Putting in A COMPOSITE SHOWER PAN IS Rapidly AND Effortless. Ahead of speaking about the basic actions to put in a composite shower pan, I felt that some clarification and definitions are needed simply because not all shower pans are alike.

WHAT IS IN A Title? A roof is a roof, even though there are several different roofing techniques and roofing materials. Not true with “shower pans.” They are often interchangeably referred to as a shower pan, shower pan liner, shower pan membrane liner, water-resistant barrier, shower foundation, shower tray, or shower receptor. Nevertheless, every has a diverse that means dependent on context and each are offered in a selection of supplies.

Bob Vila’s internet internet site defines a SHOWER PAN as “The base, that contains a water drain, of the shower enclosure.” And a SHOWER RECEPTOR as “A one-piece base (flooring) unit utilized 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 subsequent definitions.

SHOWER PAN & SHOWER Base – A finished region that is able of retaining and directing h2o to the drain plus it will not call for tiling once set up. The shower pan or foundation has a drain hole, sloped floor to correctly immediate drinking water to the drain gap, sidewalls, and a threshold (entrance to the shower that varieties a control to preserve h2o from managing out onto the toilet floor). A shower pan is synonymous with a shower base.

SHOWER PAN LINER, MEMBRANE LINER, & Water-proof BARRIER – A barrier, normally a plastic sheet or membrane, that is supposed to entice h2o that penetrates the shower flooring tile, grout, and mortar beneath the tile and force the drinking water to stream to the drain. As extended as it will not leak, it prevents drinking water from achieving the sub-flooring and bordering wall enclosure. The liner is a component inside a made shower pan. A shower pan liner is synonymous with a shower pan membrane liner and a water-proof barrier.

SHOWER TRAY & SHOWER RECEPTOR – A shower tray is synonymous with a shower receptor. Both are employed in spot of a liner. They serve the identical function as the liner, but are pre-shaped to get rid of some of the installation methods needed 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 flooring as properly as a tiled wall enclosure.

Commercially offered shower pans are total, ready-to-set up models. They eliminate the want to generate a mud sloped ground, a shower liner or tray, and tiling of the shower flooring.

COMPOSITE SHOWER PANS. As composite shower pans are manufactured from a quantity of diverse supplies and constructed in a different way. I needed to contact on every single of the most typical types. Composite shower pans tumble into several content groups cultured marble, fiberglass, acrylic, and sound surface. Normally all are manufactured by fabrication of flat sheets, thermal-formed from a solitary piece of substance, or molded or forged to form a a single piece unit. The one-piece building eradicates seams, which in switch gets rid of likely leaks. Each 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, level floor and do not require the generation of a sloped mud base. Also, the solid 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 high priced. Cultured marble is made by spraying a ‘gel-coat’ on to a mildew. This coating is about one/64″ or less in thickness. The gel-coat is coated with pigmentation and then backed with calcium carbonate. The calcium carbonate offers the finished portion its power. Also, in the casting procedure it is infused with air pockets to reduce its density and bodyweight.

The cultured marble floor is solid independently from the sidewalls. As a result, the incorporation of a shower pan liner is vital to insure a watertight, leak free set up. Although broadly used, the down side of cultured marble is that other than the gel-coat layer, the calcium carbonate is highly porous. Any crack or scratch via the gel-coat will allow drinking water penetration. Other gel-coat qualities incorporate yellowing, even without UV exposure clouding from very hot faucet water staining crazing (fantastic hairline cracks) and it is not reparable when cracked or chipped.

Fiberglass is commonly utilised as effectively. Fiberglass is robust, mild fat and inexpensive. Numerous fiberglass manufacturers make one particular-piece shower pans and enclosures and 1-piece blend tubs and showers with the wall enclosures. Similar 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 solution is about one/eight” to one/4″ in thickness. The underside of the shower pan ground has webbing additional to supply assistance to the floor. As the ground is not sound, the unsupported space in between the webbing can flex. This flexing is specifically noticeable with hefty loading or in which 1 is standing among to the webbing. Above time, the flexing can trigger content fatigue and cracking. As soon as a crack develops, the pan has failed.

Acrylic sheets are used to vacuum kind shower pans, bathtubs, spas and many other items. The vacuum forming process begins with a 1/four” sheet of pigmented acrylic that is heated to a temperature that can make the acrylic ductile. The sheet is put on a mould and stretched above the type to generate the concluded form. The heating and stretching of the sheet brings about a reduction in wall thickness. The reduction is directly proportional to the amount of stretching that happens. With shower pans there is significantly significantly less material reduction than with generating a tub or spa. The heating, stretching, and cooling of the substance could also introduce stresses to the completed pan.

Like fiberglass pans, acrylic pans need support aspects under the pan floor. A generally utilized assistance element is polyurethane foam. The foam fills the void and eliminated the flexing of the pan flooring. Acrylic sheet materials is vulnerable to crazing, moment area cracking, and cracking when cleaned with numerous widespread cleansing chemicals. Ought to crazing take place, in excess of time these cracks can guide to a pan failure.

