Garage Floor Install Gone Wrong

[Backlight]

Hoping someone can provide input into a garage floor install that did not go quite as intended.

I had my 32' x 32' garage floor poured yesterday, 6", 4500PSI with fiber on top of 2" of R10 insulation, rebar and 5/8 PEX for radiant heat. The pour went well and I was happy with the finish. Today the contractor came to saw cut the floor (it was actually one of his staff). 3 of the 4 cuts look 'ok'. Something went quite wrong with the 4th and arguably most important cut. The cut down the middle from front to back right in the middle of the double door has a huge snake in it. It's out 14 - 18" front to back. It looks horrible and considering I have OCD it's going to be hard if not impossible to look at it going forward.

The person who did the saw cut acknowledged something went very wrong. He actually said he felt sick to his stomach about the result. Possibly because I asked him at the beginning to ensure the cuts were dead on and he said he's never had an issue in the past. I'm not sure exactly what happened, might have been an issue with his saw.

I spoke with the contractor/owner, he had spoken to his employee and knew about the situation. We have to come up with a solution to the issue. Short of ripping the whole thing out and starting over what options are available? I was thinking filling the saw cuts and then doing a high end epoxy coating might be an option? Or perhaps filling the cuts and then a diamond grind? Finally maybe a floor covering of some sort? Any of the aforementioned will cost the contractor allot less than ripping it out and starting over, especially considering I have 3K in material under the concrete.

Any thoughts on the best course of action?

Thanks in advance….

 

[Jim B]

Sounds like a perfect opportunity to install epoxy, race deck, tile...whatever floor finish you like. No need to rip up a perfectly good slab just to fix the finish. Especially as your contractor may help with the cost.

 

[mtwaterguy]

Sounds like a perfect opportunity to install epoxy, race deck, tile...whatever floor finish you like. No need to rip up a perfectly good slab just to fix the finish. Especially as your contractor may help with the cost.

Doesn't sound like he's looking for "help" from the contractor. I'd approach the contractor for options for fixing "his" mess. Don't be too surprised if he says it's "just cosmetic".

 

[truckman5000]

at least he didnt cut the pex. Im a plumber and it happens more than you would think.

 

[Backlight]

Doesn't sound like he's looking for "help" from the contractor. I'd approach the contractor for options for fixing "his" mess. Don't be too surprised if he says it's "just cosmetic".

I'm not looking for help from my contractor, I'm expecting help from my contractor!! Especially after he has stated the work is not correct.

Sounds like a perfect opportunity to install epoxy, race deck, tile...whatever floor finish you like. No need to rip up a perfectly good slab just to fix the finish. Especially as your contractor may help with the cost.

I think you're right, no point ripping up a good slab, I'll have to find a covering option… Hope I can fill the saw cuts if I go with an epoxy option.

 

[Backlight]

at least he didnt cut the pex. Im a plumber and it happens more than you would think.

That would have been a nightmare and put my saw cut issue to shame!

 

[Hinez Wengler]

I'm not looking for help from my contractor, I'm expecting help from my contractor!! Especially after he has stated the work is not correct.



I think you're right, no point ripping up a good slab, I'll have to find a covering option… Hope I can fill the saw cuts if I go with an epoxy option.

Contact engineering at the cement plant. They can tell you how to go forward.

 

[JD in DFW]

sorry to hear about that mishap, but it can be resolved with a coating system or tile system if thats the route you want to go. If tile, no need to repair the saw cut. If you go the coating route, then the joints can be back filled and then coated over. May take a couple of passes with the patch, depending on the depth and width of the cut.
We have filled in many saw cuts on floor for a seamless look in tons of garages over the years, not a major deal. Just make sure when they grind that they do it as even as possible, and of course a good thick couple of coats of coating and then colored flakes and clear coat or just clear coat. Be sure they use a self leveling coating and I'd use one that is 75%-100% solids.
This is just my .02, others I'm sure would suggest other methods.
Best of luck with you new floor.
JD

 

[930dreamer]

Post some pictures of the slab.

 

[Backlight]

Just looking at epoxy floor and race deck pricing. Much more than I expected.. It will be interesting to see how this pans out.

 

[Backlight]

sorry to hear about that mishap, but it can be resolved with a coating system or tile system if thats the route you want to go. If tile, no need to repair the saw cut. If you go the coating route, then the joints can be back filled and then coated over. May take a couple of passes with the patch, depending on the depth and width of the cut.
We have filled in many saw cuts on floor for a seamless look in tons of garages over the years, not a major deal. Just make sure when they grind that they do it as even as possible, and of course a good thick couple of coats of coating and then colored flakes and clear coat or just clear coat. Be sure they use a self leveling coating and I'd use one that is 75%-100% solids.
This is just my .02, others I'm sure would suggest other methods.
Best of luck with you new floor.
JD

Thanks - I think a coating system is the way to go.. Will not be cheap, hope the contractor and I can work something out. That said, it will still be much less than busting out the floor and staring over for the sake of a bad saw cut.

