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Installing a Custom Corian Tub Surround

Bob moves on to the master bathroom and reviews the work already completed. Shelving has been installed as has paneling under the window. New double windows give a nice historic look. The windows have a historic look but hi-tech, with low-emissivity glass for improved energy efficiency. Bob then talks with Grant Garcia and Chris Dada of Sterling Surfaces who are installing a Corian tub surround. Garcia explains the caulking being applied has mildew resistance to prevent mildew that forms inside the seam between the soaking tub and the deck. Garcia explains that Corian is non-porous and won't support the growth of bacteria and mold. The Corian is custom fabricated to fit the tub. This custom fitting is done through a digital photo template system. A series of photos of the tub are taken, fed through a computer, and rendered into a CAD drawing for the cutting and construction of the tub deck. The Corian has been cut to accomodate the addition of a tile covering against the cementitious board on the back wall of the tub. The deck has a water damway to prevent water from getting through the base of the tiling, wicking up the drywall, or seeping into the wood in back of the cement boards. Garcia recommends using a tool when working with the caulking, as human hands can introduce bacteria that can cause problems.
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Installing a Custom Corian Tub Surround

  computer-generated transcript - may not be 100% accurate

" OK well we're in the master bathroom now and a lot of the detailing in here has been completed. By our homeowner who's doing the mill work himself and he's put it. Shelves and you can see behind me and nice paneling under the window opening. And the bathroom one of the great things is got double windows in here these are tell -- architectural line that they chose which is a a nice historic look it's very appropriate for this 1890s house. And which you've got here is. The two lights over one. Which is a style of window that was very popular back then but it's high tech in that we have low emissivity glass. With argon gas in between two sheets of glass and we've got. Essentially. Energy star rating on the windows they were all installed last week but right now we want to see Heidi grant Garcia and Chris. Donna who are here to install a quarry in. Tub surround about hi guys. So. This is always an interesting thing is this is not fabricated on the job right."

" That's correct it's taken and then you've got to do templates and stuff in doing in your shop and then bring it is to the house side. That's correct now is what kind of glass bead is this this caulking well Chris is applying I the high quality silicone that has mildew resistance. Integrated into it okay and that eventually -- going to seep out and form the seam between G. Soaking tub and the deck so that -- it is our. Cast iron. Enameled finish and then this is our Koran. And this will be in between the -- tell us about the quarry and what's one of the advantages of using it in this kind of situation. Well it's it's non porous. It's renewable and I it -- is not going to support the growth of bacteria or mold which in a wet area like a bathroom is absolutely essential for sure. And it is fabricated custom right that's correct -- ahead of time to make a template now this this tub over here. Is an unusual situation in that it's. Kind of an over amount. And it's been laid down on the frame. But then we're treating it as as an undermount. But turning this over it right exactly that's right. We're we're using a little different way we're using the end. -- using it just doesn't undermount just like you would sink under. A stainless steel sink under a top."

" OK so you're ready to go here can I give you a hand putting it in there. -- Catty corner."

" The other way Chris that -- Friends in first."

" And we say custom made it's even. Got a little dog ear here to -- around the trim. Now how do you go about making a template to have this cut back at the shop."

" Well because of the unusual shape of the tub. And also the space itself. What we try to do is get an exact digital template made digital photo templating allows us. To put the markers where we will around the wall. And also around that -- object itself so you've come in here physically and taken a whole bunch of photographs of the tub. 24 the exact with a digital camera correct and then what happens to those photographs well in the photographs you have the object. Dots as you can see. And then you also have the coordinate. Dots which are on those panels and -- middle of the top right well the software knows how to read all those. And is able through photograph of the tree is able to create what you might call a panorama shot. The whole object. And then it's able to give us precise. Locations of all these dot so that the fabricator can actually. Gift paper template from that to transfer onto the Corian well we actually do when buried -- before the fabricator against it. We connect all of those dots dot to dot creating cad drawing that a CNC -- actually. Cuts out all the parts of that was sheet yet and so when the fabricator receives it it's sort of like the model airplane kit. The deal puts that he puts together all right so there is a lot of behind the scenes work and we all love the instant gratification of just setting it down and seeing it. As the finished. The finished product tell me about some of the features here cause I'm looking at this edge which had no -- Well beyond. What you see here is a tile cove. The ceramic tile that nick and Maggie have chosen is going to go right down on this tile cove in fact here is an example of it. -- felt but this happens there isn't going to make it very easy to clean surface. You'll never have any water or any dark lines appearing there because water and dirt have gotten into the night and of course you can see with the tile you're holding Bob. How it matches with the storm blue Corian at 120. Colors that are available and."

" I have they've chosen a mixture of this glass tile with the white subway tile and it's a very very nice combination. All right and cement board which is again happened stake is the best. Product to use as. A substrate for ceramic tile or marble. Because of its resistance to moisture. Exactly. And we're urges stud driving screws in it and fastening. Into the studs. Grab. The the cement board is terrific for the tile but there's always the the the issue of moisture getting in down. At the joint between the cover the tub deck. And the vertical surface and when that happens repeatedly you've got health issues with mold growth et cetera for a and you got the potential for rotting lumber as you've got moisture that get in behind. So what kind of a detail are we gonna have here in in terms of the transition."

" Well when that moisture. Does -- if it should. It would probably wick up behind the -- which is setting on the tile cove and if there was some kind of sheet rock or other. Mister governor Clinton green board moisture resistant board it would actually act as a wick and it would start wicking that moisture right up the wall."

" And right into the gypsum and it is a gypsum board and that gets mushy and gets destroyed in a few years and molding."

" Yeah number of other things so what we do to eliminate that is first of all we have the secondary line of defense against moisture. Intrusion and that's this water dam right here this is also made out of Corian fabricated. Internally into the top deck yeah. And then there's an air space here it's about a half inch three quarters maybe an inch. And the tile will actually span that. So you'll never see it."

" OK now in terms of dealing with that the the the caulking that you've got in there with which is silicone product and but people hate working with the silicon because he can eat it you know -- you don't do exactly right it won't look very very good any tips on how to get a good even application. Yes we've allowed the silicone to seep out. From underneath the tub -- bead that you put on earlier before you set the deck down."

" Exactly him yes. Then what Chris did is he came back -- denatured alcohol and sprayed. The entire area. Around the bead before he tooled it at all and now while his hands are protected he is truly weird. A little piece of laminated."

" He kind of square. Stiff material that you can use. As a tour I guess you could use. A putty knife a putty knife would be good except it might scratch the these ceramic yet. So by not touching it with human hands at all you you avoid the risk of dirt getting in there or bacteria that might later on. Grow in some way. Great well that is going to be a very very neat job and can't wait CO tough finish of course you guys you hear it here in Massachusetts at sterling is it. You do all of these installations right yes I marvel and Corian whatever we do -- kitchens balance. And we specialize in Corian thanks violation thank you very much Bob can't."

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