Putting in A COMPOSITE SHOWER PAN IS Quickly AND Effortless. Before discussing the simple steps to install a composite shower pan, I felt that some clarification and definitions are essential because not all shower pans are alike.
WHAT IS IN A Title? A roof is a roof, despite the fact that there are a lot of diverse roofing systems and roofing materials. Not true with “shower pans.” They are usually interchangeably known as a shower pan, shower pan liner, shower pan membrane liner, water-resistant barrier, shower foundation, shower tray, or shower receptor. Nevertheless, each has a different indicating dependent on context and each are offered in a range of components.
Bob Vila’s web website defines a SHOWER PAN as “The base, containing a h2o drain, of the shower enclosure.” And a SHOWER RECEPTOR as “A one-piece base (flooring) device used as a shower, for instance, to catch water and direct it to a center drain.”
For the sake of clarity, I provide the subsequent definitions.
SHOWER PAN & SHOWER Base – A concluded location that is able of retaining and directing water to the drain plus it will not demand tiling as soon as put in. The shower pan or foundation has a drain hole, sloped floor to effectively direct water to the drain gap, sidewalls, and a threshold (entrance to the shower that types a suppress to keep drinking water from running out onto the bathroom floor). A shower pan is synonymous with a shower base.
SHOWER PAN LINER, MEMBRANE LINER, & Water-proof BARRIER – A barrier, typically a plastic sheet or membrane, that is intended to lure drinking water that penetrates the shower ground tile, grout, and mortar beneath the tile and drive the drinking water to movement to the drain. As prolonged as it doesn’t leak, it stops h2o from reaching the sub-flooring and bordering wall enclosure. The liner is a part in a made shower pan. A shower pan liner is synonymous with a shower pan membrane liner and a waterproof barrier.
SHOWER TRAY & SHOWER RECEPTOR – A shower tray is synonymous with a shower receptor. Both are employed in place of a liner. They serve the exact same function as the liner, but are pre-fashioned to get rid of some of the installation actions needed when utilizing a liner.
Shower pan liners, shower trays, and shower receptors are all used in conjunction with the design of a shower pan that has a tiled floor as well as a tiled wall enclosure.
Commercially obtainable shower pans are full, ready-to-put in units. They remove the need to have to produce a mud sloped ground, a shower liner or tray, and tiling of the shower floor.
COMPOSITE SHOWER PANS. As composite shower pans are manufactured from a quantity of diverse components and created otherwise. I needed to touch on each of the most common types. Composite shower pans slide into numerous materials groups cultured marble, fiberglass, acrylic, and sound surface. Normally all are produced by fabrication of flat sheets, thermal-formed from a one piece of substance, or molded or forged to type a a single piece device. The a single-piece construction removes seams, which in flip gets rid of possible leaks. Each and every has their pluses and minuses. Simply because beauty is in the eye of the beholder, I will not comment on appearance. All composite shower pans set up on a flat, amount floor and do not demand the generation of a sloped mud base. Also, the cast or molded pans typically do not call for the use of a plastic membrane.
Cultured marble and dressier variations, like cultured onyx and granite, have a tendency to be the minimum expensive. Cultured marble is produced by spraying a ‘gel-coat’ onto 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 concluded component its energy. Also, in the casting approach it is infused with air pockets to reduced its density and bodyweight.
The cultured marble floor is cast separately from the sidewalls. Thus, the incorporation of a shower pan liner is vital to insure a watertight, leak free set up. Though extensively employed, the down side of cultured marble is that other than the gel-coat layer, the calcium carbonate is hugely porous. Any crack or scratch through the gel-coat will allow water penetration. Other gel-coat qualities contain yellowing, even with no UV exposure clouding from scorching faucet water staining crazing (fine hairline cracks) and it is not reparable when cracked or chipped.
Fiberglass is extensively employed as nicely. Fiberglass is robust, gentle excess weight and inexpensive. Several fiberglass makers make one-piece shower pans and enclosures and one particular-piece mixture tubs and showers with the wall enclosures. Similar to cultured marble, fiberglass is produced with a gel-coat, then backed with pigment and chopped strands of fiberglass in a resin combination. Generally the finished item is about one/8″ to one/four” in thickness. The underside of the shower pan ground has webbing extra to give assist to the floor. As the floor is not sound, the unsupported place among the webbing can flex. This flexing is especially visible with hefty loading or the place a single is standing among to the webbing. In excess of time, the flexing can cause content tiredness and cracking. After a crack develops, the pan has unsuccessful.
Acrylic sheets are employed to vacuum kind shower pans, bathtubs, spas and a lot of other items. The vacuum forming procedure starts with a one/four” sheet of pigmented acrylic that is heated to a temperature that tends to make the acrylic ductile. The sheet is put on a mould and stretched over the form to develop the finished form. The heating and stretching of the sheet brings about a reduction in wall thickness. The reduction is directly proportional to the sum of stretching that occurs. With shower pans there is 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 completed pan.
