If you are planning a residential bathroom remodel, you already know that the foundation of a beautiful, low-maintenance space starts from the ground up. At Syn-Mar Products, we have been proudly manufacturing in Ellington, CT since 1977. We are a dedicated manufacturer, not a remodeler or installer, which means our entire focus is on crafting high-quality, beautiful grout-free shower systems and seamless Vanity Tops. 

Because many homeowners want to know exactly what goes into their new bathroom, we recently took our cameras onto the factory floor in Tolland County. By closely controlling our manufacturing process, we ensure that every custom shower base provides a completely waterproof and durable foundation that is designed to fit virtually any floor plan.

Here is an exclusive behind-the-scenes look at how we build the foundation of your new grout-free shower system.

Step-by-Step: How We Cast Your Custom Shower Base

Every custom shower base begins with a strict casting process to ensure absolute strength and color consistency. We follow four essential manufacturing steps to create a flawless foundation before any custom fabrication begins:

1. Organizing Raw Materials: We start by moving piped resin to industrial scales for highly accurate weight measurements.
   
   
2. Precision Batching & Mixing: We utilize precise formulas and recipes to guarantee absolute color consistency, thoroughly mixing resins, pigments, and stone fillers to hand-cast onto the molds.
   
   
3. Casting and Vibrating: The mixture is carefully poured into custom molds and vibrated vigorously for 10-12 minutes to force trapped air bubbles to escape, ensuring structural integrity.
   
   
4. Curing and Demolding: Finally, the piece cures to a solid state, and involves scraping waste, demolding, and transferring to the finishing department.

Behind the Scenes: Fabricating for a Perfect Fit

Once the base is demolded, it moves to our custom fabrication department. In our recent video tour, Syn-Mar Products Vice President Derek Hill and expert fabricator Nate walked us through the meticulous steps of cutting, scribing, and gluing a base so that it is completely waterproof. 

Reviewing Dimensions & Cutting

Every custom shower base starts with a unique ticket matching your specific floor plan. Nate carefully measures the slab and uses a diamond blade to cut the threshold down to the precise height requested for your custom bathroom layout.

Checking the Pitch

Ensuring water flows correctly to the drain is a mandatory step before any gluing or assembly begins. "Always make sure they're pitched," Nate explains in the video. "And if they're not pitched or they get pitched wrong, they're no good."

This accuracy actually begins earlier in the casting stage. As Derek notes,

Surface Preparation

To ensure maximum safety in your new bathroom, the non-slip texture is built directly into the custom shower base from the molding process.

Gluing & Assembly

Next, flanges and thresholds are securely attached using heavy-duty, waterproof glue to guarantee the base will never leak. "The threshold is the most important piece that's glued together," Nate notes while demonstrating the process. "The seam needs to be perfect."

Finishing & Quality Control

Once the glue cures to a solid state, Nate grinds off the excess to create a perfectly flush finish. The custom shower base is then handed off for a strict quality check, carefully caulked along all sealed edges, and immediately wrapped to protect it from factory dust before shipping.

Complete Your Bathroom: Walls and Vanity Tops

A custom shower base is just the beginning. When you pair your new base with our custom shower walls and a seamless vanity top—cast as a single solid piece with an integrated sink—you get a stunning, low-maintenance bathroom. Best of all, our manufacturing quality is backed by a robust 5-year warranty. 

4 Steps to Bring a Syn-Mar Shower System into Your Home

Because we are a manufacturer, we sell our products exclusively through trusted B2B partners. When you are ready to upgrade your space with a custom grout-free shower system, just follow these four simple steps: 

1. Plan and Measure: Note your existing curb placement and drains, and consult with a professional contractor experienced in installing grout-free shower systems.
   
   
2. Find a Dealer: Use the website tool to connect with an authorized premium dealer showroom in your area.
   
   
3. Choose Custom Options: Visit your local premium dealer showroom to view color samples, select walls, order a custom base, and discuss other custom Syn-Mar options.
   
   
4. Order the Products: Have your contractor or premium dealer showroom place an order with Syn-Mar to start manufacturing. The contractor handles receiving, pickup, and professional installation.

Ready to start your remodel? Head over to our "Find a Dealer" tool today to connect with a premium dealer showroom and build the bathroom of your dreams.

Frequently Asked Questions

Ready for a Beautiful, Grout-Free Bathroom?

Syn-Mar products are supplied exclusively through our trusted network of B2B dealer partners. If you are a homeowner looking to upgrade your space with White Onyx, connect with an authorized dealer today.