Corian, a type of surfacing manufactured by DuPont, is available in a variety of tones and patterns. It offers a seamless appearance, nonporous surface and no grout lines, so cleaning and maintenance are simple. To function as intended, Corian sheets must be properly installed, with gaps at corners to allow for expansion. A silicone adhesive is used to secure these sheets to the wall substrate and to seal joints to create a watertight shower lining.
Things You'll Need
- Corian sheets
- Tongue-and-groove cutter
- Safety gear
- Silicone adhesive
- 2- by 4-inch boards or other materials for bracing
- Corian trim pieces, if desired
Plan the placement of the wall sheets. The manufacturer advises that either vertical or horizontal seams be present, not both. There should be a small gap in each corner or, if a thermoformed or hardseamed corner piece is used, near the corner to allow for the expansion that accompanies temperature changes. Plan for a small amount space at the top and bottom of the wall to be filled with silicone later.
Cut the Corian sheets to fit the shower walls and accommodate faucets or other fixtures. Treat the Corian like wood when cutting it. Use a router to cut the sheets.
Prepare the edges of any sheets that must be joined together. A tongue-and-groove seam allows for easiest sheet alignment. Hold the sheet down and center the cut in the middle of the sheet edge. Once the tongue and matching groove cuts have been made, dry-fit the two sheets together to make sure they fit together snugly.
Secure the sheets to the wall. Run a 1/4-inch bead of silicone adhesive about 1 inch from the edge of the sheet around its perimeter and across the width of the sheet every 6 to 12 inches. Press the sheet to the wall substrate. To join adjacent sheets that have been cut to fit together, apply silicone adhesive to both sides of the tongue and in the grove before pressing the two sheets together to limit the presence of air pockets. Wipe away any excess silicone.
Brace the sheets in place until the silicone adhesive hardens. Place a two-by-four vertically against the wall every few feet and position a partner for each on the the opposite wall. Cut two-by-fours to fit snugly between each pair of two-by-fours and insert them to hold the panels securely. Cut short pieces of wood to jam between the braces and the back panel.
Complete the corners. DuPont offers a variety of ways to treat the corners. Thermoformed or hardseamed corners are designed so that one panel is curved to extend over the corner and the seam is located adjacent to the corner. The corner gap can also be filled in with silicone or a wedge or piece of vertical trim can be adhered to the corner with silicone adhesive. Trim pieces can also be applied to the junction of the wall and ceiling or wall and floor.
Apply silicone to any joints that have not yet been treated.