Emilie Meyer
Pouring a concrete shower pan is a complex process that requires careful planning and execution. It involves several steps, including preparing the shower framework, blocking the shower drain, waterproofing, creating a pre-slope for proper drainage, and finally pouring and curing the concrete. While it is possible to pour a concrete shower pan, it is crucial to follow established methods and best practices to ensure a successful and durable installation. Waterproofing is critical to prevent water intrusion and potential leaks. Additionally, achieving the correct slope for proper drainage is essential to avoid water pooling. The process requires a range of materials, including concrete, mortar, gravel, tiles, and waterproofing membranes.
| Characteristics | Values |
|---|---|
| Materials | Concrete, mortar, mud, gravel, tile, cement, sand, vinyl, acrylic, duct tape, waterproofing membrane, metal lath, nails, staples |
| Steps | Install curb, block shower drain, sweep and vacuum, caulk shower edges, measure slope height, establish rough slope, confirm smooth slope, pack down material, cure pre-slope bed, cut waterproofing membrane, install metal lath, calculate floor slope, tile |
| Considerations | Waterproofing, proper drainage, correct mix consistency, potential leaks, floor level, drain height, local building code, Tile Council of North America (TCNA) Handbook, ANSI108.1 |
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What You'll Learn
Preparing the shower pan
Planning and Materials
Before you begin, it is essential to consult local building codes and guidelines, such as the Tile Council of North America (TCNA) Handbook and ANSI108.1, to ensure your project complies with regulations. Estimate the amount of material required, assuming a standard 2-inch depth for the shower area. You can use a Slab Calculator or a specialised app to aid in measurements and estimations.
Surface Preparation
Start by installing the sub-floor, ensuring it is level and providing access to the drainpipe. Frame the walls of the shower, including the curbing for the shower entrance. Sweep the floor and remove any debris or sharp objects, and ensure that nails or screws are driven flush with the surface.
Drain Assembly
Install the shower drain into the floor drain, following manufacturer instructions. The drain assembly typically includes connecting the PVC drain to the concrete board and securing it with bolts. Ensure the drain flange is set at the appropriate height above the subfloor to facilitate proper drainage.
Waterproofing
Install a PVC pan-liner, followed by waterproof drywall or cement backer board on the walls and over the curb. Use a waterproofing membrane, such as roofing felt or building paper, to cover the shower base, providing a critical layer of protection against water intrusion.
Slope Creation
Create a pre-slope by pouring a dry pack sand mix or deck mud into the shower base, forming a level perimeter. Pack the mix down and use a hand level to ensure it is even. Then, fill in the centre, establishing a rough slope from the edges to the drain. Use a straight edge to confirm a smooth slope in all directions, making adjustments as needed. Allow this pre-slope bed to cure for 24 hours.
Final Touches
After curing, use a steel finishing trowel to smooth out the final mortar bed, creating a seamless surface for tile installation. Keep the surface damp for at least 72 hours by spraying it with water occasionally. Ensure weep holes are kept clear by placing a layer of clean gravel or crushed tile around the shower drain.
Preparing a concrete shower pan requires careful planning, attention to detail, and adherence to best practices. By following these steps, you can create a sturdy and waterproof foundation for your shower.
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Choosing the right concrete
The choice of concrete mix significantly impacts the durability of your shower pan. Here are some options to consider:
Traditional Sand and Cement Mix: This type of mix has been a popular choice for shower pans for decades. It offers excellent durability and is relatively easy to work with. It is a good option if you want a sturdy and long-lasting shower pan.
Pre-Mixed Shower Pan Mortar: Pre-mixed mortar is a convenient option, especially for DIY enthusiasts. It usually contains sand, cement, and additives for improved performance. This mix is designed to be sturdy and easy to use, so it can be a good choice if you want a straightforward option.
Lightweight Concrete Mix: Lightweight concrete mixes are becoming more popular due to their ease of handling and reduced weight. They are particularly suitable for shower pans on upper floors as they put less stress on the structure. If you are working on an upper floor, this mix is worth considering.
Polymer-Modified Concrete: This type of concrete is known for its flexibility and crack resistance. It is an excellent option for a long-lasting shower pan. Polymer-modified concrete can be more expensive, but its durability and flexibility can make it a worthwhile investment.
Deck Mud: Deck mud is a traditional and time-tested method for creating shower pans. It is essentially concrete without rocks, extra Portland cement, and water. The absence of these ingredients makes it easier to work with and less prone to shrinkage and cracking. Deck mud can be found in the tile aisle of most hardware stores.
When choosing the right concrete for your shower pan, it is important to consider the specific needs of your project. Factors such as durability, ease of use, weight, and cost should be taken into account to make an informed decision. Additionally, proper waterproofing and tiling techniques are crucial to ensure the longevity of your shower pan.
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Waterproofing the shower
Prepare the Surface
Before beginning the waterproofing process, it is essential to prepare the surface properly. This includes cleaning the surface to remove any debris. A foxtail brush can be used for this step. Additionally, it is important to ensure that the subfloor is at the necessary level for the drain.
Install a Cleavage Membrane
The first layer of the shower pan is a cleavage membrane, which serves as a protective layer underneath the waterproofing membrane. To install this, cut a sheet of building paper or roofing felt to fit the bottom of the shower base. This layer will establish a drainage path for water in case the top layers of the shower pan are compromised.
Install Metal Lath or Reinforcement
After the cleavage membrane is in place, install metal lath or reinforcement over it. Secure it to the subfloor with nails or staples. This layer provides additional strength and stability to the shower pan.
