Methods of assembling and installing prefabricated shower pan assemblies with premanufactured trenches and resulting structures

Abstract

Methods of assembling and installing prefabricated shower pan assemblies with premanufactured trenches, and resulting structures, including providing a prefabricated trench; providing a standard drain to be connected to the trench; attaching the standard drain to the trench to produce a pre-manufactured trench and standard drain assembly; providing a pre-fabricated shower pan floor; and installing the prefabricated shower pan floor adjacent the trench body, thereby forming a partially prefabricated shower pan assembly having a trench and standard drain. In another embodiment, a trench cover and supporting structure are provided. Partially prefabricated shower pan bases including a premanufactured shower pan floor comprised of one or more pieces, a pre-manufactured trench to be integrally connected to one or more of the floor pieces, the trench defining a trench floor; a standard drain connected to an aperture in the trench floor; and a standard drain attached to a waste pipe.

What is claimed is: 
     
         1 . A method of installing a partially prefabricated tileable shower pan, comprising the steps of:
 providing a prefabricated trench body:   providing a standard drain which is adapted to be connected to the trench body;   attaching the standard drain to the trench body to produce a pre-manufactured trench and standard drain assembly;   providing a pre-fabricated tileable shower pan floor; and   installing the prefabricated shower pan floor adjacent the trench body, such that a partially prefabricated tileable shower pan assembly having a trench and standard drain associated therewith is formed.   
     
     
         2 . The method of  claim 1 , further including the step of:
 incorporating into said tileable shower pan one or more components selected from a group consisting of one or more sidewalls, one or more curbs, and one or more barrier free entrances.   
     
     
         3 . A partially prefabricated tileable shower pan, comprising:
 a prefabricated molded trench body:   a standard drain which is connected to the trench body to produce a pre-manufactured trench and standard drain assembly;   a pre-fabricated tileable shower pan floor installed adjacent the trench body, such that a partially prefabricated tileable shower pan assembly having a trench and standard drain associated therewith is formed.   
     
     
         4 . The shower pan  claim 3 , further comprising:
 one or more components selected from a group consisting of one or more sidewalls, one or more curbs, and one or more barrier free entrances.   
     
     
         5 . A method of installing a partially prefabricated tileable shower pan, comprising the steps of:
 providing a prefabricated trench having a standard drain which has been integrally attached thereto prior to the assembly of the shower pan in the field; and   installing the prefabricated shower pan floor adjacent the prefabricated trench with integrally formed standard drain, such that a partially prefabricated tileable shower pan assembly having a trench and standard drain associated therewith is formed.   
     
     
         6 . The method of  claim 5 , further including the step of:
 incorporating into said tileable shower pan one or more components selected from a group consisting of one or more sidewalls, one or more curbs, and one or more barrier free entrances.   
     
     
         7 . A partially prefabricated tileable shower pan base, comprising:
 a prefabricated trench having a standard drain which has been integrally attached thereto prior to the assembly of the tileable shower pan in the field:   a pre-fabricated tileable shower pan floor installed adjacent the trench, such that a partially prefabricated tileable shower pan assembly having a trench and standard drain associated therewith is formed.   
     
     
         8 . The tileable shower pan of  claim 7 , further comprising:
 one or more components selected from a group consisting of one or more sidewalls, one or more curbs, and one or more barrier free entrances.   
     
     
         9 . A method for installing a partially prefabricated tileable shower pan in a space in which a shower is to be created, comprising the steps of:
 providing a pre-manufactured shower pan floor, said floor being comprised of one or more pieces,   providing a pre-manufactured trench defining a trench floor, the trench adapted to be integrally connected to one or more of the one or more tileable shower pan floor pieces;   providing a standard drain which is adapted to be integrally connected to an aperture in the trench floor;   placing the pre-manufactured tileable shower pan floor, the pre-manufactured trench, and the standard drain in the space; and   attaching the standard drain to a waste pipe disposed within the space.   
     
