EverFab Commercial Shower Stalls Won’t Sag, Crack, or Break

Defects and damage to fiberglass commercial shower stalls are common challenges during shipping and installation. So common, in fact, that many buyers shrug and consider it the cost of doing business. A commercial contractor may order 100 units and anticipate repairs for chips, hairline cracks, and other damage on up to 10% or even 30% of them, depending on the manufacturer they choose. 

Even if the shower unit survives the whole journey through installation, cracks and sagging in the commercial shower bottom over time are equally common—and equally frustrating.

It doesn’t have to be this way. With the right mix of superior bottom design, durable reinforcing materials, and high-quality packaging, the defect rate in shipping can drop to less than 1% and you can virtually eliminate any risk of breaks in the shower base. How do we know?  We’ve done it.

Let’s take a look at why EverFab showers get to our clients in far better condition and last longer than any other fiberglass shower on the market.

Glass vs. Calcium Sulfate

The fiberglass used in the construction of commercial shower stalls consists mostly of two materials (in addition to a color dye): glass fibers and calcium sulfate. The ratio of one to the other differs from company to company and has a significant impact on the durability of the commercial shower unit.

While calcium sulfate is needed to reduce the flammability of fiberglass, too much in the mix can make the shower too brittle and prone to cracks or breaks. At the same time, many manufacturers fall into the trap of thinking high calcium is desirable, as it lends heft and a superficial hardness to the finished product. But hardness is not the same as durability.

EverFab uses an optimized blend with higher glass concentration and lower calcium sulfate than many competitors, for a commercial shower that’s lighter and also more durable than competing brands. The strength of our materials was made clear in load-bearing tests by Carlson Testing, Inc (CTI), in which a metal grab bar pre-installed into one of our standard reinforced shower walls withstood 1,505 pounds of force before failure.

No Wood or PVC

Many manufacturers will use inexpensive plywood and cardboard backing to reinforce their shower units and wood or PVC legs extending down from the unit back to support the shower base. The problem is that these cost-effective materials can gradually distort, rot, or even break right off during transport and installation. This makes it necessary for installers to compensate with a time consuming mortar bed laid beneath the shower floor.  Even with a mortar bed, though, the weak wooden reinforcement makes the unit heavy, hard to move, and vulnerable to swelling and distortion due to rain while in a wholesaler’s lot.

Our EverFab Core Material, a fiberglass composite hexacomb mesh, provides much more reinforcement without the weight of wood and eliminates the many problems of substandard materials. The composite reinforcing layer allows fiberglass resin to soak directly into it and is strong enough to support ADA compliant grab bars and seats with no additional support structure. We also do all through-bolted accessories, which is cleaner, more sanitary, and sturdier than screwing into wood.

A Better Bottom Support

Finally, all EverFab commercial shower stalls come with a revolutionary one-piece composite fiberglass base made from the same durable material as the rest of the shower body.  This unique bottom support is pre-leveled and diamond-cut on a special machine right in our factory, with built-in legs that act as an extension of the unit base. 

Because the EverFab bottom plate is fully laminated onto the shower base, there is no risk of breaking, cracking, or sagging, as with PVC or wood-based designs. This solution, which is unlike anything else sold today, provides our customers with superior value in their commercial shower stalls. Call us up to learn more about how our durable commercial shower units can protect your investment for years to come!