Trays PDF
Trays PDF
Trays PDF
Welcome to the Shower Trays Generic Industry Guide one in a series of Industry Guides which are available free from the Bathroom Academy website www.bathroom-academy.co.uk
We believe you will find the contents of the guides both informative and relevant and hope you will consider them a valuable aid to your continuing professional development and that of your colleagues, within the Bathroom Industry.
This guide is one in a series of guides. Other guides in the series include:
Baths Bathroom Furniture Brassware Domestic Water Systems Sanitaryware & Fittings Shower Controls Shower Enclosures Thermostatic Mixing Valves
Get qualified
You can obtain valuable qualifications as proof of your knowledge and skills by completing additional components relating to this Guide and others in the series.
Customer Service
Customers are becoming more demanding and expect much higher levels of customer service and product knowledge than they have ever done in the past. Having the right product knowledge and using it effectively and with confidence creates loyal customers who will come back time and time again. It also helps you to answer questions and solve problems, creating a good impression of the company, whether you deal with your customers by telephone, email or face-to-face.
Retail Skills
Retail is one of the fastest growing sectors in the UK economy. Customers are no longer satisfied with average service. In a highly competitive market, they look for those showrooms, shops and people who are the most professional to deal withand excellent product knowledge, used well, means that customers will come back to you. Nationally recognised qualifications, examinations and assessments are regulated in England and Wales by OfQual: http://www.ofqual.gov.uk/ For more information about the Qualifications and Credit Framework, click here:http://www.qcda.gov.uk/qualifications/60.aspx
NVQ Diploma
Your completed Bathroom Academy Merits can be put forward as evidence for a nationally recognised qualification. Previously known as NVQs, the new QCF (Qualifications and Credit Framework) qualifications are tailored to the needs of the Bathroom sector. The NVQ Diploma is based on achieving a certain number of Credits (each Bathroom Academy Merit will have a QCF 'Credit Value'). By completing the Certificate in Bathroom Studies and collecting further evidence of, (for example), dealing with customers, working safely, solving problems and so on, you can achieve an NVQ Diploma. This will prove your competence in your customer service role and / or retail skills in the Showroom. Your NVQ Diploma evidence will come from what you do at work, so there is no need to attend classes or do exams. You are assessed by a friendly, qualified assessor who visits you at work, observes you dealing with customers and asks you questions relating to your work. All your evidence is kept and assessed securely on-line, so there is no need for bulky files of paperwork.
Contacts
For more information about Bathroom Academy Merits and the Certificate in Bathroom Studies, please contact:Bathroom Manufacturers Association Innovation Centre 1, Keele Science & Business Park, Newcastle Under Lyme ST5 5NB Telephone: 01782 631619 email: info@bathroom-association.org.uk Website: www.bathroom-association.org For more information about nationally recognised QCF Bathroom qualifications in Customer Service and Retail Skills, please contact:Keith Marsh Axia Solutions Limited Unit 1, Riverside 2, Campbell Road, Stoke-on-Trent, ST4 4RJ Telephone: 01782 572777 email keithm@axia-solutions.com Website: www.axia-solutions.co.uk
Contents
Introduction Section 1 Features of Different Shower Trays - Standard Shower Trays - Low Level Shower Trays - Shower Trays with Upstands - Riser Shower Trays Section 2 Materials - Moulded Acrylic with Glass Reinforced Plastic - Solid Surface - Steel Enamel - Stone Resin & Acrylic Capped Stone Resin - Fireclay Section 3 Installation - Non-Riser (Wooden Floor Installation) - Riser (Solid Floor Installation) - Finish the Installation - Basic Panel Installation Procedure - Upon Completion - User Maintenance - Low Level/Level Access - Installation Procedure Direct to the Floor - Installation Procedure Direct to the Joists - Important Notes about Installation Procedures Section 4 Frequently Asked Questions Section 5 Industry Terminology Section 6 References Section 7 Useful Sources of Information Water Efficiency
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Introduction
Shower Trays, irrespective of the material they are made from, are available in a substantial range of shapes and sizes. There are traditionally six standard shapes seen below.
