SAMUEL MUELLER Tub and Shower Wall Instructions

SAMUEL MUELLER Tub and Shower Wall

Product Usage Instructions

Measuring for Installation:

1. Determine desired wall panel height.
2. Install panels in the specified order.
3. Draw level and plumb lines on the wall.
4. Cut panels to size using appropriate tools.

Measuring and Making Cutouts:

1. Ensure inside corners have a minimum 1/4 radius.
2. Locate plumbing holes and cut them out.
3. Mark caddie cutouts and cut them out after installation.

Measuring the Panels:

1. Place shims at the base of the sheets for better silicone flow.
2. Trial fit panels and scribe if needed.
3. Clean sheets and installation area with denatured alcohol.

Frequently Asked Questions (FAQ)

• How should I store the panels before installation?
  Store panels in a flat area to avoid warpage until the time of installation. Do not store the panels vertically out of the original packaging.

• What should I do if I encounter electrical wiring or plumbing while cutting for accessories?
  Make sure no electrical wiring or plumbing is present before cutting out for accessories. If encountered, stop cutting and reassess the location to avoid damage.

INTRODUCTION

Thank you for purchasing Samuel Mueller® Tub & Shower Walls. Please read the instructions carefully prior to installing the wall system. This manual will give you basic instructions for the installation of tub and shower walls in a step-by-step sequence that will work in most types of installations. If you have an installation that is not covered in this manual, please contact your Samuel Mueller® dealer or contact Samuel Mueller® directly for additional information to cover your application.
Warning – Please inspect all items for breakage and report any damage to the store of purchase. Store panels in a flat area to avoid warpage until the time of installation. Do not store the panels out of the original packaging in a vertical position. Allow panels to acclimate to room temperature before installing.

Tools and Supplies Needed for Installation

• Circular Saw with Carbide Tip Blade (24-40 tooth)
• Random Orbital Sander
• Belt Sander with 80 Grit Belt
• 150-320 Grit Sandpaper & Scotch Brite Pad
• Installation Kit or Hot Melt Gun & Glue Sticks
• Drill, Hole Saw, 1/2” Diameter Bit (Sharp)
• Caulk Gun & Silicone
• Paintable Latex Caulk
• Level
• Square
• Jig Saw with Wood Finish Blade
• Compass or Scribe Tool
• Denatured Alcohol
• Clean Shop Rags
• 1 x 4 x 8’ Wood for Bracing (4 pcs.)

Preparing the Installation Site

• Prepare the area with moisture resistant dry wall, marine grade plywood, or tile backer board.
  Never install Samuel Mueller® directly on any wall construction that is, or may become, damp.

• When installing over ceramic tile, check for loose tiles. If you find any, correct the problem. Make sure that the area to be covered is uniform in support. If not, build up the areas without tile. Remove the bottom row of tile and cut a ventilation gap in the substrate.

• On every installation, make sure that there is a 1/2” clearance between the top of the shower pan or tub deck and the bottom of the substrate. This will allow for ventilation and keep water leaks from wicking up the substrate. (Figure 1)

Preparation for Accessories

Recessed Accessories:
Make sure the accessories will fit near, but not in, a stud and closer to the center of the sheet. Make sure no electrical wiring or plumbing is present before cutting out for the accessories. Make the cutout in the substrate to receive the accessory.

Surface Mounted Accessories:
If a surface mounted accessory, such as a grab bar, is going to be installed, make sure 2” x 6” wood blocking is installed behind the substrate where the surface mounted accessory will be located. This will insure that there is solid backing for any screws that need to be used in the installation.

Measuring for Installation

Leave the protective film on the panels until the walls are installed.

1. Determine your desired wall panel height. Allow for a 1/16” gap between the panel and shower/tub base for a better silicone seal.
2. Panels should be installed in the following order: Ceiling, Back wall, Side wall without plumbing and the plumbing wall.
3. You may need to draw level and plumb lines on the wall to determine whether your shower pan or walls are out of square. Using the reference line and measuring from the lowest point on tub or widest point on the wall, determine how your panels will need to be cut. Transfer this data to the panels. (Figure 1)
4. Check your measurements and cut the panels with a circular saw or jig saw. You may make final adjustments to your cuts with a belt sander.

Measuring and Making Cutouts

1. All inside corners of cutouts should have a minimum 1/4” radius. To avoid possible breakage, do not cut sharp inside corners.
2. Locate the location of the plumbing holes. Transfer the data to the panels. Cut the holes a minimum 1/4” larger than the pipe diameters. The cover plates for the plumbing fixtures may allow for more variance. Consult the plumbing fixture installation instructions for templates and recommended hole cut out sizes. Check your measurements and using a jig saw or standard bi-metal hole saw, cut out the plumbing holes.
3. Once the panels are cut to size, locate the caddie cutouts, marking the cut out locations. Cut the caddies out after the panels have been installed.

