GB2483660A

GB2483660A - Shower floor installation

Info

Publication number: GB2483660A
Application number: GB201015345A
Authority: GB
Inventors: Alexander Charles Hodgetts
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-09-15
Filing date: 2010-09-15
Publication date: 2012-03-21
Also published as: GB201015345D0

Abstract

A shower floor installation and associated method of installation, in which the installation comprises a sub-floor 31, a drain 3 and a substrate 36. The drain 3 includes a plurality of outwardly extending projections 5 arranged around at least part of the periphery of the drain. The substrate 36 comprises a cured filler and is mounted on the sub-floor 31 and extends between the drain 3 and the outer periphery (2, Fig 1) of the installation to define at least two inclined upper surfaces (6-11, Fig 1). The substrate also comprises a dividing strip 21, 22 which includes an upstanding rib 24 and flange portion 23. In use, at least the flange portion is embedded in the substrate filler. The dividing strip extends along the juncture between two of the inclined upper surfaces (e.g. 9 and 11, Fig 1) of the substrate. The drain projections 5 are keyed and bonded into the substrate filler 36. The drain projections may be castellated.

Description

SHOWER FLOOR INSTALLATION

DESCRIPTiON

This invention relates to a shower floor installation including a drain and a tileable substrate with a gradient extending downwardly thereto.

Many standard-sized, preformed, tileable shower floor substrates or formers which are available, are problematic, in that they are not compatible with all standard-sized shower enclosures and the position of the waste outlet may not be conveniently placed. Also, standard, preformed tileable formers may not be compatible with retro-fitted installations, as the existing waste outlet and associated plumbing may not be suitably positioned. Further, difficulty can be experienced by an installer when fitting large preformed tileable shower floor substrates into recesses and connecting the associated waste outlet plumbing to newly-installed drainage systems.

The present invention overcomes, or at least substantially reduces, the above-described disadvantages associated with known preformed shower floor substrates, former and corresponding installations by providing a bespoke shower floor installation which has a shallow gradient allowing relatively level access to the shower floor from the adjacent main floor and which allows the associated drain to be located anywhere on the shower floor, thereby avoiding any obstructions, such as joists, and facilitating connection of the drain to existing waste plumbing.

The invention also provides a method of installing a bespoke shower floor, a drain for use with the substrate of the resulting installation and a strip for use in the formation of the substrate. I'

Accordingly, a first aspect of the invention provides a shower floor installation comprising a sub-floor, a drain and a substrate, the drain including a plurality of outwardly extending projections arranged around at least part of the periphery of the drain and the substrate being mounted on the sub-floor and comprising: a cured filler extending between the drain and the outer periphery of the installation to define at least two inclined upper surfaces; a dividing strip which includes respective upstanding rib and flange portions, with at least the flange portion of the strip being embedded in the cured filler, and which extends along the juncture of the inclined upper surfaces of the substrate between the drain and the outer periphery of the substrate, wherein the drain projections are keyed and bonded into the cured filler.

A second aspect of the invention resides in a method of installing a shower floor, comprising locating a drain in a desired position with respect to a sub-floor, the drain having a plurality of outwardly extending projections arranged around at least part of the periphery thereof, providing at least one dividing strip to extend upwardly from the drain to the outer periphery of the eventually-installed shower floor, the strip including respective upstanding rib and flange portions, and applying a curable filler to the sub-floor to key and bond with the outwardly extending projections of the drain and to define respective inclined upper surfaces on opposed sides of the dividing strip.

In the first and second aspects of the invention defined above, the outwardly extending projections of the drain may be castellated and in a preferred embodiment to be described below the castellations may be dovetaited. The dividing strip may be of an inverted T-shape when installed and its flange portion(s) may be apertured, so that the filler extends therethrough. The inclined upper surfaces of the filler preferably abut respective opposed sides of the dividing strip and, more preferably, the upper edge or surface of the upstanding rib, is formed flush with the inclined upper surfaces of the filler and, during installation, acts as a screeding guide which defines the upper surfaces of the substrate.

The dividing strip is preferably supported in its inclined orientation with respect to the sub-floor and drain by means of spacing shims which are or become embedded in the cured filler, along with the flange portion(s). The dividing strip is secured firmly in place upon the spacing shims by any suitable means. For example, the width of the upstanding rib of the strip may be sufficiently wide to receive at least one fixing screw therethrough, with such screw(s) being firmly engaged with the associated shim(s) and/or the sub-floor. In a preferred embodiment, the cross-section of the rib of each dividing strip is channel-shaped, to provide a recess in which the head of the associated fixing screw can be accommodated.

Preferably, the installation comprises a plurality of spaced dividing strips.

In the installation, the highest point or line of the so-formed substrate is preferably flush with the adjacent surrounding main floor, to provide level access from, say, a bathroom floor, to the shower floor and vice-versa.

