Apparatus and method for sloped shower floors

Abstract

A variable length arm and devices to locate the inner end and outer end of the arm to set the slope of a pre-slope floor and to set the thickness of a base floor to receive tile are used in a method to create the floors.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to Provisional Application U.S. 60/898,391 filed Jan. 30, 2007 and this Provisional application is incorporated herein.

FIELD OF THE INVENTION

This invention relates to the construction of sloped floors and, more particularly, to a method and apparatus for the construction of showers and preparing the sloped surface for tile.

BACKGROUND OF THE INVENTION

Sloped floors, and particularly shower floors, are installed in most cases with the slope being determined by the eye of the installer. There is no known apparatus or method for consistently creating a sloped floor, especially a shower floor, with accurate and inexpensive tools and a consistent method.

SUMMARY OF THE INVENTION

The method of this invention involves simple and easily followed steps employing the apparatus of the invention. The method results in a uniformly sloped floor for easy covering with tile.

One embodiment of the apparatus consists of a center circular hub with adjustable height to match the thickness of the tile to be laid. The circular hub has an internal diameter corresponding to the outside diameter of a circular shower drain so that the hub sits on the drain and may be rotated around the drain. The hub has a bottom, internal plate (hub base) that sits on the drain and determines how far the sides of the hub extend down around the drain. This depth is adjustable. The hub base is threaded into the circular hub a distance determined by the user of the tools. The hub base is adjustable inside the hub to provide a depth inside the hub between, at least, ⅜^th inches and 1/16^th inch, which covers the thickness of tile typically installed on shower floors. The adjustable depth may be increased for thicker tiles if desired by making the threaded connection between the hub base and the circular hub longer and, if necessary, by making the hub taller.

The apparatus further includes an adjustable length arm having a first hollow arm attachable to the hub and a second telescoping arm inside or outside the first arm. The first arm is attachable to the circular hub and may be made of stainless steel or other rigid durable material. This arm has a rectangular cross-section and is slightly larger in cross-section then the second arm where the second arm telescopes inside the first arm. This arm being hollow receives the telescoping arm which may be made of ultra-high, molecular-weight plastic material or some other rigid durable material, preferably a material that easily slides relative to the first arm. A slot is provided in the side of the telescoping arm which cooperates with a protrusion inside the hollow arm to limit the travel of the telescoping arm in the first arm. The first arm has a bar across the inner end that is attached to the hub. The hub has a hook attached to the exterior for cooperating with the rod in the first arm to hold the adjustable arm in place.

The apparatus further includes a plurality of notched legs for attachment to the walls at a selected height to establish the correct slope of the floor. A plurality of angled channels (angles), with at least one longitudinal side having a folded edge or lip which fits in and is held by the notch in a leg, are cut to individual selected lengths. Each angle forms a shelf along a wall at a fixed height determined by the location of each leg holding the angle.

The method of creating a sloped floor for a shower consists of the steps of removing the shower drain and liner ring that has been previously installed. The method further includes the step of installing support for the walls of the shower in the form of blocking between the wall studs and also forming the curb at the entrance to the shower. To determine the correct height of the floor along the walls, the greatest distance from the center of the drain to the farthest corner of the shower is determined and this measurement is used in setting the height of the angles.

Shower floors are built on the sub-floor of a building or other floor base which typically has no slope in the shower area. A floor drain is in the sub-floor for the shower. The floor drain extends above the sub-floor with a common height being ½ inch. A liner ring and a shower drain are part of the overall drain. The ring attaches to the floor drain and the shower drain extends down into and is attached to the floor drain through the ring. The shower drain also extends above the floor drain with typical distances of 1½ inches or 2 inches. The floor drain opening is covered while forming the first layer of the shower floor, which is called the pre-slope.

Broadly the steps for forming a shower floor are: 1. Determine the desired slope and establish the pre-slope using the tools of this invention; 2. Lay the shower floor liner; and 3. Create the floor as a base for tile, with the desired thickness using the tools of this invention.

Pre-Slope.

