STEP UP SHOWER BASE INSTALLATION GUIDE FOR TIMBER AND CONCRETE FLOORS

Transcription

1 GUIDE FOR TIMBER AND CONCRETE FLOORS EDITION: APRIL 2016 IMPORTANT: This guide is for the installation of a Step Up shower base on a timber or concrete floor. If you require a walk in (flush with floor) shower base, please go to our support page at IMPORTANT: Please read all sections of this installation guide before installing your HYDRO-BLOK Shower System. Read our FAQs on or contact your local dealer if you have any questions regarding the installation process. IMPORTANT: Ensure that only HYDRO-BLOK approved and recommended materials are used in the installation of your HYDRO-BLOK Shower base kit. Failure to do so will void all warranties. Contents Section 1 - Tools & Materials Section 2 - Step-Up Shower Base Installation Section 3 - Wallboard installation Section 4 - Shower Hob (Optional) Section 5 - Final Install, Checks and Tiling Section 6 - Structural & Design Considerations Section 7 - Product Information

2 Section 1 - Tools & Materials Before installing your HYDRO-BLOK Shower System you will need: 1. HYDRO-BLOK Shower Base Kit - which includes: Information on how to download installation instructions or go to Pre-sloped HYDRO-BLOK shower base see sizes on our website 1 x 50mm wide mesh tape (for final shower base joint) 1 x Straight and 1 x corner plastic putty knives for joint sealant 1 x Brass Drain Kit. Ensure all parts of the Brass Drain Kit are present. These are: a) Solid brass caulking nut with tightening insert key b) Solid Stainless Steel Drain Cover and Drain Tray c) Plastic Drain Riser (can be trimmed to custom height) d) Solid brass drain body assembly e) Rubber and fibre gaskets 2. HYDRO-BLOK Wall Board: Ensure you have enough HYDRO-BLOK wall board to complete your installation. This is relative to your chosen shower base size. Visit to our website for sheet sizes. Also consider the thickness off the board you are intending to use. E.g. 10mm HYDRO-BLOK board to marry flush with 10mm plasterboard. 3. Additional Accessories Ensure you have the optional accessories available at the time of installation, such as HYDRO-BLOK Hobs and Niches. Go to hydroblok.com.au to find out sizes and dealers. There are separate installation instructions below for installing a hob. 4. Other Materials Required HYDRO-BLOK Joint Sealant - for installing HYDRO-BLOK shower base, wallboard and sealing all joints. HYDRO-BLOK Screws and Washers -1 x 100 piece pack for installing HYDRO-BLOK wallboard. Tile adhesive suitable for direct stick to concrete or timber (Depending on floor type) to glue the shower base to the floor. 90mm x 45mm structural pine timber to raise the bottom plate if required. 5. Tools Required Battery drill 30mm spade bit #2 Philips screwdriver drill bit Large flat head screwdriver Caulking gun(tube type or sausage type) 10mm x 10mm notch trowel 185mm Circular saw with minimum 40 tooth blade Jigsaw Hand saw Tape measure Fine point marker Level Utility knife Straight edge or large square Cleaning supplies, we recommend paper towels, citrus wipes, rags, dust pan and brush Page 2 of 13

