Make it Leak-proof! - TRU

Make it Leak-proof!
Installation Handbook 2014
Beautifully Tiled, Worry & Maintenance-Free
Showers, Steam Showers, and Bathtub Surrounds
Official Instruction Handbook for correctly installing the TRUGARD Vapor-shield Waterproofing
Membrane and TRUGARD -Drain System for tiled Showers, Steam Showers, and Bathtub Surrounds.
TRUGARD® Vapor-shield Shower & Tub System
High Quality & Efficiency... is the Key!
Ceramic and stone tiles are durable, easy to maintain, and beautiful, representing the ideal surface coverings, particularly
in wet areas such as showers and bathtub surrounds. These tile and grout coverings, however, are not actually waterproof
and must be installed in conjunction with a waterproofing system that effectively manages water and vapor moisture to
protect moisture-sensitive building materials and control mold growth and decay. The TRUGARD Vapor-shield Product
Line fills the need for an affordable innovative and superior system as today’s ultimate solution for waterproofing tile
shower and tub surround areas.
Why TRUGARD Vapor-shield waterproofing is the preferred System
The TRUGARD Vapor-shield waterproofing Shower System is a complete
assembly bonded together to create a watertight envelope for tiled tub surrounds,
showers, and steam showers to keep moisture away from and protect the
structure. Unlike shower pan liners in conventional assemblies, the TRUGARD
Vapor-shield waterproofing membrane is applied on top of and bonded directly
to the sloped mortar bed, protecting it from becoming saturated and becoming a
haven of moisture that leaves the shower area musty and humid encouraging
microorganisms, mold, and mildew growth. The TRUGARD-DRAINS provide a
simple and secure connection to the Vapor-shield membrane at the top of the
mortar bed shower base assembly. The TRUGARD Vapor-shield Shower System
eliminates the potential for leakage, efflorescence, and as mentioned mold and
mildew growth, leaving a maintenance-free healthy shower. Traditional method for
installing tiled showers is time and labor intensive, the TRUGARD System
dramatically reduces total installation time, making the overall shower installation
better and easier than the old traditional systems, making the do-it-yourselfers and
tile contractors raving fans.
We the founders of Trugard believe that Quality & Efficiency is Key!
As the founders, we have over 30 years in the construction industry and it doesn’t
take long to learn that “value” is always a win-win for everyone involved. So we
understanding that if we were not competitive, our competitors would come in
and dominate, taking much of our business away because we were not giving
as good of a value to the customer as our competitors are.
You will find that the TRUGARD Vapor-shield System does not include a bunch
of unnecessary expensive gadgets that just drive the price up for us to make
more money on the customer.
One of my favorite cost-effective benefits that do-it-yourselfers and tile contractors
also love about the TRUGARD Vapor-shield system is that it can be installed
directly over the drywall panels. This saves so much time, labor, and expense. As
the drywall contractors sheet rock the home they just continue right on through
the shower and bathtub areas. No more labor-intensive cement backer-board.
This cuts out a whole entire step of extra expense, time, and energy. You the
contractors get to be the hero, and the homeowner has a superior product for
the same or less cost.
Everybody Wins
The Trugard founders’ goal is to make this revolutionary, state-of-the-art, superior shower waterproofing system affordable and
available to every person and home, not just to the high-end homes. Now the Trugard team, the builders, the tile contractors, and
owners can enjoy peace of mind and satisfaction knowing that the homes and buildings are protected with the ultimate shower
waterproofing system, and all this without breaking the budget..
2
www.trugardshower.com
Installing the Trugard-Drain & Keys to understand
Installing the Trugard-Drain Assembly
Double Protection
Assemble Drain
Place screwdriver in upper center
hole and pry snap-in grate upward
Apply 2 Beads of Sealant
around Drain Flange
Thin-set Mortar from
the Flange outward
Mortar
Fits 2”, 3” or 4”
waste drain lines
Back butter generously under the
stainless steel grate housing
Step 1. Install the Trugard drain assembly by first dry
Step 4. Install the mortar bed ensuring a 1/4”
Step 7. Complete the installation of the Vapor-shield.
fitting the drain onto the waste pipe making sure that our
drain will be level and that the bonding flange will be a
minimum of 1” above the existing plywood substrate or
concrete slab.