Acrylic sheets have quite various bodily and chemical properties than acrylic solid surface area resources. In addition to the acrylic resin used in solid surface, the solid surface substance gets extra physical and chemical characteristics from the addition of alumina-tri-hydrate, or ATH. The ATH triggers cleaners that adversely have an effect on acrylic to have no influence on strong surface.

Solid surface area shower pans are the best-of-the-line in actual physical and chemical characteristics as effectively as functionality, reparability and a myriad of other functions and rewards. The main functions of reliable area are it is non-porous, will not assistance the growth of mould, mildew, or germs, is offered in a large variety of looks (some like organic granite) and shades, and is 100% repairable must chipping, scratching, or even cracking arise. Health departments during the region have authorized solid surface area resources for use in hospitals and foods planning places for its resistance to bacterial expansion, simplicity of cleaning and maintenance, and resistance to staining and contamination.

Some sound area shower pan producers fabricate their pans from sheet products in a equivalent trend as the acrylic shower pans. That is, they thermal kind the pan floors by heating and stretching the content and then bond sidewalls and a threshold to the flooring.

The Royal Stone model of reliable surface shower pans are the pans that I manufacture and will use to illustrate the simplicity and relieve of set up that can be had when installing a composite shower pan. As opposed to fabricated reliable floor shower pans, the Royal Stone shower pans are a solid a single-piece reliable surface area item. By casting the pan as a a single-piece unit, there are no stresses launched in the pan, and there are numerous other features engineered and made into this pan.

The most obvious characteristics are the huge radius changeover in between the pan floor and its sidewalls. Next, the flange (also referred to as a weep edge) is one-one/2″ tall. I have noticed pans that do not include an integral flange or have flanges 1/two” to one” tall. The added peak is designed to lessen, if not eradicate, any h2o being drawn up guiding the wall surround panels that could cause drinking water hurt to the shower sub-construction.

Royal Stone’s pans have a minimal wall thickness of one/2″ and the webbing elements have a wide foot with huge anxiety relieving radius corners in between the pan flooring and the webbing. All shower pans are engineered to help the weight of 3/4″ thick (two cm) granite slabs as well as all other frequently utilised wall materials like tile, fiberglass, acrylic, and reliable area panels. Last but not least, regardless of flooring loading, the Royal Stone pan flooring is so solid that it feels like a single is standing on a rigid concrete floor. There is no perceptible flexing or oil-canning of the pan ground. As shower steamer , there is no possibility of flooring tiredness and cracking in excess of time and the potential for pan failure is eliminated.

Set up IS Quick AND Effortless. As I have previously said, composite pans set up on a flat sub-floor. The pursuing installation data could not implement to all varieties of composite shower pans. Particularly, I have direct knowledge of installing the cast one-piece strong area shower pans that Royal Stone manufactures. As a result, the adhering to directly applies to Royal Stone’s common and custom shower pans. The identical steps ought to also apply to other sorts of composite pans and other supplies, nonetheless, adhere to the manufacturers advisable set up recommendations.

As a manufacturer, I do not put in pans. The images incorporated inside of this article ended up provided by a regional installer. They have been supplemented by photos of a different pan, for clarity of the set up method. Thus the different pan coloration and shape. Even more, most of the photos have been from a distinctive plumbing circumstance. The home experienced all of the plumbing over ground. Thus, a particleboard system was built previously mentioned the plumbing for the shower. The pursuing installation information applies to concrete, plywood, particleboard, wooden, and many others. sub-flooring at, over, or underneath grade.

Phase #1 – SUB-Flooring Planning: Making use of the template provided with the shower pan, spot template on the flooring and validate that the drain is in the correct spot. If the drain is NOT correctly located, relocate the drain. Note: Relocating the drain is typically considerably much less high-priced than having a customized pan cast to accommodate your existing drain spot.

The hole in the sub-ground requirements to be greater than the drain pipe. About a six” round or square gap (about the size of a espresso can) is advised. This bigger opening enables space for the drain assembly that extends beneath the bottom of the pan. Most drain pipes are 2″ PVC. The PVC pipe permits for some flexing inside the six” opening in the sub-ground. This flexing is desired and helps make the pan set up less difficult. The PVC pipe need to extend over the completed sub-floor by a least of 1/two” to about three” to four”.

The sub-floor can be wooden, plywood, concrete or any other rigid or nicely supported floor. The sub-ground should be stage and free of charge from particles. To assure a amount floor, verify the floor with a prolonged degree as shown in Fig. one. The for a longer time the stage, the far more very likely that the sub-flooring will be level at its greatest proportions. Examine front to again at the remaining and appropriate sides and at the center. Do the very same from aspect to side. Lastly, verify the diagonals. Fig. two implies the spot of the eight readings that must be taken.

Depending on the outcomes of the degree measurements, some further prep could be needed. If the sub-ground is comparatively flat, shims might be utilized to make the shower pan level. If the ground is uneven and out of degree, pouring self leveling slender-established content might be necessary.

After the sub-floor is stage and the opening for the drain is correct, the setting of the shower pan is up coming.

