Installing A COMPOSITE SHOWER PAN IS Quickly AND Easy. Just before discussing the straightforward measures to set up a composite shower pan, I felt that some clarification and definitions are necessary since not all shower pans are alike.
WHAT IS IN A Identify? A roof is a roof, despite the fact that there are many different roofing systems and roofing materials. Not accurate with “shower pans.” They are frequently interchangeably called a shower pan, shower pan liner, shower pan membrane liner, water-resistant barrier, shower base, shower tray, or shower receptor. Yet, each and every has a various which means depending on context and each and every are accessible in a assortment of supplies.
Bob Vila’s internet site defines a SHOWER PAN as “The foundation, made up of a drinking water drain, of the shower enclosure.” And a SHOWER RECEPTOR as “A one-piece foundation (ground) unit utilized as a shower, for illustration, to catch h2o and direct it to a middle drain.”
For the sake of clarity, I offer the subsequent definitions.
SHOWER PAN & SHOWER Foundation – A finished location that is able of retaining and directing h2o to the drain in addition it doesn’t demand tiling after put in. The shower pan or foundation has a drain hole, sloped floor to properly direct h2o to the drain gap, sidewalls, and a threshold (entrance to the shower that forms a curb to keep water from operating out on to the toilet flooring). A shower pan is synonymous with a shower foundation.
SHOWER PAN LINER, MEMBRANE LINER, & Water-proof BARRIER – A barrier, usually a plastic sheet or membrane, that is intended to lure water that penetrates the shower flooring tile, grout, and mortar below the tile and power the h2o to stream to the drain. As long as it does not leak, it stops drinking water from reaching the sub-floor and surrounding wall enclosure. The liner is a part in a created 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 receptor. The two are utilized in location of a liner. They provide the exact same function as the liner, but are pre-fashioned to eliminate some of the installation measures necessary when utilizing a liner.
Shower pan liners, shower trays, and shower receptors are all employed in conjunction with the development of a shower pan that has a tiled ground as nicely as a tiled wall enclosure.
Commercially accessible shower pans are complete, ready-to-set up units. They eradicate the want to generate a mud sloped flooring, a shower liner or tray, and tiling of the shower flooring.
COMPOSITE SHOWER PANS. As composite shower pans are manufactured from a variety of various materials and created in a different way. I desired to contact on every single of the most typical kinds. Composite shower pans fall into several material groups cultured marble, fiberglass, acrylic, and reliable surface. Typically all are manufactured by fabrication of flat sheets, thermal-shaped from a one piece of material, or molded or cast to kind a 1 piece unit. The a single-piece building gets rid of seams, which in switch eliminates potential leaks. Each has their pluses and minuses. Since attractiveness is in the eye of the beholder, I will not comment on look. All composite shower pans set up on a flat, degree flooring and do not need the generation of a sloped mud base. Also, the cast or molded pans normally do not demand the use of a plastic membrane.
Cultured marble and dressier versions, like cultured onyx and granite, are inclined to be the the very least pricey. Cultured marble is manufactured by spraying a ‘gel-coat’ on to a mildew. This coating is about one/sixty four” or significantly less in thickness. The gel-coat is covered with pigmentation and then backed with calcium carbonate. The calcium carbonate offers the finished portion its toughness. Also, in the casting procedure it is infused with air pockets to lower its density and fat.
The cultured marble floor is forged separately from the sidewalls. As a result, the incorporation of a shower pan liner is vital to insure a watertight, leak totally free installation. Despite the fact that commonly utilized, the down facet of cultured marble is that other than the gel-coat layer, the calcium carbonate is extremely porous. Any crack or scratch by way of the gel-coat will permit water penetration. Other gel-coat traits consist of yellowing, even with no UV publicity clouding from sizzling tap water staining crazing (wonderful hairline cracks) and it is not reparable when cracked or chipped.