Upon tiling of the upper surface(s) of the substrate, namely, the inclined upper surfaces of the cured filler formed by the inventive method, tiles may be cut to size and adhered, in overlapping relationship, to the outwardly extending projections of the drain and, possibly, any associated drain flange.

A third aspect of the invention resides in a drain for use with a shower floor installation, such as an installation as defined and described above in accordance with the first and/or second aspects of the a invention, which drain comprises a plurality of outwardly extending projections arranged around at least part of the periphery of the drain.

The drain may also comprise a peripheral flange from which the projections extend outwardly, possibly with at least some of the projections being castellated, preferably dovetailed, in the installation in accordance with the first aspect of the invention and/or the method of the second aspect of the invention, such projections are keyed and bonded with the cured filler. Upon tiling of the substrate, tiles can be arranged to extend from the substrate and overlap the drain projections and, possibly, any associated drain flange, to abut an upstanding edge of the drain.

Further, a fourth aspect of the invention provides a dividing strip for use with a shower installation, such as that defined and described above in relation to the first and/or second aspect of the invention, which strip comprises a flange portion and a rib portion upstanding therefrom.

The flange portion preferably extends along opposed sides of the rib portion and, also, may be apertured. In an installation in accordance with the invention, the flange portion is embedded in the cured filler, with the filler extending through the apertured flange portion to enhance the integrity and durability of the substrate and hence the whole installation.

The rib portion of the strip may be of any suitable width and may be such that it can receive a fixing screw therethrough for attachment of the strip to associated spacer shims and/or sub-floor which provide the strip with its upward inclination from the drain to the outer periphery of the substrate, with the shims clamped between the strip and sub-floor.

In an embodiment, the rib of the dividing strip has a V-or U-shaped channel which can accommodate the head of fixing screws attaching the strip to associated spacing shims and/or sub-floor.

In order that the invention may be more fully understood, embodiments thereof will now be described by way of example and with reference to the accompanying drawings in which: Figure 1 is a diagrammatic plan view of a shower floor installation: Figure 2 is a partial sectional view of the installation shown in Figure 1; Figure 3 is a plan view of a flange for a drain used in the installation of Figures 1 and 2; Figure 4 is a perspective view of a dividing strip used in the installation of Figures 1 and 2; and Figure S is a partial sectional view of the installation shown in Figures 1 and 2, with the dividing strip of Figure 4 illustrated in use.

Referring firstly to Figure 1 of the drawings, a rectangular shower floor, indicated generally at 1, is defined within an outer perimeter 2. A drain, indicated generally at 3, is located centrally of the floor 1 and has an outer flange 4 around whose periphery are spaced a plurality of dovetail-shaped castellations 5. A substrate comprises six generally triangular sections 6 to 11 of a cured filler, such as a quick-setting, elastomeric, cementitious mortar of two components, namely a cementitious powder, for example, that sold under the trade mark "NIVORAPID", admixed with an elasticising liquid, for example, that sold under the trade mark "LATEX PLUS", which improves adhesion of the powder on difficult surfaces, for example, stainless steel, wood and rubber, and which can accommodate operational expansion and contraction during use.

The sections 6,7 and 8,9 of the substrate define respective opposed planar upper surfaces of the substrate, whilst sections 10 and 11 define respective opposed planar upper surfaces of the substrate, all of which surfaces 6 to 11 are tileable and inclined upwardly from the drain 3 to the periphery 2, with adjacent pairs of surfaces 6,10; 10,8; 9,11; and 7,11 being inclined to each other.

The dashed lines 21',22' in Figure 1 represent dividing strips 21,22, as shown in Figure 4, which effectively constitute the junctures between adjacent upper surfaces of the sections 6 to 11 of the substrate, with strip lines 21' extending upwardly from respective corners of the drain 3 to corresponding corners of the outer perimeter 2 of the substrate and strip lines 22' extending from the centre of the longer sides of the drain 3 to corresponding longer sides of the perimeter 2.

Each dividing strip 21,22, as shown in Figure 4, comprises two flange portions 23 extending along respective opposed sides of a central rib 24 with a longitudinally extending channel-shaped section.

Each flange portion 23 has apertures 25 spaced along the length thereof, whilst the base of the channel-shaped rib 24 has holes (not shown) spaced along its length.

Upon installation of the shower floor 1, a sub-floor 31 is constructed from suitable thickness plywood between existing joists 32 supporting an existing main floor 33, as shown in Figure 2, to define a recess of the peripheral shape and size of the shower floor 1 of Figure 1. The drain 3 and associated castellated flange 4 are located and fixed in the desired position with respect to the sub-floor 31 and to a waste outlet hole 40 and the drain 3 is then connected to a waste outlet pipe (not shown).