 

[James-W]

If it were me I would go with the Racedeck floor instead of an epoxy floor. My thinking is, if for whatever reason you don’t care for the way the floor looks with the Racedeck tiles, you can always take up the tiles and sell them to someone else. Then you can use the money from the sale to do the epoxy floor.

 

[retfr8flyr]

Sounds like the perfect time to go with Porcelain Tile. Tell your contractor you will pay for half the cost of the tile and he can pay for having it installed. Much cheaper then pulling up the floor and will look great.

 

[Backlight]

Lots of options here.. Thanks for the input. I'll let you know what we agree on in the end. Might be a week or two, contractor is on vacation this week.

If I go the epoxy route how long should the floor cure for before application?

 

[ConCretin]

Backlight, I'd be as frustrated as you are with the wavy control joint but don't be surprised when your contractor baulks at ponying up thousands of dollars for a new epoxy floor.

The fact is that it is a cosmetic issue that can be repaired. There are any number if ways to simply fill the existing cut and cut a new one. Will the repair be 100% invisible?, probably not, but it will blend it pretty well.

Even if you took him to court, you probably wouldn't prevail. There is a legal principle called 'economic waste', which basically says an owner isn't entitled to complete replacement of high cost construction because of a minor deficiency. You'd probably get a credit reflecting the value of the defective work and repair costs.

Hopefully your contractor will offer up an acceptable repair and a fair credit to keep you happy but don't get your hopes up for much more. I'm not trying to minimize your aggravation, just want to offer the perspective of someone in the business. Hoping for a good outcome.

 

[Backlight]

Backlight, I'd be as frustrated as you are with the wavy control joint but don't be surprised when your contractor baulks at ponying up thousands of dollars for a new epoxy floor.

The fact is that it is a cosmetic issue that can be repaired. There are any number if ways to simply fill the existing cut and cut a new one. Will the repair be 100% invisible?, probably not, but it will blend it pretty well.

Even if you took him to court, you probably wouldn't prevail. There is a legal principle called 'economic waste', which basically says an owner isn't entitled to complete replacement of high cost construction because of a minor deficiency. You'd probably get a credit reflecting the value of the defective work and repair costs.

Hopefully your contractor will offer up an acceptable repair and a fair credit to keep you happy but don't get your hopes up for much more. I'm not trying to minimize your aggravation, just want to offer the perspective of someone in the business. Hoping for a good outcome.

Understand and agree - I'm pretty reasonable and I think the contractor is as well. Hopefully we can come up with an amicable solution.

It's unfortunate a solution that will fully satisfy me is likely gong to cost more money; money I did not intend to spend at the moment. Anyhow, can't do much about it now..

 

[retfr8flyr]

If you're like me, you will never be satisfied with a repair job because you will always be able to see the repair. The builder isn't going to pay someone to come in and do an Epoxy floor but you may be able to talk him into the Tile idea. I know paying half the cost of the tile is not money you want to put out now but it would show the builder you are willing to work with him and he can handle the labor cost. You would end up with a great looking floor that will stand up to almost anything.

 

[zporta]

post some pictures of this. i cant imagine a saw cut being 14'' off. Did he just cut it free hand without snapping a chalk line?

 

[Backlight]

If you're like me, you will never be satisfied with a repair job because you will always be able to see the repair. The builder isn't going to pay someone to come in and do an Epoxy floor but you may be able to talk him into the Tile idea. I know paying half the cost of the tile is not money you want to put out now but it would show the builder you are willing to work with him and he can handle the labor cost. You would end up with a great looking floor that will stand up to almost anything.

I hired the contractor (concrete finisher) direct. My contract is with him and as such hoping that opens up a few more options on how to remediate the issue. Yes, I expect to have to meet in the middle on this one somewhere. I would be content with purchasing the material if he would cover labour. It's just the banks money anyhow -

 

[Backlight]

post some pictures of this. i cant imagine a saw cut being 14'' off. Did he just cut it free hand without snapping a chalk line?

Sorry - did not have the camera with me this weekend. The garage is at my cottage (you can see my build thread). I hope to be back next weekend with the camera.

To answer your question, yes he did chalk a line. He had a cart mounted stihl concrete saw (actually he had two of them)... He guy had no idea why the saw curved to the left (only slightly) then to the right. Maybe the blade was not true, or the cart was wonky. It was a new saw though, might have been an issue with it.

In any case, it does not matter that much why it happened, the damage is done. Just need to find a fix. I'll update with how it all pans out, suspect it could take a week or two to come to an agreement.

 

[Backlight]

Agreed with the contractor that I would hold back 20% of the job until a solution is found.. Have the agreement in writing. A step in the right direction at least.

