Ella Walter
While it is possible to use concrete for a shower pan, it is not recommended to use mortar mix as it is porous and will eventually crack. If you want to use concrete, it is best to use a product called deck mud, which is made by Quickcrete and can be found in the tile aisle. You can also use a pre-sloped pan or dry pack if you want to slope it yourself. When using concrete for a shower pan, it is important to follow the local building codes and manufacturers' directions, and to ensure proper waterproofing and drainage.
| Characteristics | Values |
|---|---|
| Can you use concrete for a shower pan? | Yes, it can be done. |
| Concrete shower pan treatment | "Waterproof" the concrete or use a clear epoxy concrete sealer/finish. |
| Concrete shower pan slope | Create a slope of approximately 6 mm (1/4 inch) per 30 cm (1 foot) from the walls to the top of the shower floor drain. |
| Concrete shower pan curing | Keep the surface damp for at least 72 hours by spraying occasionally with water. |
| Concrete shower pan installation | Pour a cement bed for the shower on a PVC pan-liner. |
| Concrete shower pan maintenance | Regular cleaning is required to maintain the shower pan. |
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What You'll Learn
Using a pre-sloped pan or dry pack
Building a shower pan can be a challenging task, but with the proper knowledge and patience, it can be a fun and rewarding experience. One common method for constructing a shower pan is by using a pre-sloped pan or dry pack. This technique ensures proper drainage and prevents water-related issues such as mould and tile failure. Here is a detailed guide on using a pre-sloped pan or dry pack for your shower pan project:
Planning and Preparation:
Start by reinforcing the shower pan. Use an unbonded mortar bed with a tar paper slip sheet on the subfloor and staple wire mesh to the top. Calculate the drain height and the height of the perimeter screeds relative to the drain. Generally, you want 1/4 inch of pitch per linear foot for adequate drainage. Mark the high point of your mortar bed by multiplying the distance from the drain to the farthest wall by 0.25, then adding 1/2 inch.
Creating the Slope:
Set the drain flange slightly above the subfloor to use as a low-point reference for your slope. Plug the drain to keep it clear during installation. Use a dry pack Sand Mix to form a level perimeter around the shower pan at your high-point mark. Pack the perimeter layer with a rubber or wooden float, tamping the material down to ensure a smooth and level surface. Check the level on both sides and from edge to edge. Once the perimeter is level, fill in the centre of the shower pan, creating a rough slope from the edges to the drain.
Finalising the Pan:
After establishing the slope, it's time to place the final mortar bed. Make sure to tape off the drain opening to keep it clean. Place a layer of clean gravel or crushed tile around the shower drain to keep the weep holes free. Adjust the drain height to accommodate tile installation, typically by raising it by approximately 1/8 inch. Use a steel finishing trowel to smooth out the final mortar bed, allowing tiles to be set directly on it.
Waterproofing:
Before tiling, it is crucial to install a waterproofing membrane to ensure that any moisture intrusion is properly drained. Cut the waterproofing membrane to size, extending it up the walls by approximately 6 inches and securing it only at the top. Fold the corners instead of cutting them, and seal them with an approved sealant or adhesive. Make an \"X\" cut over the drain base, being careful not to extend past the base flange. Fold the cut edges into the drain base and install the clamping ring and collar bolts.
Tiling:
Finally, you can begin tiling your shower pan. Tiling should start within 16 hours of mortar bed installation. After 24 hours, the mortar bed enters a "green" state, and you will need to wait 28 days before adhering tiles. By following these steps and allowing adequate curing time, you will create a durable and leakproof shower pan using a pre-sloped pan or dry pack method.
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Waterproofing the concrete
Planning and Materials
Before beginning the waterproofing process, 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 compliance and a thorough understanding of the project requirements.
The key principle behind waterproofing a shower pan is to isolate the concrete from wood and other materials susceptible to moisture damage. Choose materials that are specifically designed for wet areas, such as a cementitious board, and ensure that they are installed correctly.
Membrane Installation
The first step in waterproofing the concrete is to install a waterproofing membrane. This membrane acts as a critical barrier to prevent water infiltration and should be installed according to the manufacturer's instructions. It is often placed underneath the shower pan, establishing a drainage path for water in case the top layers are compromised.
Multiple Coats of Sealer
After the membrane installation, it is common to apply multiple coats of a penetrating sealer. Water-based polyurethane is a popular choice for this purpose, providing a durable and protective finish. Alternatively, epoxies or two-part polyurethanes can be used, sometimes in combination, with epoxy as a primer and polyurethane on top.
Densifying the Concrete
To further enhance the waterproofing capabilities of the concrete, consider using a denser-than-average concrete mix. Additionally, a densifier can be added to the cured concrete to reduce its porosity, creating a stronger barrier against water infiltration.
Drainage and Testing
Proper drainage is essential to prevent water stagnation and potential leaks. Install the drain properly, ensuring it seats correctly, and test it by filling the shower or tub with water and letting it sit for an extended period. Take pictures to document that there is no wetting or leakage.
Slip Resistance
Finally, slip resistance is a crucial safety consideration for shower floors. The final step in waterproofing the concrete should be to add grit or roughen the surface to provide traction and prevent slipping.
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Preparing the sub-floor
First, ensure that your sub-floor is flat and sturdy. Use 3/4" plywood over reinforced floor joists to create a stable subfloor base. Make sure that any nails in the sub-floor are driven flush to create a smooth and level surface.
Next, install the lower portion of the shower drain assembly. This includes placing the drainpipe and installing the shower drain into the floor drain. The drain should be set at a specific height to create the necessary slope for drainage. For example, if your drain is 3 feet from the shower, set the drain flange 1.25" above the subfloor to establish the correct slope.
