INSTALLING A COMPOSITE SHOWER PAN IS FAST AND EASY. Earlier than discussing the easy steps to put in a composite shower pan, I felt that some clarification and definitions are essential as a result of not all shower pans are alike.
WHAT IS IN A NAME? A roof is a roof, though there are various completely different roofing techniques and roofing supplies. Not true with "shower pans." They're usually interchangeably referred to as a shower pan, shower pan liner, shower pan membrane liner, waterproof barrier, shower base, shower tray, or shower receiver. But, every has a special that means relying on context and every can be found in quite a lot of supplies.
Bob Vila's website defines a SHOWER PAN as "The bottom, containing a water drain, of the shower enclosure." And a SHOWER RECEPTOR as "A one-piece base (ground) unit used as a shower, for instance, to catch water and direct it to a middle drain."
For the sake of readability, I provide the next definitions.
SHOWER PAN & SHOWER BASE - A completed space that's able to retaining and directing water to the drain plus it doesn't require tiling as soon as put in. The shower pan or base has a drain gap, sloped ground to correctly direct water to the drain gap, sidewalls, and a threshold (entrance to the shower that varieties a curb to maintain water from working out onto the bathroom ground). A shower pan is synchronous with a shower base.
SHOWER PAN LINER, MEMBRANE LINER, & WATERPROOF BARRIER - A barrier, often a plastic sheet or membrane, that's supposed to entice water that penetrates the shower ground tile, grout, and mortar underneath the tile and pressure the water to circulate to the drain . So long as it doesn't leak, it prevails water from reaching the sub-floor and surrounding wall enclosure. The liner is a part inside a constructed shower pan. A shower pan liner is synonymous with a shower pan membrane liner and a water-resistant barrier.
SHOWER TRAY & SHOWER RECEPTOR - A shower tray is synonymous with a shower receiver. Each are used rather than a liner. They serve the identical operate because the liner, however are pre-formed to eradicate a few of the set up steps essential when utilizing a liner.
Bathe pan liners, shower trays, and shower receptors are all used along side the development of a shower pan that has a tiled ground in addition to a tiled wall enclosure.
Commercially obtainable shower pans are full, ready-to-install models. They eradicate the necessity to create a mud sloped ground, a shower liner or tray, and tiling of the shower ground.
COMPOSITE SHOWER PANS. As composite shower pans are made out of a lot of completely different supplies and constructed in a different way. I needed to the touch on every of the commonest varieties. Composite shower pans fall into a number of materials teams; cultured marble, fiberglass, acrylic, and strong floor. Typically all are made by fabrication of flat sheets, thermal-formed from a single piece of fabric, or molded or solid to kind a one piece unit. The one-piece building eliminates seams, which in flip eliminates potential leaks. Every has their pluses and minuses. As a result of magnificence is within the eye of the beholder, I cannot touch upon look. All composite shower pans set up on a flat, degree ground and don't require the creation of a sloped mud base. Additionally, the solid or molded pans usually don't require the usage of a plastic membrane.
Cultured marble and dressier variations, like cultured onyx and granite, are usually the least pricey. Cultured marble is made by spraying a 'gel-coat' onto a mould. The coating is about 1/64 "or much less in thickness. to decrease its density and weight.
The classy marble ground is solid individually from the sidewalls. Thus, the incorporation of a shower pan liner is important to insure a watertight, leak free set up. Though extensively used, the down aspect of cultured marble is that aside from the gel-coat layer, the calcium carbonate is extremely porous. Any crack or scratch by the gel-coat will permit water penetration. Different gel-coat traits embrace; yellowing, even with out UV publicity; clouding from scorching faucet water; staining; crazing (tremendous hairline cracks); and it isn't redistributable when cracked or chipped.
Fiberglass is extensively used as effectively. Fiberglass is robust, gentle weight and cheap. Many fiberglass producers make one-piece shower pans and enclosures and one-piece mixture tubs and showers with the wall enclosures. Just like cultured marble, fiberglass is made with a gel-coat, then backed with pigment and chopped strands of fiberglass in a resin combination. Typically the completed product is about 1/eight "to 1/four" in thickness. The underside of the shower pan ground has webbing added to supply assist to the ground. As the ground just isn't strong, the unsupported area between the webbing can flex. This flexing is particularly noticeable with heavy loading or the place one is standing between to the webbing. Over time, the flexing could cause materials fatigue and cracking. As soon as a crack develops, the pan has failed.
Acrylic sheets are used to hoover kind shower pans, bathtubs, spas and plenty of different gadgets. The vacuum forming course of begins with a 1/four "sheet of pigmented acrylic that's heated to a temperature that makes the acrylic ductile. the sheet causes a discount in wall thickness. The discount is immediately proportional to the quantity of stretching that happens. With shower pans there may be far much less materials discount than with creating a bath or spa. additionally introduce pressures to the completed pan.
Like fiberglass pans, acrylic pans want assist parts underneath the pan ground. A generally used assist component is polyurethane foam. The froth fills the void and eradicated the flexing of the pan ground. Acrylic sheet materials is suitable to crazing, minute floor cracking, and cracking when cleaned with many frequent cleansing chemical compounds. Ought to crazing incidence, over time these cracks can result in a pan failure.
