When picking out your tile how do you make sure that the surface is durable enough to last in that particular area? Well, being a hands-on kinda guy I use to walk into the tile shop with a belt sander and test it. If the sandpaper wore out before the surface of the tile we found a winner! This tended to piss people off, though. Then I found out there is, as most things I do, an easier way.
For everyone else in the world this is determined by using what is called the PEI, or Porcelain Enamel Institute, rating of your tile. The PEI rating is between I and V with a V being the most durable. Those are Roman numerals, not the 19 letters between I and V. 
I’ll just call them 1 to 5 – you know, since I’m not from, nor am I in, Rome.
This scale is used by most tile manufacturers to determine the surface wear durability and should be printed on the box of tile somewhere. If it is not you can always contact your tile manufacturer for the information.
General guidelines for proper installation areas are as follows:
- Group I: Tile suitable only for residential or commercial walls – stuff you don’t walk on unless you’re Spiderman. Not suitable or recommended for foot traffic (unless you are, indeed, Spiderman).
- Group II: Tile suitable for general light residential traffic. Not recommended for kitchens, entryways, heavily used bathroom floors or any other area subject to continuous use foot traffic.
- Group III: Tile suitable for all residential and light use commercial foot traffic areas. You can pretty much put this everywhere in your house except your garage floor.
- Group IV: Tile suited to all residential, medium commercial, and light industrial applications such as restaurants, hotels, and hospital lobbies.
- Group V: Tile suitable for all residential, heavy commercial, and industrial applications such as airports, malls, subways, and the Space Shuttle.
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And the rest . . .
Once you have your entire perimeter done you simply need to pack deck mud into the rest of the base from the perimeter to the drain. Once again – beat the hell out of it. Seriously, pack it in there really well. The more dense your floor is the better. You need to ensure that the line of the floor is straight from the wall to the drain all the way around without any major humps or dips. It takes time and patience – use both. This step is critical since this is the substrate your tile will be installed upon.
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Well, you’ve made it to the final step. If you have arrived at this portion of the instructions without first reading the rest, start with How to Create a Shower Floor. Go ahead, I’ll be right here when you get back. I’ll just sit back and drink this beer Pepsi while I wait.
Okay, now that we’ve ensured that your shower liner is indeed waterproof and won’t leak into your dining room and carve the Grand Canyon into your basement we’re ready for the final portion. The top mud bed is the surface onto which your shower floor tile is actually installed.
What we will now be doing is fabricating your top mud bed directly over the top of your waterproof liner. The top bed will be 1 1/4″ to 1 1/2″ thick – consistent throughout from the drain to the wall. Since you have a pre-slope beneath your liner (umm, you DO have a pre-slope beneath your liner, right?) you already have the correct slope for drainage. By making a consistent mudbed for your top slope it will follow the slope for the same amount. Know what I mean?
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Well now we’re ready to waterproof your curb. If you have reached this post before reading the previous two, start with How to build a shower floor from the beginning. Now that you’re ready to get the curb cut and waterproofed lets get it done.
And yes, I know my pictures suck – I’m a tile guy for cryin’ out loud, not a professional photographer. Until you try to balance a liner, a razor knife, a margin trowel, and a camera while trying to take a photo don’t give me any crap about it. Oh, and you can click on any of the images for a full-size version – partake in the full glory of how much my photography sucks.
We need to start by finding the inside lower corner of your shower pan and making certain that the liner is pressed firmly against it. Then follow it up the corner of the curb and wall to the top inside corner of your curb. This is the spot at which you will start the cut in your liner.
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Now that you have your curb built and your pre-slope done (if you haven’t done this yet check out How to create a shower floor, Part 1) you are ready to install your waterproof liner.
Purchasing a waterproof liner
When you order or buy your liner you need to get one large enough for your shower. The liner you get has to be at least one additional foot larger than each of your measurements. For instance, if your shower floor is three feet by five feet your liner needs to be four feet by six feet. This allows enough to run the liner up the wall behind your backerboard six inches each way. You also want to purchase two “outside” corners for your curb. These are pre-formed corner pieces to waterproof the ends of your curb after you cut the liner.
I usually order mine two feet larger in each direction. Six inches is the minimum. Specifications state that your liner must run up the wall at least three inches above your curb. So if your curb is three inches high your liner needs to run at least six inches up each wall. I usually go a foot above the curb – overbuilding your shower is rarely a bad thing.
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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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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…]
A common misconception about tile and grout is that grout will somehow assist in stabilizing a tile installation. It does not. Unless you use epoxy grout it will add no significant structural elements at all.
So why should I use grout?
Grout is, structurally speaking typing, simply there to fill the spaces between tiles. That is an oversimplification, but it describes the grout’s function. More to the point, it is there to keep other things out of that space. Without grout the possibility of dirt, grime and all sorts of unruly, unwanted things may collect in the spaces between tiles. This may lead to not only unhealthy conditions, but also the chance of damaging your tile while trying to remove those things.