An angle is positioned along each wall and the curb at a height determined by the size of the shower and the desired slope of the floor. The slope may be any amount established by the installer, with a typical slope being ¼ inch per foot. If the distance from the center of the floor drain, which is in the center of the shower, to the farthest corner of the shower is 2 feet, then the bottom of the angle must be ½ inch above the top of the floor drain. If the floor drain extends ½ inch above the sub-floor and for a slope of ¼ inch per foot, the bottom of the angle must be 1 inch above the sub-floor. Each angle is held in place by two or more legs that have a notch to engage the lip of the angle. With the angle in place in the leg, the distance from the bottom of the angle to the top of the leg is 16 inches. This distance may be some other length dependent upon the length of the leg. However, with a length of 16 inches from the top of the leg to the bottom of the angle when held in place, the top of the leg is positioned a convenient 17 inches above the sub-floor of the building. A mark is placed on each stud around the shower wall at a level 17 inches above the sub-floor. Each leg has at least two screw holes and the leg is attached loosely to each stud by a screw in the top screw hole. The angles are then placed in the notch of each leg and a screw placed in the bottom screw hole of each leg to securely hold each angle in place. An angle is placed on the shower side of the curb and held in place by some means, such as drywall screws or C-clamps.

Concrete mud or other mixed material for a floor is poured onto the floor base up to a height level with the top of the floor drain and to the bottom of each angle. The mud is then tapped into place by use of the adjustable length arm with the first part of the arm resting on top of the edge of the floor drain and the telescoping arm extended so that the end of the telescoping part rests on an angle. When the arm is in this position it is moved up and down around the entire surface of the shower floor to pack the mud in place and to screed the mud. Once the pre-slope is dry, the legs and angles are removed.

Floor Liner

A PVC liner or liner of similar material is placed over the pre-slope. The liner extends up each wall approximately 9 inches and also extends over the curb at the entry to the shower. The liner ring is then put in place over the liner on top of the floor drain to hold the liner in place. A small hole is cut in the liner and the shower drain is put in place.

Tile Floor

The height of the shower drain above the liner ring on top of the floor drain is determined. A typical height for the shower drain above the liner ring is 1½ inches or 2 inches. This is the uniform thickness of the concrete or floor material minus the thickness of the tile to be installed with thinset. Whatever the thickness is determined to be, a new line is marked on each stud at this distance above the old line. Thereafter, each angle is held in place by a leg, positioned according to the new line, and the bottom of the angle is above the pre-slope at the wall by the same distance that the shower drain extends above the liner ring less the thickness of the tile to be installed and the thinset.

Dry pack is then poured into the shower area to fill the space between the shower drain and each wall to nearly the top of the shower drain and to the bottom of each angle. The distance the dry pack is below the top of the shower drain, is determined by the thickness of the tile that is to be used and the thickness of the thinset that holds the tile in place.

The hub is used to establish the proper height of the dry pack. The depth of the inner well of the hub is established by placing a piece of the tile to be installed or a piece having the same thickness between the bottom edge of the hub and the base plate. With the hub turned upside down, the base plate may be rotated and threaded into the hub to establish the proper depth between the bottom of the base plate and the bottom edge of the hub. Alternatively, this depth may be established by using base plates of standard thickness, to provide typical depths of ¼ inch, 3/16 inch or ⅛ inch. These non-threaded base plates have a given thickness to provide a standard depth and may be employed like a shim inside the hub to establish the proper thickness of the dry pack

Before the hub is placed on the shower drain, pea gravel is placed around the bottom of the shower drain before the dry pack mud is put into place. Once the pea gravel and dry pack mud are in place, the hub is placed over the shower drain and the adjustable arm is attached to the hub. The adjustable portion is extended out and rests on an angle along each wall of the shower, one wall at a time. With the arm in this position, it is rotated around the shower drain and acts as a screed to prepare the desired surface of the dry pack mud to be the base surface for the tile. Once the dry pack is dry and has formed the shower pan, the legs are removed and the wall board and tile are installed.

The foregoing example of creating the sloped floor and particularly the base surface for the tile or pan for a shower is applicable to sloped floors in general which extend from a drain to a containment around the floor and drain.

Additionally, the method and apparatus of this invention are not limited to circular drains. Further, the drains may be in the center of the sloped floor or off center with the floor extending from all sides of the drain and having the same slope, or if desired, a different slope.

Another embodiment of the invention is more universal in use. It may be used with drains of any shape, including circular, square or rectangular. Also, for convenience of the user, each embodiment of apparatus or tools may be packaged and sold as a kit.

Each embodiment has a means at the inner end for contacting the drain and for establishing the distance of the surface of the sloped floor adjacent the drain to the top surface of the drain. This distance, less the thickness of the tile and thinset, is the thickness of the base surface or pan of a shower.

