Installing a Shower Mud Pan

Prefabricated showers are relatively easy for a homeowner to install, but they generally limit choices about design and materials. Alternatively, a DIY-er can build a custom shower pan with the desired specifications. A properly constructed shower pan includes multiple components from the chosen surfacing to an appropriate waterproof membrane, pre-pan and bed made of mud or mortar.

Instructions

Prepare the base and frame for the shower. Remove any materials necessary to expose the subfloor. Measure and cut three lengths of 2x4s to fit at the shower threshold. Stack and nail these boards to the floor joists and wall studs, and install them in the stud bays around the perimeter of the shower.

Staple a piece of building paper to the subfloor of the shower area. Cut a hole for the drain opening.

Glue the bottom portion of a three-piece shower drain into the drain opening. Stuff a rag into the drain opening to keep stray drops of mortar from falling in. Screw the bolts partway into their holes.

Determine the total rise required for the slope of the mud pan, and mark this distance on the wall. The slope, which should be at least 1/4 inch of rise for every foot of distance away from the drain, is established when you build the pre-pan. To calculate the total necessary rise, measure the distance between the center of the drain and the wall farthest from the drain, then multiply that distance, in feet, by 1/4. Measure up from the floor, and mark this spot on the wall. Use a level to draw a line at this height on the wall around the perimeter of the shower.

Staple or nail metal lath to the floor.

Prepare the mud, or mortar. Mix it so that it has a fairly dry consistency, and consider using an additive such as latex to improve the mixture's strength.

Place the mud for the pre-pan. Use a trowel to pack mud into the metal lath. Build the mud up until it roughly reflects the planned slope. Once the slope of the pre-pan has been nearly established, place a level or straight edge with one end on the drain and other on the wall line to check for low or high spots around the floor. Make adjustments as needed. Use a wood float to smooth the surface, and let the mortar cure for at least a day before continuing.

Cut a piece of waterproof membrane so that it will extend 8 inches up each wall and up and over the curb.

Attach the middle drain piece to the bottom piece already installed in the pan. Cut small slits in the waterproof membrane to accommodate the bolts, and cut a hole for the drain opening. Remove the bolts, place the second drain piece, and re-install the bolts, tightening them to create a watertight seal.

Attach the waterproof membrane to the underlying materials using an adhesive suitable for use with the specific material of the membrane.

Attach the third drain piece. Adjust its height to reflect the planned depth of the mud bed, which is typically at least 1 1/2 inches. Measure this same distance up the wall, and draw a level line around the perimeter at this height.

Prepare the mud for the pan, and lay enough mortar to fill up about half of the depth of the bed.

Cut a piece of metal lath to fit the pan, creating a hole for around the drain, and place it atop the half-laid mud bed.

Place the remainder of the mud. Build it up to the line on the wall, then use a level or straight edge to identify any unevenness. Correct these areas. Smooth the mud with a wood float, and let the mud sit for at least a day before placing tiles or other surfacing.

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