Acrylic sheets have very completely different bodily and chemical properties than acrylic strong floor supplies. Along with the acrylic resin utilized in strong floor, the strong floor materials receives extra bodily and chemical traits from the addition of alumina-tri-hydrate, or ATH. The ATH causes cleaners that adversely have an effect on acrylic to haven't any have an effect on on strong floor.
Strong floor shower pans are the top-of-the-line in bodily and chemical traits in addition to efficiency, repetability and a myriad of different options and advantages. The first options of strong floor are it's non-porous, won't assist the expansion of mould, mildew, or micro organism, is offered in a big number of appears (some like pure granite) and colours, and is 100% repairable ought to chipping , scratching, and even cracking incidence. Well being departments all through the nation have authorised strong floor supplies to be used in hospitals and meals preparation areas for its resistance to bacterial progress, ease of cleansing and upkeep, and resistance to staining and contamination.
Some strong floor shower pan producers fabricate their pans from sheet items similarly because the acrylic shower pans. That's, they thermal kind the pan flooring by heating and stretching the fabric after which bond sidewalls and a threshold to the ground.
The Royal Stone model of strong floor shower pans are the pans that I manufacture and can use as an instance the simplicity and ease of set up that may be had when putting in a composite shower pan. In contrast to fabricated strong floor shower pans, the Royal Stone shower pans are a solid one-piece strong floor product. By casting the pan as a one-piece unit, there aren't any pressures launched within the pan, and there are various different options engineered and designed into this pan.
The obvious options are the big radius transition between the pan ground and its sidewalls. Secondly, the flange (additionally referred to as a weep edge) is 1-1 / 2 "tall. I've seen pans that don't incorporate an integral flange or have flanges half of" to 1 "tall. , if not eradicate, any water being drawn up behind the wall surrounding panels that would trigger water harm to the shower sub-structure.
Royal Stone's pans have a minimal wall thickness of half of "and the webbing parts have a large foot with giant stress relieving radius between the pan ground and the webbing. (2 cm) granite slabs in addition to all different generally used wall supplies like tile, fiberglass, acrylic, and strong floor panels. Lastly, no matter ground loading, the Royal Stone pan ground is so strong that it looks like one is standing on a inflexible concrete ground. There isn't any perceptible flexing or oil-cannning of the pan ground. Thus, there isn't any chance of ground fatigue and cracking over time and the potential for pan failure is eradicated.
INSTALLATION IS FAST AND EASY. As I've already acknowledged, composite pans set up on a flat sub-floor. The next set up data could not apply to all kinds of composite shower pans. Particularly, I've direct information of putting in the solid one-piece strong floor shower pans that Royal Stone manufactures. Thus, the next immediately applies to Royal Stone's normal and customized shower pans. The identical steps also needs to apply to different kinds of composite pans and different supplies, nonetheless, observe the producers advisable set up directions.
As a producer, I don't set up pans. The pictures included inside this text have been offered by a neighborhood installer. They have been supplemented by pictures of a special pan, for readability of the set up course of. Thus the completely different pan colour and form. Additional, many of the pictures have been from a singular plumbing state of affairs. The house had the entire plumbing above floor. Thus, a particleboard platform was constructed above the plumbing for the shower. The next set up data applies to concrete, plywood, particleboard, wooden, and many others. sub-floors at, above, or under grade.
Step # 1 - SUB-FLOOR PREPARATION: Utilizing the template supplied with the shower pan, place template on the ground and confirm that the drain is within the appropriate location. If the drain is NOT correctly situated, relocate the drain. NOTE: Relocating the drain is often far inexpensive than having a customized pan solid to accommodate your present drain location.
The opening within the sub-floor must be bigger than the drain pipe. A couple of 6 "spherical or sq. gap (in regards to the dimension of a espresso can) is advisable This bigger opening permits room for the drain meeting that extends under the underside of the pan. The PVC pipe permits for some flexing inside the 6 "opening within the sub-floor. This flexing is desired and makes the pan set up simpler. The PVC pipe ought to prolong above the completed sub-floor by a minimal of half of" to about three "to four".
The sub-floor might be wooden, plywood, concrete or some other inflexible or effectively supported floor. The sub-floor have to be degree and free from particles. To guarantee a degree ground, verify the ground with an extended degree as proven in Fig. 1. The longer the extent, the extra doubtless that the sub-floor will likely be degree at its biggest dimensions. Examine entrance to again on the left and proper sides and on the heart. Do the identical back and forth. Lastly, verify the diagonals. Fig. 2 signifies the situation of the eight statements that needs to be taken.
Relying on the outcomes of the extent measurements, some extra prep could also be essential. If the sub-floor is reliably flat, shims could also be used to make the shower pan degree. If the ground is uneven and out of degree, pouring self leveling thin-set materials could also be essential.
As soon as the sub-floor is degree and the opening for the drain is appropriate, the setting of the shower pan is subsequent.
