Slate edge repair

[aslan]

I've got ~1700 lf of grout I've removed from a slate floor (which is also starting to spall). The grout joint was expanded from 1/8" to 1/4".

We did the sample grout, and emailed a photo of the outcome (attached). The customer wants a more crisp tile edge line, without any irregularities. Each tile will now be repaired. After the repair we'll be grouting, cleaning, re-honing and sealing the floor.

My proposed solution is to (dry) grind off another location at the same home, that has the same stone and is being torn out, and bagging the stone dust. Then mix that dust with a clear flowing resin of some sort (to get an exact color match) and start repairing.

My question is for product suggestions that hopefully have a long working time, so I don't have to keep mixing small batches. Other repair options, i.e. grinding the floor, beveling the joint, aren't acceptable. The tile needs to be repaired. Oh, it's interior.

Thanks

[Eric J]

why was the grout joint expanded? Was it done in the grout removal process with the tools? If so, sounds like you may have just bought that floor.

[aslan]

Eric,

Short version: the stone was installed incorrectly with varying grout joint gaps, between none and 5/16". After initial removal of the grout, the varied gaps were very noticeable, and the client wanted more uniformity. The grout joint expanded correctly, using the correct tooling. The issue is the slate is spalling/flaking.

So..., suggestions regarding the potential resin?

[Eric J]

so let me get this straight. You are trying to fill in the little chipped rough edges of the tiles I see in the pic right? With a resin.

[aslan]

Yes, that's correct. The only area the grout is installed is in the sample area. There's ~1200 sf of flooring to be done.

[Bruce Zelt]

Impossible if you asked me, if that is the spalling you are talking about then that is not the case.

The marks on the grout line are from cutting dry or not wet enough. You would not have had them
if you water cut.

[aslan]

Bruce,

The floor, once repaired (which I know I can color match/epoxy, cause I've sampled it) then consolidate/fortify the floor and re-grind/hone.

So, doing a single application in small batches works. I'm looking to do it in segments other than 10 tile at a time.

Thanks for your continued thoughts and input.

Greg

[Eric J]

I honestly don't see how it will work out. I don't see you being able to make a square right angle on the edge of the tile. Again, you may have bought the floor by cutting like that. Good luck.

[Bruce Zelt]

I wish that I could be more help Greg, but that sounds very painful.


It sounds like you have a plan, good luck.

[aslan]

Bruce and Eric, thanks for your responses.

Greg