Case studies give homeowners a real look at how a bathroom renovation actually unfolds, the starting conditions, the decisions made, the challenges encountered, and what the finished project delivered. This post walks through a completed master bathroom remodel by D.E. Mitchell Construction in New Bern NC, covering every phase from the first consultation through the final walkthrough.
Project Overview
Location: New Bern, NC Home type: Single-family, 1980s two-story Bathroom type: Master bathroom Bathroom size: 94 square feet Project scope: Full gut and rebuild, tile, shower, vanity, fixtures, lighting, ventilation Vanity type: Custom in-house built double vanity, painted finish Tile: Large-format porcelain throughout Shower system: Thermostatic with rainfall and handheld Project duration: Four weeks from demolition to final walkthrough Total project cost: $47,500
The Starting Conditions, Before
The master bathroom in this home had not been touched since the house was built in the early 1980s. The homeowners, a couple in their early 50s, had lived with the original bathroom for eleven years after purchasing the home. They described the bathroom as functional but frustrating in ways that had accumulated over time.
The shower was inadequate for two people. The original shower was a 32×32 inch prefabricated fiberglass unit, the smallest standard size available. At this size, turning around to rinse required careful maneuvering. The fiberglass surround had yellowed and developed hairline cracks at the base corners where the walls met the floor. The original single-function showerhead had reduced to a trickle due to mineral buildup in the head.
The vanity was a single, in a bathroom used by two people. The original 36-inch single vanity with a drop-in sink left one person waiting every morning. The vanity cabinet had particleboard construction, the bottom of the cabinet beneath the sink had swollen and delaminated from years of minor moisture exposure. The countertop was cultured marble with a built-in sink that was yellowed and had surface scratches that cleaning did not improve.
The tub was never used. The original garden tub, a large jetted unit that occupied a significant portion of the bathroom, had not been used in years. The jets had not been cleaned in longer than either homeowner could recall. The tub was taking up approximately 25 square feet of the bathroom footprint that the homeowners wanted back.
Ventilation was inadequate. The original exhaust fan, a builder-grade unit installed when the home was built, was significantly undersized for the bathroom’s cubic footage and was not ducted to the exterior. The duct terminated in the attic, exhausting moisture into the attic space rather than out of the building. The result was visible, mold growth on the ceiling near the fan and a persistent musty odor in the bathroom after showering.
Lighting was poor. A single overhead fixture provided general illumination. The vanity had a strip light above the mirror, four incandescent globe bulbs that cast unflattering downward light and were inadequate for the tasks performed at the vanity. The strip light had two burned-out bulbs that had not been replaced.
Tile was outdated & in poor condition. The original 4×4 ceramic floor tile was installed in a color that had not been popular since the decade the home was built. Several tiles were cracked. The grout throughout was a matching original color, now stained darker than the tile itself despite regular cleaning.
The Consultation & Planning Process
The homeowners contacted D.E. Mitchell after seeing a completed bathroom project the company had done for a neighbor. They had a clear sense of what was not working but had not yet developed a specific vision for what they wanted.
The initial consultation took approximately ninety minutes and covered the following:
The tub removal & shower expansion. Removing the unused garden tub and relocating the shower to occupy the full former tub alcove was identified as the highest-impact single change. The former tub area, approximately 35×60 inches, would become a walk-in shower nearly three times the size of the original. This change required plumbing relocation, the shower drain would move from the original 32×32 position to a new position centered in the expanded shower area. A linear drain was specified to allow a fully curbless shower entry, which the homeowners preferred for both accessibility and appearance.
The double vanity. Converting the single 36-inch vanity to a double vanity required the wall to accommodate the wider unit. The existing plumbing had both hot and cold supply lines at the original single-sink location. Adding a second sink required extending both supply lines to a second position approximately 30 inches from the original. The drain configuration required a new drain rough-in for the second sink. The homeowners confirmed a double vanity was a priority regardless of the plumbing adjustment cost.
The ventilation problem. The existing fan was replaced with a properly sized unit, calculated for the bathroom’s cubic footage, and the duct was re-routed from its attic termination point to a proper exterior discharge through the soffit. The mold on the ceiling required treatment before the new work proceeded.