     
         10 . A method for installing a partially prefabricated tileable shower pan assembly in a space in which a shower is to be created, comprising:
 providing a pre-manufactured shower pan floor, said floor being comprised of at least two independently manufactured sections, one of said floor sections having a trench integrally formed therewith;   connecting a standard drain within an aperture in a floor of the trench which drain has been integrally connected thereto prior to the assembly of the shower pan in the field;   placing the pre-manufactured shower pan floor with integrally formed trench with a standard drain connected thereto in the space;   attaching the standard drain to a waste pipe disposed within the space.   
     
     
         11 . The methods of  claim 9  or  10 , further comprising the steps of:
 incorporating into said shower pan one or more components selected from a group consisting of one or more sidewalls, one or more curbs, and one or more barrier free entrances. 
 
     
     
         12 . A partially prefabricated tileable shower pan base, comprising:
 a pre-manufactured shower pan floor, said floor being comprised of one or more pieces,   a pre-manufactured trench adapted to being integrally connected to one or more of the one or more shower pan floor pieces, said trench defining a trench floor; and   a standard drain connected to an aperture in the trench floor.   
     
     
         13 . A partially prefabricated tileable shower pan base, comprising:
 a pre-manufactured shower pan floor, said floor being comprised of at least two independently manufactured sections, one of said floor sections having a trench integrally formed therewith;   a standard drain connected within an aperture in a floor of the trench which drain has been integrally connected thereto prior to the assembly of the shower pan in the field.   
     
     
         14 . The tileable shower pan base of  claim 12  or  13 , further comprising:
 incorporating into said shower pan one or more components selected from a group consisting of one or more sidewalls, one or more curbs, and one or more barrier free entrances. 
 
     
     
         15 . A method for installing a tileable shower pan with recessed trench, comprising;
 providing a tileable shower pan which defines one or more recessed trenches, the recessed trench defined by a peripheral sidewall and a trench floor, which trench floor defines a drain aperture;   providing a trench cover, the trench cover defining a peripheral edge;   providing a standard drain attached to the drain aperture in the trench floor;   providing structure for supporting the trench cover in registry with the trench floor;   the trench cover adapted to cover a portion of the trench floor so as to conceal the drain aperture and at least a portion of the trench floor, such that when the trench cover is placed in registry with the trench floor, at least a portion of the peripheral edge of the trench cover is spaced from at least a portion of the trench peripheral sidewall so as to define a gap therebetween.   
     
     
         16 . The method of  claim 15 , wherein the gap between the peripheral edge of the trench cover and the trench sidewall permits the cover to be removed from the trench to provide access to the trench, the trench floor aperture, any trench liner, a standard drain attached to the trench, and a waste water system attached to the standard drain. 
     
     
         17 . The method of  claim 15 , wherein the gap between the peripheral edge of the trench cover and the trench peripheral sidewall is not obstructed along the entire perimeter of the trench cover so that the cover may easily be removed. 
     
     
         18 . The method of  15 , wherein gap between the peripheral edge of the trench cover and the trench peripheral sidewalls and end walls is not obstructed along the entire perimeter of the trench cover so that water may pass through the gap while flowing toward the drain aperture, thereby permitting water to exit the tileable shower pan floor while substantially concealing at least a portion of the drain aperture. 
     
     
         19 . The method of  claim 15 , wherein liquid draining from the tileable shower pan floor to the standard drain attached to the trench passes exclusively through the gap between the one or more peripheral edges of the trench cover and the one or more trench peripheral sidewalls and end walls, thereby permitting water to exit the tileable shower pan floor through the standard drain attached to the trench while substantially concealing the drain aperture. 
     
     
         20 . The method of  claim 15 , wherein liquid draining from the tileable shower pan floor to the standard drain attached to the trench passes through one or both of (a) the gap between the peripheral edge of the trench cover and the trench peripheral sidewall and end wall, and (b) any apertures in a top of the trench cover, thereby permitting water to exit the shower pan floor through the standard drain attached to the trench while substantially concealing at least a portion of the drain aperture. 
     