Fiberglass is broadly utilized as properly. Fiberglass is sturdy, mild weight and affordable. A lot of fiberglass manufacturers make one-piece shower pans and enclosures and a single-piece combination tubs and showers with the wall enclosures. Equivalent to cultured marble, fiberglass is created with a gel-coat, then backed with pigment and chopped strands of fiberglass in a resin mixture. Generally the completed product is about one/8″ to one/four” in thickness. The underside of the shower pan ground has webbing included to provide support to the flooring. As the floor is not strong, the unsupported place amongst the webbing can flex. This flexing is specifically noticeable with hefty loading or in which 1 is standing amongst to the webbing. In excess of time, the flexing can trigger substance exhaustion and cracking. Once a crack develops, the pan has unsuccessful.
Acrylic sheets are utilised to vacuum form shower pans, bathtubs, spas and numerous other products. The vacuum forming method commences with a one/four” sheet of pigmented acrylic that is heated to a temperature that tends to make the acrylic ductile. The sheet is positioned on a mold and stretched over the sort to develop the finished form. The heating and stretching of the sheet brings about a reduction in wall thickness. The reduction is straight proportional to the volume of stretching that takes place. With shower pans there is significantly much less material reduction than with creating a tub or spa. The heating, stretching, and cooling of the material could also introduce stresses to the concluded pan.
Like fiberglass pans, acrylic pans want assist elements beneath the pan floor. A typically utilized support component is polyurethane foam. The foam fills the void and eliminated the flexing of the pan ground. Acrylic sheet material is susceptible to crazing, minute surface area cracking, and cracking when cleaned with many common cleaning chemical compounds. Ought to crazing arise, over time these cracks can direct to a pan failure.
Acrylic sheets have really diverse bodily and chemical qualities than acrylic strong surface components. In addition to the acrylic resin utilised in strong area, the strong surface area content gets added physical and chemical characteristics from the addition of alumina-tri-hydrate, or ATH. The ATH brings about cleaners that adversely impact acrylic to have no affect on sound floor.
Sound surface area shower pans are the prime-of-the-line in bodily and chemical characteristics as properly as performance, reparability and a myriad of other characteristics and positive aspects. The major characteristics of solid surface area are it is non-porous, will not assist the expansion of mold, mildew, or germs, is obtainable in a huge selection of appears (some like all-natural granite) and colors, and is 100% repairable should chipping, scratching, or even cracking happen. Health departments all through the place have approved strong surface supplies for use in hospitals and meals planning locations for its resistance to bacterial progress, ease of cleaning and servicing, and resistance to staining and contamination.
Some strong surface area shower pan manufacturers fabricate their pans from sheet products in a comparable trend as the acrylic shower pans. That is, they thermal sort the pan flooring by heating and stretching the content and then bond sidewalls and a threshold to the flooring.
The Royal Stone model of solid floor shower pans are the pans that I manufacture and will use to illustrate the simplicity and ease of installation that can be experienced when putting in a composite shower pan. Unlike fabricated strong floor shower pans, the Royal Stone shower pans are a cast one-piece reliable surface area solution. By casting the pan as a one-piece device, there are no stresses launched in the pan, and there are numerous other features engineered and made into this pan.
The most obvious functions are the big radius transition between the pan floor and its sidewalls. Secondly, the flange (also called a weep edge) is one-1/two” tall. I have witnessed pans that do not incorporate an integral flange or have flanges 1/2″ to 1″ tall. The added height is designed to decrease, if not remove, any h2o currently being drawn up driving the wall surround panels that could cause h2o damage to the shower sub-composition.
Royal Stone’s pans have a minimal wall thickness of one/two” and the webbing components have a broad foot with huge anxiety relieving radius corners between the pan floor and the webbing. All shower pans are engineered to support the excess weight of 3/four” thick (2 cm) granite slabs as nicely as all other commonly employed wall resources like tile, fiberglass, acrylic, and sound surface area panels. Last but not least, no matter of ground loading, the Royal Stone pan floor is so sound that it feels like one is standing on a rigid concrete flooring. There is no perceptible flexing or oil-canning of the pan flooring. Therefore, there is no probability of floor exhaustion and cracking more than time and the likely for pan failure is eliminated.
