I wrote perviously about how the shower in the master bathroom had leaked. Now that I have researched the issue more, I understand more about how shower floors are constructed. The original floor was constructed as a “mortar bed” and it was not constructed correctly. It was missing the bottom membrane. The mortar was placed directly on the cement floor. The membrane that was installed was brittle and too far under the top layer of mortar. Finally, there was no strengthening agent, such as chicken wire.
I didn’t want to repeat what I considered a poorly engineered design so I looked into solid surface designs. Royal Stone produces a 48×48 solid surface pre-made floor that resembles stone (think Corian). The normal price is about $900, but my drain is not in the location of the pre-made floor so I would have to order a custom made floor. Since they would have to made a new mold for my application the price would be about $1600 at the cheapest. That’s way too much to spend on just the shower floor.
I then found Tile Redi products which are a thick plastic solid floor that you can tile on directly. Cheaper at $679 (not by much), but not in the size I want and the drain hole isn’t in the same location.
Now I’m back to the mortar floor shower floor as the replacement. Considering the price and how a proper floor is suppose to be built, there should not be a problem for the new floor.