Step 2. Now you are ready to prime and cement glue
the Trugard drain body to the waste pipe.
Step 3. Next, secure and level the drain body.
a. For wood floors use four non-corrosive screws to level
and secure the drain body.
b. For concrete slab floors, fill in box-outs in the concrete
floors with dry-pack mortar also packing the mortar
around the waist pipe and Trugard -Drain, including
under the drain bonding flange.
consistent slope toward the drain hole.
Step 5. Apply thin-set mortar to the floor area from the
outer edge of the drain bonding flange outward.
Step 6. Now, apply TWO beads of sealant around the
drain hole opening as shown in the above and install
floor Vapor-shield
Note: Press down the Vapor-shield squeezing the
sealant toward the drain hole and the thin-set mortar
outward toward the perimeter of the shower.
See installing the membrane instructions on page 6.
Step 8. When you are ready to install the drain
assembly, cut an X in the Vapor-shield toward the
edges of the drain hole and insert drain height
adjustment sleeve. You may need to cut excess
sealant and membrane out to give lateral movement to
the drain.
Step 9. Remove drain grate prior to grouting to protect
the finish and hassle of cleanup or tape top of the grate
housing and grate to protect it during grouting.
Attention: Most do, but not all cities allow PVC waste
drains. Check with your local building inspection
agency. We accept no responsibility for code violations.
Congratulations on the installation of your
Trugard-Drain
Keys to understand for installing the Trugard Vapor-shield Shower Waterproofing System correctly
Make it leak-proof!
The Trugard Shower Waterproofing System boldly and proudly declares “leak-proof”... when installed correctly, of course. One of the reasons the Trugard system stands out
above the rest, is because of its redundancy engineering. In the aircraft industry, most airplanes have duplication or, in other words, a backup as a “fail-safe” for critical
functions of the system.
We at Trugard believe that a waterproofing system and not having leaks is extremely critical and merits redundancy and “fail-safes” throughout the system.
Areas of redundancy and fail-safe:
Key 1. The Vapor-shield membrane is installed like a roofer would install a roof. They start at the lowest point and then overlap the next layer so that any water or moisture
running off of a higher level piece of Vapor-shield membrane will shed the moisture on top of a lower level layer of waterproof membrane. Now in the event that the home
settles, the overlap should still shed the water on top of the lower layers.
Key 2. We start with the floor Vapor-shield membrane section first, taking the perimeter of the floor membrane up the wall a minimum of 2 inches, creating a floor pan on top
of the sloped mortar bed, ensuring that the water will not climb up the wall and possibly leak at the floor/wall intersection.
Key 3. Next we apply approved adhesive sealant to the inside and outside corners as the backup or fail-safe to ensure that the Vapor-shield shower pan is watertight up the
walls for at least 2 inches.
Key 4. Install pre-formed Inside and Outside Corner Seals with approved thin-set mortar as the first barrier of water leak protection.
Key 5. Since the most critical area for possible movement and leaking is the floor/wall intersection, we have engineered our system to require that the wall Vapor-shield
membrane be brought down the walls and onto the floor a minimum of 2 inches, hence creating a double layer of protection at the wall/ floor intersection and a single layer
over top of the inside and outside corner seals.
Key 6. The thin set mortar does a great job at adhering and making it difficult for moisture to get behind the Vapor-shield membrane, however again we recommend a double
protection system by applying a small bead of sealant around the perimeter of the Vapor-shield envelope and also any other penetrations through the membrane that might
allow moisture or vapor through or behind the Vapor-shield envelope.
Bathtub Surrounds
Key 1. Keep a 1/4 inch gap between the top edge of the bathtub and the bottom of the substrate (gypsum board, cement board, or etc.) so as to prevent any wicking of
moisture upward.
Key 2. Apply an approved sealant to the top edge of the bathtub to the substrate, and then imbed the bottom edge of the Trugard Vapor-shield membrane into the sealant.
Key 3. Apply Pipe and Shower Valve Seals. Use sealant around any and all protrusions through the Vapor-shield membrane.
Keys to understanding Thin-set Mortar
Key 1. All Unmodified thin-set mortars (ANSI A118.1) are approved for use with Trugard Vapor-shield. Higher-quality unmodified thin-set mortars generally have less
course sand which allows the mortar to spread more evenly and easily behind or underneath the Vapor-shield membrane making for a simpler and better installation.