Installation IS Quickly AND Straightforward. As I have presently stated, composite pans put in on a flat sub-flooring. The following set up details might not apply to all sorts of composite shower pans. Particularly, I have direct understanding of setting up the forged one-piece sound area shower pans that Royal Stone manufactures. Therefore, the following right applies to Royal Stone’s standard and custom shower pans. The very same measures ought to also utilize to other sorts of composite pans and other materials, nevertheless, stick to the makers advisable installation recommendations.
As a maker, I do not put in pans. The images provided inside of this write-up had been offered by a nearby installer. yoursite.com They were supplemented by photographs of a different pan, for clarity of the set up procedure. Hence the different pan coloration and shape. Additional, most of the pictures were from a special plumbing predicament. The home had all of the plumbing earlier mentioned floor. Hence, a particleboard platform was constructed earlier mentioned the plumbing for the shower. The following set up data applies to concrete, plywood, particleboard, wooden, etc. sub-flooring at, earlier mentioned, or under quality.
Action #one – SUB-Floor Preparation: Using the template offered with the shower pan, spot template on the ground and confirm that the drain is in the correct place. If the drain is NOT appropriately positioned, relocate the drain. Note: Relocating the drain is typically far much less high-priced than possessing a personalized pan cast to accommodate your existing drain spot.
The gap in the sub-floor demands to be larger than the drain pipe. About a 6″ round or square gap (about the measurement of a espresso can) is advised. This greater opening makes it possible for room for the drain assembly that extends underneath the base of the pan. Most drain pipes are 2″ PVC. The PVC pipe allows for some flexing inside of the six” opening in the sub-ground. This flexing is desired and can make the pan installation less difficult. The PVC pipe must lengthen earlier mentioned the concluded sub-floor by a minimal of one/two” to about 3″ to four”.
The sub-flooring can be wood, plywood, concrete or any other rigid or nicely supported surface. The sub-ground need to be stage and totally free from particles. To assure a level floor, examine the ground with a prolonged amount as revealed in Fig. one. The longer the stage, the more very likely that the sub-ground will be level at its best proportions. Check front to again at the remaining and proper sides and at the heart. Do the exact same from side to side. Last but not least, verify the diagonals. Fig. 2 indicates the spot of the 8 readings that should be taken.
Dependent on the final results of the stage measurements, some added prep could be required. If the sub-ground is comparatively flat, shims might be used to make the shower pan stage. If the ground is uneven and out of amount, pouring self leveling slender-set content might be essential.
After the sub-flooring is amount and the opening for the drain is appropriate, the environment of the shower pan is up coming.
Stage #two – Connect DRAIN ASSEMBLY TO PAN: A normal two component Brass Drain Assembly is recommended, as demonstrated in Fig. 3. This kind of assembly should be conveniently obtainable at any plumbing offer shop or home enhancement keep. Royal Stone also sells this drain assembly. Disassemble the drain assembly. Trying to keep the parts in order helps make reassembly faster and easier.
Location the pan on noticed horses or any raised system that enables obtain to the leading and base of the pan. Spray the drain opening with rubbing alcoholic beverages, Fig. 4. With a thoroughly clean rag, wipe the floor and inside edge of the pre-lower drain opening, to take away any dust or other contaminants from the pan’s drain spot. All around the drain opening apply a generous bead of one hundred% silicone, Fig. five.
Insert Brass Drain Physique, Part #five of the Brass Drain Assembly into the drain hole, Fig. six, and press firmly into place, Fig. 7.
Step #three – Eliminate Extra SILICONE: Get rid of the excess silicone from the Drain Body, Element #5. Spray an liquor mist above the drain location and the silicone, Fig. eight. With a Dap-Cap, scoop absent the surplus silicone, Fig. nine. This stage may possibly have to be recurring numerous occasions to completely take away the silicone. Final, spray a mist of alcohol and wipe remaining film absent from the Drain Human body, Part #5, with a soft fabric.
