Date: 3/2/2008 6:09 pm EDT
I finished placing the Avaire tiles in my basement bathroom yesterday. I put them over an existing vinyl-on-concrete floor. The installation was a lot easier than I thought!
This morning I grouted using the flexible grout. I followed all of the instructions and the grouting was pretty easy too!
I did find one problem. After about 30 minutes of drying I noticed small "holes" or "pockets" starting to form in the grout. They are about about 1/8" deep. I would describe them as "sinkholes" or "pock marks", like the grout started contracting or sinking in spots as it dried. They didn't form everywhere, but there are about 30 holes scattered throughout the 35 sq. ft. room. There are enough of them, and they are noticeable enough, that they definitely need to be fixed.
So I have 2 questions:
1. Any ideas on why these holes appeared, or what I might have done to cause the holes to appear?
2. Can I "re-grout" over the affected areas to fill-in the holes? If so, how long should I wait before re-grouting? I wouldn't need to re-grout the whole floor, I would just fill in the holes.
Any advice is appreciated. Thanks.
P.S. Other than the holes the floor looks great!
Date: 3/2/2008 6:10 pm EDT
A few more things:
After I started noticing the "holes" forming, I tried going back and filling them in again. After about 20 or 30 minutes, the holes started forming again. I went back 3 or 4 times, but the holes kept coming back in different areas.
I did not add water to the grout. I mixed it thoroughly before using it. The room was about 65 degrees.
Thanks again for any advice.
Date: 3/2/2008 6:39 pm EDT
You’ve already answered a couple of questions: you stirred it thoroughly, and you didn’t add anything to the grout. Both good answers.
Let me ask you a couple of other questions:
1) Where did you purchase the Avaire Flexible Grout?
2) Is there a “batch number” or similar anywhere on the grout pail? It would be on a sticker.
We’ve heard of this on a few rare occasions. Usually it happened when the grout wasn’t properly stirred – the lower viscosity portions of the pail can sag in the grout joints, especially in the gaps between the interlocking tabs. The other way it can happen is if the joints are not thoroughly packed with grout; that is, make sure to force the grout all the way into the gaps between the interlocking tabs.
The good news is the Avaire Flexible Grout adheres very well to itself and it is not a problem to go back over the top with another layer in those areas that sank. The bad news is that is additional work – certainly not what you or we had in mind when you started your floor.
Based on what you've described so far, I would recommend waiting 24-48 hours and let everything settle before adding the final layer of Avaire Flexible Grout.
Date: 3/2/2008 7:09 pm EDT
Thanks for the really quick answer.
I purchased the Grout at the Menards in Red Wing, MN. The sticker says "705-4857 12KDMXCGV exp.12/11/2009".
I spent a relatively long time mixing the grout with a trowel to create a consistent mix, and I tried to pack it as tight as possible, especially after going over the same areas 3 or 4 times. But this is my first time grouting anything so an installation error is certainly possible.
In looking closer at the pattern of the holes, it does look like they only occur where there were gaps between the interlocking tabs.
It's good to hear that "re-grouting" over the saging areas should work. It's a small room, so it should not take more than an hour. I'll wait until Tuesday night to do it and we'll see what happens.
Thanks again for the quick response.
Date: 3/2/2008 7:36 pm EDT
It sure sounds like you've done everything right.
If possible, I'd like to get your partial pail back for analysis. Please send me an email directly at firstname.lastname@example.org and we'll make arrangements to deliver a replacement pail, and pick-up your partially used pail.
Author: Margaret Taylor
Date: 3/18/2008 11:28 am EDT
I had the same problem. When I opened the pail, it was only half full and I had about two inches of liquid on the top that had to be mixed. I worked for almost 45 minutes before I could even begin.
Now, I'm not perfect, but I have completed four rooms of ceramic tile as well as shower walls, so I am used to grouting.
I had wholes too all over my floor. I kept going back with my fingers to smooth them out. However, now I realize that all my grouting has sunk and is no longer flush with the tiles. I know that this is going to cause a horrible problem with dirt in the grouting.
I read that I can go back over the floor and regrout on top, but what a job. I still have half of the floor to do, so any suggestions as to what I can do to prevent the problem in the rest of the room?
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