Measuring the Panels (Figure 2)

1. Shim: Place shims (1/16” thick) at the base of where the sheets will rest. This allows for better flow of the silicone. Laminate chips make great shims. (Shims may not be necessary if the slope of the pan creates a natural adhesion gap.)

2. Trial Fit & Scribe the Panels As Needed: Place the panel on the shims where it will be installed and check the fit. If necessary, scribe the panel for a better fit. Trim the scribe with a belt sander.

3. Clean the Sheets and Installation Area: With denatured alcohol and a clean rag, clean the back of the sheets and the substrate, along with any other area that will be in contact with the silicone.

4. If using an installation kit, prior to applying the silicone adhesive, apply the butyl tape abut 2” from the edge, around the perimeter of the panel.

5. Apply the silicone adhesive, about 1” from the edge, around the perimeter of the panel. Place quarter sized dots of silicone adhesive every 8-10 inches apart over the surface of the panel. If Accessories are being used, on the wall, place a bead of silicone around the cut out location.

6. Place the panel on the 1/16” shims, line up any holes, and firmly press the panel in place.

7. If using a hot melt glue gun, apply the silicone as stated in steps 4 & 5, apply hot melt along the back edge of the panel of Transolid where it will be attached to the substrate and press the panel firmly into place. The hot melt will hold the panel until the silicone sets up.

8. For Ceilings: Use a T-brace to hold the ceiling panel in place for a minimum of 12 hours.

9. If you find the panel pulling from the wall, bracing may be necessary. Use 1 x 4 boards, or other dimensional lumber, and brace the panels where needed as illustrated. (Figure 3)

10. Allow the silicone to cure. Make all remaining cut outs. Silicone between the panel and the substrate along the cut out edge and install the accessory.

11. Once the silicone is set up and the panel is secure, pull away the protective plastic an install the trim and cove.

12. Install any surface mounted items, such as grab bars, shower seats, etc., make sure that the screw hole drilled into the Transolid panel is 1/16” larger than the screw so that the accessory is held in place by the wood blocking and not the Transolid panel. If the accessory is to be ADA compliant, please refer to the ADA manual for the proper heights and locations.

Installing the Trim & Cove

• Clean all joints to be siliconed well with denatured alcohol
• Trim & Cove should be installed using silicone adhesive. Hot melt glue should be used to tack the trim in place while silicone cures.
• Caulk all inside joints with the color matched silicone.
• Caulk outside joints with paintable caulk where wall surfaces are painted, or silicone if wall surfaces are unpainted.
• Clean up silicone with denatured alcohol while silicone is still wet.

Cove moldings and trim pieces not only enhance the looks of a wet wall installation, but also provide extra protection against water. Cove moldings and trim pieces can also be used to better fit panels when walls are not standard sizes. You can install the cove moldings and trim pieces using stretched out butyl tape or hot melt, along with the color matched silicone. If adding cove moldings and a trim kit, start with the trim pieces and finish with the corner cove moldings. (Figure 4)

1. Dry fit the trim pieces along the top of the wall panels, marking the measurements on each trim piece. Outer corners should be mitered together, at 45 degree angles, while inner corners should rest flush against the next trim piece. Make all necessary cuts. Decorative corner blocks can be used for finishing off the trim.
2. Adhere each trim piece to the outer wall and the Transolid wall panel, using spots of butyl tape or hot melt.
3. Dry fit the cove strips into each corner, measuring the length from the pan ledge to the location where the cove strip reaches the bottom of the top trim piece (or the top wall panel if a trim kit is not in use). The cove strip should rest flush against the bottom of the trim pieces. Cut the cove piece to size.
4. Adhere the cove strip to the corner using pressure spots of butyl tape or hot melt.
5. Use the color matched silicone or caulk to seal all joint areas.

Sealing the Walls & Trim

1. Clean all joints to be siliconed well with denatured alcohol.
2. Using the color coordinated silicone in the installation kit, or silicone of your color choice, silicone all internal joints with a uniform consistent bead. Use denatured alcohol for cleanup while silicone is still wet.
3. Using a paintable latex caulk (not supplied) caulk the outside perimeter of the shower wall and paint with the exterior wall color. If a non-paintable surface butts up to the shower walls (i.e. tile or stone), silicone can be used.

ABOUT COMPANY

• SAMUEL MUELLER
• 800 Bronze Road
• Warren, OH 44483
• Phone: 844-974-2400

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