Stage #2 – Attach DRAIN ASSEMBLY TO PAN: A standard 2 component Brass Drain Assembly is advisable, as proven in Fig. three. This sort of assembly should be readily available at any plumbing supply shop or property enhancement shop. Royal Stone also sells this drain assembly. Disassemble the drain assembly. Retaining the parts in buy helps make reassembly more rapidly and less difficult.

Place the pan on observed horses or any lifted platform that makes it possible for entry to the best and bottom of the pan. Spray the drain opening with rubbing alcoholic beverages, Fig. four. With a clear rag, wipe the floor and inside edge of the pre-minimize drain opening, to remove any dust or other contaminants from the pan’s drain region. Around the drain opening apply a generous bead of 100% silicone, Fig. 5.

Insert Brass Drain Body, Part #5 of the Brass Drain Assembly into the drain hole, Fig. six, and press firmly into area, Fig. 7.

Stage #three – Get rid of Surplus SILICONE: Get rid of the excessive silicone from the Drain Human body, Component #five. Spray an liquor mist over the drain area and the silicone, Fig. 8. With a Dap-Cap, scoop absent the surplus silicone, Fig. nine. This step might have to be recurring many instances to fully eliminate the silicone. Last, spray a mist of alcoholic beverages and wipe remaining movie away from the Drain Body, Element #five, with a comfortable fabric.

Phase #four – MOUNT DRAIN LOCKING RING: Attach the Drain Strainer, Element #1, to guarantee that the Drain Body, Part #five, is centered within the drain gap, Fig. 10. From the base side of the shower pan, attach Areas #6, 7, & 8 to Part #five. Tighten the Locking Ring, Portion #eight right up until cosy. DO NOT Above TIGHTEN. In excess of tightening might crack the shower pan. Get rid of the Drain Strainer, Part #one, and established aside.

If any additional silicone has been squeezed out from between the shower pan drain and the Drain Entire body, Part #5, repeat Action #3 till all extra silicone has been taken out.

Dealing with Suggestion: Making use of a set of glazer’s grips allows for less difficult handling and shifting the pan into the appropriate place. If these are not accessible, brute pressure also works.

Step #5 – DRY In shape THE SHOWER PAN: Lower the shower pan into spot. Make certain that about one/8″ 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 shown in Fig. eleven & twelve. If extra shimming is required, lift pan and area shimming content where essential. Lower the pan into area and check out for stage. Repeat right up until the pan is stage.

Caution: When leaning and managing the shower pan, deal with cautiously to stop damage to the shower pan’s flange.

A Level PAN IS Crucial FOR Suitable DRAINAGE.

Action #six – SILICONE THE Base OF THE PAN: Elevate pan and lean towards one particular of the studded walls. Implement one hundred% silicone caulking to the webbing, Fig. thirteen, on the underside of the shower pan . Also, use a thick silicone ring all around the drain opening in the sub-ground, Fig. fourteen. If shims had been used, silicone all shims into position on sub floor as necessary.

Step #seven – Established SHOWER PAN: Reduced shower pan into place. Verify the pan for stage. Push down as essential to re-amount the shower pan. Apply a silicone bead alongside the front edge of the threshold to seal the threshold of the pan to the sub-floor.

Action #eight – Hook up DRAIN PIPE TO DRAIN ASSEMBLY: Inject silicone totally around and among the drain pipe and the Brass Drain Entire body, Component #5, as demonstrated in Fig. fifteen. Area the Rubber Gasket, Part #four of the Drain Assembly, above the PVC pipe and slide down until finally the best of the Rubber Gasket, Component #four, is completely seated and is underneath the prime of the Drain Assemble, Fig. 16. Screw the Locking Ring, Component #three of the Drain Assembly on to the Drain Human body, Portion #five. Tighten the Locking Ring, Part #three, with the Tightening Tool, Part #two right up until the Rubber Gasket, Portion #4, is seated and tightly in location.

Step #9 – TRIMMING THE PVC: The top of the PVC drain pipe Have to NOT lengthen previously mentioned the Brass Drain Physique, Part #5. If it is at the best of the Brass Drain Human body, Part #five, or extends previously mentioned the best, trim the PVC so that it is about 1/4″ lower than the leading of the Brass Drain Physique, Element #five but is taller than the best of the Rubber Gasket, Component #four. Cut the PVC pipe with a Dremel and a cut-off wheel.

If the Tightening Resource, Portion #two has not currently been eliminated, remove it and push the Drain Strainer, Portion #1, into location. The installation is complete. Excluding any sub-floor preparation, the set up must take about a single hour or significantly less.

Action #10 – CURING: Enable the shower pan set for 24 to forty eight hours to enable the silicone to properly heal. Once remedied, the wallboard and wall panels can be set up.

Warning: When attaching solid floor shower pans and wall panels, ONLY use a hundred% SILICONE. Other adhesives or caulks may harden. The reduction of the elastic bond in between the sound area and other materials can result in stresses in the strong surface area. In flip, these stresses may possibly result in fractures of the element and void the manufacturer’s warranty.