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May 8, 2015

Protechwood – In Fewer Than A person Hour – Remove Shower Leaks by Setting up a Stable Floor Shower Pan

Setting up A COMPOSITE SHOWER PAN IS Fast AND Simple. Prior to talking about the uncomplicated techniques to put in a composite shower pan, I felt that some clarification and definitions are essential mainly because not all shower pans are alike.

WHAT IS IN A Name? A roof is a roof, although there are quite a few distinctive roofing devices and roofing components. Not true with “shower pans.” They are frequently interchangeably named a shower pan, shower pan liner, shower pan membrane liner, water-resistant barrier, shower base, shower tray, or shower receptor. Nevertheless, just about every has a distinctive meaning dependent on context and just about every are offered in a range of components.

Bob Vila’s internet web page defines a SHOWER PAN as “The base, that contains a water drain, of the shower enclosure.” And a SHOWER RECEPTOR as “A just one-piece base (ground) device employed as a shower, for illustration, to capture water and direct it to a heart drain.”

For the sake of clarity, I provide the pursuing definitions.

SHOWER PAN & SHOWER Foundation – A completed location that is capable of retaining and directing water to the drain plus it would not require tiling once put in. The shower pan or base has a drain gap, sloped ground to appropriately direct water to the drain gap, sidewalls, and a threshold (entrance to the shower that types a curb to preserve water from running out onto the toilet ground). A shower pan is synonymous with a shower base.

SHOWER PAN LINER, MEMBRANE LINER, & Water-resistant BARRIER – A barrier, generally a plastic sheet or membrane, that is meant to lure water that penetrates the shower ground tile, grout, and mortar less than the tile and power the water to stream to the drain. As lengthy as it would not leak, it helps prevent water from reaching the sub-ground and surrounding wall enclosure. The liner is a element within just a manufactured 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 employed in position of a liner. They provide the identical functionality as the liner, but are pre-fashioned to get rid of some of the set up techniques essential when applying a liner.

Shower pan liners, shower trays, and shower receptors are all employed in conjunction with the design of a shower pan that has a tiled ground as well as a tiled wall enclosure.

Commercially offered shower pans are complete, all set-to-put in units. They get rid of the want to generate a mud sloped ground, a shower liner or tray, and tiling of the shower ground.

COMPOSITE SHOWER PANS. As composite shower pans are manufactured from a variety of distinctive components and manufactured in another way. I wished to contact on just about every of the most common forms. Composite shower pans slide into a number of materials teams cultured marble, fiberglass, acrylic, and stable surface. Generally all are manufactured by fabrication of flat sheets, thermal-fashioned from a single piece of materials, or molded or cast to sort a just one piece device. The just one-piece design eradicates seams, which in turn eradicates likely leaks. Every single has their pluses and minuses. For the reason that beauty is in the eye of the beholder, I will not remark on overall look. All composite shower pans put in on a flat, degree ground and do not require the creation of a sloped mud base. Also, the cast 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 least expensive. Cultured marble is manufactured by spraying a ‘gel-coat’ onto a mould. This coating is about one/64″ or much less in thickness. The gel-coat is covered with pigmentation and then backed with calcium carbonate. The calcium carbonate presents the completed part its strength. Also, in the casting method it is infused with air pockets to decreased its density and fat.

The cultured marble ground is cast separately from the sidewalls. Thus, the incorporation of a shower pan liner is vital to insure a watertight, leak cost-free set up. Though commonly employed, the down aspect of cultured marble is that other than the gel-coat layer, the calcium carbonate is extremely porous. Any crack or scratch as a result of the gel-coat will allow water penetration. Other gel-coat properties contain yellowing, even devoid of UV exposure clouding from sizzling tap water staining crazing (wonderful hairline cracks) and it is not reparable when cracked or chipped.