Square
Rectangle
Quadrant
Offset Quadrant
Pentangle
Offset Pentangle
The diagram shows an example of a standard height shower tray. This type of shower tray, usually made in stone resin (either with an Acrylic or gel coat surface) allows for ease of access. The stone resin does not require legs or a base board. Owing to its inherent strength it can sit directly onto a floor, supporting the weight of the person showering.
Some manufacturers recommend that they be fitted to a flat wooden or concrete floor. However, in all cases installers must be careful to follow the installation instructions provided by the manufacturer of the tray. These trays can simulate the wetroom look and can eliminate any step into the shower.
This shows a shower tray with adjustable feet or risers. A set of adjustable legs is added to enable pipe work to be fitted above floor level. Risers allow for levelling on uneven floors. Riser shower trays are available with and without up stands. This type of shower tray is generally made from Acrylic or Stone Resin and will be supplied with matching panels.
Section 2 Materials
There are 5 main types of materials used in the construction of Shower Trays.
Moulded acrylic or Acrylic capped ABS with glass reinforced plastic Stone Resin & Acrylic capped Stone Resin Solid Surface Steel Enamel Fireclay
Adjustable Legs The diagram shows a typical acrylic shower tray with its baseboard and adjustable feet. The baseboard is a reinforcement and the adjustable feet compensate for uneven floors and to allow for height adjustment.
Solid Surface Shower Trays Moulded acrylic or Acrylic capped ABS with glass reinforced plastic
The advantages and features of moulded Acrylic trays are: Warm to the touch Extremely durable Lightweight Designed for domestic use Easily transported Easy to install Easily located and installed Available at the higher end of the price range Available in a wide range of colours Resistant to staining Hardwearing Suitable for domestic use Excellent resistance to water staining Available throughout the price range Upstand options available Construction These shower trays are manufactured from a range of Acrylic and Acrylic capped ABS sheets and reinforced for strength and rigidity. Generally reinforcement is provided by spraying glass reinforced plastic (GRP) to the underside. The shower trays are manufactured from a range of acrylic sheets having different thicknesses typically 3mm 5mm or 8mm thick. As a rule the greater the thickness the less GRP reinforcement is needed on the underside. Solid surface technology means that a liquid mix is poured into a mould, set and then released and the shower tray material is therefore consistent throughout. This gives a shower tray of great strength which then needs no additional reinforcement as the minimum wall thickness of the material is likely to be 10mm or 12mm. Construction Consequently they can then be installed directly onto wooden or concrete floors - when tiles or carpet is then laid up to the tray, the step into the shower has been eliminated as the tray will be only of 50mm height in total. Advantages and features of Solid Surface trays are: Low Level/Level Access Warm to the touch
Section 2 Materials
Construction A surface of a sprayed polyester gel coat or moulded acrylic or acrylic capped ABS sheet is placed in the mould. A polyester stone and resin mix is cast onto this surface to form a complete tray. This sets to form a strong durable product. Leg sets can be fitted to accommodate plumbing that is above floor level if required.
Fireclay
Advantages and features of these trays are: Available in a wide range of colour sizes and prices Higher end of the price range Easy to clean Resistant to staining Heavier than Acrylic Long lasting Fade proof Resistant to acids and alkalis Suitable for domestic use Construction The traditional method is to pour slip into a plaster mould. Slip is made by mixing together water, various clays and minerals. The plaster of the mould absorbs the water from the slip leaving a firm clay piece. This is then carefully removed from the mould and trimmed and smoothed {fettled}. The mould is dried and reused. The clay piece is dried in a warm air dryer and then sprayed with glaze. The piece is fired after spraying in a kiln where temperatures exceed 1200C. This results in a strong ceramic product with a surface impervious to acids and alkalis. Fireclay shower trays are not fitted with adjustable legs.
