Cody Casey
Building a shower pan can be a tricky process, but it can save you thousands in labour costs. There are several methods for building a shower pan, and the best method for you will depend on your specific needs and requirements. For example, if you are building a shower pan for a bus, you will need to consider the vibrations from the vehicle and the potential for leaks. In this case, a pre-formed, pre-sloped foam pan that is waterproofed and tiled over may be the best option. On the other hand, if you are looking for a unique, handcrafted look, you may want to consider a traditional shower pan made with mortar and tile. This method is more labour-intensive and requires more skill, but it will give you a one-of-a-kind shower that is sure to impress.
| Characteristics | Values |
|---|---|
| Materials | Tile, mortar, rubber, styrofoam, fabric membrane, liquid system, cement, fiberglass, acrylic, sand, Portland cement, sloped fill, waterproof membrane, metal lath, sloped mortar bed |
| Steps | Prepare the subfloor, mix and apply mortar, trowel it flat, lay tile, waterproof, add a curb, slope towards the drain |
| Tips | Use a pre-formed pan to save time and cost, ensure proper waterproofing to prevent leaks, consult a building inspector if necessary, turn off the main breaker before cutting into walls |
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What You'll Learn
Preparing the subfloor
First, check if your subfloor is level. Place the shower pan on the subfloor and ensure it is flat and level from left to right and from front to back. Most homes have a standard subfloor made of running boards over floor joists, a plywood layer, or a concrete slab on the first floor. If your subfloor is not level, you will need to apply a self-levelling compound following the manufacturer's instructions. Make sure to choose a compound that adheres well to your subfloor material, such as OSB, cement board, or plywood. Allow the compound to cure completely before proceeding.
Next, dry-fit the shower pan again and draw a reference line along its edge onto the subfloor. This line will be used to contain the self-levelling compound within the shower pan area. If necessary, screw a piece of 1x2 along the line to act as a dam. Check if the shower drain hole aligns with the existing shower drain. If not, trace the hole location and cut a hole in the subfloor for the shower drain pipe using a jigsaw or circular saw. Typically, the hole should not exceed 5 inches, but always refer to the shower pan manufacturer's specifications.
Now, you will need to prepare the shower drain flange, also known as the "drain basket" or "drain body." Set the drain flange 1/2" above the subfloor to establish the low point reference for your slope. Line the underside of the flange's rim with latex/acrylic or silicone caulk, following the manufacturer's instructions. Avoid using plumber's putty as it may degrade the shower pan material. Place the flange through the top side of the shower pan and press down firmly without twisting, allowing excess caulk to squeeze out. Wipe away the excess caulk before it dries.
Finally, install a cleavage membrane by cutting a sheet of building paper or roofing felt to fit the bottom of the shower base. This layer is crucial as it establishes a drainage path for water in case the top layers of the shower pan are compromised. Secure a metal lath or reinforcement over the cleavage membrane using nails or staples. Calculate your floor slope by measuring the distance from the drain to the farthest wall. The target is a 1/4" slope per foot from the wall to the drain. Mark the high point of your mortar bed by multiplying the distance by 0.25 and adding 1/2". For example, if the drain is 3' from the shower, your high point should be 1.25" above the subfloor.
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Using a pre-formed pan
If you're looking for a quicker and more modern alternative to building a shower pan, you can opt for a pre-formed pan. This method has been used for decades and is preferred by many contractors today because it is faster to install.
A pre-formed shower pan is typically a pre-sloped foam pan that you can waterproof and tile over. You can find these pre-formed pans at home centres, usually in fiberglass or acrylic. The cost of a shower base typically ranges from $500 to $1,000, which is more expensive than a traditional shower pan but offers quicker installation.
To install a pre-formed shower pan, you'll first need to prepare the subfloor. Ensure that the area is level and free of any debris. You may need to cut into the existing walls to fit the shower pan, but be cautious and turn off the main breaker to avoid electrical shock. Consult your local building code for any specific requirements or guidelines.
Once the area is prepared, set the pre-formed shower base into a mud base on the floor. You can then screw it into the wall to secure it in place. Ensure that the slope of the shower pan directs water towards the drain to prevent water accumulation and mould growth.
After installing the shower pan, you can begin tiling. It is recommended to start within 16 hours of installing the mortar bed. Allow sufficient time for the mortar to cure before using the shower.
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Traditional methods
Building a shower pan can be a complex task, and it is recommended that you hire a professional to do it. However, if you have intermediate DIY skills, you can build a traditional shower pan yourself.