Now, you'll need to install a cleavage membrane. Cut a sheet of building paper or roofing felt to fit the bottom of the shower base. This layer will protect the sub-floor and provide a path for drainage in case of any leaks. Install metal lath or reinforcement over the cleavage membrane, securing it to the subfloor with nails or staples.
At this point, you can begin framing the shower curb and pan box. If you're using lumber for the curb, stack and fasten the necessary number of 2x4s or 2x6s to the subfloor, screwing each consecutive piece to the one below it. You can then add blocking between the wall studs to create the shower pan "box" frame.
Finally, cover the subfloor plywood with a layer of tar paper or another recommended moisture barrier. This will help protect the subfloor from moisture damage. You can also add stucco wire or galvanized wire mesh at this point to reinforce the mud mortar.
By carefully following these steps, you'll have a well-prepared sub-floor that's ready for the next stages of your concrete shower pan installation.
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Installing the shower drain
Installing a shower drain in a concrete floor requires careful planning and execution to ensure a watertight seal and proper drainage. Here is a detailed guide on how to install the shower drain:
Planning and Preparation:
Start by marking the location of the shower drain, typically at the centre of the shower space, and outline the area on the concrete floor. Check your shower pan specifications to ensure accuracy. It is crucial to have a proper drainage system, so make sure to plan the layout and measure carefully.
Breaking the Concrete:
Use a hammer drill with a masonry bit to create a pilot hole. Then, switch to a chisel and hammer or a jackhammer to break up the concrete around the marked area. Be cautious to avoid damaging any plumbing or compromising the floor's structural integrity. Remove the concrete and dig out the dirt to create space for the drain assembly and pipe. Ensure you dig deep enough to accommodate the trap and any necessary piping connections to your home's drainage system.
Installing the Drain Assembly:
Place the drain assembly into the hole, fitting the trap and pipes securely and ensuring they are leak-proof. If you're using PVC pipes, use PVC primer and cement to bond the joints. The top of the drain assembly should be level with or slightly below the surrounding concrete surface to accommodate the shower pan and tiles.
Backfilling and Stabilising:
Backfill the hole using gravel or a concrete mix to stabilise the drain assembly. If using concrete, prepare it according to the manufacturer's instructions, carefully pour it around the assembly, and smooth the surface. Allow the concrete to cure as per the recommended time.
Installing the Shower Pan:
Apply a layer of thin-set mortar to the concrete floor where the pan will sit. Place the shower pan, pressing it firmly into the mortar for a strong bond. Ensure the pan is level in all directions. Attach the pan to the drain assembly by tightening a compression fitting, following the manufacturer's instructions.
Waterproofing and Testing:
Apply a waterproofing membrane to the shower pan and the surrounding area to prevent water damage. Follow the manufacturer's instructions for proper application and drying times. Seal the drain connection using a rubber gasket or silicone sealant, creating a watertight seal. Finally, test your installation by running water through the drain to check for leaks and ensure proper drainage. Address any issues before proceeding with tiling or finishing your shower space.
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Installing ceramic tiles
Concrete is a suitable material for building a shower pan, and it can be done in two stages, both using the same "dry pack" mixing method. However, it is important to consult local building codes and relevant handbooks for additional details before starting the project.
Step 1: Measurements and Markings
- Measure the width of the back wall and mark a vertical line at the centre point.
- Measure and mark the height of one tile resting on the shower pan.
- Use this measurement to mark a horizontal line on the wall with a level.
- Repeat this process for the remaining walls.
- Measure each shower wall to obtain the dimensions for installing the cement board.
Step 2: Cutting and Installing the Cement Board
- Score the cement board multiple times with a backer board scoring knife.
- Secure the board with clamps to maintain a straight cut and run a utility knife over the scored line.
- Gently bend the board to break it off.
- Screw each panel of the cement board to the studs using screws.
- Apply flexible adhesive caulk to seal the gaps between the cement panels.
- Add cement board mesh tape to the seams and corners for reinforcement.
Step 3: Installing Supports
- Fasten supports (1x4s) to the walls with screws.
- These supports will act as a guide and ensure a straight level for the first row of tiles.
Step 4: Applying Mortar and Tiles
- Apply mortar to the shower walls, using a drop cloth underneath.
- Push each tile into the mortar, ensuring no empty spaces are left between the tile and mortar.
- Place spacers between the tiles and clean excess mortar with a damp sponge.
Additional Tips:
- Most people start tiling the floor first so that there is a place to lay the wall tiles as you install them.
- Ceramic tiles are a popular choice for shower pans due to their affordability and wide range of styles.
- Before laying the tiles, cut, dry fit, and number them, especially if they are larger than 4 inches.
- For curved cuts and holes, use an angle grinder with diamond hole saw bits or a wet saw for outside edges.
- Ensure proper waterproofing of the shower pan and drain assembly.
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Frequently asked questions
Yes, you can use concrete for a shower pan. However, it is important to note that the concrete will need to be waterproofed, and regular cleaning can render that treatment useless over time.
A product called "deck mud" is recommended for shower pans. Quickcrete makes a version of this product that can be used to create a concrete shower pan.
The process involves multiple steps, including installing a floor drainpipe, framing the walls and curbing, sweeping and preparing the floor, and installing a shower drain. A full list of steps and instructions can be found online.
Mortar is extremely porous and is only used to adhere tiles to a substrate. A concrete shower pan, on the other hand, can be made with a product like deck mud, which is less porous and more suitable for a shower pan.
Yes, prefab pans are a quick and cheap alternative to using concrete. These can be purchased and installed without the need for mixing and curing concrete.