The first step of the installation is to decide whether you need a non-riser or riser installation for your tray. To find out answer these simple questions. 1. Is the floor out of level by 1/4" (6mm) or more across the tray length? - then the installation of a riser tray is recommended. 2. Can a hole be made to fit the waste into the floor/timber/between the joists?
Shower trays are designed to be fitted to flat, even floors. It is vital that the whole of the shower tray base is supported. Determine the type of floor and follow the instructions.
Preparation - It is recommended that the shower tray is installed before tiling to ensure the rim of the tray is recessed behind the tile face, thus helping to achieve a water tight joint.
1. Ensure that the floor is clean, dry, firm and level. If siting your tray on a relatively level wooden/stone floor use a silicone based adhesive to bed the tray. If the floor is a rough but relatively level stone floor it is suggested the installer uses a purpose made floor screed to smooth the area beforehand. Coat the ribbed underside of the tray with silicone sealant. Then press down into place ensuring the tray is positioned into rebates. 2. Ensure that the tray is level.
Note: Please note the bottom of the shower tray has a built in fall to allow for correct drainage. Therefore please check the edges of the tray with a spirit level. 3. Connect the waste pipe. 4. If not applying a seal directly to the shower tray specifically designed to accommodate movement (see section on movement), then seal the joint between the shower tray and wall with silicone sealant to provide a secondary seal. 5. The area is now ready for tiling. 6. Remove the protective film.
Install the drain in accordance with the manufacturers instructions making sure that a water tight seal exists on all drain connections. Be sure to provide access to the plumbing connections for future plumbing maintenance.
8. Once the tray is level - tighten the individual lock nuts on the legsets and check the tray is firm and secure 9. Tighten the waste being careful not to overtighten. Make sure that the seal is in place, additional beads of silicone sealant must be used. 10. Seal the joint between the shower tray and adjoining wall with silicone sealant to provide a secondary seal. 11. The area is now ready for tiling.
Note: Please note the bottom of the shower tray has a built in fall to allow for correct drainage, therefore please check the edges of the tray with a spirit level. Adjust the height of the feet so that the tray is level in all directions and tighten the nuts.
9. Fit the end piece and the corner to the other panel. 10. Fit the corner onto the fixed panel and continue along pressing firmly. 11. Seal the top edge of the panel to the tray wall using a line of silicone sealant. Upon Completion If the shower tray has been raised off the floor, a suitable panel will need to be installed correctly to finish off the installation. This can either be painted or tiled to suit. User Maintenance Cleaning - Once installed, the shower tray must be thoroughly cleaned with hot soapy water and fully dried with a soft clean cloth before use. Risk of product damage - Many cleaners contain abrasives and chemical substances and should not be used for cleaning enamel or plastic. These surfaces like stainless steel or plated surfaces should be cleaned using a mild washing up detergent or soap solution, rinsed and then wiped dry with a soft clean cloth. The gel coat surface of stone resin shower trays has good resistant properties to acids but should not come into contact with alkalis or organic solvents such as caustic soda, dry cleaning agents and paint strippers. If in doubt contact your supplier.
End Piece
End Piece
Panel
Corner
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Note: Fit enough timber in-fills to support the entire area on which the tray will sit. When fitting the waste assembly one of the timbers may need moving slightly to allow for clearance.
5. Once the mortar has set, spray the tray with water to check all plumbing for leaks. Tile the walls at this point, trimming the tiles to the top of the tray. 6. The tray should be fully sealed along the tiled walls, check for leaks.
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Important notes about Installation procedures. I. Movement: When all trays are installed, bear in mind that movement may occur. This can be due to drying out within the building, natural settlement and even deflection due to the weight of the occupant. The installer must give careful consideration to the likely degree of movement. (There are now products on the market that have been specifically designed to accommodate movement and still maintain a waterproof seal, thus preventing any leaks). One such innovative product is pictured below.
