Marianne Martinez
Building a shower can be a complex process, and it's important to ensure that it is done correctly to avoid leaks and mould. One of the key steps is installing the shower pan, which forms the base of the shower and collects water. This can be done using a pre-fabricated shower pan or by building a custom one using mortar and tile. Once the shower pan is installed, you can move on to installing the shower walls. In this article, we will explore the process of building a shower wall on a shower pan, including the materials needed and the steps to follow for a successful installation.
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What You'll Learn
Building a mortar shower pan
If you do choose to take on the project yourself, the first step is to build a shower curb frame using stacked 2 x 4s. Add blocking between the wall studs to form the shower pan "box". You can also use a commercial slope guide to help create a uniform pitch mortar bed. With your shower walls marked, place your mixed mortar into the shower pan and begin forming your base ("pre-slope") mortar layer.
The shower pan liner is the most critical aspect of waterproofing your shower. It protects the porous shower wall framing and lower floor layers from water permeation and mould outbreaks. When preparing the slope, you have two options: mortar or a pre-made slope product. If you choose to use mortar, pour it onto the subfloor at 1/4 inch per foot, sloping inward from the wall framing to the top of the drain base. After this, leave the mortar bed to cure according to the manufacturer's instructions.
Before installing the liner, ensure that you have an additional 8 to 12 inches of liner at the shower walls, allowing you to carry the liner up the walls above the level of the shower curb. Flatten the liner along the surface and corners of the pan and curb, and then cut the liner according to your markings. Secure the top edges of the liner with roofing nails or exterior-grade screws. Do not penetrate the liner below the level of the shower curb, as this can lead to leaks.
Finally, screw the shower pan rim into the wall studs using 1 1/4-inch exterior-grade screws through the pre-drilled holes.
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Preparing the shower pan box frame
First, ensure your shower area is prepped and ready. You will need enough support under your house for the added weight of the mortar and tile. If your floor joists are only 2 x 6 or 2 x 8, reinforce them with added support. Make sure you have a solid 3/4" subfloor. If there are gaps in your subfloor, add a layer of 1/4" cement board.
Next, create a "curb" or shower curb frame around the surround of your shower. This is the open entry point where the user enters the shower. The curb should be between 2 and 6 inches above the level of the shower drain. A typical curb height is 4 1/2", which can be achieved by stacking three pressure-treated 2 x 4s on top of each other.
Now, add blocking between the wall studs to form the shower pan "box". Use framing pieces or sheathing material as blocking. The blocking should be at least as high as the shower curb. You can use scraps of leftover 3/4" subfloor plywood.
Before installing the shower pan, ensure the subfloor is completely flat and level. If it is not, apply a self-leveling compound following the manufacturer's instructions. Once the compound has cured, test-fit the shower drain flange to ensure it fits flush with the shower base. Line the underside of the flange's rim with latex/acrylic or silicone caulk, per the manufacturer's instructions.
Finally, place the shower pan in the opening and mark the locations of the mounds of mortar or adhesive per the manufacturer's instructions. Position the mounds of mortar or adhesive on the marks and place the shower pan onto them, pressing firmly in place. Screw the shower pan rim into the wall studs using 1 1/4-inch exterior-grade screws through the pre-drilled holes.
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Installing the shower liner
Installing a shower liner is a complex process that requires careful attention to detail to ensure a waterproof seal. Here is a step-by-step guide to installing a shower liner:
Prepare the Subfloor
First, prepare the subfloor by pouring a mortar bed over it. Mix and pour mortar to create a slope of 1/4" per foot, sloping inward from the wall framing toward the drain base. Ensure the slope does not extend over the drain base. Allow the mortar bed to cure according to the manufacturer's instructions.
Measure and Cut the Shower Liner
Once the mortar bed is cured, measure and cut the shower liner to fit your shower. The liner should extend at least 2 inches above the finished curb height on all sides, with additional 8 to 12 inches of liner at the shower walls. This will allow you to carry the liner up the walls, ensuring a watertight seal.
Secure the Shower Liner
Before installing the liner, apply a bead of 100% silicone caulk around the upper surface of the drain base, approximately 1 inch from the outside edge. This will create a seal between the liner and the drain base. Place the liner over the drain body and secure it with clamping ring bolts, screwing them into the drain base. Ensure the weep holes are clear of any liner material or silicone.
Water Test
Before proceeding, it is crucial to test the installation for watertightness. Close the drainpipe with a test plug and fill the shower floor with water, just below the top of the curb. Let the water sit for at least two hours, or preferably four hours, to ensure there are no leaks. If the water level remains unchanged, and the surrounding area is dry, your installation is watertight.
Final Steps
After confirming watertightness, you can proceed with the final steps. Apply a mortar base on top of the pan liner, followed by thinset, which serves as the adhesive between the mortar and tile. Choose your tiling and proceed with the application, carefully following the manufacturer's instructions for a secure and long-lasting installation.
