Installing ceramic tile on the floor of a ready for tile shower pan is tricky business to start with because the smallest misalignment will make a puddle and trap water in your shower pan. Even with pre-made shower pans it is best to rub a rubber float or grout float over the tile to be sure it is all in the same plane. Installing them with epoxy mortar is even trickier because the mortar sets so fast and it is so sticky. The good news is that once you trowel out the mortar you are basically building a second pan inside the first which is good since some of the pans out there are prone to developing hairline cracks especially when shipped by freight or package service or if they get dropped or manhandled….unfortuately you can’t see the cracks sometimes. Buyer beware.
Once you have mixed the components you need to work really fast because you only get thirty to forty five minutes to work and less in hot weather. It may be best to split the batches up but you end up having to waste a bucket usually and sometimes the tools are hard to get clean once it starts to set. Tilesetters always work with epoxy in small batches because of the impossibility of cleaning it up once it starts to set. Measuring it out can be really messy and sticky but epoxy is the best method to put it down if you want it to be permanent. Just dont make a mistake. Certainly dont leave any on the face of the tile. Not even a little bit because it will never come off.
Using a 3/16″ inch notch is usually the best choice since if you go larger the mortar will usually sag. Using a 1/4″ notch will usually cut your coverage pretty dramatically also. It is not unusual to run out of mortar or time before a project is finished especially with a larger notch. Companies will let you think it is your fault but the dice are loaded against you especially if you are a first timer with epoxy. The stuff is expensive and it may not be worthwhile to buy a full two unit pail at the tile store. Very few places carry the epoxy mortar. Overall if you run out you are going to have delays or extra expense so lay out your tile ahead of time and then work quickly and confidently.
Cutting batches in half may be a good idea but it is very messy business. You also want to be extra careful measuring and handling the resins since most epoxies are known to have pthalates in them. Always use rubber gloves and have solid cross ventilation. It will be nice when there are other options in the marketplace.
Do I really have to mention how important it is to keep pets and kids out of the work area, have really good ventilation and to have the finished floors and carpeting covered before you work with this product?
Pan Man – OUT
PS: If you haven’t worked with epoxy before or are prone to brain farts, be sure to either order a second bag or get help from someone with experience.