The dividing strips 21,22, as shown in Figures 2 and 5, are then located to extend between the drain 3 and the outer periphery of the recess at the edge of the existing main floor 33, the inclination of each strip 21,22 with respect to the sub-floor 31, and hence the horizontal, being determined by plastics spacing shims 34 mounted to the sub-floor 31, as shown also in Figure 5. Each strip 21,22 is secured to the sub-floor 31 by screws 35 passing through the holes in the base of the centrally-extending channel 24 of the strip 21,22 and, optionally through the shims 34, and into the sub-floor 31. The heads of the screws 35 are effectively countersunk in the channel 24. It is important that the strips 21,22 are maintained securely in position with respect to the sub-floor 31, in that they determine the boundaries or junctures of the sections 6 to 11, as well as the exact inclination of the eventual upper surfaces of the shower floor 1. Spacer shims 34 can be located in spaced positions along the length of each strip 21,22.

A curable filler, namely the above-described quick-setting, curable mortar 36, is then applied to the sub-floor 31, so that it embeds the shims 34 and the flange portions 23 of the dividing strips 2 1,22, with the inclined upper surfaces of the mortar 36, and hence substrate, lying flush with the top edges 26 of the channel-shaped rib 24 of the strips 21,22 (as shown in Figure 5). Usually, the central channel portions of the ribs 24 will also be filled with the mortar, thus embedding the screw heads therein.

The highest point of the so-formed substrate lies flush with the existing, untiled main floor 33. This smooth intersection between the shower and main floors 1,33 provides tileable level access therebetween.

The flange 4 of the drain 3 acts as a convenient screeding land for the mortar 36, lying generally flush with the upper surface thereof, as shown in Figure 2. The mortar 36 used in this embodiment sets within about twenty minutes but other quick-selling mortars may be used. Also, as the mortar 36 is quick setting, this precludes the traditional use of temporary wooden screeding battens to define the various top surface lands of the substrate. For example,e when using a sand and cement mix, the temporary battens would easily be removed and the resulting cavity back filled using the same sand and cement mix.

What the invention provides is a bespoke tileable shower floor substrate of thin section with dividing strips 21,22 which are incorporated in the substrate permanently to become an integral part thereof.

It is to be understood that the term "tileable" embraces not only ceramic tiles but also other waterproof and water resistant floor coverings such as sheet vinyl, ceramic mosaic, marble and stone.

The Nivorapid mortar 36 should be mixed in batches because of the short pot life and applied progressively as the substrate, so that it flows beneath the dividing strips 21,22. Thus, all sections 6 to 11 will be conjoined to form a unitary, tuleable substrate.

Claims

CLAIMS1. A shower floor installation comprising a sub-floor, a drain and a substrate, the drain including a plurality of outward'y extending projections arranged around at east part of the periphery of the drain and the substrate being mounted on the sub-floor and comprising: a cured filler extending between the drain and the outer periphery of The installation to define at least two inclined upper Surfaces; a thvidlng strip which includes respective upstanding rib and flange portIons, with at least the flange portion of the strip being embedded in the aired filler, and which extends along the juncture of the indined upper surfaces of the substrate between the drain and the outer periphery of the substrate, wherein the drain projections are keyed and bonded into the cured filler.
2. An installation according to claIm 1, whereIn the outwardly extending projections of the drain are castellated.
3. An installation according to claim 2, wherein the castellated projections are dovetailed.
4. An Installation according to claim 1,2 or 3, wherein the dividing strip, when installed, is of an inverted T-thape.
S. An installation according to any preceding claim, wherein the flange portionfsj of the * dividing strip is apertured. *.*.
6. An installation according to any preceding claim, wherein the inclined upper surfaces of the filler abut respective opposed sides of the dividing strip.

: :°,
7. An installation according to any preceding daim, wherein the Upper edge or surface of the * r upstanding rib of the dividing strip is formed flush with the inclined upper surfaces of the fifler, to act, during installation, as a screeding guide defining the upper surfaces of the substrate.
8. An installation according to any preceding claim, wherein the dividing strip Is supported in its inclined orientation with respect to the sub-floor and drain by means of spacing shims embedtjetj in the wred filler, along with the flange portions.
9. An Installation according to claim 8, wherein the dividing strip is secured firmly in place upon the spacing shims.

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10. An installation according to claim 8 or 9, wherein the width of the upstanding rib of the dividing strip is sufficiently wide to receive at least one fixing screw therettirough, with such screw(s), ujxrn installation, being firmly engaged with the associated shim(s) and/or the sub-floor.
11. An installation according to claim 10, wherein the cross-section of the rib of the dividing strip is channel-shaped, to provide a recess in which the head of the associated fixing screw can be accommodatetj.
12. An installation according to any preceding claim comprising a plurality of spaced dividing strips.