 

[Trey T]

can you show some photo, please?

 

[cagullett1]

You should consider a porcelain tile... I was very skeptical but wanted an option that would handle a beating.

Here is an awesome install that looks great: http://www.garagejournal.com/forum/showthread.php?t=212509

Jack took some **** for his floor, but if you ask him, he wouldn't change it one bit: http://www.garagejournal.com/forum/showthread.php?t=55006

 

[swamplaw]

IMHO , You really need to hold back enough $$, (if it is available at contract end) to ensure his cooperation towards an amicably resolution. Too little and he just walks. Yes, as an attorney, I realize you both can have protracted litigation making each of your lawyers very happy. However, if you are holding his money, you have a much better bargaining position. Finally, most people do not really understand how lean many, many contractors run their respective businesses and how many subs they employ with a promise of payment at contract conclusion. If they mess up too many jobs, they have a financial house of cards.

Assuming this was a mistake, the contractor could file a bankruptcy proceeding if you hit him too hard and he has other financial head-aches in addition to yours... Keeping your cash close, is really the best option for you Good luck.

 

[Zeke]

I'd be happy with a shallow ribbon wide enough to cover the mistake cut into the floor and tiled.

 

[stangkid14]

great idea

 

[Backlight]

IMHO , You really need to hold back enough $$, (if it is available at contract end) to ensure his cooperation towards an amicably resolution. Too little and he just walks. Yes, as an attorney, I realize you both can have protracted litigation making each of your lawyers very happy. However, if you are holding his money, you have a much better bargaining position. Finally, most people do not really understand how lean many, many contractors run their respective businesses and how many subs they employ with a promise of payment at contract conclusion. If they mess up too many jobs, they have a financial house of cards.

Assuming this was a mistake, the contractor could file a bankruptcy proceeding if you hit him too hard and he has other financial head-aches in addition to yours... Keeping your cash close, is really the best option for you Good luck.

Agree with your points..

End of the day, if he walks he walks. I have 20% of the job to put towards a fix. It won't cover a full fix but it will help. Life is a bit short to drag something like this through the courts where no one but the lawyers win.

I don't expect to get a full epoxy, tile or race deck floor for free out of this. Just want to come to a fair resolution (for both parties).

 

[Backlight]

I'd be happy with a shallow ribbon wide enough to cover the mistake cut into the floor and tiled.

This is a really good idea! Have you seen anything like this before on the forum?

 

[Zeke]

This is a really good idea! Have you seen anything like this before on the forum?

No. I just thought it up. I'm a contractor and design things when I get a chance. In fact, I looked at Google images and couldn't find anything too much like I was thinking. Saw a lot of brick ribbons but that's too deep for your Pex.

1/4" contrasting tile would be the ticket. Maybe matching your cabinets or feature stripe.

 

[EpoxyCoat2]

At least 30 days of curing time for concrete.

If I go the epoxy route how long should the floor cure for before application?

 

[Backlight]

So the update is.. Concrete finisher has gone quite, has not returned my last two calls. Would seem as though he's not interested in resolving the issue nor does he care about the rest of his money.

Assuming nothing else transpires I'll have to put the money towards a fix of my own at some point....

 

[James-W]

Have you decided what you want to do in order to "fix" this problem?

 

[Backlight]

Have you decided what you want to do in order to "fix" this problem?

Thinking I'll wait until Spring, have the relief cuts filled, and do an epoxy. Was considering race deck however I suspect I'll be forever lifting it and cleaning (I do a fair amount of wood work and the driveway is gravel so dirt is constantly being tracked in).

 

[James-W]

Was considering race deck however I suspect I'll be forever lifting it and cleaning (I do a fair amount of wood work and the driveway is gravel so dirt is constantly being tracked in).

I am considering putting Racedeck down as well, but right now I am working on my basement. I will be a couple months getting the basement done, I don't work on it constantly, but I do work on it a little pretty much every day.

I need to get hold of the Racedeck people and get a price, I have been meaning to do that for quite awhile now, but something always seems to come up and I don't do it.

 

[rsanter]

how about epoxy fill the cut.
polish the concrete and acid stain the concrete with a rubbed in finish so there is some variation in colors and patterns....etc
would look high end and hide the mistake at the same time as giving a great durable finish

bob

 

[Backlight]

how about epoxy fill the cut.
polish the concrete and acid stain the concrete with a rubbed in finish so there is some variation in colors and patterns....etc
would look high end and hide the mistake at the same time as giving a great durable finish

bob

Hi Bob,

I don't think I've seen anything like this before. Have a picture of something similar you can point me to or share?

Thanks!

 

[duc916]

Use the 20% for a cover up, tile, vct, epoxy, etc, and move on. You will end up with a better looking floor than bare concrete and save 20% on it.