Key 2. Approved Modified/fortified thin-set mortars (ANSI A118.4 and ANSI A118.11) may be used for both the installation of the Vapor-shield membrane and the
installation of tiles. Most modified thin-set mortar will work with the following conditions: See approved list at: www.trugardshower.com/learn-center
Key 3. Do use Modified thin-set mortar on porous substrates that will absorb the moisture and allow air to react with the thin-set mortar.
Key 4. Do Not use Modified thin-set mortar where the application requires the thin-set mortar to have greater than 1/4” in thickness under or behind Vapor-shield membrane.
Key 5. Do not use Modified thin-set mortar to install tile larger than 18” x 18” square on to the Trugard Vapor-shield membrane. The weight of the tiles combined with the
extra time the modified thin-set requires for drying time when attached to the impervious Vapor-shield membrane may cause failure.
Key 6. The complete installation instructions consist of the written handbook of instructions, the training videos, and the current and updated instructions, information,
approved practices and products list on the company website at: www.trugardshower.com/learn-center
Make it leak-proof!
3
Bathtub System
Specifications
SHOWERSShower
& TUB &
SURROUNDS
Technical
Specifications
TECHNICAL INSTALLATION SPECIFICATIONS
Areas of application
Acceptable Solid Backing Materials
Interior Showers, Steam Showers, and bathtub surrounds
Limitations
Certain glass tiles may not be compatible with bonded waterproof
membranes and/or may require special setting materials. Consult glass
tile manufacturer and TRUGARD® for more information.
Certain moisture-sensitive stones, e.g. green marble or resin-backed tiles,
may not be appropriate for use in wet areas or may require special setting
materials. Consult supplier and Truco Solutions for more information.
Treated lumber for curbs is required on concrete subfloors per code.
Gypsum wallboard – ASTM C1396/C1396M
Cementitious backer unit – ANSI A118.9 or ASTM C1325
Fiber-cement underlayment – ASTM C1288
Fiber-reinforced water-resistant gypsum backerboard/underlayment –
ASTM C1278
Coated glass mat water-resistant gypsum backerboard – ASTM C1178
Portland cement mortar – ANSI A108.1B
Concrete
Masonry
Setting and Grouting Materials
Requirements
Solid backing – gypsum wallboard, cementitious backer unit, fiber- cement
underlayment,
fiber-reinforced
water-resistant
gypsum
backerboard/underlayment, coated glass mat water-resistant gypsum
backerboard, portland cement mortar bed, concrete, or masonry
Solid backing panels shall be spaced a minimum of 1/4" (6 mm) above the
lip of the tub.
TRUGARD® Vapor-shield waterproofing membrane shall be installed up to
the height of 3 inches above the showerhead at minimum.
Any protrusions through the Vapor-shield membrane (e.g., tub spout,
showerhead, mixing valve, etc.) must be treated with TRUGARD® -Vaporshield - Pipe or Shower Valve Seal and one of the following approved
adhesive/sealant: Trugard’s Tru-Seal Adhesive Sealant, Schluter® KERDI-Fix, Wedi Joint Sealant, also all inside and outside corner cuts
must be sealed with sealant prior to installation of the pre-formed
corners.
Substrate Preparation
Verify that solid backing is properly fastened to framing members.
Unmodified thin-set mortar – ANSI A118.1
Approved modified thin-set – ANSI A118.4 (visit official company website
for approved thin-set mortars)
Grout – ANSI A118.3, A118.6, A118.7
Installation Specifications
Solid backing panels – follow manufacturer’s instructions
Portland cement mortar bed – ANSI A108.1B
Tile – ANSI A108.5
Grout – ANSI A108.6, A108.10
Other Considerations
When Trugard Vapor-shield and tile are installed on the ceiling, the solid
backing and fasteners must be able to support the load of the tile and
setting/grouting materials.
One of the approved adhesive sealants is required at all inside and
outside corners and along seams in the floor area prior to the water test.
Notice: The complete installation instructions consist of the written handbook of instructions, the training videos, and the current and updated instructions,
information, approved practices and products list on the company website at: www.trugardshower.com/learn-center
4
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The Mortar Bed Shower Base
Mortar Bed Shower Base Assembly
Areas of application and Requirements
Mortar beds are required to create the slope for interior showers over wood or concrete subfloors. Note: Plywood, OSB, or concrete subfloor must be clean,
even, and load bearing. A solid backing is required around the perimeter of the shower base mortar bed.