The means for contacting the drain of the second embodiment is at the inner end of the first piece of an adjustable length arm. The second piece of the adjustable length arm telescopes inside or outside the first piece. An adjustable height block is held in place at the inner end of the first piece. The first piece preferably has a rectangular cross-section with a notch at the inner end. The notch has sufficient length to accommodate the adjustable block and an end block attached to the first piece at the extreme of the inner end of the first piece.

The back of the notch, where the first piece has its full height and width, is sealed by a sealing piece. This piece may be permanently fixed in place or removably fixed in place. In either case, the sealing piece keeps sand and other matter out of the first piece, if it is hollow.

The face of the sealing block facing out provides a guide for the abutting face of the adjustable block. The adjustable block may be moved at least from a position where its bottom surface is in line with the bottom surface of the inner arm to a height to provide a spacing between the top surface of the drain and the surface of the pre-slope wall at the drain. This height and spacing is determined by the thickness of the tile and thinset to be placed on top of the pre-slope floor.

The notched legs and angles of the first embodiment are replaced by a self-adhesive angle having a first shelf to receive the outer end or distal end of the adjustable length arm. The self adhesive angle also has a second shelf extending longitudinally above the first shelf to support any board or other material which may be used above the containment for the sloped floor. The second shelf is positioned above the first shelf by a vertical longitudinal wall. The inner edge of the second shelf is bent down to form an opening for a dowel which extends into adjoining angles to hold them together and in place. The angle has a rear wall which extends above the top surface of the first shelf and cooperates with the bent edge of the second shelf to form the dowel opening.

The wall of the angle has the upper vertical portion and an inwardly curving bottom portion extending from the vertical portion. In the construction of a shower, the curved portion rests on the shower liner. The bottom portion of the wall is curved to avoid damage to the liner. The distance from the edge of the curved portion to the top surface of the first shelf is the desired thickness of the base floor, which results from the dry-pack mud.

An adhesive material, such as sticky tape, is on the back of the upper vertical portion of the angle, for attachment of the angle at the desired height along the outer perimeter of the sloped floor. The angle is attached to the PVC liner which is in place for a shower.

The angle is not used to establish the outer height of the pre-slope as is done with the first embodiment. Instead, selected lengths, such as four (4) feet, of a rectangular cross-section Styrofoam stick is used. The kit includes a number of sticks of Styrofoam which are notched along a vertical wall at ¼″ intervals from the top surface. The typical height of the Styrofoam stick is 1½″. Each stick has adhesive material along the back wall for attaching the stick to the wall material of the containment for the sloped floor. The adhesive material may be sticky tape to hold the Styrofoam stick in place. The height of the Styrofoam stick is selected to provide the desired slope for the pre-slope floor.

The upper surface of each Styrofoam stick is used to guide the outer end of the second piece (the telescoping piece) of the adjustable length arm.

Objects, features and advantages of this invention will become apparent from consideration of the foregoing and the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of the hub and adjustable arm, in accordance with this invention;

FIG. 2 is a left-end perspective view of an angle, in accordance with this invention;

FIG. 3 is a bottom-end perspective view of a leg, in accordance with this invention;

FIG. 4 is a front-elevation view of a hub. partially cut away in cross-section, in accordance with this invention;

FIG. 5 is a bottom-plan view of the hub, in accordance with this invention;

FIG. 6 is a top-plan view of the hub base, or removable plate, in accordance with this invention;

FIG. 7 is a front-elevation view, partially cut away in cross-section, of an alternative hub, in accordance with this invention;

FIGS. 8A, 8B and 8C are side-elevation views of base plates for the hub of FIG. 7, in accordance with this invention;

FIG. 9 is an exploded view of a typical drain and shower containment, in accordance with this invention;

FIG. 10 is an interior-elevation view of the rear of the containment with legs in place, in accordance with this invention;

FIG. 11 is a perspective view of an angle attached to a leg, in accordance with this invention;

FIG. 12 is an elevation view of the pre-slope floor being formed, in accordance with this invention;

FIG. 13 is an elevation view of the pre-slope floor with the liner ring and drain in place, in accordance with this invention;

FIG. 14 is a perspective view of the bottom of the hub shower adjustment of the base, in accordance with this invention;

FIG. 15 is an elevation view, partially in cross-section, showing the forming of the base floor for tile or pan of the shower with tools, in accordance with this invention;

FIG. 16 is an elevation view of the adjustable arm attached to the center hub, in accordance with this invention;