3 Section 2 - Step-Up Shower Base Installation STEP UP SHOWER BASE INSTALLATION Important: Attached to this guide are two cross sections for timber floor and concrete installations. Ensure you are familiar with all the elements of your particular floor type. STEP 1 - Preparing Installation Space The drain pipe must be securely fastened below the subfloor so that it will not move under load. The drain should be centred through a 150mm opening in the subfloor to allow the proper fit of the drain assembly. Important: Cut the 50mm PVC drain pipe 5mm higher than the subfloor. Clean off any burrs on the 50mm pipe after cutting. If the top edge of the shower base is higher than the wall bottom plate, either add another 90mm x 45mm piece of structural pine to the bottom plate at framing stage. If you have a pre-existing wall frame add a 90mm x 45mm noggin on top of the existing bottom plate between each wall stud. This is to ensure the HYDRO-BLOK wallboard with the necessary support needed at the shower base joint to provide a proper seal. Perform a final floor checks to ensure that it is level. If the floor is NOT level you will not get proper fall required for drainage. If you are installing on a concrete floor, ensure that all high spots are grinded level and flat. Perform a final wall measurement to ensure all walls are square and make any adjustments required BEFORE installing your HYDRO-BLOK shower system. Installation area must be dry, free of moisture and fully cured. Clean installation area of dust, dirt and debris before starting your installation. STEP 2 - Measure the Installation Area 150mm clearance Measure the area where the shower base will be installed to determine if the base must be cut to size. STEP 3 Cutting the Shower Base Pay special attention to the drain location when cutting a shower base to size. The waste pipe must be in the centre of where the shower base drain assembly will sit. TIP: Measure twice and cut once! Once you have ascertained the correct measurements, transpose onto your shower base. If you need to cut edge of the shower base that is against the wall(s) a 10mm x 10mm channel MUST be re-cut on any side where it is trimmed away. This is to ensure a proper seal between the wallboard and shower base is obtained. Important: If you are NOT installing shower hobs, you can cut the open end 10mm channel as you will not require these. STEP 4 Trimming Your Base to Size The HYDRO-BLOK Shower base can be cut to size using a 185mm circular saw with a minimum 40 tooth blade or a sharp utility knife. IMPORTANT: If the shower base is trimmed on the wall side, the 10mm channel MUST be re cut to ensure a proper seal with the wallboard. To re-cut the channels, working from the top, set your blade to 10mm in depth and the guide 10mm in from the edge to make the cut. Standing the base on edge, use a straight edge and a sharp utility knife to make a 10mm deep cut 10mm in from the top of the base to complete the notch. Important: Change 10mm to 13mm if you are using 13mm HYDRO-BLOK wallboard. Page 3 of 13

4 STEP 5 Dry Fitting the Shower Base Section 2 - Step-Up Shower Base Installation Continued Dry fit the shower base on the subfloor and ensure that the subfloor opening and drain pipe are centred inside your shower base drain opening. Ensure all sides of the shower base fits comfortably to the walls. Important: DO NOT try to force the shower base into its location. STEP 6 Install Drain Fitting to Base Apply a 4mm continuous bead of HYDRO-BLOK Joint Sealant around the top edge of the first notch inside the shower drain profile ensuring that the bead is consistent and full. Drop the solid brass drain body into the joint sealant and seat it firmly. STEP 7 Install Drain Fitting to Base Continued Carefully place the shower base on its edge. Then slide the rubber gasket followed by the fibre gasket over the drain body threads. Ensure you firmly holding the drain body from the front to ensure it remains seated in the shower base. STEP 8 Install Drain Fitting to Base Continued STEP 9 Gluing Your Shower Base to the Floor Thread the solid brass locking nut onto the drain body while continuing to hold the drain body from the front. Hand-tighten the nut until the gasket is snug against the stainless steel support ring on the underside of the shower base. Once snug, check the positioning of the drain body to ensure it is in the proper position. Continue to tighten to a firm tension (do not use tools to tighten!). Use a paper towel or citrus wipes to wipe away excess sealant from the edge of the solid brass drain body on the top of the shower base. Mix the tile adhesive as per manufacturer s instructions. Apply the adhesive to the floor starting at the back of the shower area, troweling towards the front. Ensure the trowel lines are pointing to the front of your shower base. This will ensure there will be air pockets or voids in the installation. Apply tile adhesive to the back of your shower base using the smooth side of a trowel. Do not apply adhesive on or within 12mm of the stainless steel drain support ring. Important: DO NOT cross channel trowel lines as excess air will not be able to escape. Page 4 of 13