*
13. An installation according to any preceding claim, wherein the highest point or line of the *....: substrate is flush with the adjacent surrounding main floor, to provide level access to the * 0 * 000 shower floor. * 0*
14. A shower floor installation substantially as hereinbefore described with reference to the accompanying drawings. * to * * S *0**
15. A shower incorporating a shower floor installation according to any preceding claim.* 0*... * S
16. A method of installing a shower floor, comprising locating a drain in a desired position with respect to a sub-floor, the drain having a plurality of outwardly extending projections arranged around at lean part of the periphery thereof, providing at least one dlvithng strip to extend upwardly from the drain to the outer periphery of the eventually-installed shower floor, the strip including respective upstanding rib and flange portions, and applying a curable filler to the sub-floor to key and bond with the outwardly extending projections of the drain and to define respective inclined upper surfaces on opposed skies of the dividing stripS
17. A method according to claim 15, wherein the outwardly extending projections of the drain are castellated.
18. A method according to cia Em 17, wherein the castellations are dovetailed.
19. A method according to claim 16, 17 or LB. wherein the dividing strip is of an inverted T-shape
20. A method according to any of claims 16 to 19, wherein the flange portion(s) of the dividing strip are apertured, so that the filler extends therethrough.
21. A method according to any of claims 15 to 20, wherein the inclined upper surfaces of the filler abut rpective opposed sides of the dividing strIp.*
22. A method according to any of claims 16 to 21, wherein the upper edge or surface of the * ** S.5 * upstanding rib, depending upon its thickness, is formed flush with the inclined upper *55* * S * surfaces of the filler to act as a screeding guide which defines the upper surfaces of the substrate. * .. * S * SS*5S*S.5*s -* S
23. A method according to any of claims 16 to 22, wherein the dividing strip is supported in its inclined orientation with respect to the sub-floor and drain by means of spacing shims which are or become embedded in the cured filter, along with the flange portion(s).
24. A method according to any of claims 16 to 23, wherein the dividing strip is secured firmly in place upon the spacing shims.
25. A method according to any preceding claim, wherein the width of the upstanding rib of the strip is sufficiently wide to receive at least one fixing screw theremrough, with such screw(s) being firmly engaged with the associatedshim(sJ and/or the sub-floor.
26. A method according to claim 25, wherein the cross-section of the rib the dividing strip is channel-shaped, to provide a recess in which the head of the associated fixing screw(s) is/are accommodated.
27. A method according to any of claims 16 to 26comprisirtga pluralityof spaced dividing strips.
28. A method according to any of claims 16 to 2?, wherein the substrate is loaned with its highest point or tine flush with an adjacent surrounding main floor, to provide level access to the shower floor.
29. A method according to any of claims 161o28, wherein, upon titing of the upper surface(s) of the substrate, tiles are cut to size and adhered, in overlapping relationship, to the outwardly * extending projections csf the drain and, possibly, any associated drain flange.* .. *** * S
30. A method of Installing a shower floor substantially as hereinbefore described. *0 * S *31. A drain for use with a shower floor installation according to any of claims I to 15, which drain comprises a plurality of outwardly extending projections arranged around at least part of the periphery of the drain. * UCaj3...32. A drain according to claim 31 also comprise a peripheral flange from which the projections extend outwardly.33. A drain according to claIm 31 or 32, wherein at least some of the projections are castellated, preferably dovetailed.34. A drain according to claim 31, 32 or 33, wherein projections are keyable and bondable with a curable filler.35. A drain according to any of claims 31 to 34,, wherein tiles are arranged to overlap the drain projections and, possibly, any associated drain flange, to abut an upstanding ette of the drain.36. A drain subs1ntiaffy as hereinbefore described with reference to the accompanying drawings.37. A dividing strip for we with a shower installation according to any of claims 1 to IS or for use in a method according toariy of claims 16 to 30, which strip comprises a flange portion and a rib portion upstanding therefrom.38. A dividing strip according to claim 37, wherein the flange portion extends along opposed sides of the rib portion.39. A dividing strip according to claim 37or 38, whereIn the flange portion is apertured.Sa.....40. A dividing strip according to claim 37, whereIn the flange portion is ernbeddable in a cured as....* filler extending through the apertured flange portion. *.a 41. A dividing strip according to any of claims 37th 40, wherein the rib portion of the strip is of a suitable width for receiving a fbdng screw thererthrough for attachment of the strip to a j.* associated spacer shims andfor sub-floor, to provide the strip with an upward inclination.S*Ss u*a S * eJ4...42. A dividing strip according to any of claims 37 to 41, wherein the rib portion has a V'-or li-shaped channel arranged to accommodate the head of fixing screws attaching the strip to associated spacing shims and,tor sub-floor.43. A dividing strip substantially as hereinbefore described with reference to the accompanying drawings.S S5* * S*5545$ * S S. 55 * * S. * * *5 S -*S* SSStq * S