     
         21 . The methods of any of  claims 15  through  20 , wherein the gap is obtained and maintained at a predetermined width by one or more structures for supporting the trench cover so that the trench cover is firmly held in place yet easily removed. 
     
     
         22 . The method of  claim 21 , wherein the spacers are made from any material selected from the group comprising plastic such as PVC or ABS, polyurethane, polyethylene, rubber, metal such as copper, cast iron, aluminum, steel, building products such as stone, concrete, marble, cultured marble, mortar and stucco, rubber, and any other appropriate material. 
     
     
         23 . The method of any of  claims 15  through  22 , wherein the trench cover is made from any material selected from the group comprising plastic such as PVC or ABS, polyurethane, polyethylene, metal such as copper, cast iron, aluminum, steel, building products such as stone, rubber, concrete, marble, cultured marble, mortar and stucco. 
     
     
         24 . The method of  claim 22 , wherein the one or more spacers are attached to one or more of the group consisting of one or more of the vertical sides of the trench cover, the trench cover top, one or more of the trench peripheral sidewalls, one or more of the trench peripheral end walls, one or more liners partially or fully covering one or more of the one or more trench peripheral sidewalls, one or more trench end walls, and the trench floor. 
     
     
         25 . The method of  claim 15 , wherein the spacers are attached by adhesive, repositionable adhesive, a gripping means or a peg and hole arrangement. 
     
     
         26 . The method of  claim 15 , wherein the trench cover is selected from a group consisting of non tileable trench covers defining one or more apertures in a top of said cover, non tileable trench covers defining no apertures in a top of said cover, and tileable trench covers defining no apertures in a top of said cover. 
     
     
         27 . The method of  claim 15 , wherein the trench cover does define apertures in a top of said cover. 
     
     
         28 . The method of  claim 15 , further comprising placing an upper surface of the tileable shower pan adjacent to the recessed trench in substantially coplanar orientation with an upper surface of the trench cover when the trench cover is placed in registry with the trench. 
     
     
         29 . The method of  claim 15 , wherein the recessed trench is sufficiently recessed into or below an upper surface of the tileable shower pan floor adjacent the recessed trench so that an upper surface of the trench cover is substantially coplanar with an adjacent upper surface of the tileable shower pan floor. 
     
     
         30 . The method of  claim 15 , wherein:
 the trench cover and the tileable shower pan floor are covered with wall or flooring material;   an upper surface of the wall or flooring material on the trench cover is substantially coplanar with an adjacent upper surface of the wall or flooring material on the tileable shower pan floor when the trench cover is placed in registry with the trench; and   the gap is defined on one side by the wall or flooring material on the tileable shower pan floor and on the other side by the wall or flooring material on the trench cover, such that water drains between opposed perimeter tiled edges of the trench cover and tiled perimeter edges of the tileable shower pan adjacent the trench cover.   
     
     
         31 . The method of  claim 15 , wherein:
 the trench cover is not covered with wall or flooring material, and the tileable shower pan floor is covered with wall or flooring material;   an upper surface of the trench cover is substantially coplanar with an adjacent upper surface of the wall or flooring material on the tileable shower pan floor when the trench cover is placed in registry with the trench; and   the gap is defined on one side by the wall or flooring material on the tileable shower pan floor and on the other side by the un-tiled trench cover, such that liquid may drain between opposed perimeter edges of the un-tiled trench cover and tiled perimeter edges of the tileable shower pan adjacent the trench cover   
     
     
         32 . The method of  claim 15 , wherein the recessed trench is sufficiently recessed into or below an upper surface of the tileable shower pan floor adjacent the recessed trench so that an upper surface of a tileable trench cover is substantially coplanar with an adjacent upper surface of the tileable shower pan floor when both are either tiled or untiled, and the peripheral edge of the tiled or un-tiled tileable trench cover is spaced from the upper surface of the tiled or un-tiled tileable shower pan floor adjacent the tiled or untiled trench body so as to allow for water to drain there between. 
     
