Ella Walter
A shower pan is the foundation of a stand-up shower, and it is important to get it right to avoid water damage. While it is possible to create a shower floor using a pan liner and tile, a ready-made shower pan makes installation easier. Ready-made shower pans are typically made of acrylic, fiberglass, or composites. However, if you want to make your own shower pan, you can use a dry pack mortar bed or a cement board. The entire bottom of the shower pan needs to sit on a flat, level surface. If the subfloor is not flat and level, you can use a self-leveling compound. The shower pan should be adjusted until it is level in all directions. Once the shower pan is level, you can install the drain and test for leaks. Finally, you can move on to installing the shower walls.
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What You'll Learn
Using a pre-slope system
Building a shower pan can be a tricky process, and it's important to get it right to avoid water damage and expensive repairs. One popular method is to use a pre-slope system, which helps to ensure that water drains properly and doesn't pool in the shower. Here's a step-by-step guide to using a pre-slope system to make a shower pan with cement board:
First, it's important to understand why a pre-slope system is necessary. If the shower pan is installed flat on the subfloor, water will have no path to the drain, which can cause mould, tile failure, and eventually, failure of the entire mortar pan. The pre-slope system creates a slight incline that motivates water to drain properly.
To begin, you'll need to prepare the shower base. Place a layer of clean gravel or crushed tile around the shower drain to keep the weep holes free. This will provide a stable base for your pre-slope system. You should also plug the drain to ensure it stays clear during the installation process.
Next, you'll create the pre-slope. Using a dry pack Sand Mix, form a level perimeter around the shower pan at your desired high-point mark. Pack the perimeter layer with a rubber or wooden float by tamping the material down repeatedly. Use a hand level to ensure that the perimeter is level on all sides and from edge to edge. Once the perimeter is level, fill in the centre of the shower pan, establishing a rough slope from the edges to the drain. You can use a 2 x 4 to pack down the outside edges and a hammer to tap it into place. The goal is to bring the pre-slope down to match the height of the drain flange. Be sure to clear any mortar mixture from the bolts on the drain flange and test that they are still functioning properly.
After the pre-slope is in place, you can install your waterproofing membrane. This step is crucial to prevent water damage. Cut a sheet of building paper or roofing felt to fit the bottom of the shower base, ensuring it covers the pre-slope. Some sources recommend placing a water barrier, such as plastic or tar paper, between the cement board and the pre-slope for added protection.
Finally, you can install your cement board and tile. It's important to follow the manufacturer's instructions for your specific cement board and tile products. Make sure to allow adequate time for the mortar bed to cure before tiling, typically at least 24 hours.
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Preparing the subfloor
Assess the Existing Subfloor
Before starting any installation work, it is essential to assess the condition of the existing subfloor. Check if the subfloor is level and make any necessary adjustments to ensure that the shower pan will sit evenly. If the subfloor is uneven, you may need to reinforce it or add additional layers of material to create a smooth and level surface.
Choose the Right Subfloor Material
The subfloor material plays a vital role in supporting the weight of the shower pan and providing durability. Common materials used for subfloors include plywood and cement backer boards. Plywood is readily available and can be purchased in thicknesses of 1/2" or 3/4". Cement backer boards typically come in thicknesses of 1/4", 1/2", or 5/8". Consider the thickness of your chosen material and how it will affect the overall height of the shower pan in relation to your shower curb.
Measure and Cut the Subfloor Material
Accurately measure the length and width of your shower pan, taking into account any non-square corners. Cut single, large pieces of your chosen subfloor material to fit the shower area floor size. If needed, cut any finishing pieces to size to complete the subfloor installation.
Install the Subfloor
Install the subfloor by screwing the pieces into the running boards or concrete slab. If you are using a cement backer board, be sure to use the manufacturer's recommended backer board screws. Ensure that the subfloor is securely attached and level. If you are using plywood, use non-moisture corrosive screws to prevent water damage.
Add a Cleavage Membrane (Optional)
Before installing the cement board, you may choose to add a cleavage membrane to enhance waterproofing. Cut a sheet of building paper or roofing felt to fit the bottom of the shower base. Install metal lath or reinforcement over the cleavage membrane, securing it to the subfloor with nails or staples.