FIG. 17 is an exploded perspective view of the inner end of an alternative adjustable length arm, in accordance with this invention;

FIG. 18 is an elevation view of the inner end of the alternative adjustable length arm resting on a straight edge drain, in accordance with this invention;

FIG. 19 is a perspective view of an alternative angle, in accordance with this invention;

FIG. 20 is an elevation view, partially in cross-section, of a portion of a pre-slope floor with the alternative tools in place, in accordance with this invention; and

FIG. 21 is an elevation view of two angles being joined with a dowel, in accordance with this invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

The apparatus or tools for forming or creating a sloped floor includes a circular hub 10 with a cut-out recess 11 from the bottom side of the hub. The recess 11 receives an adjustable base plate 14. The hub 10 has a threaded hole 12 to receive a threaded extension 16 of base plate 14. Base plate 14 is threaded into hub 10 a selected distance consistent with the thickness of the tile to be laid on the sloped floor created by the use of the tools of this invention. The base plate 14 has a snug fit around its perimeter inside the hub to prevent sand and other material from getting into this space and above the plate 14.

The depth 15 of the base plate inside the hub 10 is set to the thickness of the tile and the thinset that holds the tile in place. The depth 15 is measured from the bottom of the base plate 14 and the bottom edge 17 of hub 10. A locking pin 19 holds the base plate 14 in place to maintain the selected depth 15. A circular hole 20 of selected depth is drilled in the hub 10 to accommodate the locking pin 19. A slightly larger hole 21 is drilled at the bottom of hole 20 and a low-friction material, such as a nylon bushing 22, is pushed into the hole 21. When the hub 10 is turned upside down, locking pin 19 falls away from the adjustable base plate 14 permitting rotational movement of the base plate 14 inside the recess 11 of hub 10 to adjust the depth.

A plurality of locking holes 24 are drilled into the top of the base plate 14, as shown in FIG. 6, for locking the base plate to provide the selected depth 15. Adjustment indentions 25 are formed in the bottom of the base plate as shown in FIG. 5. The tips of fingers of the user of the hub 10 are inserted into one or more of the indentations 25 to rotate the base plate in the hub 10 to adjust the depth 15 or to remove the base plate 14 from the hub 10.

A hook 26 is attached to the hub 10 to receive and hold in place the adjustable length arm 28. A flat surface 27 is created along the outside edge of the hub 10 to receive the hook 26. The hook 26 is attached to the hub 10 by screws 29 or by some other suitable means, such as by gluing the hook 26 to the hub 10.

The adjustable length arm 28 has a rigid first part or arm 30 that is next to and attaches to the hub 10. The first arm 30 is hollow and is made of a rigid material, such as stainless steel, for rigidity and longevity. This hollow arm may be 1 inch×2 inches in cross-section and 13¼ inches in length with a sloped end 36 at the connecting end or inner end.

A bar 31 is positioned at the inner end of the first arm 30 to cooperate with the hook 26 to hold the adjustable length arm 28 in place. The bar 31 is inserted in the first arm 30 and held in place by a screw 32. Bars of other design may also be employed in place of bar 31.

The adjustable length arm 28 also has a telescoping arm 33 that telescopes in the first part 30. Arm 33 is also made of a rigid material and may be made of ultrahigh molecular-weight (UHMW) plastic. This arm may be 13/16 inches wide×1 13/16 inches tall to fit inside the hollow arm. A slot 34 is provided in the arm 33 to limit the movement of arm 33 within arm 30. A screw 35 protrudes through the side of arm 30 into the slot 34 to limit the travel of the telescoping arm 33.

The apparatus further includes an angle 40 and a leg 41 (FIGS. 2 and 3). Each angle 40 has a length determined by the size of the shower. For example, in a 5 foot by 5 foot shower with a back wall 5 feet wide, the angle 40 for the back wall will be cut to a length of 5 feet.

Each angle has two walls or sides 43 and 44 joined at one edge. There is an interior or subtended angle 42 between the two sides that is slightly greater than 90°. The outside edge of each side 43 and 44 is turned back to form a lip 45 on side 43 and a lip 46 on side 44. The width of each side is ⅞ths inches. Either lip 45 or 46 fits in a notch 47 in the leg 41. An assembled angle 40 and leg 41 are shown in FIG. 11.

An alternative hub 50 is shown in FIG. 7. Hub 50 has a recess 51 to receive a base plate 52. The thickness of the base plate 52 is selected to provide the desired depth 53 to accommodate the tile to be laid on the floor and the thinset that holds the tile in place.

