Putting in A COMPOSITE SHOWER PAN IS Fast AND Easy. Ahead of talking about the basic actions to set up a composite shower pan, I felt that some clarification and definitions are essential because not all shower pans are alike.
WHAT IS IN A Name? A roof is a roof, even though there are numerous distinct roofing programs and roofing materials. Not accurate with “shower pans.” They are frequently interchangeably named a shower pan, shower pan liner, shower pan membrane liner, water-proof barrier, shower base, shower tray, or shower receptor. However, every has a different that means dependent on context and each are offered in a range of materials.
Bob Vila’s web website defines a SHOWER PAN as “The base, made up of a drinking water drain, of the shower enclosure.” And a SHOWER RECEPTOR as “A one particular-piece base (floor) device employed as a shower, for case in point, to catch h2o and immediate it to a middle drain.”
For the sake of clarity, I supply the pursuing definitions.
SHOWER PAN & SHOWER Base – A finished location that is capable of retaining and directing drinking water to the drain in addition it will not call for tiling as soon as installed. The shower pan or base has a drain hole, sloped floor to appropriately immediate drinking water to the drain gap, sidewalls, and a threshold (entrance to the shower that forms a control to keep drinking water from operating out onto the bathroom floor). A shower pan is synonymous with a shower foundation.
SHOWER PAN LINER, MEMBRANE LINER, & Water-proof BARRIER – A barrier, typically a plastic sheet or membrane, that is supposed to trap h2o that penetrates the shower flooring tile, grout, and mortar beneath the tile and power the h2o to stream to the drain. As prolonged as it will not leak, it helps prevent water from achieving the sub-flooring and bordering wall enclosure. The liner is a component inside of a built shower pan. A shower pan liner is synonymous with a shower pan membrane liner and a watertight barrier.
SHOWER TRAY & SHOWER RECEPTOR – A shower tray is synonymous with a shower receptor. Equally are utilised in place of a liner. They provide the same function as the liner, but are pre-fashioned to get rid of some of the set up actions necessary when utilizing a liner.
Shower pan liners, shower trays, and shower receptors are all used in conjunction with the building of a shower pan that has a tiled flooring as properly as a tiled wall enclosure.
Commercially offered shower pans are comprehensive, ready-to-put in units. They remove the require to produce a mud sloped flooring, a shower liner or tray, and tiling of the shower floor.
COMPOSITE SHOWER PANS. As composite shower pans are manufactured from a quantity of various resources and built differently. I desired to touch on every of the most common kinds. Composite shower pans drop into a number of substance groups cultured marble, fiberglass, acrylic, and solid surface. Typically all are manufactured by fabrication of flat sheets, thermal-formed from a one piece of materials, or molded or forged to sort a one particular piece device. The 1-piece construction eliminates seams, which in switch eradicates potential leaks. Every has their pluses and minuses. Due to the fact attractiveness is in the eye of the beholder, I will not comment on physical appearance. All composite shower pans install on a flat, stage floor and do not require the creation of a sloped mud foundation. Also, the forged or molded pans typically do not require the use of a plastic membrane.
Cultured marble and dressier variations, like cultured onyx and granite, are inclined to be the minimum high priced. Cultured marble is created by spraying a ‘gel-coat’ on to a mold. This coating is about one/64″ or much less in thickness. The gel-coat is protected with pigmentation and then backed with calcium carbonate. The calcium carbonate gives the finished element its power. Also, in the casting procedure it is infused with air pockets to reduce its density and fat.
The cultured marble floor is forged separately from the sidewalls. Therefore, the incorporation of a shower pan liner is essential to insure a watertight, leak totally free set up. Though extensively utilised, the down side of cultured marble is that other than the gel-coat layer, the calcium carbonate is extremely porous. Any crack or scratch by means of the gel-coat will let drinking water penetration. Other gel-coat qualities contain yellowing, even with out UV exposure clouding from very hot tap drinking water staining crazing (good hairline cracks) and it is not reparable when cracked or chipped.
