Fractured my fifth metatarsal 8 weeks ago, and was given walking boot, leaflet and discharged from 'virtual fracture clinic'. Made me really uneasy to be left to my own devices but I followed the vague advice about recovery.
Because of ongoing pain I (armtwisted) asked GP for an X-ray, got results today and it is a nonunion, so fracture hasn't healed. I need to see the clinic again to discuss surgical options which has absolutely floored me. It's been so disruptive to family, work, the poor dog 
Anyone with knowledge/experience know reasons this can happen and is surgery the only option?