Various base plates of selected thickness to provide a desired depth 53 are shown in FIGS. 8A, 8B and 8C. Common thicknesses of base plate provide a depth 53 for ¼^th inch, 3/16^th inch and ⅛^th inch tile. The base plate 52 in FIG. 7 has at least two indentations 54 so that fingers may be inserted into the indentations for removal of a base plate 52 from the hub 50. As an alternative means for removal of a base plate from the hub 50, the base plate may have a T-extension 55 that may be grasped by the user to pull the base plate from the hub 50. In use the extension 55 extends into the drain hole.

The method of forming a shower floor ready for tile is as follows and is shown in FIGS. 9-16. A floor drain 56 with a liner ring 57 and shower drain 58 are generally in place in the sub-floor or other base floor of a building where a shower is to be constructed. The drain 58 and liner 57 are removed and the floor mounted drain 56 is left in place. The opening of the floor drain 56 is covered in some manner, such as by the use of duct tape 59. The support for the lower section of the shower walls is added in the form of blocking 60, which are typically pieces of 2×6 wood that fit between the wall studs 61. A curb 62 is formed at the entrance of the shower by use of 2×4 wood cut to the length of the entry. Three or more pieces of 2×4 may be used to form the curb to give it a height of approximately 6 inches. Initially the shower drain and liner ring are set aside while the pre-slope of the shower floor is created. The pre-slope may be any desired slope, but for showers it is typically ¼ inch per foot.

Using a slope of ¼ inch per foot and assuming the greatest distance from the center of the floor drain 56 to a corner of the shower is 4 feet, then the slope will be 1 inch for the 4 feet of distance. The thickness or height of the floor drain 56 or the distance of the top surface of the floor drain above the sub-floor is measured. This thickness or distance is typically ½ inch. Thus, from the top surface of the floor drain 56 to the farthest point of 4 feet from the floor drain, the height of the pre-slope at this point will be 1½ inches above the sub-floor. Thus, to establish this 1½ inch above the sub-floor, the bottom side of the angle 40 should be 1½ inches above the sub-floor. This height is easy to establish by the use of the tools of this invention.

The distance from the bottom side of an angle 40 in a notch 41 in a leg to the top of the leg 41 is 16 inches. This distance places the top of each leg at a height that is convenient for the installer. If the slope is to be 1 inch for a four foot distance and the height of the top surface of the floor drain 56 is ½ inch above the sub-floor, then the bottom side of the angle 40 should be 1½ inches above the sub-floor and the top of the leg should be 17½ inches above the sub-floor. Thus, at 17½ inches above the sub-floor, a level line is marked on each stud for the location of each leg on the individual studs around the walls of the shower.

The angle 40 for the back wall is cut to the width of the back wall and the angle for the side walls is cut ⅞ inch shorter than the length of the side wall to compensate for the angle positioned at the back wall. Further, the angle for the curb is cut 1¾ inch shorter than the length of the curb. The angles are installed along each wall as shown in FIG. 11 by first placing a screw 63 in the upper hole 65 of a leg positioned with the top edge at the marked level line (FIG. 10). The angle 40 is fixed in place by inserting a lip 45 in the slot 47 of a leg (FIG. 11). Once the angle is attached to the leg, then a screw 64 is placed in the lower hole 66 of the leg 41.

With the angles 40 in place, and the opening of the floor drain 56 covered by duct tape 59, mixed mud is poured onto the base floor up to the top of the floor drain 56 and to the bottom of each angle 40. The adjustable length arm 28 is then used to screed the mud to the desired height relative to the sub-floor and the top of the floor drain 56 and angles 40 (FIG. 12). The inner end of the hollow arm 30 is placed on top of the floor drain 56 and the telescoping arm 33 is extended so that the outer end rests on the shelf provided by the lower side of the angle 40. The mud is packed in place by a light tapping motion by raising and lowering the adjustable length arm 28 and moving it around the drain. The adjustable length arm 28 will have a length between the hollow arm 30 and extended telescoping arm 33 to reach between the top of the floor drain 56 and the shelf of each along the length of each angle 40. After the pre-slope is dry, the legs 41 are removed along with the angle 40.