Fiberglass is broadly used as effectively. Fiberglass is robust, light bodyweight and economical. Numerous fiberglass companies make a single-piece shower pans and enclosures and a single-piece combination tubs and showers with the wall enclosures. Comparable to cultured marble, fiberglass is made with a gel-coat, then backed with pigment and chopped strands of fiberglass in a resin mixture. Typically the completed merchandise is about 1/8″ to 1/4″ in thickness. The underside of the shower pan ground has webbing additional to give assist to the floor. As the ground is not strong, the unsupported place between the webbing can flex. This flexing is specially visible with large loading or the place one particular is standing amongst to the webbing. More than time, the flexing can result in material exhaustion and cracking. As soon as a crack develops, the pan has unsuccessful.
Acrylic sheets are used to vacuum kind shower pans, bathtubs, spas and numerous other objects. The vacuum forming procedure begins with a one/four” sheet of pigmented acrylic that is heated to a temperature that helps make the acrylic ductile. The sheet is put on a mold and stretched more than the sort to generate the finished shape. The heating and stretching of the sheet causes a reduction in wall thickness. The reduction is straight proportional to the sum of stretching that occurs. With shower pans there is considerably much less materials reduction than with producing a tub or spa. The heating, stretching, and cooling of the content could also introduce stresses to the finished pan.
Like fiberglass pans, acrylic pans need assist aspects below the pan ground. A typically used assistance element is polyurethane foam. The foam fills the void and eliminated the flexing of the pan flooring. Acrylic sheet materials is susceptible to crazing, minute area cracking, and cracking when cleaned with several widespread cleaning chemical compounds. Need to crazing occur, above time these cracks can lead to a pan failure.
Acrylic sheets have extremely distinct physical and chemical houses than acrylic sound floor resources. In addition to the acrylic resin used in strong surface, the reliable surface area substance receives additional bodily and chemical qualities from the addition of alumina-tri-hydrate, or ATH. The ATH triggers cleaners that adversely affect acrylic to have no affect on strong surface.
Reliable area shower pans are the best-of-the-line in bodily and chemical attributes as well as efficiency, reparability and a myriad of other attributes and advantages. The main characteristics of reliable surface area are it is non-porous, will not assistance the progress of mold, mildew, or bacteria, is available in a huge selection of appears (some like normal granite) and colours, and is one hundred% repairable need to chipping, scratching, or even cracking take place. Overall health departments through the nation have accepted reliable surface area supplies for use in hospitals and foodstuff preparing locations for its resistance to bacterial expansion, ease of cleaning and upkeep, and resistance to staining and contamination.
Some sound floor shower pan companies fabricate their pans from sheet goods in a equivalent fashion as the acrylic shower pans. That is, they thermal type the pan floors by heating and stretching the content and then bond sidewalls and a threshold to the ground.
The Royal Stone model of strong surface area shower pans are the pans that I manufacture and will use to illustrate the simplicity and simplicity of installation that can be had when putting in a composite shower pan. Unlike fabricated sound surface area shower pans, the Royal Stone shower pans are a forged 1-piece solid floor product. By casting the pan as a one particular-piece device, there are no stresses launched in the pan, and there are many other attributes engineered and created into this pan.
The most evident functions are the big radius transition in between the pan floor and its sidewalls. Secondly, the flange (also called a weep edge) is 1-one/two” tall. I have witnessed pans that do not include an integral flange or have flanges 1/2″ to 1″ tall. The included top is designed to minimize, if not get rid of, any water getting drawn up driving the wall surround panels that could trigger h2o hurt to the shower sub-composition.
Royal Stone’s pans have a minimal wall thickness of one/2″ and the webbing factors have a extensive foot with huge tension relieving radius corners amongst the pan floor and the webbing. All shower pans are engineered to assist the weight of 3/4″ thick (2 cm) granite slabs as nicely as all other frequently used wall resources like tile, fiberglass, acrylic, and strong area panels. Lastly, no matter of ground loading, the Royal Stone pan flooring is so strong that it feels like a single is standing on a rigid concrete ground. There is no perceptible flexing or oil-canning of the pan ground. Hence, there is no possibility of flooring fatigue and cracking over time and the possible for pan failure is eliminated.
