler installed crazy pave and the grout cracked within days - problem?

[tombullen]

We got a tiling company to install some crazy pave on to our concrete al fresco and the concrete front porch of our new build. The company didn't say they do crazy pave on their website but they quoted for it so we assumed they could do it. We noticed issues while the installer was gluing them down but because he didn't speak any English we had to call his supervisor to explain, who would call him. For example we noticed that the gaps between paves was up to 7cm which seems larger than most grout can handle - but his supervisor didn't seem too worried and said the would use a booster in the grout.

Anyway, he came out again to do the grout over a really hot day, and within 24 hours hairline cracks have appeared in the al fresco (which had the largest gaps) and the grout seems to be failing in the porch where the tiles meet the exposed aggregate concrete driveway. We called and texted the supervisor but he didn't call back even after a few days so we called the business and they were helpful but didn't seem concerned and told us to point the issues out to the tiler when he arrives to seal it. 

Can anyone give us their expert advice on whether this is a big problem or not? Can this be repaired easily when the tiler comes back on site, before he seals it? Or does this need the grout removed and re-installed? I can't find any answers online.

The al fresco is the first set of pictures and the porch is the second set.

Thanks!

[JacobZ]

Hi @tombullen,

Thank you for your question about cracked grout between your crazy pavers.

As you've mentioned, the gaps are quite wide which can be troublesome when grouting. Using a booster or grout additive such as Davco 4 In 1 Grout Additive can increase the flexibility of the grout to help prevent cracking, but if the gaps are as wide as yours, this might not completely solve the problem.

I wouldn't say it's a massive problem as grout is not supposed to be waterproof, but from an aesthetics standpoint and considering how quickly it has cracked, you are well within your rights to request they chip out the cracked sections and regrout them before sealing. 

It shouldn't be a difficult job, but I'd suggest having this conversation with the company before the tiler returns to the site to ensure they have the materials required to rectify the issue.

Allow me to tag @Nailbag and @Dave-1 for their thoughts.

Let me know if you have any further questions.

Jacob 

[JacobZ]

Hi @tombullen,

I forgot to mention that at the transition between your exposed aggregate concrete and your paving, a flexible silicone such as Sika White Sikaflex 11FC Purform should be used instead of grout as this area will experience the most movement from expansion and contraction. Grout at this transition will crack almost immediately regardless of additives being added to the grout.

Let me know if you have any further questions.

Jacob

[Dave-1]

Afternoon @tombullen 

I havnt installed any crazy paving as yet but figure due to the nature of crazy paving there will be some movement. That said within days is a little too short a time frame for cracks and I would be questioning it like you. Id contact the company and ask to have it sorted as its cracked within daysand easier to chase an issue now instead of a months time.

Dave

[Nailbag]

Hi @tombullen 

Firstly I agree with @JacobZ that the transition from tiles to exposed Ag needs to be a flexible outdoor sealant. 

I’m assuming the purpose of the sealant on the tiles is not for waterproofing but to make the surface easier to clean?

Regardless of that, the grout between should definitely not be raised above the paver level and needs to be rectified prior to the seal going down as that’s going to just be a waste of time and money. 

Personally, I would be insisting the supervisor or someone senior from the company comes out to inspect the issue. I would then be asking that the grout be removed in those areas and it be done correctly. It wouldn’t need to be removed full depth. But enough to cover the gouges that most like will be left during the removal process. 

regards, Nailbag

[tombullen]

Morning all - thanks so much for the replies - it's confirmed some things so very helpful. I've emailed the tiling company and sent the photos of the cracks so that we have something on record, and they've said they'll be out next week after the rain stops to fix it.

I'll post an update when I know more, in case this problem happens with someone else in the future!