A.Contributing editor
Michael Byrne, a tile-setter and consultant in Los
Olivos, Calif., and moderator of JLC Online's tile
forum, responds: If the old tub-surround tiles
are uncracked and in good shape and you're
confident they've been installed over a sound
mortar bed or cement backerboard substrate, you can
install new tiles directly over the old. But be
sure to verify that the faucet valve stems are long
enough to accommodate the old escutcheons, and that
your client won't mind the slightly diminished
ledge around the tub.
You'll need to abrade the surface of the old
tile before installing new tile (for proper
adhesion, 95 percent of the tiles' surface should
be abraded). First, though, thoroughly clean the
tile and grout with a tile cleaner containing
phosphoric acid to remove soap and other films;
rinse with clear water. Then mask off the tub ledge
with heavy paper.
To abrade glazed wall tiles, I usually use a
coarse hand-rubbing stone designed for rubbing down
concrete. For unglazed porcelain tiles, which have
a much harder surface, I prefer to use a diamond
cup wheel mounted on an angle grinder; it works
fast without digging too deeply into the tiles. For
a small area, I've found that you can get excellent
results using the side of a regular dry-cutting
diamond blade.
To shim out the wall above the existing tile
(thinset mortar should never be used as a filler),
the best approach is to nail up galvanized diamond
lath, float cement mortar over the mesh, and use
the original tile surface as a screed guide for
removing the excess mortar. You could also use
backerboard, plywood, or another hard composite to
achieve the desired thickness.
Industry specs require an isolation membrane
where there is a change in backing materials, to
prevent a crack from appearing between the old and
new fields of tile. In your case, I would specify a
reinforced membrane that offers both crack
isolation and waterproofing properties —
like Nobleseal TS
(www.noblecompany.com,
800/878-5788) — to cover the whole area to
be tiled. When installing the membrane, pay
particular attention to the movement joints between
the tiles and tub and in the two vertical inside
corners. Hard grout in those areas can cause a
membrane system failure.
At the ceiling, my guess is that there is
moisture-resistant drywall (greenboard) fastened to
framing installed 16 inches on-center. This is
inadequate for even one layer of tile, and should
be replaced with a suitable substrate. In fact, if
any of the old wall tiles are installed over
greenboard, your best bet is to remove all the old
tile and the greenboard, and replace the entire
installation.
In 2006, because of its very poor performance in
wet areas, moisture-resistant gypsum board was
removed from the list of acceptable substrates for
tile. It's possible that an older installation
could still be in good shape, but only because the
tile-setter applied an organic mastic using the
two-coat method (which resembles application of the
surface-applied waterproofing membrane systems used
today). Solvent-based organic adhesives have little
adverse effect when applied to greenboard, but most
of today's waterproofing membrane systems and
thinsets are latex-based, which means they hold
moisture long enough to destroy the bond between
the paper and the greenboard's moisture-resistant
core.