3. Place the tray in position on the joists. Where necessary, cut slots in the supporting timbers to allow the waste pipe work to run correctly. Caution: Care should be taken when cutting through the original floor joists, as extra reinforcement may be required. If in doubt, seek professional advice. 4. Check the tray is level and that there is no rocking. Connect the waste pipe work and test plumbing for leaks. At this point, fix a timber support under the front edge of the entrance to the tray which will give greater strength. 5. To achieve a more flush fit, floor tiles may be laid up to the tray. This can help provide a Tray height in the range of 10mm - 25mm. 2. Manufacturers installation instructions: Shower Trays are manufactured from different materials and installation procedures vary dependent on the type of material used. It is essential to remember that whatever the material, the manufacturers installation instructions must be strictly followed when installing any Shower Tray.
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Should walls be tiled before fitting a shower tray? No, if walls are tiled after installing a shower tray a much better leak free seal can be made between the shower tray and wall. How high above the bathroom floor should a shower tray be installed? The simple answer is it depends on many factors, such as, is the plumbing running above or below the bathroom floor? Is access to the trap required? As a general rule the shower tray base , that is the area a person stands on to shower should be as close as possible to the bathroom floor level. When installing a shower tray how do I ensure that I can unblock the trap? Shower trays use less water than a bath and as a result the water flow rate through the waste trap is lower, this can cause a blockage in the trap. If possible always make sure there is a moveable panel to access the trap for cleaning purposes. Alternatively fit a top access waste designed to be removed from the inside of the shower tray to facilitate cleaning. Is it necessary to buy a shower tray specifically designed for top waste access? No, wastes and traps are manufactured to install in shower trays having a conventional waste outlet. I want to install a ceramic shower tray but my bathroom floor is uneven, what do I do? Use a thin bed of silicone sealant or a weak sand and cement mixture (5:1) between the shower tray and floor to level the floor. Do the patterns on shower trays make them antislip? No, unless the manufacturer states this. Always consider using a wall handrail and/or an anti-slip mat.
How long are most shower trays guaranteed for? Depends on brand and material and varies from manufacturer to manufacturer. Should I buy a tray and shower enclosure at the same time? It is advisable to buy them together to ensure that they are compatible and of the same size. Do shower trays move? Any product, shower tray or bath that sits on a wooden floor is subject to movement. The installer must always bear in mind the likely degree of movement. e.g. in a newly completed home. The gap between the floor finish and the skirting may increase because of drying out shrinkage and deflection, particularly in timber floors. A gap of up to 10mm is normal but exceptionally 15mm may be seen where timber floors have long spans.
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Locking Nuts Additional nut on a nut and bolt to prevent movement of the bolt once adjusted. Non-Riser A Shower Tray that rests flat directly onto a floor without adjustable legs. Panel Trim panel fitted to the front and/or sides to complete the installation on a riser Shower Tray. Rebate Area of tiling which is behind the front tiled surface. i.e. Balked into the wall. Acrylic A flat plastic sheet moulded into shape and reinforced with either GRP or Stone resin. Acrylic capped ABS A flat plastic sheet, consisting of 2 layers of different materials, where the top layer is Acrylic and the backing is ABS. This is moulded into shape and reinforced with either GRP or Stone resin Acrylic Capped Stone Resin Polyester stone and resin mixture is cast onto an Acrylic surface to form a complete tray. Adjustable Legs Devices by which trays are supported above the floor incorporating a mechanical adjustment facility which accommodates unevenness in the floor and usually provides adjustment of the rim height within a limited range. Baseboard Usually made of chipboard. Bonded to the bottom of a tray to provide support and rigidity. Fireclay A ceramic based product used for stronger shower trays. Glass Reinforced Plastic (GRP) Reinforcing material comprising strands of glassfibre and high quality resin (sometimes known as Glass Reinforced Polyester). Level Access When shower trays are installed below the floor so that any step into the shower is eliminated. Risers See adjustable legs. Screed If the tray is being fitted onto a floor that is not flat or level a layer of mortar or screed must be spread evenly over the area where the tray is to be fitted. This will ensure that the floor is level. Solid Surface A liquid which is poured into a mould to produce an extremely strong low level shower tray. Porcelain Steel Enamel A coated steel tray pressed into shape and sprayed with an enamel coating which is fired on at high temperature. Upstand Lipped area around the edge of a Shower Tray to tile down over.