Does epoxy grout help stabilize tile?
If you’ve read any of my other posts regarding grout you have more than likely seen me state that epoxy is different. This subject is no exception.
Epoxy grout will actually add to the stability of your tile installation – to an extent. Epoxy will stabilize only the area between the tiles – the grout lines. It does not stabilize your tile enough to replace proper installation methods. This is not what epoxy grout is intended for.
A couple of reasons for using epoxy grout include the durability, ease of cleaning, and its ability to withstand staining. It is not intended as a product to make a sub-par installation correct. [continue reading…]
Elastomeric or liquid waterproofing membranes are one of the most convenient methods of waterproofing shower walls before installing tile. These membranes consist of products such as Custom Building Products’ Redgard and Laticrete’s Hydrobarrier and Hydroban and Mapei’s Aquadefense. I will refer to all the membranes as Redgard for the purposes of this post, but they all work nearly the same way.
These materials can be installed with a regular paint brush, paint roller, trowel, or even sprayed on. They are applied to your shower walls then tile is installed directly onto it. When I use these products I always use a cement-based backerboard as the wall substrate without a plastic vapor barrier.
It is imperative that you do not install plastic behind your walls since this would create two waterproof membranes with your substrate between them. Having two barriers this close together leaves open the chance of trapping moisture between them with no way for it to evaporate. This may lead to mold.You must also tape the backerboard seams with fiberglass mesh drywall tape. [continue reading…]
Installing cement backerboard is one of the more popular choices for a shower wall substrate. Cement backerboards include Hardiebacker, Durock, Fiberboard, wonderboard, and similar products. These materials bridge the gap between expense and effectiveness. When installed properly they will give you many, many years of durable shower construction.
The advantage of cement backerboards is that, while not waterproof, they are dimensionally stable when wet. That just means that when they get wet they do not swell up. Any swelling behind tile is a bad thing. It will lead to cracking grout, tile, and all sorts of bad things.
Waterproofing your studs
To install the backerboard you must have a vapor barrier between it and the wooden wall studs. While the backerboard will not swell when wet, your wall studs will. You must prevent any moisture from reaching them. The preferred material for a vapor barrier would be 4 mil or thicker plastic sheeting which can be purchased at places like Home Depot or any hardware store. You can also use tar paper or roofing paper, the thick black paper used under shingles. Although I personally do not use that, it is an acceptable barrier. [continue reading…]
Before installing tile on your floor you must make sure your floor is properly prepared. A properly prepared floor does not have to be level. It must, however, be flat.
The only time the levelness (is that a word?) must be taken into consideration is when drainage is an issue, such as on a porch or in a shower. In those cases you must make sure your floor is not level – it has to be angled toward a drainage area.
If your floor will not be subjected to water regularly, such as a kitchen or bathroom floor, it does not necessarily have to be level. That does not mean you can have a 45 degree angle from your door to the cabinet (although I suppose you could if you wanted), it just means if your floor is not absolutely level it will not negatively affect your tile installation.
One of the things you must make sure of, among other things, is that your floor is flat. If it is not it will be difficult to set your tiles without what we call “lippage”. That’s a ridiculous word, isn’t it? Lippage simply describes the difference in the height of two adjacent tiles. If you have a tile that sticks up higher than the tile next to it you have lippage. You don’t want that. Starting with a flat floor helps prevent it.
When prepping your floor for tile trade your level for a straight edge. Don’t be concerned with how level your floor is, be concerned with how flat it is.
When there is a significant amount of movement on the substrate of a tiled floor or wall it may lead to grout cracking. When this happens it will leave what looks like a crack in the grout where it has come away from the tile. Unless your grout was installed very recently this is always due to movement in the tile. If your grout is new it may be caused by incorrectly mixed grout. With grout that has been doing this for a while it may lead to whole chunks of grout coming loose and leaving large voids in your grout lines.
While it may be tempting to simply mix up some more grout and fill these voids you need to know that it will not last. If you do this it will fill the grout lines just like new but over time will lead to the same problem. Grout over grout is not a permanent solution.
Why it won’t last
The first reason is that when you go over the top of grout that is already cured with new grout, there is no adhesion to the old grout. It will instead simply create a layer of grout on top of the old grout. These layers have no way of sticking to each other. When you grout tile the grout actually sticks to the sides of the tile rather than whatever substrate is beneath it. While it will stick to the substrate at the bottom of the grout lines to an extent, it is not a permanent bond. Attempting to grout over the top of old grout is simply stacking two seperate layers of grout. It will always remain two seperate layers.
The second reason is no matter how much of the old grout you may take out to install new, if you do not fix the actual reason the grout failed in the first place, eventually the same thing will happen again. As with any problem you may encounter with a tile installation, you must figure out the initial cause and fix it to prevent repeated problems. This is an involved process which I will cover in a different article. For now I’ll stick with the solution for the grout problem. [continue reading…]
