Back in the 1940s, when Ray McIntire of Dow Chemical was laboring to create flexible electri- cal insulation, he could not have foreseen that his efforts would someday evolve into routine tile- setting practices such as prefabri- cated foam shower pans and other shower waterproofing elements. McIntire’s experiment involved gases directed into heated poly- styrene – and a “happy accident” resulted: a product that was 95% air! This product became best known for use in disposable cups, coolers, and packing materials: “Styrofoam” was the end result. From these humble beginnings, Styrofoam™ (aka EPS or expanded polystyrene foam) is now used extensively in construction, from road building to home building. In the late ‘90s a U.S.-based com- pany and another in Europe start- ed to explore ways in which EPS foam might be used as part of the shower pan waterproofing system. The practice of using EPS foam as a substrate for tile and stone which functions as a suitable foundation for a shower pan, has grown to become a legitimate alternative (not replacement), to conventional dry-pack mor- tar substrates. Product offerings TECHNICAL FEATURE ––––––––––––––––––––––––––– Make sure things “pan out” By Dean Moilanen, Director of Architectural Services, The Noble Company “We are very aware of the various prefabricated foam trays and pans available for shower pan waterproofing, and they are not created equal. Strength and durability of the tile substrate is paramount in our selection process.” – Michael Lee, Senior Associate, CDC Consultants One of the first EPS foam pre-pitch prod- ucts introduced was designed to replace dry-pack mortar slope to drain beneath a loose-laid shower pan. 46 TileLetter | May 2018