custom design countertops

CDCCDC

2011 CATALOG

Custom Design CountertopsCustom Design CountertopsCustom Design Countertops

TABLE OF CONTENTS ProductName

INTEGRAL BOWLS

SHOWER PANS

FLAT STOCK

ACCESSORIES

Standard OvalSmall OvalRecessed OvalCanadian OvalStandard Shell

Savanah Rectangle

Custom Shower Pan38" x 38" Neo Angle36" x 36"

Soap HolderSoap/Shampoo ComboLarge Soap/Shampoo Combo

101102103104105106107

500501502

801802803

48" x 36"42" x 42"60" x 32"60" x 34"

Shower Pan Installation Procedure/DiagramsShower Drain Assembly

504505506507

CDCCDC

ProductNumber

42” 1/4" x 36" 503

Small Shell

CAST POLYMER COLOR CHART

Shower Pan Drain Locations

42" x 42" Neo Angle 50848" x 42" 509

VANITY TOPS 19" Vanity Top22" Vanity Top

22 1/4 Vanity Top25 1/4 Vanity/Laundry Top

25" Vanity/Laundry Top

NO DRIP EDGE

180 BULLNOSE EDGE

CUSTOM VANITY/LAUNDRY TOPS

16” To 30” 3/4” Flat Edge16” To 29” 3/4” Ogee Edge16” To 29” 1 ½”Bullnose Custom Edge

48" x 34” 510

200210

230240

220

250260270

TOP MOUNT BOWLSOval -Top MountDiamond -Top Mount

Vanity Top Installation Procedure

Standard Tub / Shower SurroundTub / Shower Surround Installation ProcedureSilicone Procedure

Care And Maintenance Guidelines

120121

MOLDINGS

Diamond Corner Soap ShelfDiamond Corner Soap/Shampoo ComboWindow SillOval Corner SeatFlat Stock Corner Seat

Beveled TrimCap TrimEdge TrimSeam TrimInside Corner TrimOutside Corner Trim

804805806807808

901902903904905906

Oval Corner Seat (Installation)

3/4" Bullnose Trim 907

ProductName

ProductNumber

CAST POLYMER COLOR CHART

White on White

Almond Beige

Fawn Beige

Taupe

Country Gray

Vermont Blue

Sea Foam Green

Dusty Rose

Everest

Fashion Gray

Pewter

Moss

Aurora

Sea Shell

Mocha

Sandstone

Blue-Jeans

Medium Gray

O20

O21

O22

O23

O24

O25

O26

O27

GE241

GE130

GE240

GE170

GE123

GE220

GE323

DGE300

DGE725

DGE210

White on White

Almond Beige

Fawn Beige

Taupe

Country Gray

Vermont Blue

Sea Foam Green

Dusty Rose

White on Almond

M04

M05

M06

M07

M08

M09

M10

M11

M12

MARBLE STONE

ONYX STONE

GRANITE STONE

CDCCDC

Terra Cotta GE122

Coal

Storm Cloud

Golden Tortilla

Cobblestone

GE100

LXS230

LXS370

LXS322

XXX White on White M03

White/Fawn Beige on Almond M13

Winter Moss DGE622

Sand GE121

Ecru GE111

STANDARD OVAL BOWL Part No. 101

17" (43.2cm)

14" (36cm)

5 5/8" (14.3cm)

CDCCDC

SMALL OVAL BOWL Part No. 102

5 1/8" (13.0cm)

2 3/4" (7.0cm)

11 5/8" (29.5cm)

15 1/8" (38.5cm)

Note: Two Tone Bowls Available


6 1/4" (15.8cm)

17 1/4" (43.8cm)

22 3/4" (57.8cm)

18" (45.7cm)12" (30.5cm)

6 3/8" (16.2cm)

RECESSED OVAL BOWL Part No. 103

CDCCDC

13 3/4" (35cm)

20" (50.8cm)6 3/4"(17.2cm)

6 5/8" (16.9cm)

3" (7.7cm)

20" (50.8cm)

13 1/2" (34.3cm)

CANADIAN OVAL BOWL Part No. 104

SAVANAH RECTANGLE BOWL Part No. 107

3 1/4" (8.3cm)

13 1/2" (34.3cm)

6 1/2" (16.5cm)

19" (48.3cm)