     
         33 . The method of  claim 15 , wherein the recessed trench is sufficiently recessed into or below an upper surface of the tileable shower pan floor adjacent the recessed trench so that an upper surface of a non tileable trench cover without apertures in the top thereof is substantially coplanar with an adjacent tiled upper surface of the tileable shower pan floor, and the peripheral edge of the such non-tileable trench cover is spaced from the upper surface of the tiled tileable shower pan floor adjacent the side draining non-tileable trench cover so as to allow for water to drain there between. 
     
     
         34 . The method of  claim 15 , wherein the recessed trench is sufficiently recessed into or below an upper surface of the tileable shower pan floor adjacent the recessed trench so that an upper surface of a non tileable trench cover with apertures in the top thereof, is substantially coplanar with an adjacent tiled upper surface of the tileable shower pan floor, and the peripheral edge of such non-tileable trench cover is spaced from the upper surface of the tiled tileable shower pan floor adjacent the side draining non-tileable trench cover so as to allow for water to drain there between. 
     
     
         35 . The method of  claim 31  wherein the recessed trench is sufficiently recessed into or below an upper surface of the tileable shower pan floor so that an upper surface of the tileable trench cover when attached in registry with the recessed trench is substantially coplanar with the adjacent tileable upper surface of the tileable shower pan floor, and a lower surface of the trench cover and an upper surface of the recessed trench floor are spaced so as to allow for water to drain there between into the drain aperture. 
     
     
         36 . The method of  claim 33  wherein the recessed trench is sufficiently recessed into or below an upper surface of the tileable shower pan floor so that an upper surface of the non-tileable trench cover with apertures in the top thereof, when attached in registry with the recessed trench, is substantially coplanar with the adjacent tileable upper surface of the tileable shower pan floor, and a lower surface of the trench cover and an upper surface of the recessed trench floor are spaced so as to allow for water to drain therebetween into the drain aperture. 
     
     
         37 . The method of  claim 32  wherein the recessed trench is sufficiently recessed into or below an upper surface of the tileable shower pan floor so that an upper surface of the non-tileable trench cover when attached in registry with the recessed trench is substantially coplanar with the adjacent tileable upper surface of the prefabricated shower pan floor, and a lower surface of the trench cover and an upper surface of the recessed trench floor are spaced so as to allow for water to drain therebetween into the drain aperture. 
     
     
         38 . The method of  claim 15 , wherein the trench cover is adapted to be removable and/or interchangeable with other tiled, tileable and/or non tileable trench covers so that the tileable shower pan can selectively have either a tiled, tileable or a non tileable trench cover associated therewith. 
     
     
         39 . The method of  claim 15 , wherein the trench cover is adapted to be removable and/or interchangeable with other tiled and non tileable trench covers so that the tileable shower pan can selectively have either a tiled, tileable or a non tileable trench covers associated therewith. 
     
     
         40 . The method of  claim 15 , wherein the trench cover is vertically adjustable so that an upper surface of the trench cover may be positioned to be coplanar with an adjacent tiled or tileable upper surface of the tileable shower pan. 
     
     
         41 . The method of  claim 15 , wherein the trench cover is of the non-tileable variety and is adapted to be interchangeable with covers of the tileable variety in such a fashion that any of the tiled, tileable and non tileable drain covers are vertically adjustable so that an upper surface thereof can be oriented so as to be substantially coplanar with an tiled or tileable upper surface of any adjacent tileable shower pan floor. 
     
     
         42 . The method of  claim 41 , wherein the trench covers are adapted to be removable so as to provide, among other things, access to the drain aperture and the waste water system and to provide different trench drain top, grate and cover finishes and styles for the tiled tileable shower pan. 
     