Fiberglass is commonly employed as well. Fiberglass is sturdy, mild fat and affordable. Lots of fiberglass producers make just one-piece shower pans and enclosures and just one-piece mixture tubs and showers with the wall enclosures. Related to cultured marble, fiberglass is manufactured with a gel-coat, then backed with pigment and chopped strands of fiberglass in a resin combination. Generally the completed product or service is about one/eight” to one/4″ in thickness. The underside of the shower pan ground has webbing extra to deliver help to the ground. As the ground is not stable, the unsupported area concerning the webbing can flex. This flexing is specifically apparent with weighty loading or where by just one is standing concerning to the webbing. More than time, the flexing can bring about materials fatigue and cracking. At the time a crack develops, the pan has unsuccessful.

Acrylic sheets are employed to vacuum sort shower pans, bathtubs, spas and quite a few other merchandise. The vacuum forming method starts with a one/4″ 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 around the sort to generate the completed condition. The heating and stretching of the sheet causes a reduction in wall thickness. The reduction is straight proportional to the amount of money of stretching that happens. With shower pans there is significantly much less materials reduction than with generating a tub or spa. The heating, stretching, and cooling of the materials could also introduce stresses to the completed pan.

Like fiberglass pans, acrylic pans want help features less than the pan ground. A normally employed help aspect is polyurethane foam. The foam fills the void and eliminated the flexing of the pan ground. Acrylic sheet materials is vulnerable to crazing, moment surface cracking, and cracking when cleaned with quite a few common cleaning chemical substances. Should really crazing take place, around time these cracks can lead to a pan failure.

Acrylic sheets have really distinctive actual physical and chemical attributes than acrylic stable surface components. In addition to the acrylic resin employed in stable surface, the stable surface materials gets added actual physical and chemical properties from the addition of alumina-tri-hydrate, or ATH. The ATH causes cleaners that adversely impact acrylic to have no impact on stable surface.

Stable surface shower pans are the top-of-the-line in actual physical and chemical properties as well as performance, reparability and a myriad of other functions and benefits. The major functions of stable surface are it is non-porous, will not help the advancement of mould, mildew, or bacteria, is offered in a big range of looks (some like pure granite) and hues, and is one hundred% repairable must chipping, scratching, or even cracking take place. Well being departments in the course of the country have authorized stable surface components for use in hospitals and food preparation locations for its resistance to bacterial advancement, ease of cleaning and maintenance, and resistance to staining and contamination.

Some stable surface shower pan producers fabricate their pans from sheet merchandise in a similar vogue as the acrylic shower pans. That is, they thermal sort the pan floors by heating and stretching the materials and then bond sidewalls and a threshold to the ground.

The Royal Stone brand name of stable surface shower pans are the pans that I manufacture and will use to illustrate the simplicity and ease of set up that can be had when setting up a composite shower pan. Unlike fabricated stable surface shower pans, the Royal Stone shower pans are a cast just one-piece stable surface product or service. By casting the pan as a just one-piece device, there are no stresses introduced in the pan, and there are quite a few other functions engineered and designed into this pan.

The most apparent functions are the big radius transition concerning the pan ground and its sidewalls. Secondly, the flange (also named a weep edge) is one-one/two” tall. I have noticed pans that do not include an integral flange or have flanges one/two” to one” tall. The extra height is designed to lower, if not get rid of, any water becoming drawn up driving the wall surround panels that could bring about water damage to the shower sub-construction.

Royal Stone’s pans have a bare minimum wall thickness of one/two” and the webbing features have a wide foot with big tension relieving radius corners concerning the pan ground and the webbing. All shower pans are engineered to help the fat of three/4″ thick (two cm) granite slabs as well as all other normally employed wall components like tile, fiberglass, acrylic, and stable surface panels. Lastly, regardless of ground loading, the Royal Stone pan ground is so stable that it feels like just one is standing on a rigid concrete ground. There is no perceptible flexing or oil-canning of the pan ground. Thus, there is no chance of ground fatigue and cracking around time and the likely for pan failure is eliminated.