A plastic liner 68, such as a PVC liner, is then laid down over the pre-slope and extends across the entire surface at the bottom of the shower and up each wall approximately 9 inches. When the liner 68 is in place, a hole is cut above the opening in the floor drain 56 and the liner ring 57 is put in place to hold the liner down on top of the floor drain 56. The shower drain is inserted through the liner ring and into the floor drain 56 for final construction of the floor of the shower.

The height of the upper surface of the floor drain 58 to the surface of the pre-slope floor at the drain is measured. A typical height is 2 inches which will be the uniform thickness of the next layer of shower floor less the thickness of the tile to be installed and thinset. Using either the hub 10 of FIG. 4 or the hub 50 of FIG. 7 and the respective cooperating base plate, a piece of the tile 69 is inserted in the recess 11 or 51 of the hub to establish the depth 15 or 53 to accommodate the thickness of the tile and the thinset, which holds the tile in place.

If the hub of FIG. 4 is employed, then the hub 10 is turned upside down so that the locking pin 19 falls away from the base plate 14 to permit rotation of the base plate to adjust the depth 15. Alternatively, if the hub 50 of FIG. 7 is employed, the depth 53 for the tile and thin set is established by selecting the base plate 52 that has the correct thickness to provide the desired depth 53. Once the depth 15 or 53 is established, the hub is placed on top of the shower drain 58 where it is free to rotate around the shower drain 58 to establish the correct height of the next layer of shower floor. Once the height of the top of the shower drain 58 above the pre-slope floor at the drain is determined, the distance, less tile and thinset thickness, is used to locate and position the angles 40. A level line at this distance above the first line is drawn on each stud for the top of the legs 41. Pea gravel is then placed around the shower drain and compacted. The area between the shower drain and walls is filled with dry pack up to the top of the shower drain 58 and to the bottom of each angle 40 (FIG. 15). Each angle 40 has been put in place by placing the top of each leg at the second level line and attaching the screws 63 and 64 in the upper and lower holes 65 and 66 of the leg 41. The adjustable length arm 28 is attached to the hub 10 or 50 at the inner end of the hollow arm 30 and the telescoping arm 33 is extended to rest on the angle 40. In this position, the adjustable arm 28 is rotated around the shower drain 58 to screed the dry pack and establish the proper surface height over the entire floor of the shower. When the floor of the shower is dry, the shower pan has been formed and the legs 41 are removed, leaving the angles 40 in place. The top edge of each angle 40 provides a stopping point or resting point for the wall board so that it is above the floor of the shower to avoid wicking by the wall board.

Alternatively, the apparatus or tools of FIGS. 17 through 20 may be used in constructing sloped floors. The tools may be provided in a kit or individually. The use of these tools results in a simple method for a quicker formation of sloped floors including sloped floors for a shower finished with tile.

The means for contacting the lower floor drain and an upper drain and establishing the height of the base floor for tile relative to the top of the drain is a notch in the inner end of an adjustable length arm and an adjustable pad or block providing a surface at a selected distance above or in line with the bottom surface of the first piece 101 of the adjustable length arm 100.

The first piece or inner arm 101 of the adjustable length arm 100, as seen in FIG. 17, has a notch 102 at its inner most end.

An adjustable length arm 100, which is useful in creating sloped floors about a drain or other selected points, has a first piece made of a rigid durable material, such as stainless steel. Other materials having the desired characteristics, such as aluminum with walls having a thickness required for rigidly and longevity, may be used in place of stainless steel. The adjustable length arm 100 has a second piece or outer arm 103, which is also made of rigid durable material. The second piece 103 may be solid or hollow and telescopes inside the first piece 101 or outside the first piece. A suitable material for the second piece 103 is ultrahigh molecular weight (UHMW) plastic, which slides easily inside stainless steel.

Useful dimensions, although not to be limiting, for the adjustable length arm 100 with notch 102 to be used in creating shower floors are:

Inner arm 101 is a hollow 1″×2″ (rectangular in cross-section) tube and of sufficient length to reach the outer perimeter of the sloped floor in conjunction with the outer arm 103 or arms, which telescope. The outer arm 103 is slightly smaller in cross-section than the inner arm 101 to permit the desired telescoping movement.

A notch 102 is cut or otherwise formed at the inner end of arm 101. The opposing sides have the bottom half removed for a distance of two inches. The bottom wall is also removed the same distance to create the notch 102.

A sealing block 104, having a width and height to fit snugly inside the hollow arm 101 closes the arm at the back of the notch 102. This block 104 keeps sand and other materials out of arm 101.