STANDARD SHELL BOWL Part No. 105

CDCCDC

SMALL SHELL BOWL Part No. 106



OVAL - TOP MOUNT Part No. 120

CDCCDC

25”5 1/4”

20”

DIAMOND TOP MOUNT Part No. 121

CDCCDC

19" VANITY TOP Part No. 200

19"

4 3/4"

3/4"

4"

CDCCDC

22" VANITY TOP Part No. 210

22"

4 3/4"

3/4"

4"

Part No. 220

25”

5 1/2”

3/4"

4"

25" VANITY / LAUNDRY TOP

VANITY TOPS NO-DRIP EDGE

CDCCDC

Part No. 240

22 1/4"

4 3/4"

3/4"

4"

1 1/2"

22 1/4” VANITY 180 BULLNOSE TOP Part No. 230

22 1/4"

4 3/4"

3/4"

4"

1 1/2"

25 1/4” VANITY / LAUNDRY 180 BULLNOSE TOP

4 3/4"

3/4"

4"

1 1/2"

25 1/4"

4 3/4"

3/4"

4"

1 1/2"

VANITY TOPS 180 BULLNOSE EDGE

3/4” FLAT EDGE Part No. 250

CDCCDC

3/4” OGEE EDGE Part No. 260

4 3/4"

3/4"

4"

Part No. 270

4 3/4"

3/4"

4"

1 ½”CUSTOM BULLNOSE

Variable 16” to 30"

4 3/4"

3/4"

4"1/4” Radius

Variable 16” to 29”

Variable 16” to 29”

CUSTOM VANITY / LAUNDRY TOPS

VANITY TOP INSTALLATION PROCEDURE

CDCCDC

1. Trial fit vanity onto vanity to ensure correct size and level fit.

2. If the walls are not square, the top must be cut to fit on the job. Use a masonry blade in a skill saw. Cutting marble produces a harmless white powder and it is advisable to cut outside or another suitable location.

3. If the back wall is not straight, the sheet rock may be cut to get a snug fit. If the

irregularity is slight, the gap can be filled with silicone.

4. When ready to install place 4 dabs of paintable silicone at each corner of the vanity. Carefully place vanity top on vanity and press firmly into place. It is not necessary to glue the top of the cabinet on a wall to wall application. The weight of the top and the plumbing will keep it secure.

5. To silicone the back and the side splashes, follow the instruction sheet called

Silicone Procedures.

6. For vanity tops with splashes higher than 4” high, separate splashes are necessary.

7. Do not touch silicone for 24 hours to avoid fingerprints or smearing. Also, avoid dust around wet silicone.

8. Banjo tops require support for the arm extension. This can be achieved by a cleat

or spine along the wall level with the cabinet. A 1 x 1 may also be used.

9. Undermount bowls are secured with bowl clips and silicone. The bowl should be mounted by a plumber or qualified technician. If the faucet holes are in the bowl, you may want to set the plumbing first.

10. Faucet holes are drilled to 1 1/8”. If a larger diameter is needed, use a rat-tail file

to enlarge hole.

11. Be sure that the top lays flat and that there are no obstructions such as a nail, chip of wood or too small an opening for the bowl to fit in.

12. Use silicone on the top and bottom of drain to avoid leaks. Do not over tighten

drain. This can cause the bowl to crack.

13. If the top is scratched or burned, the top can be restored by using 1200 grit wet/dry sandpaper using water and a small sanding block. Avoid over sanding which will remove the Gel Coat. Follow with a good polish. We recommend Gel Gloss cleaner and polish. See instruction sheet “Care, Cleaning and Repair of Cultured Marble.

Part No. 500

CDCCDC

CUSTOM SHOWER PAN

96"

72"

48"

36"

4"

4"TexturedSurface

End Viewof Threshold

Maximum Make Size94" x 70" Drain CenteredCall for Special Sizes and Shapes

Maximum Size is 94" x 70" Outside DimensionsSpecify Drain Location When Ordering

Note: When ordering cultured marble panels for a custom pan, add 4" in height to allow panels to reach floor of pan.