Areas requiring disabled access/barrier-free applications – Consult the appropriate government agencies and disabilities experts.
Note: If a traditional wood curb is used, it is required to be installed using liquid nail type adhesive and rust resistant grabber screws so as to keep the
wood from twisting and or movement. Wrap the wood curb with an appropriate substrate to meet the government regulatory building codes.
Installation Steps and Process
Step 1. Check and make sure that your floor and
wall substrates are secure and solid.
Step 2. For wood floors, locate, position, and cut out
a 4-1/2 inch hole in the floor substrate for the shower
drain assembly.
Step 3. Clean and prepare the mortar bed area.
Note: Best understood when used in conjunction with watching the Website Training Videos.
Step 4. For wood floor substrates, a vapor barrier
such as polyethylene plastic or roofing felt paper
must be placed over the plywood to prevent the
cement from condensing next to the wood which
would cause decay over time. For concrete slab
floors, a vapor barrier is not necessary.
Step 5. For wood floors, a piece of galvanized metal
lath, with an opening for the drain hole, is placed
over the vapor barrier membrane and fastened to
the floor... Again, for concrete slabs this step is not
necessary.
Perimeter Guide Line
Flange - Minimum 1” above Floor
Step 6. Install the Trugard drain assembly by first dry
Step 8. Secure and level the drain body.
Step 9. Using a level and measuring tape, create a
fitting the drain onto the waste pipe, making sure that
our drain will be level and that the bonding flange will be
a minimum of 1” above the existing plywood substrate
or concrete slab.
Step 7. Now you are ready to prime and cement glue
the Trugard drain body to the waste pipe.
a. For wood floors, use 4 non-corrosive screws to level
and secure the drain body.
b. For concrete slab floors, fill in box-outs in the
concrete floors with dry-pack mortar, also packing the
mortar around the waist pipe and Trugard drain,
including under the drain bonding flange.
line around the perimeter of the shower ensuring a
minimum of 1/4” per foot slope will be achieved. (For a
wall 2 feet away from the drain, that would place the line
1/2” higher than the center of the drain)
Now is the perfect time to also mark the top and side
lines of where your tile will be placed.
Step 10. Prepare for placing the cement mortar. a. Protect the drain hole by covering it with tape or some other adequate method. b. For concrete slab
floors, dampen generously the concrete slab under the mortar bed. This will bond them together. c. Mix your Portland cement mortar, on the dry side but damp
enough that it will form a ball in your hand, but not too wet that it squishes through your fingers. d. For concrete slab floors, dampen generously the concrete
slab under the mortar bed. This will bond them together.
Step 11. A mortar screed is now placed around the
perimeter base of the shower and tamped to the
guideline around the shower.
Step 12. The remainder of the shower base is filled
with mortar.
Step 13. The mortar is spread and tamped firmly
throughout the floor area.
Step 14. Create a uniform slope from the perimeter
screed line to the drain bonding flange using a
straight edge screed board. The extra wide bonding
flange makes for an easy guide to blend the mortar
bed to the drain.
Step 15. With a level, Double check that there is a
uniform slope toward the drain throughout the
mortar bed shower base.
Congratulations, you have completed the sloped mortar bed shower base!
Tip: Again, for smaller shower mortar beds, experienced contractors will often use a rapid/quick set mortar which sets up in about one hour after finishing the mortar
Bed. This allows a quick install process. If you have other areas to work on to be productive, the standard mortar is generally dry by the next morning.
High Quality… Low Prices
5
Installing the Vapor-shield Membrane
Installing the Vapor-shield Waterproof Assembly
Once the mortar bed has cured enough to walk on, waterproofing with the Trugard Vapor-shield can begin.
Keep in mind that we are working with water and, like a roofer, we will start with the lowest point of the waterproofing envelope, the
floor.
Tip: For smaller shower mortar beds, experienced contractors will often use a rapid/quick set mortar mix which sets up in about
one hour after finishing the mortar bed. This allows a quick install process. Cut membrane pieces while the concrete cures.