Step # 2 - ATTACH DRAIN ASSEMBLY TO PAN: An ordinary 2 half Brass Drain Meeting is advisable, as proven in Fig. three. The sort of meeting needs to be available at any plumbing provide retailer or residence enchancment retailer. Royal Stone additionally sells this drain meeting. Disassemble the drain meeting. Protecting the elements so as makes reassembly sooner and simpler.
Place the pan on noticed horses or any upgraded platform that permits entry to the highest and backside of the pan. Spray the drain opening with rubbing alcohol, Fig. four. With a clear rag, wipe the floor and inside fringe of the pre-cut drain opening, to take away any mud or different contaminants from the pan's drain space. Across the drain opening apply a beneficiant bead of 100% silicone, Fig. 5.
Insert Brass Drain Physique, Half # 5 of the Brass Drain Meeting into the drain gap, Fig. 6, and firmly into place, Fig. 7.
Step # three - REMOVE EXCESS SILICONE: Take away the surplus silicone from the Drain Physique, Half # 5. Spray an alcohol mist over the drain space and the silicone, Fig. eight. With a Dap-Cap, scoop away the surplus silicone, Fig. 9. This step could need to be repeated a number of occasions to utterly take away the silicone. Final, spray a mist of alcohol and wipe remaining movie away from the Drain Physique, Half # 5, with a delicate fabric.
Step # four - MOUNT DRAIN LOCKING RING: Connect the Drain Strainer, Half # 1, to insure that the Drain Physique, Half # 5, is centered inside the drain gap, Fig. 10. From the underside aspect of the shower pan, connect Elements # 6, 7, & eight to Half # 5. Tighten the Locking Ring, Half # eight till comfortable. DO NOT OVER TIGHTEN. Over tightening could crack the shower pan. Take away the Drain Strainer, Half # 1, and put aside.
If any extra silicone has been squeezed out from between the shower pan drain and the Drain Physique, Half # 5, repeat Step # three till all extra silicone has been eliminated.
HANDLING TIP: Utilizing a set of glazer's grips permits for simpler dealing with and transferring the pan into the correct location. If these usually are not obtainable, brute pressure additionally works.
Step # 5 - DRY FIT THE SHOWER PAN: Decrease the shower pan into place. Guarantee that about 1/eight "area exists between the shower pan flange and the studs.With the extent, affirm that the pan is sitting flat on the ground as proven in Fig. 11 & 12. If extra shimming is required, carry pan and place shimming materials the place required. Decrease the pan into place and verify for degree. Repeat till the pan is degree.
CAUTION: When leaving and dealing with the shower pan, deal with rigorously to forestall harm to the shower pan's flange.
A LEVEL PAN IS ESSENTIAL FOR PROPER DRAINAGE.
Step # 6 - SILICONE THE BOTTOM OF THE PAN: Raise pan and lean towards one of many studded partitions. Apply 100% silicone caulking to the webbing, Fig. 13, on the underside of the shower pan. Additionally, apply a thick silicone ring across the drain opening within the sub-floor, Fig. 14. If shims have been used, silicone all shims into place on sub ground as required.
Step # 7 - SET SHOWER PAN: Decrease shower pan into place. Examine the pan for degree. Press down as essential to re-level the shower pan. Apply a silicone bead alongside the entrance fringe of the brink to seal the brink of the pan to the sub-floor.
Step # eight - CONNECT DRAIN PIPE TO DRAIN ASSEMBLY: Inject silicone utterly round and between the drain pipe and the Brass Drain Physique, Half # 5, as proven in Fig. 15. Place the Rubber Gasket, Half # four of the Drain Meeting, over the PVC pipe and slide down till the highest of the Rubber Gasket, Half # four, is totally separated and is under the highest of the Drain Meeting, Fig. 16. Screw the Locking Ring, Half # three of the Drain Meeting onto the Drain Physique, Half # 5. Tighten the Locking Ring, Half # three, with the Tightening Instrument, Half # 2 till the Rubber Gasket, Half # four, is situated and neatly in place.
Step # 9 - TRIMMING THE PVC: The highest of the PVC drain pipe MUST NOT prolong above the Brass Drain Physique, Half # 5. Whether it is on the prime of the Brass Drain Physique, Half # 5, or extends above the highest, trim the PVC in order that it's about 1/four "decrease than the highest of the Brass Drain Physique, Half # 5 however is taller than the highest of the Rubber Gasket, Half # four. Lower the PVC pipe with a Dremel and a cut-off wheel.
If the Tightening Instrument, Half # 2 has not already been eliminated, take away it and press the Drain Strainer, Half # 1, into place. The set up is full. Excluding any sub-floor preparation, the set up ought to take about one hour or much less.
Step # 10 - CURING: Let the shower pan set for 24 to 48 hours to permit the silicone to correctly treatment. As soon as cured, the wallboard and wall panels might be put in.
CAUTION: When attaching strong floor shower pans and wall panels, ONLY use 100% SILICONE. Different adhesives or caulks could harden. The lack of elastic bond between the strong floor and different supplies could cause stresses within the strong floor. In flip, these stresses could trigger fractures of the half and void the producer's guarantee.