Part No. 501

CDCCDC

38" x 38" NeoAngle SHOWER PAN

12"

12

"

4 1/2(11 cm)

Part No. 502

CDCCDC

36" x 36" SHOWER PAN

18"

17

"

4 1/2(11 cm)

Part No. 503

CDCCDC

42 1/4" x 36" SHOWER PAN

4 1/2

21 1/8"

17

1/2

"

Part No. 504

CDCCDC


4 1/2

24"

17

"

4 1/2(11 cm)

Part No. 505

CDCCDC


4 1/2

21 1/4"

20

"

42”

42”

60" x 32" SHOWER PAN Part No. 506

CDCCDC

4 1/2

30"

16

"

(11 cm)

60" x 34" SHOWER PAN Part No. 507

CDCCDC

34"

4 1/2

30"

16 1

/4”

Part No. 508

CDCCDC

42" x 42" NeoAngle SHOWER PAN

12"

12

"

24"(61cm)

42"(107cm)

42" (107cm)

25"(64cm)

4 1/2(11 cm)

Part No. 509

CDCCDC


24" (61cm)

21

" (5

3.3

cm

)

42"(106.7cm)

4 1/2(11 cm)

Part No. 510

CDCCDC

48" x 34” SHOWER PAN

4 1/2

24"

16

”

4 1/2(11 cm)

34"

(40

.7c

m)

(61 cm)

4 ½"(11.4 cm)

5 ½"(14 cm)

SHOWER PAN INSTALLATION PROCEDURE

CDCCDC

To insure proper installation, a reasonably level floor is required. Check floor for uniformity before beginning installation. Any unusual problems with uniformity (such as not level) should be noted prior to beginning installation. Each of the following kinds of shower pans should be installed pre-drywall or the drywall should be cut to accept the shower pan. NOTE: Onyx shower pans may need to have sub floor and/or mortar of a lighter color due to the translucence of onyx. Neo-Angle Shower Pan – Diagram 1 Neo-Angle shower pans are the simplest to install because there are only two sides against the wall.

1. The shower pan is meant to be installed with the water dam in contact with the studs or framing. Therefore, install pre-drywall or cut drywall to accept the shower pan.

2. Measure off from the wall where the drain should be. Cut a hole in the floor to accept the drain.

3. Lay the shower pan in place and check level at top of shower base. Place shims to

achieve level. Nail shims to floor; remove pan and mix mortar. Put enough mix on the floor to level the base. Wiggle the shower pan around until it is down to the shims. Pan should be supported evenly and not wiggle when you step in it.

4. When mortar is dry, remove the shims.

Standard/Rectangle/Custom Shower Pans – Diagram 2 and 3 Installation of a rectangular shower pan is basically the same as a Neo-Angle shower base, but there are three walls around it.

1. Check the measurement of the opening; cut hole in the floor for the drain. It is easiest to install in new construction because you can usually get to most sides through the walls. In remodeling you may have to make a level line on the walls and see how far out of level the pan is going to be before sliding it into place.

2. Shim to level; remove pan, mix and put mortar on floor. Replace pan and wiggle

down until it is level against the shims. Remove the shims from the front when mortar is dry.

SHOWER PAN INSTALLATION DIAGRAMS

CDCCDCCDCCDC

CDC Panel

Sheetrock/Greenboard

Shoulder of pan

Edge of pan

2" x 4" Wall Stud

Air Gap

Water Lip

CDC Panel


Custom shower pan

2" x 4" Wall Stud

Air Gap

5” Water Lip

CDC Panel


Shoulder of pan

Edge of pan

2" x 4" Wall Stud

Air Gap

Water Lip

Diagram 1. Neo Angle Pan

Diagram 2. Standard Rectangle Pan

Diagram 3. Custom Pan

SHOWER DRAIN ASSEMBLY

CDCCDC

Note: Black rubber gasket and paper (fiber) gasket will be under CDC pan.

Apply silicone caulk between the drain flange and top of CDC pan.

