Cracked shower tray

[akist]

Would anyone be able to recommend a shower tray repairer who does not charge an arm and a leg?

The shower tray, since fitted a year ago, has developed two hairline cracks around the waste, which is in the middle. The tray sits on plywood, but is not well supported (fitter used foam), and in the middle section there is an A5 sized cutout to accommodate the waste, which means that area sits over nothing but thin air.

The hairline cracks have got progressively a bit larger over a year, even though we do not step on the middle area.

The tray which costs only around £250, cannot be removed as that would require breaking a lot of very large tiles and injuring the tanking as well.

I have read about professional repair which injects foam under the cracks and then glues the cracks together - but one place I asked he wants £400-£500. And in any case, if their plan is to inject foam, it will only disappear into the void under the plywood, through the A5 sized opening.

Alternatively I had another idea, to install a very thin film over the existing tray, or just over the area with the cracks - we will continue not to step on the cracks, and the film will form a barrier ?

 

[Exedon]

We subcontracted to a specialist insurance contractor for over 10 years.
I've seen just about ever conceivable of attempted repair on shower trays.
The 'invisible ' repair people can make a good looking repair but I have seen cracks return.
Have you contacted original installer? It obviously wasn't fixed to manufacturers instructions.
To be blunt tray needs changing
Maybe have a accident with something heavy and have a insurance claim?

 

[Madrab]

+1 -

Not what you want to hear but - once they are cracked then really it's time to change, the trouble is the existing cause would still be there so those cracks would invariably return. do the crack fully penetrate and is the tray leaking through?

As far as the section removed from the ply, obviously some of it has to be cut out to accommodate the waste and trap, how much is usually dictated by the size of the trap and waste setup, unfortunately can't get away from that. How long has it been in?

 

[akist]

The 'invisible ' repair people can make a good looking repair but I have seen cracks return.

Yes but a repair might prevent the crack extending further, especially since we do not step on the centre. But at £500 it seems crazy money.

Have you contacted original installer? It obviously wasn't fixed to manufacturers instructions.

Yes, he says he uses foam everywhere and is adamant that the tray was defective ... The manufacturer explicitly specifies a bed of sand and cement with special attention to the waste area...

Regardless who pays, replacing it is a very painful process that will result in a lot of collateral damage to the bathroom.

do the crack fully penetrate and is the tray leaking through?

Not sure, the only way to detect the leak would be to wait to see stains on the ceiling below ...

How long has it been in?

A year, and the cracks were there from installation. The tray was covered with some hardboard and the tiler used it as a prep area putting a lot of tiles on it, bags of adhesive and large mixing buckets! The cracks were discovered when the cover was removed.

This is a photo from a year ago when the cracks were fresh (hairline). And the next photo is today, you can see the progress of the fault.

 

[Madrab]

If that happened right after the install then TBH that's when it should have been taken up with the installer.

It would be interesting though to know what the installation instruction detailed with regards to the install method, I have seen a manufacturer mention using expanding foam (can't remember which one off hand). Also I presume the tray is stone resin, is it flat bottomed or ribbed? Do you have a make?

You could call the installer but it would all come down to what agreement re guarantee etc is in place.

 

[akist]

I have seen a manufacturer mention using expanding foam

This manufacturer ( cannot recall name ), and another ( MIRA ), both DEMAND a bed of sand and cement, and go to great lengths to emphasize that and absolutely no foam or silicones.

Also I presume the tray is stone resin, is it flat bottomed or ribbed?

Stone resin, flat bottomed, 25mm overall, thinning to about 10mm as you get into the centre where the water collects and drains off.

You could call the installer

Denies any responsibility and will cost me £1000 labour + maybe £700 materials to replace it. It is a big task as bathrooms are built over and around the shower tray (or bath). You'd have to break out a lot of tiles, the niches, trims, the floor tiles too, you may end up redoing half the bathroom and you'd be compromising the tanking that was done before. Maybe £1000 labour is cheap for this task.

 

[Exedon]

Should have been sorted as soon as cracks appeared.
Who supplied tray?
If your installer didn't fix tray as per manufacturers instructions they really can't just deny responsibility.

 

[Madrab]

Yes but a repair might prevent the crack extending further, especially since we do not step on the centre. But at £500 it seems crazy money.

Nope - unless they can grind out the whole crack there is nothing really that will stop cracking from getting worse.

Stone resin, flat bottomed, 25mm overall, thinning to about 10mm as you get into the centre where the water collects and drains off.

Very low profile - not surprised it's cracking if it's down to 10mm with nothing underneath it.

It is a big task as bathrooms are built over and around the shower tray (or bath).

Says who? I've taken out and replaced loads of tray's and baths and only ever had to remove the enclosure (shower) and 1 row of tiles. £1000 labour!! to take a tray out and replace wow that's quite a labour cost but then again I'm not in Surrey.

Denies any responsibility

Cop out, again what make of shower tray and if it's not fitted to spec then of course they're responsible.

 

[amfisted]

For what its worth, I've just installed a stone resin shower tray and enclosure, employing the very welcome guidance and advice from contributors to this forum. I was left in little doubt that the tray had to be bedded properly with tile adhesive or sand and cement, and the former is what I used. I'm only a DIYer, but had someone suggested expanding foam I would have been somewhat sceptical, to say the least.

OP, in your position I'd be thinking "shower tray replacement", I'm afraid, starting from scratch and having the job done as I was advised to do it by members of this forum.