Installation IS Quickly AND Easy. As I have already mentioned, composite pans put in on a flat sub-ground. The pursuing set up data might not use to all kinds of composite shower pans. Especially, I have direct information of setting up the solid one-piece sound area shower pans that Royal Stone manufactures. Thus, the subsequent directly applies to Royal Stone’s standard and personalized shower pans. The very same actions must also apply to other types of composite pans and other resources, nonetheless, adhere to the manufacturers advisable set up guidelines.
As a producer, I do not set up pans. The photographs incorporated in this post ended up provided by a local installer. They had been supplemented by photographs of a various pan, for clarity of the set up method. Therefore the various pan coloration and condition. Further, most of the photos ended up from a distinctive plumbing scenario. The residence had all of the plumbing above ground. Therefore, a particleboard platform was developed previously mentioned the plumbing for the shower. The subsequent set up info applies to concrete, plywood, particleboard, wooden, and many others. sub-flooring at, above, or underneath grade.
Action #1 – SUB-Flooring Preparation: Employing the template offered with the shower pan, location template on the ground and validate that the drain is in the right area. If the drain is NOT properly situated, relocate the drain. Note: Relocating the drain is usually considerably considerably less high-priced than obtaining a custom made pan solid to accommodate your current drain area.
The hole in the sub-ground wants to be larger than the drain pipe. About a 6″ round or sq. hole (about the dimension of a espresso can) is advised. This greater opening enables room for the drain assembly that extends under the bottom of the pan. Most drain pipes are two” PVC. The PVC pipe enables for some flexing inside of the six” opening in the sub-flooring. This flexing is preferred and tends to make the pan set up less difficult. The PVC pipe ought to prolong previously mentioned the concluded sub-floor by a minimum of 1/2″ to about 3″ to 4″.
The sub-floor can be wooden, plywood, concrete or any other rigid or properly supported surface. The sub-floor have to be amount and free from debris. To guarantee a amount flooring, verify the flooring with a long degree as shown in Fig. one. The lengthier the amount, the far more very likely that the sub-ground will be amount at its best dimensions. Check out entrance to again at the remaining and appropriate sides and at the center. Do the identical from side to facet. Lastly, check the diagonals. Fig. 2 indicates the location of the 8 readings that ought to be taken.
Relying on the benefits of the level measurements, some additional prep may possibly be required. If the sub-ground is relatively flat, shims may possibly be utilised to make the shower pan amount. If the ground is uneven and out of degree, pouring self leveling slender-set content may possibly be required.
As soon as the sub-ground is level and the opening for the drain is appropriate, the environment of the shower pan is following.
Step #two – Connect DRAIN ASSEMBLY TO PAN: A normal two component Brass Drain Assembly is advisable, as proven in Fig. 3. This sort of assembly ought to be commonly accessible at any plumbing provide store or property improvement retailer. Royal Stone also sells this drain assembly. Disassemble the drain assembly. Keeping the components in purchase can make reassembly more quickly and less difficult.
Area the pan on saw horses or any raised system that allows entry to the top and base of the pan. Spray the drain opening with rubbing alcohol, Fig. 4. With a clear rag, wipe the floor and inside edge of the pre-minimize drain opening, to take away any dust or other contaminants from the pan’s drain location. About the drain opening apply a generous bead of 100% silicone, Fig. five.
Insert Brass Drain Body, Part #5 of the Brass Drain Assembly into the drain gap, Fig. six, and press firmly into spot, Fig. 7.
Step #three – Take away Excessive SILICONE: Take away the surplus silicone from the Drain Body, Part #five. Spray an liquor mist more than the drain area and the silicone, Fig. eight. With a Dap-Cap, scoop away the extra silicone, Fig. nine. This stage might have to be repeated many occasions to completely take away the silicone. Very last, spray a mist of liquor and wipe remaining film away from the Drain Body, Component #five, with a comfortable cloth.