5 STEP 10 Gluing Your Shower Base to the Floor Continued Section 2 - Step-Up Shower Base Installation Continued Carefully place the shower base in the proper position on the subfloor and press into place by walking on the shower base. Ensure the shower base is level and firmly pressed into the adhesive. Wipe away any excess adhesive which may have accumulated on the drain pipe. STEP 11 Fitting the Waste Pipe Slide the rubber gasket (bevel side up) over the 50mm drain pipe or 50mm PVC Male connector (for connection to waste trap) until it is flush with the top of your drain pipe. Ensure that the rubber gasket is not higher than the top of the 50mm drain pipe or 50mm PVC Male connector (for connection to waste trap). Soapy water may be used to help ease the rubber gasket onto the pipe. Important: DO NOT use a petroleum based lubricant. STEP 12 Fitting the Waste Pipe Continued Thread the solid brass caulking nut into the drain body to compress the rubber gasket onto the 50mm drain pipe or 50mm PVC Male connector. Once it is hand tight, take the flat tightening key and place it into the solid brass caulking nut and then further tighten with a large flat screwdriver by placing the screwdriver in the slit in the middle of the tightening key. TIP: Tape the tightening key to the screwdriver so you do not drop it down the drain. Continue to Section 3 - HYDRO-BLOK Wallboard Installation Page 5 of 13

6 Section 3 HYDRO-BLOK Wallboard Installation You MUST ensure that you waterproof at a minimum height of 1800mm from finished floor level. In the case of a ceiling mounted shower head this must be to ceiling height. This will need to be achieved to comply with the Building Code of Australia (BCA) and AS STEP 1 Measuring Your Wall Area STEP 2 Transposing Your Measurements You MUST also ensure that the waterproof board finishes minimum of 40mm past the shower base and/or shower screen to comply with the Building Code of Australia (BCA) and AS To make it easier to comply with AS-3740, the best method to install your HYDRO-BLOK wallboard is to install it vertically rather than horizontally. This method ensures less work, less joins and less board to cover the wet area. This is however, entirely optional as long as you adhere to the code. Important: If you are installing HYDRO-BLOK recessed niches, all framing must be done before the wall board is installed. Go to download the HYDRO-BLOK Recessed niche installation guide. Measure from the shower base to 1800mm or to ceiling height (if you intend to tile up to the ceiling). Do this for both walls. IMPORTANT: Add 10mm for your recessed channel. Measure from internal corner to 40mm past shower base or where the shower screen will be situated. Do this for both walls. Measure out where your taps, shower head and recessed inches are situated. TIP: Measure twice - Cut once! Transpose all your wall measurements onto your HYDRO-BLOK board(s). Cut the HYDRO-BLOK board using a straight edge and either your circular saw or with your utility knife. Transpose your tap and niche measurements onto your HYDRO-BLOK board. Using your battery drill and your 30mm spade bit, drill holes for your tap ware to go through. If you are using a tap mixer then you may need to use a hole saw large enough to cater for the mixer. Important: Dry fit the HYDRO-BLOK board to ensure you have access to the tap ware so tap washers and cartridges can be changed when worn. Ensure that the board fits snugly into the wall corner and shower base and does not impede with the plumbing fittings. Important: Do not force the board into position. STEP 3 Installing Your First Wallboard Install the wallboard with the tapware holes first. Begin installing your wallboard by applying an 8mm continuous bead of HYDRO-BLOK Joint Sealant inside the channel created by the shower base and the bottom wall plate. Place your pre-cut HYDRO-BLOK wallboard into the channel and firmly press it into place, using a level to ensure the board is properly positioned. Page 6 of 13

