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To cut a Lauxes grate accurately, use a compound mitre saw with a multi-material blade of 80 teeth or more. For the grate-top procedure, make the bottom tray 3 mm shorter than the required finished length, then make the top grate 1 mm shorter than the tray. Drill the waste opening to suit the selected pop waste and align it with the floor-waste pipe. Lauxes says installation must be carried out by a licensed plumber in accordance with AS/NZS 3500.2.
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These dimensions are fit allowances, not general manufacturing tolerances. They come from Lauxes Grates’ cutting and installation instructions, so confirm that the instructions match your grate model before marking it.
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Confirm which Lauxes grate instructions apply
Lauxes publishes separate cutting instructions for different grate constructions, including grate tops and tile-insert tops. Start at the Lauxes Grate Resources page, identify the product and open the current instructions for that model. The tray-and-top dimensions described in this article are the procedure shown for grate-top models; do not assume that a tile-insert model uses exactly the same sequence.
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Download and read the complete Lauxes Cutting and Installing Instructions for All Grates before cutting. Check the nominal finished length, the direction in which the grate will sit, the end-cap style and the waste outlet you intend to use. A few minutes spent identifying the model prevents an irreversible cut based on the wrong diagram.
Measure the finished opening, not the old grate
Measure the opening where the new grate will actually be installed. Take measurements at both ends and in the middle, because a channel can be slightly out of square or vary along its length. Record the smallest usable length and check it against the end-cap arrangement shown in the model instructions. If the opening is not straight, ask the plumber how the finished dimension should be established before cutting.
Keep a written cut list. Record the finished opening, the tray cut length, the top cut length and the centreline of the waste outlet. Mark the face and orientation of each component so a part cannot be turned around after cutting. Measure twice from the same reference edge; changing reference edges is a common way to introduce a small but consequential error.
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Lauxes’ cutting PDF states: “For ease of cutting Lauxes grates, we recommend using a compound mitre saw fitted with a multi-material cutting blade 80 tooth or more.” Use that configuration rather than selecting a blade solely by diameter or by the appearance of its teeth. The recommendation is specific to the grate-cutting task and is attributed to Lauxes Grates.
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Confirm that the blade is approved for the material of your particular grate and that its diameter and arbor fit the saw. Secure the workpiece against the saw fence and support long pieces so they cannot twist or drop as the cut finishes. Follow the saw manufacturer’s guarding, clamping and personal-protection requirements. A clean, square cut makes the end caps and the rolling top easier to fit; forcing a crooked cut into place can damage the tray or leave an uneven joint.
For the outlet, Lauxes recommends a Lauxes TCT hole saw. Select the diameter required by the pop waste you have chosen rather than assuming that every waste outlet uses one standard hole. Keep the hole saw, pilot and saw arbor compatible with the drill, and support the tray on a stable sacrificial surface while drilling.
Apply the two fit allowances in the correct order
Cut the bottom tray first
Transfer the tray cut length from your cut list to the bottom tray. Measure from a square factory edge or another clearly identified datum, mark the cut line all the way across and verify the mark on both faces. Place the tray in the mitre saw with the side that must remain visible oriented safely and consistently. Make one controlled cut with the recommended blade setup.
The tray is cut before the top because the top dimension is taken from the finished tray. After cutting, check that both end-cap locations are present and that the tray has not been shortened by an accidental second cut. Do not trim additional material merely to make an end cap fit; recheck the model drawing and the opening measurement first.
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Cut the top grate from the finished tray dimension
Use the actual tray length after cutting as the reference for the top grate. Mark the top at the specified shorter dimension, keeping the top’s orientation and rolling direction clear. Make a straight cut with the same saw discipline, then test the top in the tray without sealant or permanent fixing.
The top should roll into position without binding and should sit neatly when the end caps are installed. If it stops early, rocks or requires force, stop and inspect the cut for a measurement, squareness or orientation error. Removing more material without finding the cause can create excessive clearance that the end caps cannot hide.
Plan and drill the waste-outlet hole
Locate the floor-waste pipe before drilling. The hole centre in the tray must line up with that pipe, and the hole diameter must match the selected pop waste. The official instructions do not establish one universal diameter because the correct size depends on the waste component. Dry-position the tray over the channel and transfer the pipe centreline to the tray rather than estimating from the room or wall.
Use the recommended TCT hole saw and drill at the marked centre. Keep the tray supported so the saw does not snag as it breaks through. Remove the cut slug and check the opening against the pop waste before applying silicone. The waste should pass through the hole as designed, with its sealing surfaces sitting flat; a hole that is merely close in size can still leak or prevent the waste from seating.
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Lauxes’ FAQ notes that outlet sizing and the number of outlets can depend on plumbing size, outlet choice, whether the installation is indoors or outdoors, and the location. If any of those factors are uncertain, have a local plumber select the waste and confirm the hole requirement. Do not enlarge a drilled opening to compensate for a pipe position that has not been verified.