The shower system upgrade. The homeowners were interested in a thermostatic shower system, they had used one in a hotel and wanted separate control of temperature and flow. A thermostatic valve with a ceiling-mounted rainfall head and a separate handheld was specified. The thermostatic valve requires specific rough-in positioning, the plumber was briefed on the valve specification before rough-in began so the blocking and valve position were correct.
Material selections. All selections were made during the design phase before the contract was signed. The selections schedule had a two-week window for decisions, which the homeowners completed in one meeting.
Material Selections
Tile, Floor: 12×24 porcelain tile in a warm gray. Installed in a running bond pattern with 1/16-inch joints. Extended from the shower threshold through the full bathroom floor including the vanity area.
Tile, Shower Walls: 12×24 porcelain tile matching the floor. Full height on three walls. Linear mosaic tile accent strip at shoulder height on the back wall.
Shower Niche: Single built-in niche on the back shower wall, 12 inches high by 24 inches wide. Tiled to match the shower walls.
Shower System: Thermostatic shower system, separate temperature and volume controls. 10-inch ceiling-mounted rainfall head. Wall-mounted handheld on a slide bar. Matte black finish throughout.
Shower Door: Frameless glass door, single hinged panel on a curbless threshold. Matte black hardware.
Vanity: Custom double vanity built in-house by D.E. Mitchell’s woodwork team. 60 inches wide. Painted white, shaker door style. Three drawers on each side with a center door section for plumbing access. Soft-close hinges and drawer glides throughout. Plywood box construction.
Vanity Countertop: White quartz with minimal veining. Two undermount rectangular sinks. Polished edge profile.
Faucets: Deck-mounted faucets in matte black, one per sink, matching the shower hardware finish.
Toilet: Comfort-height elongated toilet, white, with a soft-close seat.
Lighting: Two wall-mounted sconces at eye level, one per sink position, in matte black. One recessed ceiling fixture over the toilet area. Two recessed ceiling fixtures in the shower area rated for wet locations.
Ventilation Fan: Bathroom exhaust fan sized for the bathroom cubic footage, rated for 110 CFM. Re-routed to exterior soffit discharge. Timer switch rather than standard on-off toggle.
Mirror: Two rectangular frameless mirrors, one centered above each sink, mounted at a height appropriate for the household.
Accessories: Matte black towel bars, robe hooks, and toilet paper holder, matching the fixture and hardware finish throughout.
The Construction Process, Week by Week
Week 1, Demolition, Mold Treatment, & Rough-In
Demolition began Monday morning. The original fiberglass shower unit was removed in sections. The garden tub was disconnected and removed, this required two crew members and careful maneuvering through the bathroom door given the tub’s size. Original tile, the single vanity, toilet, and all fixtures were removed. The existing exhaust fan and duct were removed.
During demolition, two conditions were assessed:
Condition 1, Mold extent. The mold on the ceiling near the original fan location extended further than was visible before demolition. When the fan housing was removed and the ceiling drywall around it was opened, mold growth on the drywall backing extended approximately 18 inches in each direction from the fan location. The affected drywall was removed and the framing behind it was treated with an antimicrobial solution. New moisture-resistant drywall was installed in the ceiling section before work proceeded. This added $650 to the project cost.
Condition 2, Subfloor condition beneath the garden tub. The subfloor beneath the garden tub had minor staining from what appeared to be a slow leak at the tub drain connection, consistent with what the homeowners described as an occasional musty smell near the tub. The staining was limited to surface discoloration without structural compromise. The affected plywood was assessed by the project lead, confirmed sound, and sealed before new work proceeded. No cost addition was required for this condition.
Both conditions were communicated to the homeowners before any remediation proceeded. Written documentation of each condition and the remediation approach was provided.
After the demolition conditions were addressed, the plumbing subcontractor began rough-in. The shower drain was relocated to the center of the new shower footprint, a curbless linear drain positioned at the low point of the shower floor slope. The second vanity sink drain and supply lines were roughed in at the specified position. The thermostatic shower valve was roughed in at the specified height and position with the correct blocking for the valve body. The plumbing inspection was scheduled and passed by Thursday of Week 1.