7 Section 3 HYDRO-BLOK Wallboard Installation Continued STEP 4a Fastening Your First Wallboard (Vertical Installation) Fasten the wallboard to the studs using HYDRO-BLOK screws and washers. Place the first washer 300mm up from the bottom of the shower base and screw it in flush to the surface of the wallboard. Continue placing washers and screws every 300mm along each stud until the entire sheet is fastened to each stud. Use the HYDRO-BLOK corner putty knife to smooth out the excess joint sealant from the seam between the shower base and the wallboard (excess joint sealant can be used in the following steps to cover washers and screws). STEP 4b Fastening the Bottom Wallboard (Horizontal Installation) If you are installing sheets horizontally (Generally done if you are fully tiling the bathroom wall) Fasten the bottom wallboard to the studs using HYDRO-BLOK screws and washers. Place the first washer 300mm up from the bottom of the shower base and screw it in flush to the surface of the wallboard. Continue placing washers and screws every 300mm along each stud until the entire sheet is fastened to each stud. Apply a 10mm bead of joint sealant along the entire edge of the lower board. Place a new piece of pre-cut HYDRO-BLOK wallboard on top of an existing one. Press the new HYDRO-BLOK wallboard firmly into the joint sealant and hold against the studs. Install a washer and screw 300mm up from the seam close to the centre of the board to provide initial support. Install washers and screws along the seam before continuing to add washers and screws at 300mm intervals to secure the HYDRO-BLOK board to the studs. Use the HYDRO-BLOK corner putty knife to smooth out the excess joint sealant from the seam between the shower base and the wallboard. Use a HYDRO-BLOK standard putty knife to smooth out the excess joint sealant along the seam, using it to cover the seam as well as the HYDRO-BLOK screws and washers. STEP 4b Part 2 Fastening the Top Wallboard STEP 5 Fastening Your Second Wallboard Attach the wallboard to the studs with washers and screws using the same method as was used for the first wallboard. Use the HYDRO-BLOK corner putty knife to smooth out the excess joint sealant from the seam between the shower base and the wallboard. Use a HYDRO-BLOK standard putty knife to smooth out the excess joint sealant along the seam, using it to cover the seam as well as the HYDRO-BLOK screws and washers. Apply a 12mm continuous bead of joint sealant in the side shower base channel and down the edge of the rear wall board so that the side wallboard can be pressed firmly into the shower pan channel and against the rear wallboard. Place the pre-cut side wallboard approx. 25mm from the rear wallboard and press it firmly into the shower pan channel. Once in place, begin to push it towards the rear wall board and press firmly into the vertical line of joint sealant. Ensure the wall board is firmly and equally in the shower pan channel using a level. Page 7 of 13

8 STEP 6 Fastening Your Second Wall Board Continued Section 3 HYDRO-BLOK Wallboard Installation Continued STEP UP SHOWER BASE INSTALLATION Attach the wallboard to the studs with washers and screws using the same method as was used for the first wallboard. Use the corner putty knife to smooth out the excess joint sealant from the seam between the shower base and the wallboard (excess joint sealant can be used in the following steps to cover washers and screws). STEP 7 Sealing All Wall Board Joins Once all wallboard is in place, apply a final bead of 10mm joint sealant on all wallboard joints, seams and washers to complete installation. Use a HYDRO-BLOK corner putty knife for all 90 degree seams and the standard putty knife for all flat seams and washers. Ensure there is at least 25mm of joint sealant on either side of any seam. Important: DO NOT apply additional joint sealant to finish the seam between the wallboard and shower base until the optional shower curb has been installed. Section 4 - Shower Hob Installation (Optional) This section covers the optional HYDRO-BLOK shower hob installation. Go to the attached cross section to understand the elements required to install a hob. Important: If you DO NOT require a shower hob please go to section 5. STEP 1 Measure your Shower Hob Begin installing the HYDRO-BLOK shower hob by measuring from the wall to the channel corner at the top of the shower base channel. Important: Ensure the pre-cut channels on the HYDRO-BLOK Shower Hobs are on the bottom internal side. This is to ensure the hob channel marries up with the channel on the shower base. See cross section drawing attached to this guide. STEP 2 Cutting your Shower Hob If you are installing one hob you can cut the shower hob on 90 degree angle. Mark your measurements and use a square to square off at 90 degrees. Cut your shower hob using your hand saw. You cut the other channel off with a utility knife as you will not need it. If you are installing two hobs, you must cut the hobs on a 45 degree angle out from your measurement on each hob. These 2 hobs need to meet and join at a 90 degree angle on the external corner of your shower base. Mark your measurements and use a square to mark at 45 degrees from that measurement. Cut your shower hob using your hand saw. Page 8 of 13