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Section 6 References
BS EN 251: 2003 Shower Trays: Connecting dimensions. BS EN 14527: 2006+A1:2010 Shower Trays for domestic purposes. BS EN 249:2010 Sanitary appliances. Shower trays made from crosslinked cast acrylic sheets. Requirements and test methods. BS EN 15636:2010 Sanitary appliances. Shower trays made from impact modified extruded acrylic sheets. Requirements and test methods. BS EN: 15720:2009 Sanitary appliances. Shower trays made from impact modified coextruded ABS/acrylic sheets. Requirements and test methods. BS EN 263: 2008 Sanitary appliances. Cross linked cast acrylic sheets for Baths and shower trays for domestic purposes. BS EN 13558: 2003 Specification for impact modified extruded acrylic sheets for shower trays for domestic purposes. BS EN 13559: 2003 Specification for impact modified coextruded ABS/Acrylic sheets for baths and shower trays for domestic purposes.
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Building Regulations
Communities and Local Government is responsible for building regulations, which exist to ensure the health and safety of people in and around buildings, and the energy efficiency of buildings. The regulations apply to most new buildings and many alterations of existing buildings in England and Wales, whether domestic, commercial or industrial. General public users and professional users can access building regulations guidance, including the Approved Documents and associated guidance from the Planning Portal at: www.planningportal.gov.uk/approveddocuments
Waterwise
Waterwise is a UK NGO (non-governmental organization) focused on decreasing water consumption in the UK and building the evidence base for large scale water efficiency. They are the leading authority on water efficiency in the UK. Waterwise have produced a number of product brochures covering a wide range of water efficient products suitable for the bathroom, enabling you to easily identify and incorporate water efficient products into the bathroom design. www.waterwise.org.uk
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Water Efficiency
Bathroom manufacturers across the globe are aiding national governments in their quest to reduce water consumption by producing new, exciting, innovative and technologically advanced bathroom products that deliver the bathing experience which consumers demand, but using less water. The key to water efficiency is reducing waste, not restricting use. User behavioural changes can also save water. The installation of water efficient bathroom products will save water and energy. To influence the supply and demand for water the two must go together. The BMA Water Efficient Product Labelling Scheme has been developed by the Bathroom Manufacturers Association (BMA), the lead trade association for manufacturers of bathroom products in the United Kingdom. The membership of the Association represents major manufacturers of bathroom products who trade in the United Kingdom. The Scheme aims to raise awareness of bathroom products that if installed and used correctly will use less water whilst delivering the bathing experience that the consumer has come to expect. The BMA Water Efficient Product Labelling Scheme is open to all companies who manufacture or sell product in the United Kingdom that meets the criteria for water efficient products as defined by technical experts within the United Kingdom Bathroom Industry.
As a result of this, Government wants to reduce water consumption from between 150 and 160 litres per person per day to approximately 120 litres per person per day and the Bathroom Industry wants to play its part in facilitating better water efficiency. The Water Efficient Product Label achieves this. To find out more go to: www.water-efficiencylabel.org.uk
The Bathroom Manufacturers Association (BMA) is the trade association that represents the major manufacturers of bathroom products, ranging from sanitaryware, baths, taps, showers, enclosures, accessories and furniture. Members of the BMA offer products with an outstanding combination of quality, style, design, colour and availability.
Website www.cskills.org
The Bathroom Academy Innovation Centre 1 Keele Science & Business Park Newcastle-under-Lyme ST5 5NB t: 01782 631619 f: 01782 630155 e: info@bathroom-academy.co.uk