Phase #4 – MOUNT DRAIN LOCKING RING: Connect the Drain Strainer, Part #one, to assure that the Drain Human body, Part #5, is centered inside the drain gap, Fig. 10. From the base facet of the shower pan, connect Elements #6, seven, & 8 to Component #five. Tighten the Locking Ring, Element #eight until finally cosy. DO NOT More than TIGHTEN. Above tightening might crack the shower pan. Eliminate the Drain Strainer, Portion #one, and set apart.
If any additional silicone has been squeezed out from among the shower pan drain and the Drain Physique, Element #5, repeat Stage #3 until all surplus silicone has been taken out.
Handling Tip: Making use of a established of glazer’s grips allows for less complicated dealing with and transferring the pan into the appropriate spot. If these are not offered, brute pressure also works.
Step #five – DRY In shape THE SHOWER PAN: Reduced the shower pan into place. Make positive that about one/8″ area exists between the shower pan flange and the studs. With the level, validate that the pan is sitting flat on the ground as shown in Fig. eleven & 12. If extra shimming is essential, raise pan and spot shimming materials exactly where essential. Reduced the pan into spot and verify for amount. Repeat right up until the pan is level.
Warning: When leaning and handling the shower pan, handle cautiously to stop injury to the shower pan’s flange.
A Stage PAN IS Essential FOR Proper DRAINAGE.
Action #6 – SILICONE THE Bottom OF THE PAN: Carry pan and lean towards a single of the studded walls. Apply one hundred% silicone caulking to the webbing, Fig. thirteen, on the underside of the shower pan . Also, utilize a thick silicone ring around the drain opening in the sub-ground, Fig. fourteen. If shims had been utilised, silicone all shims into position on sub ground as required.
Stage #seven – Set SHOWER PAN: Decrease shower pan into spot. Examine the pan for stage. Push down as needed to re-amount the shower pan. Utilize a silicone bead alongside the entrance edge of the threshold to seal the threshold of the pan to the sub-floor.
Phase #8 – Link DRAIN PIPE TO DRAIN ASSEMBLY: Inject silicone totally close to and in between the drain pipe and the Brass Drain Body, Component #five, as proven in Fig. fifteen. Place the Rubber Gasket, Element #four of the Drain Assembly, in excess of the PVC pipe and slide down till the top of the Rubber Gasket, Element #4, is totally seated and is underneath the leading of the Drain Assemble, Fig. 16. Screw the Locking Ring, Part #3 of the Drain Assembly on to the Drain Physique, Part #5. Tighten the Locking Ring, Portion #three, with the Tightening Instrument, Component #two until the Rubber Gasket, Portion #four, is seated and tightly in location.
Action #nine – TRIMMING THE PVC: The leading of the PVC drain pipe Have to NOT lengthen earlier mentioned the Brass Drain Physique, Component #5. If it is at the leading of the Brass Drain Human body, Element #five, or extends over the top, trim the PVC so that it is about 1/4″ lower than the best of the Brass Drain Physique, Component #5 but is taller than the leading of the Rubber Gasket, Element #4. Cut the PVC pipe with a Dremel and a lower-off wheel.
If the Tightening Tool, Element #2 has not already been taken out, get rid of it and press the Drain Strainer, Component #one, into area. The set up is full. Excluding shower steamers australia -flooring planning, the set up need to consider about one particular hour or significantly less.
Step #10 – CURING: Permit the shower pan established for 24 to forty eight hrs to let the silicone to appropriately remedy. When healed, the wallboard and wall panels can be put in.
Caution: When attaching solid floor shower pans and wall panels, ONLY use a hundred% SILICONE. Other adhesives or caulks could harden. The reduction of the elastic bond amongst the strong surface area and other resources can result in stresses in the sound surface. In change, these stresses could result in fractures of the part and void the manufacturer’s guarantee.