The traditional method involves creating a sloped mortar base with an embedded waterproof membrane or liner. This is known as a water-in/water-out (WIWO) shower system. The process begins by framing the shower walls and installing a subfloor. The next step is to create a sloped fill layer, which is a mortar subfloor slanted towards a specialised drain. This is followed by installing a durable chlorinated polyethylene (CPE) membrane or vinyl liner, which creates a waterproof barrier. The final step is to apply a top layer of mortar and tile.
Another traditional technique involves mixing and applying mortar, trowelling it flat, and laying ceramic shower floor tiles. This method uses a five-to-one ratio of sand and Portland cement, along with a metal lath and sloped mortar bed. A curb is also integrated into the design to contain water and is usually four inches from the floor.
It is important to ensure that the shower pan is properly waterproofed to prevent issues such as water damage and mould. This can be achieved by using a waterproofing liquid or membrane and ensuring that the drain is sealed correctly.
Building a traditional shower pan requires patience and work, but it can be a rewarding project that increases the value of your home and offers a unique look.
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Waterproofing
Firstly, select a suitable waterproofing membrane. There are two main types: sheet membranes and liquid membranes. Sheet membranes, such as Kerdi or Laticrete, offer excellent flexibility and robustness. They are easy to install, and you can immediately tile over them. Sheet membranes are also approved for steam showers, providing a fully waterproof barrier.
Liquid membranes, on the other hand, include products like Redgard or Hydroban. These require careful application at a specific thickness, and a gauge is necessary to ensure accuracy. Liquid membranes also need at least two coats and take a considerable amount of time to dry.
If you opt for a liquid membrane, pay extra attention to the corners of your shower pan. It is recommended to use anti-fracture fabric in these areas to reinforce and prevent cracking and leaking.
For a robust waterproofing system, you can combine both methods. Start by using a sheet membrane like Kerdi, and then apply a liquid membrane such as Hydroban on the seams or where it connects to the flange. This will reinforce the weak points of the sheet membrane system.
Additionally, if you are using cement board for your shower walls and ceiling, ensure that you tape the seams of the cement board before tiling over it. This provides a secure base for your waterproofing system and helps prevent any potential leaks.
By carefully following these waterproofing instructions and choosing suitable products, you can effectively waterproof your shower pan, ensuring a long-lasting and leak-free shower installation.
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Installation
To install a shower pan, you can either opt for a pre-formed shower pan or build a custom one.
Pre-formed Shower Pan Installation
Pre-formed shower pans are faster to install and are available in a variety of materials, including styrofoam, rubber, and fibreglass. They typically come with a built-in slope and can be cut to fit the size of your shower. To install a pre-formed shower pan, follow these steps:
- Ensure that your subfloor is level and sturdy. If you have an older home with 2x6 or 2x8 floor joists, you may need to reinforce the floor with additional beams or joists.
- Draw the outline of the shower pan on the subfloor, marking the location of the drain.
- Cut the pre-formed shower pan to size, if necessary.
- Place the shower pan in the marked area, ensuring it is level and properly aligned with the drain.
- Secure the shower pan in place using the recommended method for your chosen material. For example, a rubber shower pan may use a different adhesive than a fibreglass pan.
- Install the drain assembly according to the manufacturer's instructions, ensuring a proper connection to the plumbing lines.
- Test the shower pan for leaks by filling it with water and observing any drainage issues or leaks.
Custom Shower Pan Installation
Custom shower pans are typically built using mortar and tile, and the process is more time-consuming and skilled. To install a custom shower pan, follow these steps:
- Prepare the subfloor by ensuring it is level and sturdy, as mentioned earlier.
- Draw the outline of the shower pan on the subfloor, including the location of the drain.
- Create a sloped fill layer using a mixture of sand and Portland cement in a recommended ratio, such as five parts sand to one part cement. Slope the fill layer towards the drain to ensure proper water drainage.
- Install a waterproof membrane over the sloped fill layer to protect against moisture.
- Install a metal lath or wire mesh over the waterproof membrane to provide a base for the mortar.
- Apply a layer of mortar over the metal lath, trowelling it flat and ensuring a smooth surface.
- Install the tiles of your choice over the mortar bed, following standard tile installation procedures.
- Allow the mortar and tile adhesive to cure completely before testing the shower pan for leaks by filling it with water and checking for any signs of water escape.
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Frequently asked questions
You can buy a pre-formed shower pan and cut it to the size of your shower. Then, lay plywood, mesh or medium on top.
The traditional way to build a shower pan is to mix and apply mortar, trowel it flat and lay ceramic shower floor tile.
The steps for building a shower pan on a concrete floor are pretty similar to those on a framed wooden floor. You will need to draw the outline of the shower floor on the subfloor and use it as a pattern for setting the mortar forms.
