When a ceramic tile or stone floor is installed, it is important to have a proper backing to create a solid foundation for the surface. Durock is a popular backer board that is used regularly in the construction trade. It is manufactured with cement and mesh fiber to create extra strength and durability for the floor surface. It also gives the mortar extra grip. Durock must be placed over a proper subfloor material, such as plywood, oriented strand board (OSB) or concrete. Installing Durock requires careful measurement, but it is a job that can be tackled by a seasoned do-it-yourselfer.
Instructions
1. Sand any high spots on the plywood, with a belt sander. Pay close attention to the plywood joints because they have a tendency to swell.
2. Vacuum dust and debris from the subfloor, with a shop vac.
3. Lay the Durock sheets onto the subfloor with the smooth side down, starting in a corner. The sheets should span lengthwise across the floor joists in the same fashion as the plywood. It should also overlap the plywood joints. Leave a 1/8-inch gap between all edges of the Durock sheets.
4. Measure the remaining area that is not covered with full sheets of Durock, with a tape measure.
5. Transfer the measurement to the Durock sheet and mark with a pencil.
6. Score both sides of the Durock with a utility knife deep enough so that the mesh fabric on both sides of the sheet is cut through.
7. Break the Durock sheet into two pieces by snapping it at the score line.
8. Cut the Durock with a circular saw to fit around any obstructions in the floor, such as vents or toilets.
9. Fasten the Durock sheet to the floor with 1-1/4-inch wood screws. Space the screws four inches apart. A screw gun will make fastening go much quicker. If you do not have a gun, a power screwdriver will also work.
10. Fill the gaps between the Durock sheets with mastic or thin set mortar. Use a trowel to level the mortar flush with the top of the Durock.
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