By carefully following these steps, you can ensure that your subfloor is properly prepared to support the cement board shower pan and provide a durable foundation for your shower.
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Creating a dry pack mix
The next step is to add water to the Sand Mix. Add about a quarter of the recommended water to the mix and start blending. The consistency of the mixture is crucial. It should be damp, but not so wet that water drips out when squeezed. A good test is to form a snowball with the mix in your hands. If you can toss it a few inches in the air without it breaking, you have the right consistency. If it crumbles, add a little more water and remix. Conversely, if the mix is too wet, add more of the dry mix. Keep a record of your mixing ratios for future batches.
Once you have the correct consistency, it is time to pack the mix into your shower base. Use a rubber or wooden float to tamp down the material, creating a level perimeter around the shower pan. Use a hand level to check that the perimeter is even. Once the perimeter is level, fill in the centre of the shower pan, creating a rough slope from the edges to the drain. This slope is important to ensure water drains away. Generally, you want a quarter-inch of pitch per linear foot, but this may vary depending on the position of your drain.
Finally, smooth out the top of the dry pack with a wood float, removing any imperfections and flattening out the surface. Then, use a steel trowel to slick down the surface, creating a thin, smooth crust on the top layer of the dry pack. This will seal the mix and embed any loose particles.
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Installing the liner
Installing a shower pan liner is a crucial step in ensuring your shower is watertight and preventing leaks. Here is a detailed guide on installing the liner:
Prepare the Subfloor
Before installing the liner, ensure that the subfloor is flat and level. Use a self-levelling compound if necessary, following the manufacturer's instructions. This step is essential to ensure a smooth and even surface for the liner to sit on.
Install the Liner
Begin by covering your pan with a liner. Use a 40-mil liner or a waterproof membrane that is 80-mil thick, as per the instructions provided with the product. Nail the liner at least 8 inches up the studs, and wrap it over the curb, nailing it on the outside only. Ensure the liner is secure and fits snugly around the pan.
Drain Assembly
For the liner to be effective, it must be integrated into the drain assembly. Make sure the shower drain hole lines up with the existing shower drain. Test the pan and shower drain connection for any leaks. This is crucial to ensure that water is directed towards the drain and does not cause damage to the surrounding areas.
Additional Tips
When using a mortar bed, it is essential to ensure that no air is trapped between the mortar and the pan. Additionally, consider using a cleavage membrane by cutting a sheet of building paper or roofing felt to fit the bottom of the shower base. This will provide an extra layer of protection and help establish a drainage path for water in case the top layers of the shower pan are compromised.
Remember, a shower liner serves as a backup in case of leaks, so it is better to have one and not need it than to need one and not have it. Always follow the manufacturer's instructions and local building codes when installing a shower pan liner.
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Finishing the surface
- Creating a Smooth Surface: After the shower pan's initial rough slope has been established, use a steel finishing trowel to smooth out the final mortar bed. This step is not mandatory but highly recommended. The trowel helps create a smooth finish, ensuring that the waterproofing membrane remains undamaged by the pre-slope mortar bed's surface.
- Waterproofing Membrane: Cut the waterproofing membrane to the appropriate size. This membrane is essential as it establishes a drainage path for water in case the top layers of the shower pan are compromised. Grout and mortar are not fully waterproof, so this step is critical to prevent water damage.
- Applying the Membrane: Install the waterproofing membrane over the smoothened mortar bed. Make sure to follow the manufacturer's instructions for proper application. This membrane will protect the shower pan from moisture intrusion.
- Curing: Allow the shower pan to cure for an extended period. For example, the SAKRETE Sand Mix instructions recommend keeping the surface damp for at least 72 hours by spraying it occasionally with water. Refer to your product's guidelines for specific curing instructions.
- Tile Installation: Once the curing process is complete, you can proceed with installing tiles. For the SAKRETE Sand Mix, the next step is installing ceramic tiles. Ensure that you follow the local building code and manufacturers' directions for tile installation.
Remember, while creating a shower pan with cement board, it is essential to follow the guidelines provided by your local building code, the Tile Council of North America (TCNA) Handbook, and ANSI108.1. These sources will provide additional details specific to your region and materials.
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