Set up IS Fast AND Simple. As I have currently stated, composite pans put in on a flat sub-ground. The pursuing set up information may possibly not implement to all forms of composite shower pans. Exclusively, I have direct understanding of setting up the cast just one-piece stable surface shower pans that Royal Stone manufactures. Thus, the pursuing straight applies to Royal Stone’s common and personalized shower pans. The identical techniques must also implement to other forms of composite pans and other components, however, observe the producers suggested set up instructions.

As a manufacturer, I do not put in pans. The photos involved within just this article have been supplied by a neighborhood installer. They have been supplemented by photos of a distinctive pan, for clarity of the set up method. Thus the distinctive pan color and condition. More, most of the photos have been from a exclusive plumbing predicament. The house had all of the plumbing earlier mentioned ground. Thus, a particleboard system was constructed earlier mentioned the plumbing for the shower. The pursuing set up information applies to concrete, plywood, particleboard, wooden, and so on. sub-floors at, earlier mentioned, or under quality.

Phase #one – SUB-Floor Preparing: Making use of the template supplied with the shower pan, position template on the ground and validate that the drain is in the right spot. If the drain is NOT appropriately found, relocate the drain. Note: Relocating the drain is generally significantly much less pricey than getting a personalized pan cast to accommodate your current drain spot.

The gap in the sub-ground requires to be much larger than the drain pipe. About a 6″ round or square gap (about the sizing of a coffee can) is suggested. This much larger opening permits area for the drain assembly that extends under the bottom of the pan. Most drain pipes are two” PVC. The PVC pipe permits for some flexing within just the 6″ opening in the sub-ground. This flexing is ideal and tends to make the pan set up much easier. The PVC pipe must prolong earlier mentioned the completed sub-ground by a bare minimum of one/two” to about three” to 4″.

The sub-ground can be wooden, plywood, concrete or any other rigid or well supported surface. The sub-ground need to be degree and cost-free from particles. To assure a degree ground, verify the ground with a lengthy degree as demonstrated in Fig. one. The more time the degree, the extra probable that the sub-ground will be degree at its biggest dimensions. Examine entrance to back at the left and right sides and at the heart. Do the identical from aspect to aspect. Lastly, verify the diagonals. Fig. two implies the spot of the eight readings that must be taken.

Dependent on the outcomes of the degree measurements, some added prep may possibly be essential. If the sub-ground is reasonably flat, shims may possibly be employed to make the shower pan degree. If the ground is uneven and out of degree, pouring self leveling slender-set materials may possibly be essential.

At the time the sub-ground is degree and the opening for the drain is right, the environment of the shower pan is future.

Phase #two – Connect DRAIN ASSEMBLY TO PAN: A common two part Brass Drain Assembly is suggested, as demonstrated in Fig. three. This type of assembly must be conveniently offered at any plumbing provide shop or house enhancement shop. Royal Stone also sells this drain assembly. Disassemble the drain assembly. Trying to keep the parts in purchase tends to make reassembly faster and much easier.

Location the pan on noticed horses or any raised system that permits entry to the top and bottom of the pan. Spray the drain opening with rubbing alcoholic beverages, Fig. 4. With a thoroughly clean rag, wipe the surface and inside edge of the pre-cut drain opening, to get rid of any dust or other contaminants from the pan’s drain location. Around the drain opening implement a generous bead of one hundred% silicone, Fig. 5.

Insert Brass Drain Human body, Portion #5 of the Brass Drain Assembly into the drain gap, Fig. 6, and push firmly into position, Fig. seven.

Phase #three – Clear away Excess SILICONE: Clear away the excessive silicone from the Drain Human body, Portion #5. Spray an alcoholic beverages mist around the drain location and the silicone, Fig. eight. With a Dap-Cap, scoop absent the excessive silicone, Fig. nine. This action may possibly have to be repeated a number of periods to absolutely get rid of the silicone. Final, spray a mist of alcoholic beverages and wipe remaining film absent from the Drain Human body, Portion #5, with a soft cloth.