Fit the end caps and pop waste
Secure the end caps
Insert the end caps into the ends of the bottom tray and check that they are fully seated. Apply a continuous bead of silicone to the outside of the tray as directed by the installation instructions, then position the caps without shifting the tray length. Wipe away excess sealant before it cures, using a method compatible with the grate finish.
Seal the pop waste
Apply silicone around the lip of the pop waste and secure the waste to the underside of the tray at the drilled opening. Lauxes’ FAQ recommends neutral-cure silicone. Use a product suitable for the surrounding materials and follow its curing and cleaning instructions; the manufacturer’s documents do not specify a universal cure time.
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Before the plumber completes the connection, inspect the underside for a continuous seal and verify that the waste has not rotated away from the pipe centreline. Do not rely on silicone to correct a wrongly sized hole or a misaligned outlet.
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Keep cement-based products away from the grate
Lauxes cautions against contact with wet cement-based material during installation. Wet mortar, grout, screed or similar products can contaminate the grate while surrounding work is still being completed. The WaterMark installation guidance recommends using a template to protect the grate from contact. Fit that protection before wet materials are brought into the area, and remove it only when the installer confirms that the surface is safe.
Keep the cut components clean and protected while the channel, waterproofing and floor finishes are prepared. Avoid placing tools or wet materials on the grate. If cement-based material does touch it, follow the product and grate-cleaning guidance rather than scraping aggressively or using an unapproved chemical.
Licensed installation and Australian standards
The Lauxes instructions state that installation is to be by a licensed plumber and in accordance with AS/NZS 3500.2. Cutting a component to length does not turn the complete drainage installation into an unregulated DIY task. The plumber must confirm the waste connection, waterproofing interfaces, falls, access and any local requirements that apply to the project.
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Random freezes, missing sound and display glitches usually trace back to one bad driver. Find and replace yours safely.Free scan · under a minuteLauxes’ separate WaterMark Instructional Installation Guidelines say that applicable standards prevail if the guidance conflicts with a standard. Give the plumber the product instructions, the selected waste details and your cut measurements so the installed assembly can be checked against the approved method.
Quality checks before permanent installation
- Confirm the product model and use its matching cutting diagram from the official resource page.
- Verify the finished opening measurement at several points and record the reference edge used for every mark.
- Check that the mitre saw accepts a multi-material blade meeting Lauxes’ stated tooth-count recommendation.
- Cut the tray, then measure the finished tray before marking the top.
- Roll the top into the tray dry and check the end-cap fit before applying silicone.
- Mark the waste centre from the actual floor-waste pipe location, not from a nominal plan dimension.
- Confirm that the TCT hole saw size matches the pop waste and dry-fit the waste before sealing.
- Protect the grate with a template before wet cement-based products enter the work area.
- Have the licensed plumber inspect the complete assembly and install it to AS/NZS 3500.2.
Troubleshooting common fit problems
| Symptom | Likely check | Action |
|---|---|---|
| The top will not roll into the tray | Recheck the top measurement, cut squareness and orientation. | Stop before trimming again; compare both pieces with the model instructions and ask the installer to confirm the required clearance. |
| An end cap will not seat | Check that the tray was cut from the correct datum and that no burr or obstruction remains. | Do not force the cap. Confirm the tray length and cap type before making any further cut. |
| The waste hole misses the pipe | Compare the marked centre with the actual floor-waste location. | Do not seal the waste in place. Have the plumber resolve the alignment and determine whether a replacement tray or an approved connection detail is required. |
| The pop waste does not sit flat | Check the hole diameter, tray support and waste orientation. | Remove the waste before curing and correct the component or hole only after the plumber confirms the required size. |
| Wet cement-based material reaches the grate | Protection was missing, moved or removed too early. | Stop the wet work and follow the grate and material manufacturer’s cleaning directions; avoid abrasive or unapproved solvents. |
What the measurements do—and do not—tell you
The tray and top deductions are specific installation allowances for the covered grate-top procedure. They allow the end caps to occupy the tray ends and give the top enough clearance to roll into place. They do not specify the waste-hole diameter, guarantee that every opening is square, or replace the dimensions in a model-specific diagram.
Likewise, the recommended saw configuration is a tool specification, not a comparison proving that other saws are unsuitable in every circumstance. If you cannot safely use the specified setup, ask the plumber or the grate supplier how the particular product should be cut rather than improvising a blade and hoping the edge will fit.
Where to verify components and instructions
Use the Lauxes FAQ for questions about saw choice, silicone and outlet selection, and the Lauxes official site for product information. Keep the exact grate model, end caps and pop waste together when checking dimensions. This avoids mixing an instruction sheet or accessory intended for another grate construction.
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