Like fiberglass pans, acrylic pans need to have assist elements below the pan floor. A commonly used help component is polyurethane foam. The foam fills the void and eliminated the flexing of the pan floor. Acrylic sheet material is vulnerable to crazing, minute floor cracking, and cracking when cleaned with a lot of typical cleansing chemicals. Need to crazing occur, more than time these cracks can direct to a pan failure.
Acrylic sheets have really distinct actual physical and chemical qualities than acrylic reliable area components. In addition to the acrylic resin used in reliable surface, the solid surface area content receives extra bodily and chemical traits from the addition of alumina-tri-hydrate, or ATH. The ATH brings about cleaners that adversely affect acrylic to have no influence on sound area.
Sound area shower pans are the prime-of-the-line in actual physical and chemical qualities as properly as overall performance, reparability and a myriad of other characteristics and advantages. The major features of strong area are it is non-porous, will not assist the growth of mold, mildew, or bacteria, is offered in a massive selection of seems to be (some like all-natural granite) and colors, and is 100% repairable need to chipping, scratching, or even cracking take place. Well being departments through the place have approved solid floor materials for use in hospitals and meals preparation regions for its resistance to bacterial growth, ease of cleansing and upkeep, and resistance to staining and contamination.
Some solid surface shower pan producers fabricate their pans from sheet products in a similar vogue 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 ground.
The Royal Stone model of sound surface area shower pans are the pans that I manufacture and will use to illustrate the simplicity and ease of set up that can be experienced when installing a composite shower pan. Not like fabricated solid surface area shower pans, the Royal Stone shower pans are a solid 1-piece solid 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 created into this pan.
The most clear functions are the big radius transition among the pan ground and its sidewalls. Secondly, the flange (also referred to as a weep edge) is one-1/two” tall. I have seen pans that do not integrate an integral flange or have flanges 1/2″ to 1″ tall. The extra peak is designed to decrease, if not eradicate, any h2o currently being drawn up behind the wall surround panels that could cause drinking water hurt to the shower sub-framework.
Royal Stone’s pans have a least wall thickness of 1/two” and the webbing aspects have a vast foot with huge pressure relieving radius corners in between the pan floor and the webbing. All shower pans are engineered to help the weight of three/four” thick (2 cm) granite slabs as effectively as all other generally used wall supplies like tile, fiberglass, acrylic, and solid area panels. Lastly, no matter of ground loading, the Royal Stone pan ground is so sound that it feels like a single is standing on a rigid concrete floor. There is no perceptible flexing or oil-canning of the pan floor. As a result, there is no likelihood of flooring tiredness and cracking over time and the prospective for pan failure is eradicated.
Installation IS Quickly AND Straightforward. As I have presently mentioned, composite pans put in on a flat sub-floor. The pursuing set up details may not use to all varieties of composite shower pans. Specifically, I have direct information of setting up the solid 1-piece strong surface area shower pans that Royal Stone manufactures. As a result, the pursuing right applies to Royal Stone’s standard and custom shower pans. The exact same actions must also utilize to other kinds of composite pans and other materials, nevertheless, follow the makers recommended installation instructions.
As a manufacturer, I do not set up pans. The photos incorporated in this article had been presented by a neighborhood installer. They have been supplemented by photos of a various pan, for clarity of the set up procedure. Thus the distinct pan shade and condition. Even more, most of the photos had been from a distinctive plumbing predicament. The home experienced all of the plumbing earlier mentioned ground. Therefore, a particleboard system was developed over the plumbing for the shower. The subsequent set up information applies to concrete, plywood, particleboard, wooden, and so forth. sub-flooring at, previously mentioned, or below grade.
Stage #one – SUB-Ground Preparation: Employing the template presented with the shower pan, area template on the ground and confirm that the drain is in the appropriate area. If the drain is NOT correctly located, relocate the drain. Notice: Relocating the drain is normally considerably considerably less costly than obtaining a custom pan cast to accommodate your present drain location.
The hole in the sub-ground needs to be bigger than the drain pipe. About a 6″ spherical or sq. hole (about the size of a espresso can) is suggested. This larger opening permits room for the drain assembly that extends under the base of the pan. walk in showers Most drain pipes are two” PVC. The PVC pipe makes it possible for for some flexing inside the six” opening in the sub-flooring. This flexing is wanted and helps make the pan set up simpler. The PVC pipe ought to prolong over the finished sub-ground by a minimal of 1/2″ to about three” to 4″.
The sub-flooring can be wooden, plywood, concrete or any other rigid or effectively supported floor. The sub-flooring have to be stage and free of charge from particles. To assure a level ground, verify the ground with a lengthy degree as proven in Fig. one. The for a longer time the stage, the far more likely that the sub-ground will be stage at its biggest proportions. Verify front to back again at the remaining and proper sides and at the center. Do the same from aspect to aspect. Last but not least, check out the diagonals. Fig. 2 indicates the location of the 8 readings that must be taken.
Based on the benefits of the amount measurements, some additional prep could be needed. If the sub-floor is comparatively flat, shims may be utilized to make the shower pan amount. If the floor is uneven and out of amount, pouring self leveling slender-set content may possibly be required.
After the sub-flooring is stage and the opening for the drain is correct, the placing of the shower pan is following.
