Install Durock Bathroom Walls
Durock, the brand name of a product manufactured by USG (United States Gypsum), is a fibrous cement product manufactured in 4 foot by 8 foot sheets. You can purchase Durock in 1/2 inch and 5/8 inch thickness. Its hardness and waterproof qualities make it suitable as an underlayment for bathroom wall and floor tile installations. Other trade names for this product are backer board and HardiBacker board. (HardiBacker is the brand name of a similar product manufactured by James Hardie Building Products.)
Instructions
Preparing the Wall
1. Ensure the studs around the tub are exposed to the ceiling and free from any old fasteners. Remove old nails with a nail puller and remove old screws with an electric drill.
2. Insert insulation in the channels between the studs. Staple the paper wings of the insulation to the sides of the studs with a hammer-tacker. (Insulation is used on the interior walls for sound deadening, and on the exterior walls for weatherization.)
3. Use finishing nails and install furring strips to the face of the studs and framing members. Butt the furring strips up to the tub or shower pan lip, in order to eliminate any offset in the Durock board when it is installed.
4. Install a vapor barrier to the face of the studs around the entire shower area. Use .03 mil polyurethane plastic sheeting.
Cutting Durock
5. Measure and mark the Durock sheet with a pencil to indicate where you may need any cuts in the board. Mark both sides of the panel for all necessary cuts.
6. Score the Durock along the marks on both sides of the panel using a utility knife.
7. Use a power drill with a 1 inch masonry bit to drill holes in the board as needed for plumbing pipe and fixture access. For example, drill one hole each for the shower head pipe, the spigot pipe and the hot and cold water valve pipes.
Install Durock to the Back Wall
8. Install the Durock on the back wall (long wall) first. Install the sheets horizontally starting with the bottom sheet. Mark and cut the sheet as necessary to fit the space.
9. Put the sheet in place and attach it using stainless steel, countersunk, masonry screws. Insert the screws 1 inch down from the top of the sheet at each stud and in each corner.
10. Screw the bottom edge of the Durock sheet 2 inches up from the bottom on each stud. Use caution not to screw through the tub or shower pan lip.
11. Install screws into the studs in the field of the sheet. Use four screws, evenly spaced.
12. Cut and install the upper sheet with screws, in the same manner as the lower sheet.
Install Durock to the End Walls
13. Install the end sheets vertically. Mark and cut the Durock sheet to fit the opening. One end wall requires holes cut in it to accommodate the plumbing.
14. Mark the front of the sheet with a pencil indicating where the studs are located behind the sheet.
15. Install the end sheets by putting them in position and inserting screws in the same manner as before.
Finishing the Job
16. Apply a coat of thin set mortar on the joints and corners of the Durock with a 6 inch drywall taping knife.
17.Place the fiberglass mesh tape into the thin set mortar over the joints and in the corners. Center the tape on the joints.
18. Drag the drywall taping knife over the mesh tape. Remove any excess thin set mortar from the Durock.
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