Tiffany Haney
When building a custom shower, there are various methods for installing a backer board. One method is to install the backer board about a quarter of an inch above the pan, with a backer rod or sealer to prevent wicking. Another method is to set the backer board directly on the finished pan without sealing. A third method is to install the backer board before the pan is formed and then level the pan mud above the board's bottom, encasing it within the pan. Durock Cement Boards, a type of drywall reinforced with cement for a harder surface, can be embedded in the top mud bed.
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What You'll Learn
Embed Durock in the top mud bed to lock it in place
Embedding Durock in the top mud bed is a recommended method for installing a shower pan. This method helps to lock the Durock in place and ensures a secure installation.
To embed Durock in the top mud bed, follow these steps:
First, ensure that your preslope is complete and that your PVC liner is installed. Wrap the PVC liner up, over, and down the front of the curb, fastening it only at the bottom of the outside curb face. Use preformed PVC corner dams where the curb meets the walls for added protection.
Next, avoid using Ardex 8+9 on the curb, as it will provide an unnecessary second layer of waterproofing. Instead, use a length of metal lath, bending it into a "U" shape lengthwise and friction-fitting it over the curb. Only fasten the metal lath at the bottom of the outer curb face, forming the curb with fat mud rather than thinset.
When embedding the Durock, ensure that there are no fasteners lower than 2-3 inches above the curb height. This will help create a smooth and secure installation.
After embedding the Durock, you can proceed with waterproofing the entire surface using Ardex 8+9 and taped seams. This will provide a strong and durable base for your shower pan installation.
By following these steps, you can effectively embed Durock in the top mud bed, creating a stable and secure foundation for your shower pan installation.
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Durock installation: 1/4 inch above the pan or directly on it
Durock is a cement board that is used as an underlayment for tile. It comes in 1/4" and 1/2" thicknesses. The 1/4" thickness is typically used for flooring installations, while the 1/2" thickness is required for wall installations.
When installing Durock for a shower, it is recommended to start with a pre-made shower pan as they are difficult to create yourself. The Durock is then attached to the studs on the walls, keeping it level. For the back wall of the shower, full sheets of Durock will fit, and it is recommended to use 1 5/8" Rock-On Screws spaced 8" apart along the studs. The first screw should be placed within 1/2"–2 1/2" from the edge of the backer board. For the side walls, it is preferable to use full sheets with a small piece on top to avoid having too many seams in one spot on the corners.
There are different opinions on whether to install the Durock 1/4" above the pan or directly on it. Some people recommend installing the Durock 1/4" above the pan to prevent wicking water into the board. This method may require a backer rod or some type of sealer. Others suggest setting the Durock directly on the finished pan without mentioning the need for sealing. Another approach involves installing the backer board before the pan is formed, with the pan mud levelled above the bottom of the board, encasing the bottom of the board within the pan.
It is important to note that the fasteners for the Durock should be placed no lower than 2-3" above the curb height. Additionally, it is recommended to use a waterproofing membrane and avoid using screws on the inside of the shower. The seams between the Durock should be taped with a special mesh tape designed for cement board and covered with thinset or tile mortar. For installations outside of the shower that need to be waterproofed, Durock boards can also be installed on the walls.
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Durock Cement Boards can be finished like drywall
Durock is a cement board that can be used in place of drywall or Sheetrock. It is a harder and more expensive variant of gypsum-based drywall. Durock is commonly used in areas that might be exposed to liquid water, such as bathrooms and kitchen backsplashes.
Durock Cement Boards can be finished like ordinary drywall using joint tape and joint compound. The first step is to tape all the Durock seams and joints on the wall with self-adhesive drywall tape. Smooth the tape over the seams and joints, pressing it down firmly. Then, apply a joint compound over the tape with a drywall knife. Hold the knife at a 45-degree angle to the wall and smooth the compound over the tape in a thin layer, extending about 1/2 inch on each side. Sand the joint compound smooth with fine-grit sandpaper to remove any ridges and give the wall a level finish.
It is important to note that the seams between Durock panels require a special mesh tape designed for cement boards, which can be purchased from a tile supply house. Additionally, the joint compound used with Durock should be the same thinset that is used to set tiles. Unlike drywall, Durock does not require mudding or taping to create a smooth surface for painting. However, a skim coat of mud can be applied if desired.