Stage #four – MOUNT DRAIN LOCKING RING: Connect the Drain Strainer, Component #one, to assure that the Drain Human body, Component #5, is centered within the drain hole, Fig. ten. From the bottom aspect of the shower pan, connect Elements #six, seven, & eight to Portion #5. Tighten the Locking Ring, Element #eight right up until snug. DO NOT In excess of TIGHTEN. Over tightening may possibly crack the shower pan. Get rid of the Drain Strainer, Element #one, and established aside.
If any further silicone has been squeezed out from between the shower pan drain and the Drain Physique, Part #5, repeat Stage #3 till all extra silicone has been removed.
Dealing with Idea: Making use of a set of glazer’s grips enables for less complicated dealing with and transferring the pan into the correct spot. If these are not available, brute pressure also operates.
Phase #five – DRY In shape THE SHOWER PAN: Reduced the shower pan into spot. Make positive that about 1/eight” space exists amongst the shower pan flange and the studs. With the level, confirm that the pan is sitting flat on the flooring as proven in Fig. 11 & twelve. If extra shimming is required, elevate pan and location shimming material the place required. Lower the pan into place and examine for stage. Repeat until the pan is stage.
Warning: When leaning and handling the shower pan, deal with cautiously to avoid damage to the shower pan’s flange.
A Amount PAN IS Vital FOR Correct DRAINAGE.
Stage #6 – SILICONE THE Bottom OF THE PAN: Carry pan and lean from one of the studded partitions. Implement a hundred% silicone caulking to the webbing, Fig. thirteen, on the underside of the shower pan . Also, utilize a thick silicone ring close to the drain opening in the sub-flooring, Fig. 14. If shims have been used, silicone all shims into position on sub ground as essential.
Stage #7 – Established SHOWER PAN: Lower shower pan into spot. Verify the pan for amount. Press down as required to re-degree the shower pan. Implement a silicone bead along the entrance edge of the threshold to seal the threshold of the pan to the sub-flooring.
Stage #eight – Hook up DRAIN PIPE TO DRAIN ASSEMBLY: Inject silicone entirely close to and amongst the drain pipe and the Brass Drain Body, Element #five, as proven in Fig. 15. Spot the Rubber Gasket, Element #four of the Drain Assembly, above the PVC pipe and slide down until the leading of the Rubber Gasket, Portion #four, is fully seated and is under the top of the Drain Assemble, Fig. sixteen. Screw the Locking Ring, Component #3 of the Drain Assembly onto the Drain Body, Portion #5. Tighten the Locking Ring, Part #3, with the Tightening Device, Portion #2 until finally the Rubber Gasket, Portion #4, is seated and tightly in location.
Stage #9 – TRIMMING THE PVC: The best of the PVC drain pipe Should NOT extend previously mentioned the Brass Drain Body, Component #five. If it is at the leading of the Brass Drain Entire body, Portion #5, or extends over the top, trim the PVC so that it is about 1/four” lower than the top of the Brass Drain Entire body, Element #five but is taller than the best of the Rubber Gasket, Component #4. Lower the PVC pipe with a Dremel and a lower-off wheel.
If the Tightening Instrument, Element #2 has not currently been taken off, eliminate it and push the Drain Strainer, Portion #one, into spot. The installation is full. Excluding any sub-ground planning, the installation must just take about 1 hour or less.
Phase #ten – CURING: Permit the shower pan set for 24 to forty eight hrs to allow the silicone to properly heal. Once remedied, the wallboard and wall panels can be mounted.
Caution: When attaching solid area shower pans and wall panels, ONLY use 100% SILICONE. Other adhesives or caulks might harden. The reduction of the elastic bond among the strong floor and other components can trigger stresses in the reliable surface. In turn, these stresses may result in fractures of the portion and void the manufacturer’s guarantee.