     
         43 . The method of  claim 18 , wherein the trench covers are adapted to be removable so as to provide, among other things, access to the drain aperture and the waste water system and to provide different trench drain top, grate and cover finishes and styles for the tiled tileable shower pan. 
     
     
         44 . The method of  claim 15 , wherein the trench cover is held in registry with the trench body through an attachment structure which allows the height of an upper surface of the trench cover to be vertically adjusted so as to be positioned coplanar with an upper surface of the adjacent tileable shower pan. 
     
     
         45 . The method of  claim 43 , wherein vertical adjustment of the trench cover is accomplished by the use of adjusting structure selected from the group consisting of shims, spacers, washers, ball and detent arrangements, gripping means, support tabs and threads. 
     
     
         46 . The method of  claim 15 , wherein a strainer is attachable over the drain aperture. 
     
     
         47 . The methods of any of  claims 15  through  46 , wherein the tileable shower pan is selected from a group of tileable shower pans consisting of prefabricated shower pans, partially prefabricated shower pans, or mortar bed or other handmade shower pans. 
     
     
         48 . A method for manufacturing a tileable shower pan and recessed trench, comprising the steps of:
 providing a tileable shower pan including a pan floor, the floor defining one or more peripheral edges;   providing a recessed trench selected from a group of trenches consisting of (a) a standalone prefabricated shower pan trench recessed relative to the shower pan floor, (b) a prefabricated shower pan trench formed simultaneously with, as part of, and recessed into, the shower pan floor, and (c) a prefabricated trench formed simultaneously with, as part of, and recessed into a floor of the shower pan;   such recessed trench defined by one or more peripheral sidewalls and a trench floor, which trench floor defines at least one drain aperture;   installing at least one standard drain in each respective drain aperture at the time the trench floor is formed or any time thereafter; and;   
       providing a liner adapted to be located at least partially within the trench, the liner defining a liner floor which in turn defines one or more apertures which are adapted to align with the at least one aperture defined by the trench floor. 
     
     
         49 . The method for manufacturing a tileable shower pan and recessed trench of  claim 48 , wherein the liner is comprised of one piece. 
     
     
         50 . The method for manufacturing a tileable shower pan and recessed trench of  claim 48 , wherein the liner is comprised of two or more independent component parts. 
     
     
         51 . The method for manufacturing a tileable shower pan and recessed trench of  claim 48 , wherein the liner is comprised of two or more independent component parts fabricated into a single component and inserted into the trench as one component. 
     
     
         52 . The method for manufacturing a tileable shower pan and recessed trench of  claim 48 , further comprising placing one or more reducers in registry with one or more of the trench floor, the one or more trench side walls, and the one or more trench ends walls, to reduce a volume defined by the trench. 
     
     
         53 . The method for manufacturing a tileable shower pan and recessed trench of  claim 52 , wherein the reducer is placed in registry with the trench at the time of manufacture of the trench or any time thereafter. 
     
     
         54 . The method for manufacturing a tileable shower pan and recessed trench of  claim 53 , wherein the reducer is placed in registry with the trench first, and the liner placed in registry with the reducer second. 
     
     
         55 . The method for manufacturing a tileable shower pan and recessed trench of  claim 52 , wherein the liner is placed in registry with the trench first, and the reducer placed in registry with the liner second. 
     
     
         56 . The method for manufacturing a tileable shower pan and recessed trench of  claim 52 , wherein the reducer is placed in registry with the liner first, and the liner thereafter placed in registry with the trench second. 
     
     
         57 . The method for manufacturing a tileable shower pan and recessed trench of  claim 52 , further comprising one or more reducers connected within the trench to one or more of the trench floor, the one or more trench side walls, and the one or more trench ends walls. 
     
     
         58 . The method for manufacturing a tileable shower pan and recessed trench of  claim 48 , wherein the reducer is connected to the liner at the time of manufacture of the trench or any time thereafter. 
     