The electrical subcontractor ran the new circuits, dedicated circuits for the new fan, the sconce positions, and the shower lighting. The fan duct was re-routed through the attic to the soffit discharge location. The electrical inspection was scheduled and passed Friday afternoon.
Week 2, Waterproofing, Shower Floor, & Tile Preparation
Waterproofing began Monday of Week 2. A full waterproofing membrane system was applied to the shower walls and floor, on the cement board substrate before any tile was installed. The membrane was applied to the full height of the shower walls, wrapped at the corners, and extended across the full shower floor and up the curb, or in this case, the curbless threshold transition. The niche pocket was waterproofed on all five interior surfaces.
The shower floor was sloped toward the linear drain at the specified pitch, 1/4 inch per foot minimum. The slope was verified with a level before waterproofing was applied and again after to confirm the membrane application had not disturbed the pitch.
The vanity area drywall was patched where the second sink plumbing penetrated the wall and where the original single vanity had been removed. Moisture-resistant drywall was used throughout the vanity area.
Tile layout was planned before any tile was set. The 12×24 format on the floor was laid out to center the pattern on the visible axis from the bathroom entry door, full tiles in the sight line, cuts pushed to the less visible edges. The shower wall layout was planned to keep the mosaic accent strip at a consistent height on all three walls. The niche was positioned to align with the tile grid on the back wall, a niche that falls mid-tile rather than on a grout line requires additional cuts and looks inconsistent. Positioning it on the grid avoided this.
Floor tile installation began Thursday of Week 2. The shower floor tile, a smaller format mosaic on the shower floor for slip resistance and to accommodate the slope, was set and grouted by end of day Friday.
Week 3, Shower Wall Tile, Vanity Installation, & Drywall
Shower wall tile began Monday of Week 3. The three shower walls were tiled full height, from the waterproofed floor to the ceiling. The mosaic accent strip was installed on the back wall at the specified height. The niche was tiled on all five interior surfaces with tile cut to fit precisely. Corners were handled with mitered tiles rather than surface-mounted metal profiles, a more labor-intensive approach that produces a cleaner finished result.
The frameless glass door was measured and ordered at the beginning of Week 3. Frameless glass doors are fabricated to the specific opening dimensions, they cannot be ordered before the tile is complete because the opening dimensions are determined by the as-built tile work. Standard lead time was 10 to 14 business days, which fit within the project schedule with a delivery expected during Week 4.
The custom vanity was delivered from the D.E. Mitchell shop on Wednesday of Week 3 and installed by the same team that built it. Installation required precise positioning, the vanity was set at the correct height, leveled, and secured to the wall studs. The plumbing connections for both sinks were made after the vanity was positioned and confirmed level.
Remaining drywall work, the patched ceiling section, the wall areas adjacent to the vanity, and any other surfaces affected during demolition, was finished and primed by end of Week 3.
Week 4, Countertops, Fixtures, Lighting, & Close-Out
Countertop fabricators templated the vanity on Monday of Week 4 after confirming the vanity was level and the plumbing rough-in positions were correct. The template captured the two sink cutout positions and the edge profile. Fabrication and delivery were scheduled for Thursday.
The bathroom floor tile was grouted Monday and Tuesday, the shower wall grout had been applied in Week 3, so the floor grout completion was the final tile work on the project.
The frameless glass door arrived Wednesday and was installed. The door was set in the matte black hinges and confirmed for plumb and smooth operation. The magnetic closure strip was adjusted for a positive close.
Countertops arrived Thursday and were installed. The two undermount sinks were secured from below and the faucets were installed through the deck-mounted holes.
The electrician returned Thursday to install the sconce fixtures, the recessed ceiling fixtures, the exhaust fan, and all outlet covers and switch plates. The timer switch for the fan was installed and set.
The plumber returned Thursday to connect the toilet, install the faucet supply connections, connect the shower system and test for pressure and temperature function, and install the shower drain cover.