An end block 105 fits between the walls of arm 101 at the inner end of the arm 101. Block 105 has a height that is the same as the walls of arm 101 at the notch 102. The block 105 is wide enough to fit snugly inside arm 101 to provide strength at the opening in the end of the arm 101. Typical dimensions for block 105 are 3/16″ thick, 1″ high and approximately 1″ wide.

An adjustable block 106 has one end surface positioned to ride against the outer surface 107 of sealing block 104. In this way the desired orientation of adjustable block 106 is maintained while it is adjusted up and down.

A nut 108 is fixed in the top of block 106 and cooperates with a screw 109 to move block 106 up and down. The block 106 has a range of movement from where the bottom surface is in line with the bottom surface of arm 101 to where the distance between the bottom surface of block 106 is above the bottom surface of arm 101 the thickness of the tile to be installed on the sloped floor and the thinset. This distance is similar to the adjustable depth 15 and 53 of hubs 10 and 50, respectively.

The adjustable block 106 is shown above the bottom wall of arm 101 a selected distance to provide the desired depth 112 of the sloped floor below the top edge of a shower drain 110 for tile and thinset.

The tools in a kit or separate pieces of the tools also include Styrofoam sticks 115 having a rectangular cross section and convenient lengths, such as 4 feet (FIG. 20). Useful dimensions for the sticks are 1″ by 1½″ with notches every ¼″ from the top. The sticks 115 have an adhesive material, such as sticky tape 116, on the back side for attachment in use.

The tools further include one or more angles 120 (FIGS. 19 and 20). Each angle 120 is designed to be left in place when forming the sloped floor on top of the pre-slope floor. Angle 120 has a flat back wall 121 which curves down into a narrow flat bottom wall 122.

A longitudinal shelf 123 extends out from the back wall 121 a selected distance above the bottom flat wall 122. This distance is the typical thickness of the floor (base floor for tile in a shower) formed over the pre-slope floor. A typical distance and thickness is 1¼″.

The shelf 123 has a depth to receive the outer end of an adjustable length arm, such as arm 100.

An upside-down L-shaped portion 124 of the angle 120 extends longitudinally from the shelf 123 and cooperates with an extension 125 of the back wall 121 above the shelf 123 to form an opening 126 to receive and hold a dowel 129 for joining the ends of two angles 120 (FIG. 21).

Adhesive material, such as sticky tape 127, is attached to the back of the flat back wall 121 to hold the angle 120 in place.

The method of forming a sloped floor using the alternative tools of FIGS. 17 to 20 is similar to the method described above using the tools of FIGS. 1 through 8. However, the method using these alternative tools is simpler, quicker and less expensive.

The steps of the method associated with FIG. 9 are the same. It is to be noted that the drain may have a configuration other than a round top. For example, the drain may be square or rectangular in shape. The tools of FIGS. 1-8 are most useful with circular drains, while the tools of FIGS. 17-10 are useful with drains having other shapes, including circular. The circular drain 58 and its component parts, liner ring 57 and floor mounted drain 56, are representative of all shower drains for purposes of explaining the method.

Pre-Slope Floor

The pre-slope floor around the floor mounted drain 56, after the blocking 60 and curb 62 are in place involves placement of Styrofoam sticks 115 around the periphery of the floor along the side walls. Each stick 115 adheres to the wall by pressing the sticky tape 116 against the wall. The distance from the farthermost corner of the shower to the center of the drain 56 is measured. The thickness of the floor drain 56 is measured and is added to the dimension determined from the slope and measured distance. For example, if the measured distance is three feet and the desired slope is ¼″ per foot, then the surface of the floor at the farthest point should be ¾″ above the sub floor plus the thickness of the drain 56, usually ½″.

Thus, the surface of the farthest point will be 1¼″ above the sub floor. Each Styrofoam stick 115 is broken at the 1¼″ indentation and stuck along each wall.

The pre-slope is formed as shown in FIG. 20, similar to the method of FIG. 12. Styrofoam sticks 115 are used in place of angles 40 and are left in place as shown in FIG. 20. The inner end of arm 100 rests on the edge or lip of drain 56 while the outer end of arm 100 rests on a Styrofoam stick 115. In this position, the arm is moved up and down and the mud is tapped and smoothed (screeding is performed).