     
         59 . The method for manufacturing a tileable shower pan and recessed trench of  claim 48 , wherein, prior to placing the liner in registry with the trench, the reducer is attached to the trench liner for reducing a volume of the trench 
     
     
         60 . The method for manufacturing a tileable shower pan and recessed trench of  claim 48 , wherein the reducer is attached to the trench for reducing a volume of the trench before the liner is installed in the trench. 
     
     
         62 . The method for manufacturing a tileable shower pan and recessed trench of  claim 48 , wherein the liner is placed in registry with the trench before the reducer is installed in the liner. 
     
     
         62 . The method for manufacturing a tileable shower pan and recessed trench of  claim 48 , wherein the liner is made from any material selected from the group consisting of rubber, plastic such as PVC or ABS, polyurethane, polyethylene, metal such as copper, cast iron, aluminum, steel and building products such as stone, concrete, marble, cultured marble, mortar and stucco. 
     
     
         63 . The method for manufacturing a tileable shower pan and recessed trench of  claim 48 , wherein the reducer is made from any material selected from the group consisting of rubber, plastic such as PVC or ABS, polyurethane, polyethylene, metal such as copper, cast iron, aluminum, steel and building products such as stone, concrete, marble, cultured marble, mortar and stucco. 
     
     
         64 . A method for manufacturing a tileable shower pan and recessed trench, comprising the steps of:
 providing a tileable shower pan including a pan floor, the floor defining one or more peripheral edges;   providing a recessed trench selected from a group of trenches consisting of (a) a standalone prefabricated shower pan trench recessed relative to the shower pan floor, (b) a prefabricated shower pan trench formed simultaneously with, as part of, and recessed into, the shower pan floor, and (c) a prefabricated trench formed simultaneously with, as part of, and recessed into a floor of the shower pan;   such recessed trench defined by one or more peripheral sidewalls and a trench floor, which trench floor defines at least one drain aperture;   installing at least one standard drain in each respective drain aperture at the time the trench floor is formed or any time thereafter; and;   providing a trench cover adapted to at least partially cover the trench, the cover defining a trench cover top section and one of more trench cover sidewalls; and providing structure for supporting the trench cover in registry with the trench floor.   
     
     
         65 . The method for manufacturing a tileable shower pan and recessed trench as in  claim 64 , wherein the structure for supporting the trench cover in registry with the trench floor comprises one or more gripping means for releasably connecting the trench cover to the trench, said one or more gripping means being connected to one or more of the (i) one or more of the trench cover sidewalls, (ii) one or more trench cover vertical end walls, (iii) one or more unlined trench walls or floor, (iv) one or more lined trench walls or floor, and (iv) one or more reducers attached to one or more of the lined or unlined trench walls or floor. 
     
     
         66 . The method for manufacturing a tileable shower pan and recessed trench as in  claim 64 , wherein
 (a) the one or more gripping means are attached to one or more of the (i) one or more trench cover vertical side walls, (ii) one or more trench cover vertical end walls, (iii) one or more unlined trench walls or floor, (iv) one or more lined trench walls or floor, and (iv) one or more reducers attached to one or more of the lined or unlined trench walls or floors,   (b) a space is defined between the one or more trench cover sidewalls and the trench sidewalls, and   (c) the trench is selected from a group consisting of (i) trenches with no liner or reducer, (ii) trenches which have one or more liners, (iii) trenches which have one or more reducers, and (iv) trenches which have one or more reducers and one or more liners.   
     
     
         67 . The method for manufacturing a tileable shower pan and recessed trench as in  claim 64 , wherein the gripping means engage the trench in the proximity of opposite side walls of the trench. 
     
     
         68 . The method for manufacturing a tileable shower pan and recessed trench as in  claim 65 , wherein the gripping means engage the trench in the proximity of opposite end walls of the trench. 
     
     
         69 . The method for manufacturing a tileable shower pan and recessed trench as in  claim 65 , wherein the structure for supporting the trench cover in registry with the trench floor is selected from the group consisting of shims, spacers, washers, ball and detent arrangements, gripping means, support tabs and threads.