It is important to note that this is a general guide, and specific instructions may vary depending on the products used and the unique characteristics of your shower installation. Always refer to the manufacturer's guidelines and seek professional advice if needed.
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Ensuring the shower is water-tight
While it is possible to create a shower floor using a pan liner and tile, a ready-made shower pan makes installation easier and helps ensure your shower is water-tight. Here are some tips to ensure your shower is water-tight:
First, it is important to note that waterproofing is a crucial step when installing a new shower. The goal is to create a watertight seal around the stall to prevent water from leaking into crevices and causing structural issues such as rot and mould. To do this, you can use a combination of liquid waterproofing adhesive and a tightly woven reinforcing membrane.
Before applying any waterproofing materials, ensure the surface is clean and free of debris. Measure the shower stall and use a pencil to mark the dimensions along the backing board. Extend your markings an inch or so beyond the boundaries of the stall for added protection. Apply painter's tape along the markings to create an outline, which will make it clear where the waterproofing material needs to be applied.
Next, cut a roll of reinforcing membrane to fit over the walls. First, measure and trim the membrane to fit the flat sections, marking where key fixtures like the valve, shower head, and knobs will be. Cut the membrane into long, thin strips to fit around these fixtures.
Apply a coat of liquid waterproofing to the backing board using a high-quality paintbrush. Ensure the bristles can hold up to the thick waterproofing material. Brush the waterproofing over the entire wall, forming a thick and even coat with no gaps or bare spots. Allow the waterproofing to dry completely, properly ventilating the room by opening windows and running fans if possible.
Once the waterproofing is dry, press the reinforcing membrane into place. Alternatively, you can use self-adhesive waterproofing sheets, which are easy to apply and provide a water-tight seal.
If you are using a shower pan liner, ensure you have sufficient liner at the shower walls (8 to 12 inches) to carry it up the walls above the level of the shower curb. Flatten the liner along the surface and corners of the pan and curb before cutting. Secure the top edges of the liner and folds with roofing nails or exterior-grade screws. You can also use liner adhesive or silicone caulk for added stability, but be careful not to penetrate the liner below the curb, as this can lead to leaks.
Finally, be mindful of the grout between tiles, as it is not waterproof. Without a waterproof membrane beneath the grout layer, water will gradually absorb and cause damage.
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Using a pre-fabricated shower pan
Building a shower pan can be a complex process, and it is recommended that unless you have extensive plumbing and tiling experience, you should hire a professional. However, if you have intermediate DIY skills, you can build your own shower pan and save on labour costs.
One popular way to create a shower pan is to install a pre-fabricated polyurethane or fibreglass pan. Pre-fabricated pans are convenient and offer speed and ease of installation. They are also more affordable and cost-effective than building a shower pan yourself.
To install a pre-fabricated shower pan, you will first need to ensure that you have adequate sub-flooring, framing, and appropriate shower drain plumbing in place. The size of the drain hole should not exceed 5 inches, but always check the manufacturer's specifications. You will also need to relocate the P-trap for the shower drain and pipe as necessary, so the waste pipe extends approximately 1 3/4 inches above the subfloor.
Next, you will need to prepare the shower pan for the first mortar layer. Mix and place the mortar, ensuring that the shower pan pre-slope creates a general tapered slope towards the drain. This slope will be refined with a second bed of mortar. Install a layer of asphalt felt over the subfloor plywood to serve as a moisture barrier for the first layer of mud. You can use roofing nails or exterior-grade screws to secure the top of the liner and the top of the folds.
Once the first mortar layer is complete, you can install the shower liner, ensuring it runs up onto the walls at least 6 inches, with an additional 8 to 12 inches of liner at the shower walls to carry the liner above the level of the shower curb. Seal the shower liner to the shower drain, and then install the shower wall tile backer board.
After the shower liner is installed, you can place the top mortar bed, ensuring it is very smooth. Finally, you can move on to installing the shower walls, ensuring there are no leaks.
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Frequently asked questions
A shower pan is the shower floor, which is typically made of acrylic, fiberglass, or composites, or tile on a mortar base.
Shower pans are easy to install and provide design and sizing flexibility. They also ensure that your shower is water-tight.
You will need a shower pan liner, mortar, a trowel, tiles, tile spacers, grout, and a rubber drainpipe gasket. You may also need wire mesh, asphalt/tar paper, and roofing nails or staples.
First, ensure that your subfloor is level and frame your shower enclosure. Then, mix and pour the mortar onto the subfloor, creating a slope towards the drain. Next, lay the shower pan liner, ensuring it is waterproof. Finally, add another layer of mortar, followed by the tiles and grout.
Yes, but it is important to ensure that your shower pan is installed correctly and is level before building the shower wall.