Liner

Once the pre-slope floor 128 is dry, a plastic liner 130 is laid over the pre-slope floor and up each wall approximately 9 inches. When the liner 130 is in place, a hole is cut above the opening of the floor drain 56. The liner ring 57 is put in place to hold the liner on top of the floor drain 56. The shower drain, such as circular drain 58 or straight wall drain 110 (FIG. 20) is put in place. A straight wall drain will have a liner holder and floor drain configuration compatible with the shower drain.

The height of the upper surface of drain 110 above the pre-slope floor at the drain is set at 1¼″ plus the thickness of the tile and thin set or the same as the spacing between shelf 123 and bottom wall 122 of the angle 120 plus the thickness of the tile and thin set.

Sloped Base Floor

Angles 120 are placed around the perimeter of the floor on top of the Styrofoam sticks 115 and the outer edge of the pre-slope floor 128. Each angle 120 rests on the liner against a wall.

The adjustable block 106 is adjusted to provide the desired depth 112 from the top surface of the drain 110 to the top surface of the base floor to receive the tile and thin set.

Pea gravel is placed around the bottom of the shower drain 110. Dry pack is placed on top of the pre-slope floor between the drain 110 and the angles 120 along each wall. The dry pack fills the space between the shelf 123 and bottom wall 122 of each angle and to the top surface of shelf 123.

The inner end of arm 100 is placed on top of the drain 110 (FIG. 18) and the outer end of arm 100 is placed on the shelf 123 of an angle to screed the dry pack for the base floor.

While the description above contains specificity, this should not be construed as limiting the scope of the invention; but merely as providing illustrations of the presently preferred embodiment of the invention. Although preferred embodiments and methods for creating sloped floors have been described above, the inventions are not limited to the specific embodiments, but rather the scope of the inventions are to be determined as claimed.

Claims

1. Tools for use in creating a sloped floor over a subfloor having a drain with a top surface a known height above the subfloor comprising a plurality of sticks having a top surface wide enough to receive and support the outer end of an adjustable length arm and an adjustable length arm.

2. Tools in accordance with claim 1 further comprising an angle attachable to a wall and having a shelf protruding away from the wall to receive and support the outer end of the adjustable length arm, wherein the adjustable length arm comprises an inner arm having a notched end and an adjustable block movable relative to the bottom surface of the inner arm.

3. Tools in accordance with claim 1 wherein the sticks are made of Styrofoam.

4. Apparatus for use in creating a sloped floor inside containment walls and having a drain therein comprising sticks having a top surface and being of sufficient strength to support the outer end of an adjustable length arm used to screed uncured floor material between the containment walls of the floor and the drain and an adjustable length arm having an inner end designed to sit on top of the drain near the edge of the drain and an outer arm which telescopes with respect to the inner arm and designed for the outer end to rest on a stick in use.

5. Apparatus for use is screeding material used to form a floor on a subfloor sloping from outer containment walls to a drain in the subfloor comprising an adjustable length arm having at least a first inner arm and a second outer arm movable relative to the inner arm and means attached to each containment wall to receive and support the outer end of the second arm at a selected height above the subfloor relative to the height of the drain in the subfloor.

6. Apparatus in accordance with claim 5 wherein the inner arm is attached to a hub to be put on top of the drain to screed the material between the drain and containment walls.

7. Apparatus in accordance with claim 5 wherein the inner arm has a notch at the inner end and an adjustable block positioned in the notch.

8. A method of screeding material between a drain and containment walls while creating a sloped floor on top of a subfloor comprising the steps of installing sticks against each wall, the sticks having a top surface a selected distance above the subfloor, with the distance determined by the desired slope of the floor, the distance between the farthest point of a wall from the drain and the height of the top surface of the drain above the subfloor, filling the area between the drain and each stick along each wall up to the top of the drain and the top of each stick, placing an adjustable length arm between the top surface near the edge of the drain and the top of a stick moving the arm up and down on the material and sideways across the top of the material to smooth the top surface of the material.

9. A method in accordance with claim 8 wherein the sloped floor is permitted to dry and form a pre-slope floor for a shower, further comprising the steps of laying a liner over the pre-slope floor and up each containment wall, cutting a hole in the liner above the drain, placing a drain liner holder on the drain, placing a shower drain in the floor drain and liner holder, with the top surface of the shower drain at a selected distance above the pre-slope floor at the drain, attaching an angle along each wall to receive and support the outer end of an adjustable length arm at a selected height, adjusting the position of the bottom surface of an adjustable block relative to the bottom surface of the inner arm to provide for the spacing required for tile and then set for the shower floor.