When installing Durock, it is recommended to embed it in the top mud bed to lock it in place. This can be done by wrapping the PVC liner up, over, and down the front of the curb and fastening it only at the bottom of the outside curb face. It is important to avoid using fasteners lower than 2-3 inches above the curb height and to refrain from fastening any Durock to the curb itself, as this can create holes in the liner.
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Use tile thinset and fiberglass tape to mud joints
Taping and mudding joints and corners is an essential step in creating a smooth surface for drywall. The process involves using tape, mud pans, joint compound, and paint buckets. It is important to protect your clothing and the surrounding area when working with drywall mud, as it can be messy.
To begin the process of mudding joints, gather your supplies, including tile thinset, fiberglass mesh tape, mud pans, joint compound, and paint buckets. It is recommended to wear coveralls and use drop cloths or tarps to cover nearby furniture or block off your work area, making clean-up easier and preventing damage. When working with drywall, it is also advisable to wear a mask or respirator to avoid breathing in dust during sanding and finishing.
Apply about an inch of mud to fill the joints using a utility knife or paint scraper. Make sure to cover the spots where screws attach the drywall sheets to the studs, and then wipe away any excess mud. When hanging drywall, pair the long, bevelled edges of each sheet to create a seamless joint.
Next, place a piece of fiberglass mesh tape over the wet mud in the joint. Every 12 inches or so, push the tape into the mud with your finger to secure it in place. Use a utility knife to cut along the tape, embedding it into the mud and removing any air bubbles. Work from the center of the tape towards the corners until the ends are fully embedded.
After taping, apply a second coat of compound to the joints and corners. No additional tape is needed for this step. Apply a thin layer of mud with a 10-inch drywall knife, using consistent strokes, and then wipe away any excess. Allow this second layer to dry for 24 hours or overnight.
Finally, apply a third coat of mud to cover any remaining imperfections. Thin the mud with water before applying it with a 12-inch drywall knife. Wipe away any excess, and let it dry overnight. Once dry, sand and smooth the wall with 120-grit sandpaper to complete the process.
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Durock and greenboard intersection: use normal joint compound
When installing Durock and greenboard, it is essential to understand the specific steps and materials required for a successful installation. Here is a detailed guide on the process, focusing on the use of normal joint compound at the intersection of Durock and greenboard:
Planning and Materials:
Before beginning the installation, it is important to plan the layout of the Durock and greenboard. In a typical bathroom setup, Durock is used for the shower area walls, while greenboard is used for the ceiling and non-shower walls. Ensure that your framing is no more than 16" apart on the ceiling to prevent the greenboard from sagging. For the installation process, you will need Durock or cement boards, greenboard, tape, joint compound, thinset, and tiles.
Durock Installation:
Start by installing the Durock or cement boards in the shower area. Ensure that the preslope is done correctly and install the 40-mil PVC liner. Embed the Durock in the top mud bed to lock it in place. Wrap the PVC liner up, over, and down the front of the curb, fastening it only at the bottom of the outside curb face. Use preformed PVC corner dams where the curb meets the walls. Do not use fasteners lower than 2-3" above the curb height and avoid fastening any Durock to the curb to prevent holes in your liner.
Greenboard Installation:
Install the greenboard on the ceiling and non-shower walls. It is recommended to use a fan to control moisture instead of using greenboard everywhere, as it may be overkill.
Taping and Joint Compound:
At the intersection of Durock and greenboard, use normal joint compound from the green or blue bucket. Do not use thinset in this area, as it does not finish well and may be painted over. Apply the joint compound using tape designed for cement board/Durock, such as the special mesh tape. Do not use regular mesh tape from the drywall section. You can also use paper tape and a setting compound like Durabond or Easy Sand. For the Durock to Durock seams, use alkaline tape and thinset (optional Redgard depending on waterproofing).
Tiling:
After taping and applying joint compound, you can proceed with tiling. Use thinset to set the tiles, ensuring that you do not use mastic. By thinsetting the tape first and then applying more thinset, you can avoid humps and bumps. Feather the finished wall side out like normal drywall. Bridge the mesh with tile or bullnose to prevent the break/transition from occurring on a grout line. Take the tile up to the ceiling and caulk the gap.
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Frequently asked questions
Durock is a type of drywall reinforced with cement for a harder surface.
Yes, you can embed Durock in the top mud bed.
You should not fasten any Durock to any part of the curb. Wrap the PVC liner up, over, and down the front of the curb, only fastening at the bottom of the outside curb face.
You can use tile thinset and a fiberglass tape made for cement boards.
No, drywall mud should not be used to mud the joins between Durock and cement boards.