Shower Pan Strainer Drain Flange

Brass Locking Nut

Drain Body

Black Rubber Gasket

Paper (Fiber) Gasket

2" ABS Pipe

12"

12

"

4 1/2

18"

17

"

4 1/2

24"

17

"

4 1/2

21 1/8"

17

1/2

"

4 1/2

CUSTOM DESIGN COUNTERTOPSStandard Shower Pan / Drain Locations

38" x 38" NeoAngle (Part No. 501)36" x 36" Shower Pan (Part No. 502)

42 1/4" x 36" Shower Pan (Part No. 503) 48" x 36" Shower Pan (Part No. 504)

CDCCDC

4 1/2

30"

16

"

4 1/2

21 1/4"

20

"

42" x 42" Shower Pan (Part No. 505) 60" x 32" Shower Pan (Part No. 506)

42"

42"

12"

12

"

24"(61cm)

42"(107cm)

42"(107cm)

25"(64cm)

34"

4 1/2

30"

16

1/4

”

CUSTOM DESIGN COUNTERTOPSShower Pan / Drain Locations

42" x 42" NeoAngle (Part No. 508)60" x 34" Shower Pan (Part No. 507)

4 1/2

24" (61cm)

21

" (5

3.3

cm

)

48" x 42" Shower Pan (Part No. 509)

42"(106.7cm)

4 1/2

24"

16

”

4 1/2(11 cm)

34"

(40

.7c

m)

(61 cm)

4 ½"(11.4 cm)

5 ½"(14 cm)

48" x 34” Shower Pan (Part No. 510)

STANDARD TUB / SHOWER SURROUNDS

CDCCDC

* Wall Panel Thickness is Typically 3/8” Thick

1/ 2”, 3/4” & and CustomThicknesses Available

Panel FlushWith Tub Panel Extended

With Leg to FloorTypically 2” Wide

TUB / SHOWER SURROUND INSTALLATION PROCEDURE

CDCCDC

1 OF 3

Wall panels can be installed on existing tubs in remodeling jobs, or in new construction on any tub, i.e. marble, cast iron fixtures, enameled steel, or fiberglass tubs. The critical area is the seal between the tub and the wall. This seal is particularly vulnerable in a remodeling job, in which the tub may be sound but the wall has failed, and therefore the replacement could fail rather easily too, if not installed properly. Adhesive: You can use 100% silicone 1. Tub surrounds are at least five feet above ex isting tub. 2. Clean the surface of all dirt, paint, wax, grease or other wall finishes. Paint First: It is advisable to pain t the bathroom first. This will prevent paint from splattering onto the walls and avoid having paint stick to the silicone bead. NOTE: If you are installing onyx panels, make sure the walls are light-colored because of the translucency of onyx panels. The adhesive used must also be a clear silicone.

3. Examine the panels to m ake sure they are free of any defects. Determine where the finished edges are to be placed, by noticing the slightly rounded edge versus a very sharp or ground, unfinished edge. Determine whether the finished edge goes on the left, right, top, or bottom and orient the panel accordingly. If adjustments to the size of the panel are necessary, do not cut the finished edge. Make all your cuts on the edge that is going against the wall.

4. Draw a level, vertical line approx imately in the center of where the panels will be

installed. You can now measure to each corne r and determine if the corners are square. If necessary, cut the back panel so that it fits easily into place, though a tight fit is not necessary. The end walls will cover a sm all gap up to ¼” in the corners.

5. Determine the location of the studs. If you are going to install any recessed

accessories you must know the location of the studs.

6. Dry fit the back panel. If the back panel fits withou t binding, is level at the top and fits tightly and evenly to the tub , then it is ready to be glued. Clean the back of the panel, and make sure the wall is clean.

7. Apply adhesive in small dabs across the wall, approximately six to eight inches

apart. One click of the caulking gun and you are ready to place another. A four foot by eight foot panel should use a least two tubes of silicone/adhesive, one and a half tubes for a three foot by eight foot panel. Once the panel is aligned, push it against the wall. Next pull the panel off the wall to m ake sure that the


CDCCDC

2 OF 3

4. silicone/adhesive has adhered to both the wall and the panel. Place the panel into position and press it firmly into place. Brace with 1 x 2’s for 24 hours.

5. The next panel to be installed is the faucet wall. Place masking tape on the

finished side of the panel in the approximate location for the plumbing fixtures. Mark the centerlines. You need a one inch hole at the top to accept ½” pipe, and you need to check the manufacturer’s instructions for the hole size required for the mixing valve. If you have a two-handed shower, then the holes will be the same size as the shower head.