The toilet was installed and tested. All plumbing connections were checked for leaks with supply water on and pressure applied.
Painting was completed Friday morning, the ceiling, the walls, and all trim surfaces.
Accessories, towel bars, robe hooks, toilet paper holder, and mirrors, were installed Friday afternoon.
The final walkthrough was scheduled for Friday at 3:00 PM.
The Final Walkthrough, Punch List
The homeowners and project lead walked the bathroom together for approximately 45 minutes. The punch list included:
Item 1, Shower door alignment. The frameless door had a slight gap at the top of the door on the hinge side, a 1/16-inch gap that was visible when looking at the door from the side. The hinge adjustment was made on-site during the walkthrough. The door was re-checked and confirmed square.
Item 2, Grout touch-up in the niche. One grout joint in the niche had a small void at the corner intersection. The tile setter returned the same afternoon to fill and clean the grout touch-up.
Item 3, Caulk line at vanity base. The caulk line at the base of the vanity where it met the tile floor had a small section that was not fully tooled smoothly. Re-caulked and tooled the same day.
Item 4, Mirror height verification. One mirror was installed at a height that did not align with the adjacent mirror when viewed straight on, a 3/8-inch difference between the two bottom edges. The mirror was repositioned and re-anchored to the correct height.
All four punch list items were resolved before end of business on the day of the walkthrough.
The Results, After
The homeowners moved back into the master bathroom at the end of Week 4. Here is what changed.
The shower is functional for two people. The curbless walk-in shower at the former tub footprint is nearly three times the size of the original. Two people can shower simultaneously without interference. The thermostatic system allows each person to preset their preferred temperature, the dial is turned and the water comes out at the right temperature without adjustment. The rainfall head provides coverage across the full shower floor area. The homeowners noted in a follow-up conversation that the shower was the element that most exceeded their expectations, they had thought the thermostatic system was a luxury preference, not a daily functional improvement.
Two people can use the vanity simultaneously. The 60-inch double vanity with two sinks eliminated the morning scheduling conflict that had been a daily frustration. The drawer configuration, three drawers per side, provides enough storage that neither person needs to use the under-sink cabinet for daily-use items.
The bathroom is 25 square feet larger in effective use. The garden tub occupied approximately 25 square feet of floor space. Removing it and incorporating that area into the shower and vanity zone made the bathroom feel significantly larger despite the same physical footprint. The homeowners noted that they had not appreciated how much space the unused tub was consuming until it was gone.
Ventilation works correctly. The properly sized fan on a timer switch, set to run for 20 minutes after the switch is turned off, keeps the bathroom dry between uses. The mold that had been present on the ceiling before the remodel has not recurred. The musty odor that the homeowners had associated with the bathroom for years is gone.
Lighting is adequate at the vanity. The side-mounted sconces at eye level eliminate the shadows on the face that the original overhead strip light created. The recessed ceiling fixtures provide even overhead light. The homeowners noted that the lighting difference alone made the bathroom feel like a different room.
Total project cost came in at $47,500, within the $44,000 to $50,000 budget range established at contract signing. The mold remediation added $650 and was absorbed within the contingency reserve. The contingency was not fully consumed.
Timeline: Four weeks from demolition start to final walkthrough, on schedule as projected at project start.
Key Decisions That Made This Project Successful
Removing the unused tub rather than working around it. The garden tub was the single biggest obstacle to the bathroom functioning well. Removing it required accepting that the bathroom would have no tub, a decision the homeowners were comfortable with given they had two other bathrooms in the home. A contractor who had designed around the tub rather than removing it would have produced a less functional result.
Specifying the thermostatic valve before rough-in. The thermostatic valve requires specific rough-in positioning and blocking that is different from a standard pressure-balance valve. Specifying the valve before rough-in began meant the plumber could set the position correctly. Adding a thermostatic system after rough-in is set for a standard valve requires either accepting the wrong position or reopening the wall, neither is acceptable on a fresh tile installation.