Installation Steps and Process
Step 1. First, pre-cut your Trugard Vapor-shield
membrane allowing the membrane to go from the
floor up the walls a minimum of 2 inches. This will
create a floor pan and a double crack-bridging layer
at the wall-floor intersection giving double protection
as we will bring the vapor-shield membrane down
the walls onto the floor a minimum of 2 inches also.
Step 2. Clean the mortar bed surface thoroughly.
Step 3. Dampen particularly dry or porous
substrates in order to help prevent premature drying
or skinning of the thin-set mortar.
Note: The Trugard Vapor-shield is installed using
unmodified or approved modified thin-set mortar
(mixed to a fairly fluid consistency, but still able to
hold a notch)
Step 4. The bonding coat of thin-set mortar is
applied, using a 1/4” x 3/16” V-notched trowel, to
the shower floor base including the Trugard-Drain
bonding flange except the inner 3/4” area . Apply a
1/4” Bead of approved Sealant around the drain hole.
Step 5. Apply the Vapor-shield membrane to the
entire floor mortar bed surface and up the walls 2
inches. Cut the excess out of the corners.
Step 8. Caulk generously all inside and outside
corner areas or any area that might present a
potential leak, with a Trugard approved sealant.
Step 9. Apply with thin-set, the inside corner seals
first, followed by the outside corner seals.
Step 10. Pre-cut your Trugard Vapor-shield wall
pieces remembering to add 2 inches that will go
down onto the shower floor mortar base.
Step 11. Dampen the wall substrate to prevent
premature drying.
Step 12. Firmly press the membrane into the thinset mortar starting with the top edge and then
pressing a line all the way down the middle of the
membrane, then working from the center of the
membrane outward in every direction removing all
air pockets to ensure complete adhesion.
Sealant around Drain
hole opening
Prior to membrane
Step 6. Embed the membrane into the mortar
throughout its entire surface to ensure proper
adhesion and to remove air pockets. Periodically
lift up a corner to check the fleece/webbing for full
coverage.
Step 7. Now place cardboard over the Trugard
membrane to protect it from damage or puncture,
leaving adequate workroom for the corner seals.
Note: If roofers find it necessary to overlap waterproofing materials at higher elevations over top of those at lower elevations then it only makes good sense that
we would want to do the same. This way if the homes settles or any other unforeseen movement happens, we are prepared and should still not have any leaks.
Pipe Seal
Step 13. Periodically peal a corner back, to make
sure the vapor-shield membrane is receiving
complete coverage of the thin-set mortar.
Step 14. Now you're ready to continue on to the
second section of wall installation of the vaporshield membrane.
Step 15. Follow the same steps, this time
overlapping the first section of membrane with a 2”
overlap of thin-set and the next strip of membrane.
Step 16. Finish applying the vapor-shield
membrane to the wall areas that will be tiled.
Note: Trugard Vapor-shield can also be applied on
ceiling areas for steam showers. A modified rapid
set thin-set mortar should be used for ceilings.
www.trugardshower.com
Step 17. The final step in creating a watertight
envelope is to install the Trugard Shower Valve and
Pipe Seals around protruding pipes and shower
valves per videos, ensuring a tight leak proof fit.
Congratulations your state-of-the-art shower
waterproofing system is complete and you are now
ready to install your stone or tile.
6
Shower Installation, Sizing & Diagram
Complete Waterproof System
Total items needed:
36”x 36” requires 80 sqft*
48”x 36” requires 94 sqft*
48”x 48” requires 110 sqft*
48”x 60” requires 138 sqft**
*Estimates. Actual may vary.
4’
4’
4’
1 TG Drain Kit
72”
3” Pan Lap up walls and
2” down walls onto floor
1 - TGVS-110
6” Curb
+ 1 - TGVS-55**
= approved Sealant
Critical: Seal any and all Vapor-shield penetrations and the perimeter with a
Trugard approved Sealant to prevent wicking of moisture behind the Vaporshield.