Use a hole saw if possible to make these holes. Hole saws are inexpensive and good for home repair projects. Be careful when drilling, especially after the pilot bit is through the panel and before the hole saw grips. The torque of an 80 tooth hole saw is strong enough to spin you around. Before drilling, put a piece of 5/8” OSB or similar material across saw horses, large enough to support the panel you are going to drill. When you drill, and reach the wood, stop, and remove drill. This will eliminate the possibility of drilling thru the panel too fast, and the drill causing damage to the panel.

6. Dry fit the panel. Make sure the panel fits tight across the tub and that the outside

edge is sound. You may have to sand or grind the edge that fits into the corner. The back and side panel should meet at the same height in the corner. If it fits, you are ready to glue. Clean the wall and panel and place adhesive as described above. Brace.

7. The last panel of the surround is easiest to install because it contains no holes.

Simply draw scribe the panel to ensure proper fit. Next clean the panel, silicone it, and put it in place. Brace. If the wall panels reach the ceiling, you must measure very carefully to allow for skewed walls. Inside corner molding should be used if the corners are not tight, to ensure a watertight fit. Inside corner molding and corner soap/shampoo holders require less cutting.

Shower walls are at least 6’ above shower pan. Installing shower walls to the shower

base is very similar to installing the tub surround. The panel should be set in silicone and fit tightly at the bottom against the shower base. The top of the panel should be level. The side panels should meet the back panels evenly at the top. Holes for plumbing should be cut with a hole saw.


CDCCDC

3 OF 3

Installing panels that reach the ceiling is a little harder unless molding or edge trim are provided. Measurements must be more accurate and panels may have to be cut to achieve the same uneven height of the walls. Wainscoting This is as easy as installing splashes. Simply measure, cut to fit, have finished side up and glue to wall. This can be topped off with a cap or edge trim.

SILICONE PROCEDURE

CDCCDC

1. Area should be clean and dry. 2. Use a high grade, 100 percent silicone with a mildew resistant additive.

3. Using a caulking gun, apply a bead of silicone into the seam.

4. Spray silicone bead with denatured alcohol to prevent smearing when wiping

excess. Denatured alcohol can be purchased at a hardware store and put into a spray bottle.

5. Spread evenly using finger.

6. Clean excess off finger using paper towels.

7. Allow silicone to dry 24 hours before using. Do not touch or get wet while

drying.

SOAP HOLDER Part No. 801

CDCCDC

SOAP/SHAMPOO COMBO DISH Part No. 802

LG SOAP/SHAMPOO COMBO Part No. 803 DIAMOND CORNER SOAP SHELF Part No. 804

DIAMOND CORNER SOAP/SHAMPOO COMBO Part No. 805

10 1/4"(26 cm)

WINDOW SILL Part No. 806

CDCCDC

12” (30.48 cm)

13” (33.02 cm)

OVAL CORNER SEAT Part No. 807

CDCCDC

FLAT STOCK CORNER SEAT Part No. 808

CDCCDC

Standard 3/4" Flat Stock Corner SeatCustom Sizes Available

Seat Edge Detail

1/4" Rad18" Rad18"

OVAL CORNER SEAT INSTALLATION

CDCCDC

13 1/2"From Top ofPan to Bottomof Seat

Figure 1 Figure 2

Figure 3 Figure 4

Corner Seat

18"

18" 8"

16"

2" x 8" Wood Backing20"

2" x 8"Center

Floor

1 1/2"

7" 6" 2 pilot holeson each side

First drill 3/16" pilot holes through seat panel and into the 2" x 8" wood backing, the length of 3" stainless steel lag bolts. Then drill 5/16" hole through the seat and panel only to allow lag bolt to clearentry into 2" x 8" wood backing.

Note:

5/8"

2"

1.0"

1/4"

1/4" Rad1 1/2"

5/16"

1 1/2"

3/4"

NOTE: Only available in 9 foot lengths

1 1/2"

3/4" Rad

BEVELED TRIM Part No. 901

CDCCDC

CAP TRIM Part No. 902

EDGE TRIM Part No. 903 SEAM TRIM Part No. 904

INSIDE CORNER TRIM Part No. 905 OUTSIDE CORNER TRIM Part No. 906

3/4" BULLNOSE TRIM Part No. 907

2 ½" (6.35cm)

1 1/2"

NOTE: Bold Outlines Indicate Finished Cast Surface

3/8"

1/8" Rad

custom design countertops

Documents