2009 May

How to Create a Shower Floor – Part 1

by Roger

The following five-part series gives a basic overview of building a shower floor for tile. If you would like a complete step-by-step of the entire process with all the little idiosyncrasies and details I now have manuals describing the complete process for you from bare wall studs all the way up to a completely waterproof shower substrate for your tile.

If you are tiling your walls and floor you can find that one here: Waterproof shower floor and wall manual.

If you have a tub or pre-formed shower base and are only tiling the walls you can find that one here: Waterproof shower walls manual.

Curb and Pre-slope

Properly built shower

There are a couple of options to create a shower floor for tile using deck mud. The first is a single-layer shower floor which can then be coated with RedGard or a similar product or covered with kerdi to waterproof it. The other is a normal shower floor with a liner which will have two layers – a preslope, the liner, then the top slope which is then tiled. This series of posts will describe the latter.

Before we start I should note that unless you are using the kerdi waterproofing method or utilizing a liquid membrane as your floor liner you should not have the backerboard installed in the bottom part of the shower. Your waterproof membrane for a shower floor will be installed behind your backerboard. The curb and pre-slope need to be completed before installing the lower wall substrate.

Creating the curb for a wooden floor

The first thing you must do is create the outside curb of your shower. You need to create the “box” which will become the inside of your shower floor. Depending upon whether your shower will be created on a wood or concrete floor will dictate what material you use for your curb.

If you have a wooden floor you want to use regular dimensional lumber. The 2 x 4’s they carry at Home Depot – those. That is the easiest and most readily available material. Ideally you want to use kiln-dried lumber. That is lumber that is, well, dried in a kiln. By removing moisture in this manner the moisture content of KD lumber is normally between six and eight percent compared to regular dimensional lumber at close to 15%. Why does that matter? Well moisture and wood don’t mix. As it dries wood has a tendency to warp and twist. The less moisture initially in the wood the better. KD lumber is best and regular air-dried dimensional lumber is also acceptable. NEVER use pressure treated lumber – ever.

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How to Make Deck Mud

by Roger

To create a shower floor from scratch we use what is commonly referred to as “dry pack mortar” or deck mud. Deck mud contains three ingredients: regular portland cement, sand, and water. That’s it. Don’t let anyone tell you that a latex additive or anything else is necessary. It is not. Properly mixing and installing deck mud will create a shower floor that will last for years and years.

The ratio is very important to achieve the correct consistency and stability. You want 5 parts sand to 1 part cement. Your ratio can vary from 4 to 6 : 1 but the 5 : 1 is what I use and find to be the easiest to work. You want just enough water to dampen the mixture. It’s not a lot. Too much water will cause your mud to shrink as it cures and compromise the stability of your base. You just want it damp – really.

The easiest and most convenient way to get your mixture correct is to buy the quikrete “sand and topping” mix which is sold at all the big home centers. This is already mixed at a 3 : 1 ratio. For a 60lb. bag you need only add 30lbs. of sand to it. This is how I mix mine – it’s convenient. The easiest way to mix it is with a regular shovel or garden hoe in a mixing box or regular wheelbarrow, although you can mix it with and in anything that works for you.

After it’s mixed it should just be damp. When you pick up a handful of it you should be able to squeeze it without water dripping from it. It should be able to hold it’s shape when you squeeze it, just like a snowball. [continue reading…]