Phase #4 – MOUNT DRAIN LOCKING RING: Connect the Drain Strainer, Portion #one, to assure that the Drain Human body, Portion #5, is centered within just the drain gap, Fig. 10. From the bottom aspect of the shower pan, attach Pieces #6, seven, & eight to Portion #5. Tighten the Locking Ring, Portion #eight right up until snug. DO NOT More than TIGHTEN. More than tightening may possibly crack the shower pan. Clear away the Drain Strainer, Portion #one, and set aside.

If any added silicone has been squeezed out from concerning the shower pan drain and the Drain Human body, Portion #5, repeat Phase #three right up until all excessive silicone has been taken off.

Managing Suggestion: Making use of a set of glazer’s grips permits for much easier dealing with and shifting the pan into the appropriate spot. If these are not offered, brute power also functions.

Phase #5 – DRY Healthy THE SHOWER PAN: Decrease the shower pan into position. Make positive that about one/eight” area exists concerning the shower pan flange and the studs. With the degree, validate that the pan is sitting down flat on the ground as demonstrated in Fig. eleven & 12. If added shimming is necessary, carry pan and position shimming materials where by necessary. Decrease the pan into position and verify for degree. Repeat right up until the pan is degree.

Caution: When leaning and dealing with the shower pan, deal with carefully to reduce damage to the shower pan’s flange.

A Stage PAN IS Essential FOR Proper DRAINAGE.

Phase #6 – SILICONE THE Base OF THE PAN: Raise pan and lean against just one of the studded walls. Implement one hundred% silicone caulking to the webbing, Fig. thirteen, on the underside of the shower pan . Also, implement a thick silicone ring close to the drain opening in the sub-ground, Fig. fourteen. If shims have been employed, silicone all shims into placement on sub ground as necessary.

Phase #seven – Established SHOWER PAN: Decrease shower pan into position. Examine the pan for degree. Press down as essential to re-degree the shower pan. Implement a silicone bead alongside the entrance edge of the threshold to seal the threshold of the pan to the sub-ground.

Phase #eight – Connect DRAIN PIPE TO DRAIN ASSEMBLY: Inject silicone absolutely close to and concerning the drain pipe and the Brass Drain Human body, Portion #5, as demonstrated in Fig. fifteen. Location the Rubber Gasket, Portion #4 of the Drain Assembly, around the PVC pipe and slide down right up until the top of the Rubber Gasket, Portion #4, is absolutely seated and is under the top of the Drain Assemble, Fig. sixteen. Screw the Locking Ring, Portion #three of the Drain Assembly onto the Drain Human body, Portion #5. Tighten the Locking Ring, Portion #three, with the Tightening Tool, Portion #two right up until the Rubber Gasket, Portion #4, is seated and tightly in position.

Phase #nine – TRIMMING THE PVC: The top of the PVC drain pipe Need to NOT prolong earlier mentioned the Brass Drain Human body, Portion #5. If it is at the top of the Brass Drain Human body, Portion #5, or extends earlier mentioned the top, trim the PVC so that it is about one/4″ decreased than the top of the Brass Drain Human body, Portion #5 but is taller than the top of the Rubber Gasket, Portion #4. Minimize the PVC pipe with a Dremel and a cut-off wheel.

If the Tightening Tool, Portion #two has not currently been taken off, get rid of it and push the Drain Strainer, Portion #one, into position. The set up is complete. Excluding any sub-ground preparation, the set up must consider about just one hour or much less.

Phase #10 – CURING: Allow the shower pan set for 24 to forty eight hrs to allow the silicone to appropriately overcome. At the time treated, the wallboard and wall panels can be put in.

Caution: When attaching stable surface shower pans and wall panels, ONLY use one hundred% SILICONE. Other adhesives or caulks may possibly harden. The loss of the elastic bond concerning the stable surface and other components can bring about stresses in the stable surface. In turn, these stresses may possibly bring about fractures of the part and void the manufacturer’s warranty.

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+86(752) 2222-845