Calculate the Floor Slope
The floor slope is crucial for proper drainage. Measure the distance from the drain to the farthest wall in feet, and aim for a target slope of 1/4" per foot from the wall to the drain. Use this calculation to determine the high point of your mortar bed and mark this point around the perimeter of the shower.
Install the Waterproofing Membrane
The waterproofing membrane is a critical layer that ensures any moisture intrusion is properly drained. Cut the membrane to the appropriate size and install it over the metal lath or reinforcement. This step should not be skipped, as grout and mortar are not completely waterproof.
Apply Final Layer of Sand Mix or Concrete
The final layer of the shower pan can be a sand mix or concrete, depending on your preference. The depth of this layer will depend on the height of the adjustable drain but must be a minimum of 1/2". Ensure that the drain opening is taped off to keep it clean.
It is important to note that concrete is not inherently waterproof, so additional measures should be taken to ensure complete waterproofing. This can include using a waterproofing sealer on the concrete surface.
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Creating a slope for drainage
Planning the Slope
Before beginning any work, it is essential to plan the slope carefully. The pitch or slope angle should be at least 1/8 inch per linear foot of run. However, for added assurance against drainage dead spots, a slope of 1/4 inch per foot of run is recommended. This translates to a gradient of approximately 2-4 percent, or a decline of 1/4 to 1/2 inch for every 12 inches from the shower enclosure to the drain.
Calculating the Slope
To calculate the slope, start by measuring the distance from the drain to the farthest wall in feet. Multiply this distance by 0.25, then add 1/2 inch to determine the high point of your mortar bed in inches. For example, if the drain is 3 feet from the shower wall, your high point will be 1.25 inches above the subfloor (3 x 0.25 = 0.75, plus 0.5 = 1.25).
Preparing the Subfloor
Before installing the slope, ensure that the subfloor is level and at the necessary height for the drain. It is also crucial to waterproof the subfloor. You can do this by installing a waterproofing membrane, such as Kerdi fabric or PVC vinyl, which will prevent moisture from leaking into the wall framing.
Building the Pre-Slope
To begin creating the slope, establish a level perimeter around the shower pan at your marked high point. Pack this perimeter layer with a rubber or wooden float, tamping the material down repeatedly. Use a hand level to ensure that the perimeter remains level on all sides and from edge to edge.
Forming the Rough Slope
Once the perimeter is level, start filling in the centre of the shower pan to create a rough slope from the edges towards the drain. As you add material, pack it down firmly. Use a straight edge to check that you have achieved a smooth slope from the edges to the drain in all directions. If necessary, add more material and continue packing it down until the slope is consistent.
Finalising the Slope
Allow the pre-slope bed to cure for at least 24 hours before proceeding to the next phase. Although it is not mandatory, you may want to use a steel finish trowel to create a smooth finish surface. This step will ensure that the waterproofing membrane is not damaged by the rough surface of the pre-slope mortar bed.
By following these steps and paying close attention to the recommended slope angles, you can effectively create a slope for drainage in your concrete shower pan, ensuring proper water flow and preventing potential issues caused by water stagnation.
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Installing the tiles
Tiling a shower pan requires careful preparation and attention to detail. Here is a step-by-step guide to installing tiles for a shower pan:
Preparing the Surface:
Before beginning, ensure that the shower pan's framework is in place, including the curb and drain assembly. Install a waterproofing membrane to prevent moisture intrusion. Use a product like Wedi board, which is specifically designed for this purpose. Apply the membrane to the backer board, extending it a few inches up the wall. This step is crucial to prevent water damage.
Creating a Pre-Slope:
Establish a rough slope from the edges of the shower pan towards the drain. Pack down the material as you go, using a straight edge to ensure a smooth slope in all directions. Add more material where needed and use a steel finish trowel for a smooth finish. Allow this pre-slope bed to cure for 24 hours.
Installing Gravel or Crushed Tile:
Place a layer of clean gravel or crushed tile around the shower drain to protect the weep holes. This step is important to ensure proper drainage and prevent the weep holes from becoming clogged with mortar.
Setting the Tiles:
Begin tiling within 16 hours of installing the mortar bed. Using a steel finishing trowel, smooth out the final mortar bed to create an even surface for the tiles. Set the tiles directly on the mortar bed, ensuring they are level and properly spaced. Allow the mortar to cure for 24 hours before using the shower.
Grouting and Sealing:
After the tiles have been set and the mortar has cured, apply grout to fill the spaces between the tiles. Ensure that you leave any weep holes in the tile wall ungrouted to allow for proper drainage. Finally, seal the tiles and grout with a waterproof sealant to protect against moisture and mould.
It is important to follow local building codes and industry standards, such as the Tile Council of North America (TCNA) Handbook and ANSI108.1, for additional guidelines and requirements when installing tiles for a shower pan.
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Frequently asked questions
Yes, but it is a complex process. It is recommended that you consult a professional or a DIY guide before attempting to do this yourself.
Mud is a good option as it is easier to shape and screed than concrete. It is also usually dry when you use it, so there is no shrinkage.
You should be able to form a "snowball" with the mix using your hands. If the "snowball" holds when you toss it a few inches in the air, the consistency is correct.
Calculate the floor slope by measuring the distance from the drain to the farthest wall in feet. The general rule of thumb is to add 1/4″ in height for every foot you move away from the shower drain.
You can use a waterproofing membrane to ensure that any moisture intrusion is properly drained.