9 STEP 3 Gluing Your Shower Hob Section 4 - Shower Hob Installation (Optional) Continued Apply a 12mm continuous bead of HYDRO-BLOK Joint sealant along the shower base channel as well as the corresponding channel on the shower hob. Apply a generous amount of HYDRO-BLOK joint sealant where the shower curb will be located on the wall. Apply a generous amount of joint sealant to the 45 degree joint on both hobs. STEP 4 Gluing Your Shower Hob Trowel tile adhesive out from the shower base edge to the edge of the hob location. Trowel away from the base in one direction. Apply tile adhesive on the underside of the shower hob with the smooth edge of the trowel. Important: Ensure the adhesive does not contact or mix with the joint sealant, cleaning off any excess adhesive from the joints of the shower curb. STEP 5 Installing Shower Hob Position the shower hob ensuring the hob is firmly pressed into place against the shower base channel and the adhesive on the sub-floor. We recommend placing the hob from the top down at a slight angle to avoid the tile adhesive from contacting or mixing with the joint sealant. Section 5 - Final Sealing and Checks To provide extra strength and further waterproofing you will need to run the supplied 50mm mesh tape along all joints. This includes the shower base to wall board, shower base to optional hob and wall board to wall board. STEP 1 Reinforcing and Sealing Shower Base Joints Apply a continuous 12mm bead of joint sealant into the corner seam of the shower base where it meets the wallboard. Use the corner putty knife to smooth out the sealant so that there is at least 25mm wide skim of sealant on either side of the seams. Press your 50mm mesh tape (supplied) into the seam, pressing it into the existing joint sealant. Use a sharp utility knife to make small slits to fit the corners. Use a corner putty knife to smooth the mesh tape into the joint sealant. Apply another continuous 12mm bead of joint sealant on top of the mesh tape and smooth out again with the corner putty knife to fully cover the mesh tape. Page 9 of 13

10 STEP 2 Reinforcing and Sealing Shower Base Joints Continued Section 5 - Final Sealing and Checks Continued Repeat the above step for all seams between the wallboards and the optional shower hob. Important: Mesh tape should always be pressed into joint sealant and should not make any contact with the cement surface of the wallboard, shower base, or hob. It should always be fully covered by the final application of joint sealant. STEP 3 Sealing All Joints STEP 4 Final Checks Step 5 - Tiling Perform a final check of all joints and screws/washers to ensure they are completely covered in joint sealant. After approximately one hour, (at room temperature of at least 18 C or 65 F) the joint sealant will skin over. You can now start tiling. Ask your tile retailer for an appropriate rubber modified tile adhesive for your tile or stone type. Follow the tile adhesive manufacturer s instructions to ensure proper adhesion. Check the caulking nut on the drain assembly again to ensure it is tight and cannot be turned by hand with a screwdriver. The drain assembly and shower base can be water tested to confirm a leak free installation. Loosely fit the HYDRO-BLOK stainless steel drain and tray into the shower base drain opening while installing tiles (tile up to the edge of the tray). DO NOT glue the tray into the opening. Should the drain cover need to be raised to accommodate thicker format tile or stone, cut the supplied plastic riser to adjust the height of the drain cover. IMPORTANT: The HYDRO-BLOK system does not need any further waterproofing membranes. Once properly installed you can direct stick your tiles or stone to the HYDRO-BLOK product. Ask your tile retailer for an appropriate polymer modified flexible tile adhesive for your tile or stone type. Follow the tile adhesive manufacturer s instructions to ensure proper adhesion. If using tile or stone that is smaller than 50mm x 50mm on the shower base, then a high compression epoxy grout must be used to comply with the HYDRO-BLOK warranty. Page 10 of 13