Installing the waterproofing membrane correctly. The membrane was applied to the full shower wall height and floor before any tile was set, with proper corner treatment and niche waterproofing. This step adds cost and time. It is the difference between a shower that lasts twenty-five years and one that develops water intrusion problems within seven. The homeowners were specifically informed of this step and why it was being done.
Centering the tile layout on visible axes. The floor tile layout was planned before the first tile was set. Centering the pattern on the sight line from the entry door and pushing cuts to less visible edges is a planning step that requires time before installation begins. The result is a tile floor that looks intentional rather than one that reveals that installation started in a corner and the layout was figured out as it went.
Mold assessment before closing the ceiling. The mold found during fan removal was assessed and remediated before new work covered the area. Covering mold without remediation would have allowed it to continue growing behind the new ceiling and would have eventually required a much more extensive remediation effort. Addressing it during the remodel, when the ceiling was already open, was the correct and least disruptive approach.
What This Case Study Shows
The right scope addresses the actual problems. The homeowners’ frustrations were specific, the undersized shower, the single vanity, the unused tub taking up space, the ventilation failure. The remodel scope was built around addressing those specific problems rather than replacing everything. The result is a bathroom that solves what was not working.
Removing elements that are not being used delivers more value than keeping them. The garden tub was original to the home and was a selling point when the house was built. After eleven years of non-use, it was a liability, consuming floor space and creating a maintenance obligation. Removing it and reclaiming the space was the right decision for this household.
Discovered conditions managed with transparency keep projects on budget. The mold condition was identified, communicated to the homeowners before remediation proceeded, documented, and resolved within the project timeline. The total added cost was $650, absorbed within the contingency reserve. The homeowners were not surprised by a cost addition at the end of the project because they were informed of it at the time it was discovered.
Custom cabinetry built in-house fits the space. The 60-inch double vanity was built to the exact width available in the bathroom, not a standard size that happened to be close. The interior drawer configuration was designed for the household’s storage needs. The installation was handled by the team that built it, producing a result where the door gaps are consistent, the drawers operate smoothly, and the vanity fits the space as if it was always there.
Frequently Asked Questions
How did a 94 square foot master bathroom accommodate a 60-inch double vanity & a walk-in shower?
The garden tub removal was the enabling factor. A 94 square foot bathroom with a garden tub, a 32×32 shower, and a 36-inch single vanity is a crowded room. The same 94 square feet with no tub, a 35×60 walk-in shower in the former tub alcove, and a 60-inch double vanity in the former shower and transition area is a significantly more functional room. Square footage is not the determining factor, how it is allocated is.
Could the thermostatic system have been added later without redoing the tile?
No. The thermostatic valve body sits inside the wall and requires specific blocking and positioning that is set during rough-in. The trim kit, the visible controls, can be swapped at any time. But converting from a pressure-balance rough-in to a thermostatic rough-in after tile is set requires opening the wall, removing and replacing the valve body, and repairing the tile work. The cost of doing it during the remodel is a fraction of the cost of doing it after.
What is the expected lifespan of this bathroom remodel?
With proper waterproofing, quality tile installation, and plywood vanity construction, the structural elements of this remodel should last 25 to 40 years without needing replacement. Faucets and fixtures have shorter service lives, typically 15 to 25 years, depending on water quality and maintenance. The tile and cabinetry are the long-duration elements. The fixtures are the replaceable components.
Would this project cost more in today’s market?
Material and labor costs in Eastern NC have increased since this project was completed. A comparable project in the current New Bern market would likely fall in the $52,000 to $62,000 range, depending on specific fixture selections and tile material. Contact D.E. Mitchell for a current estimate based on your specific bathroom.
Plan Your Bathroom Remodel With D.E. Mitchell Construction
D.E. Mitchell Construction handles bathroom remodeling in New Bern, Havelock, Morehead City, Jacksonville, and the surrounding Eastern NC communities. We build custom vanities in-house, handle the full remodel scope, and provide written estimates at no charge after a site visit.
If you are planning a master bathroom remodel or any bathroom renovation project and want to talk through what the process would look like for your specific bathroom, reach out and we will set up a consultation.
No obligation. No pressure. A direct conversation about your bathroom and what it will take to remodel it right.