Action #2 – Attach DRAIN ASSEMBLY TO PAN: A normal 2 element Brass Drain Assembly is suggested, as proven in Fig. 3. This kind of assembly need to be readily accessible at any plumbing supply store or home advancement keep. Royal Stone also sells this drain assembly. Disassemble the drain assembly. Keeping the factors in order can make reassembly faster and simpler.
Place the pan on observed horses or any lifted platform that enables accessibility to the leading and base of the pan. Spray the drain opening with rubbing liquor, Fig. four. With a cleanse rag, wipe the area and inside edge of the pre-cut drain opening, to get rid of any dust or other contaminants from the pan’s drain spot. About the drain opening use a generous bead of one hundred% silicone, Fig. 5.
Insert Brass Drain Body, Part #five of the Brass Drain Assembly into the drain gap, Fig. 6, and push firmly into location, Fig. 7.
Stage #three – Get rid of Extra SILICONE: Take away the extra silicone from the Drain Body, Element #5. Spray an liquor mist over the drain area and the silicone, Fig. eight. With a Dap-Cap, scoop away the excessive silicone, Fig. nine. This phase might have to be repeated many instances to totally get rid of the silicone. Previous, spray a mist of alcoholic beverages and wipe remaining movie absent from the Drain Physique, Part #five, with a comfortable fabric.
Action #4 – MOUNT DRAIN LOCKING RING: Connect the Drain Strainer, Part #one, to assure that the Drain Body, Part #5, is centered inside the drain hole, Fig. ten. From the base facet of the shower pan, attach Parts #6, seven, & eight to Element #five. Tighten the Locking Ring, Component #8 until finally cosy. DO NOT Above TIGHTEN. More than tightening may crack the shower pan. Get rid of the Drain Strainer, Element #one, and set apart.
If any additional silicone has been squeezed out from amongst the shower pan drain and the Drain Entire body, Element #5, repeat Action #three right up until all excessive silicone has been taken off.
Handling Idea: Employing a set of glazer’s grips enables for easier managing and shifting the pan into the appropriate spot. If these are not available, brute force also functions.
Phase #5 – DRY Suit THE SHOWER PAN: Reduced the shower pan into place. Make confident that about one/eight” area exists in between the shower pan flange and the studs. With the degree, affirm that the pan is sitting flat on the flooring as proven in Fig. 11 & twelve. If further shimming is necessary, raise pan and place shimming substance exactly where needed. Lower the pan into location and check out for amount. Repeat until finally the pan is amount.
Caution: When leaning and handling the shower pan, deal with cautiously to stop injury to the shower pan’s flange.
A Level PAN IS Essential FOR Correct DRAINAGE.
Action #six – SILICONE THE Base OF THE PAN: Lift pan and lean against 1 of the studded walls. Use a hundred% silicone caulking to the webbing, Fig. thirteen, on the underside of the shower pan . Also, implement a thick silicone ring about the drain opening in the sub-floor, Fig. 14. If shims had been utilized, silicone all shims into position on sub flooring as essential.
Stage #7 – Established SHOWER PAN: Decrease shower pan into spot. Examine the pan for stage. Press down as necessary to re-amount the shower pan. Utilize a silicone bead along the entrance edge of the threshold to seal the threshold of the pan to the sub-flooring.
Action #8 – Link DRAIN PIPE TO DRAIN ASSEMBLY: Inject silicone completely all around and among the drain pipe and the Brass Drain Body, Component #five, as demonstrated in Fig. 15. Spot the Rubber Gasket, Part #4 of the Drain Assembly, above the PVC pipe and slide down until the leading of the Rubber Gasket, Element #4, is completely seated and is beneath the top of the Drain Assemble, Fig. sixteen. Screw the Locking Ring, Element #3 of the Drain Assembly on to the Drain Body, Part #5. Tighten the Locking Ring, Component #three, with the Tightening Resource, Component #2 until the Rubber Gasket, Part #four, is seated and tightly in spot.
Phase #nine – TRIMMING THE PVC: The best of the PVC drain pipe Have to NOT increase earlier mentioned the Brass Drain Entire body, Part #five. If it is at the prime of the Brass Drain Physique, Element #5, or extends earlier mentioned the prime, trim the PVC so that it is about 1/four” reduce than the prime of the Brass Drain Human body, Element #five but is taller than the leading of the Rubber Gasket, Component #four. Minimize the PVC pipe with a Dremel and a minimize-off wheel.
If the Tightening Tool, Element #two has not currently been removed, get rid of it and press the Drain Strainer, Element #one, into area. The installation is complete. Excluding any sub-flooring preparing, the set up ought to just take about a single hour or much less.
Stage #ten – CURING: Permit the shower pan set for 24 to 48 hours to enable the silicone to properly treatment. As soon as remedied, the wallboard and wall panels can be put in.
Warning: When attaching solid surface shower pans and wall panels, ONLY use 100% SILICONE. Other adhesives or caulks may possibly harden. The loss of the elastic bond among the solid area and other resources can cause stresses in the solid area. In change, these stresses may cause fractures of the portion and void the manufacturer’s guarantee.