11 Section 6 - Structural & Design Considerations For maximum performance of the HYDRO-BLOK system a minimum building standard must be adhere to. Here are the design considerations you will need to obtain a fully waterproof wet area set under the Australian Standard AS-3740 (Waterproofing of domestic wet areas). Ensure you read this section to fully understand these requirements. Timber Walls Timber frame must be built square, straight with appropriate tolerances in accordance with AS-1684 (residential timber-framed construction) or as appropriate and The Building Code of Australia (BCA). Important Stud spacing s can only be a maximum of 450mm apart. If the top edge of the shower base is higher than the wall bottom plate, either add another 90mm x 45mm piece of structural pine to the bottom plate at framing stage. If you have a pre-existing wall frame add a 90mm x 45mm noggin on top of the existing bottom plate between each wall stud. This is to ensure the HYDRO-BLOK wallboard with the necessary support needed at the shower base joint to provide a proper seal. Double studs must be adopted at the exterior edge of the HYDRO-BLOK board to facilitate the correct fixing of shower screens or glass panels. Ensure that any board joins are situated along the centre line of the studs. Metal Walls Metal framing must be built square, straight and in accordance with AS-3623 (Domestic Metal Framing) or as appropriate and The Building Code of Australia (BCA). Important Stud spacing s can only be a maximum of 450mm apart. If the top edge of the shower base is higher than the wall bottom plate, either add another 90mm x 45mm piece of structural pine to the bottom plate at framing stage. If you have a pre-existing wall frame add a 90mm x 45mm noggin on top of the existing bottom plate between each wall stud. This is to ensure the HYDRO-BLOK wallboard with the necessary support needed at the shower base joint to provide a proper seal. Double studs must be adopted at the exterior edge of the HYDRO-BLOK-Blok board to facilitate the correct fixing of shower screens and glass panels. Ensure that board joins are situated along the centre line of the studs. Timber Sub-floor and Flooring The timber sub-floor and flooring must be solid, level and properly constructed in accordance with AS-1684 (residential timberframed construction) or as appropriate and The Building Code of Australia (BCA). Important Timber joist spacing must be no more than 450mm with 19mm tongue and groove plywood, particle board, floorboards or equivalent. With joist spacing more than 450mm, use 22mm tongue and groove plywood, particle board, floorboards or equivalent. All flooring must be nailed, screwed and glued in accordance with AS-1684 (residential timber-framed construction) or as appropriate and The Building Code of Australia (BCA). Page 11 of 13

12 Section 6 - Structural & Design Considerations Continued Concrete Slabs The concrete slab must be solid, level and properly constructed in accordance with AS-2870 (residential slabs and footings construction) and AS-3600 or as appropriate and The Building Code of Australia (BCA). The concrete slab must be cured, dry, and free of dirt, dust and debris for proper adhesion. Plumbing Water pipes and drain pipes must be installed in accordance to The Plumbing Code of Australia (PCA) or as appropriate and The Building Code of Australia (BCA). Important The drain pipe must be securely fastened below the subfloor so that it will not move under load. The drain should be centred through a 150mm round opening in the subfloor to allow the proper fitting of the drain assembly. Reactive soil sites may need to adopt an expansion joint connected to the 50mm waste pipe to allow for movement. Waterproofing The HYDRO-BLOK waterproofing system complies with The Building Code of Australia (BCA) when used in wet areas as a water proof substrate. IMPORTANT: The HYDRO-BLOK system does not need any further waterproofing membranes. Page 12 of 13

13 Section 7 - Product Information HYDRO-BLOK board and shower base products are made from a non-toxic, non-carcinogenic material that is not considered harmful. However we do recommended that inhalation be avoided and proper Personal Protection Equipment (PPE) be used when cutting this material. This includes protection for eyes, ears and mouth. Gloves are recommended when applying adhesives. Please see our MSDS on our website for more information. Storage and Handling HYDRO-BLOK should always be stored flat and on a level surface. DO NOT store the board resting on its side long term. Adhesion Joint Sealant HYDRO-BLOK Joint Sealant Joint is a non-hazardous, low VOC polyurethane formula provides a strong, flexible & watertight seal. HYDROBLOK Joint Sealant has a wet working life and will skin over within 1 hour at 18 degrees. Temperature and humidity may change these times slightly. HYDRO-BLOK Joint Sealant features a 20-year performance warranty. Refer to the product label and MSDS for additional health and safety information. Tile Adhesive for Shower Base to Concrete Floors Ask your tile retailer for an appropriate rubber modified tile adhesive for direct stick to concrete floors. Follow the tile adhesive manufacturer s instructions to ensure proper adhesion. Tile Adhesive for Shower Base to Timber Floors Ask your tile retailer for an appropriate rubber modified tile adhesive for direct stick to timber floors. Follow the tile adhesive manufacturer s instructions to ensure proper adhesion. Tile Adhesive for Your Tiles or Stone Ask your tile retailer for an appropriate rubber modified tile adhesive for your tile or stone type. Follow the tile adhesive manufacturer s instructions to ensure proper adhesion. Gloves are recommended when applying all adhesives. Clean up Please dispose of offcuts responsibly. For cleaning and disposal of adhesives please follow the manufacturer s instructions. Page 13 of 13