12-0”
39”
37”
37”
1 Sealant
37”
6” Cut off
6” excess
39”
39”
39”
39”
2 Overlap
Shower Floor
54”
A
B
C
39”x75” sqft
20.32 sqft
39”x75” sqft
20.32 sqft
39”x75” sqft
20.32 sqft
D
39”x75” sqft
20.32 sqft
2” Pan Lap up the Walls
For sides & 2” on ends
54”x 54” Bottom Liner
22 sqft
17”
39”
48”
48”
48”
2” Pan Lap
21”x 58” Liner
9 sqft
6” Curb
The Ultimate Shower Waterproofing System
7
BATHTUB SURROUNDS
Complete Waterproof System
Total items needed:
30”x 60” requires 55 sqft
36”x 60” requires 60 sqft
60”x 42” requires 65 sqft
60”x 48” requires 72 sqft
1 TG-Shower Valve Seal
1 TGVS Pipe Seal
1 Approved Sealant
21”
A
C D
2 Overlap
F
60” 8’
B
G
G
2 Overlap
E
Shower Valve Seal
Tape straight edge around top of tub
to ensure a clean professional job.
Approved adhesive/sealant: Trugard’s Tru-Seal Adhesive Sealant,
Seal Tite EvoSeal, Schluter® -KERDI-Fix, and Wedi Joint Sealant.
10’ or 120”
60”
30”
TGVS-55 or
TGVS-110
E
Cut these & Place
2 - 12” Side Pieces
D 30”
39”
37”
37”
12”
39”
39”
39”
12”
D
Bathtub Cross Section
Detail Diagram
Wall
Substrate
Thin-set
Vapor-shield
Tile
Sealant
Flexible Grout
Tub
Pipe Seal
Sealant
Critical to seal at tub-Vapor-shield connection and
13”
perimeter with a Trugard approved Sealant to
prevent wicking of moisture behind the Vapor-shield.
Substrate to be 1/4” away from tub. Vapor-shield to
touch the tub and sealed to tub by approved sealant.
1/4”
H
2 Overlap
A
B
39”x60” sqft
16.25 sqft
39”x60” sqft
16.25 sqft
C
39”x60” sqft
16.25 sqft
E
12”
9’
30”
60”
Total Length =10’
www.trugardshower.com
30”
The Ultimate Shower Waterproofing System
High Quality…
Low Prices
Tools and Materials Required to Install
Wood or Steel Stud Wall
(not included):
Gypsum Board, Cement Backer board,
Fiber Backer board, or other approved Substrates.
PVC primer and Cement Glue - for Drain
Phillips head Screwdriver, Level
Measuring Tape, Utility Knife, Pencil
Thin-set Mortar Mixing Tools
Thin-set mortar (no pre-mixed mortar)
1/4” x 3/16” Square or V-notched & Smooth Trowels
Appropriate sized Trowel for tile installation
Jigsaw or Reciprocating Saw
Tile or Natural Stone
Tile Grout
1st Layer of Unmodified Thin-set Mortar
Under the Trugard Vapor-shield membrane
TRUGARD Vapor-shield Membrane
2nd Layer of Unmodified Thin-set Mortar
over the Vapor-shield membrane
Natural Stone or Ceramic Tile
Trugard Warranty requires a double Lap of Trugard membrane
at the Shower floor wall intersection. Placing the Floor membrane
first with a 3” perimeter return up the walls to create a pan and a
wall membrane overlap of 6” with a 3” return onto the floor for a
double layer of leak and crack-bridging protection.
Note:Trugard Warranty requires prefabricated Trugard TGVS corners
to ensure inside and outside corners have full coverage
completing the water tight envelope.
Note: Follow all manufacturers instructions
Recommended Tools
TRUGARD SHOWER DRAIN
Unmodified thin-set Mortar to lock
PVC Sleeve and Drain grate into place
1/16” Nub on adjustment
Ring and weep holes
NUBS TO SECURE SLEEVE
PVC SLEEVE
Sloped Mortar Bed
(1/4” per foot)
Trugard Vapor-shield with unmodified thin-set Subfloor Hole opening
mortar below and above the membrane
to be 4-1/2” diameter
Metal Lath or equivalent
Plastic or roofing felt paper vapor barrier
Note:Cross section Diagram is not to scale
between the mortar bed and a wood subfloor
PVC Height
Adjustment Ring
3.0” Waste Line
2.0” Waste Line
Customer Service and Support
email:[email protected]
Sugar Hill GA 30518 Tel:1(800)427-3450
www.trugardshower.com
Tel:(678) 367- 0350
Fax:(678) 367- 4262