Pod Construction

The construction of the UNIPODS bathroom pod is based on formation of the room or box by combining separately fabricated floor slab, wall panels and ceiling panel componenst.

Pod Floor

The pod floor is formed as a self- supporting pre-cast concrete slab. The floor is cast with a perimeter up-stand to provide maximum water-tightness. The minimum floor thickness is 50mm (concrete) plus finishes however concrete thickness may increase depending on layout and overall size of span.

• 30MN/m2
• Reinforced Concrete Density: 2300 – 2400 Kg/m3 All necessary holes and penetrations for service and drainage runs can be incorporated within the floor design as well as inserts necessary for pod assembly and lifting. The concrete pod floor can be cast with built-in gradient/falls and steps as necessary to form wet room shower floors or shower tray details.

Wall Construction

UNIPODS offer two pod wall construction options

• Lightweight Steel Frame Gypsum Board Lined Walls Lightweight Concrete Walls
• Lightweight Steel Frame Gypsum Board Lined

The lightweight steel wall consists of sub-frame formed from cold-rolled galvanised steel c-section studs and lined internally with moisture resistant gypsum plasterboard to form a rigid wall construction ready for factory applied internal finishes.

The c-section studs are produced in our factory via an automated roll forming process whereby each section is cut to the exact length with notches, swage, rivet punch and countersinks to exacting requirements. This eliminates significant material off-cut waste that would be associated with traditional on-site gypsum board standard length studs. The studs are formed from 0.70 gauge galvanized steel which is thicker and more rigid than typical gypsum board metal stud sections. The wall panels are designed with studs at max 400mm centres providing a robust and rigid wall panel construction.

Walls are lined internally with moisture resistant gypsum plasterboard ready to accept finishes within the factory.

Gypsum Plaster board is selected to meet specific performance requirements for the finished wall. Insulation can be included between studs if required. It is normal for UNIPODS to provide external lining to specific pod walls that have been designed to form riser shaft or duct areas and are required to meet specific fire and acoustic performance ratings.

Generally the external layer of dry-lining is applied on-site by the main contractor once the pod has been placed in its final location within the building.

Lightweight Concrete Walls

The concrete pod wall is produced in two thicknesses dependant on required performance rating of the wall.

Wall Thickness:

• 60mm + finishes
• 80mm + finishes

Each concrete wall is cast as a single reinforced lightweight concrete panel.

• Leca Concrete: ƒck > 20 MN/m2
• Weight: 1600 – 1700 Kg/m3

Panels are formed with pipe routes and electrical conduits and outlets cast within the wall panel and inserts required for connections at floor to wall, wall to wall and wall to ceiling junctions. Floor to wall (horizontal junction) connections are made at max 800mm intervals and wall to wall (vertical junction) connections are made at max 600mm intervals. In both cases the connections and joints are sealed with a mortar adhesive.

The external face of the concrete pod wall provides a good quality smooth surface and once pods have been installed to final location within the building structure the external face of the concrete pod wall will require only minimal filling prior to application of finishes.

Ceiling Construction

The pod ceiling is formed as a single panel consisting of steel sub-frame lined internally with gypsum plasterboard. Any joints are taped and filled and ceiling receives painted finish internally. A protective layer of 9mm plywood is provided externally.

Dependant on specific project design requirements we can offer two sub-frame construction options.

• Mild steel welded sub-frame formed from hot rolled hollow section steel coated with anti-rust protection.
• Cold rolled galvanised steel c-section stud frame as per wall panel construction.

It is also possible for the pod ceiling to be formed with built in access panels or with demountable ceiling tiles providing access to any services located in void above the pod.

Cabin Assembly

The pod floor, wall panels and ceiling panel are brought to the assembly point. The Floor is levelled and wall panels are then located, with inserts and fixing points aligned and mechanically fixed in place. The pod Ceiling panel is then lowered into place and secured. Lifting rods are located that connect to the pod floor and terminate at ceiling level for connection of lifting eyes for site lift/installation (see pod lifting). All fixings are secured and checked as part of the quality assurance procedure for pod assembly.

Tanking System

The UNIPODS bathroom pod receives a comprehensive tanking system to ensure water tightness of the pod construction. The overall design of tanking system, tile adhesives and grouting systems have been developed in conjunction with BASF Construction Chemicals (PCI) to specifically meet the requirements of off-site construction with consideration given to our assembly process, transportation and installation of the pod bathrooms.

The process begins with application of primer to all floor and wall surfaces. The tanking system is then applied to the whole floor area and floor/wall junctions returning 200mm up all walls. The same tanking system is also applied full height to walls in wet areas such as shower areas. The tanking system consists of a solvent-free synthetic resin which is painted on to the floor and walls and dries to form a flexible waterproof membrane. This membrane is applied in two coats and combined with waterproof reinforced membrane tape at floor to wall junctions and vertical corners (wall to wall junctions).

Tiling, Adhesives & Grout

Tile adhesives and grout form part of the approved tiling and tanking system which has been developed in conjunction with BASF Construction Chemicals to meet UNIPODS exacting requirements in line with our manufacturing, delivery and installation processes. The adhesives and grouts used are selected for their specific application based on tiling substrate and selected floor & wall finishes.

The pod floors are tiled and grouted prior to cabin assembly. The pod floors are placed on trestles at waist level providing best possible conditions and ergonomics for our tile fixers enabling us to achieve best possible finish. Wall tiling and grouting is carried out on the production line following cabin assembly. All tiling within the pods is set-out to designed tile grids meaning each pod of a specific type will have identical set-out points and tile grids.

Our designers work with the client’s consultants to achieve an agreed tile design for each pod type using our experience to achieve the best possible aesthetic whilst minimizing waste and avoiding unsightly cuts or detailing.

Internal Finishes

UNIPODS can work with almost any specified finish for a particular project. We will work with ceramic, porcelain, natural stone and glass products. We can source and procure specified products or can work with our clients nominated supply chain. The same applies for sanitary ware, brassware and any other fittings required within the pod. In most cases we have access to an equal or alternative product through our supply chain and will be able to propose this as value engineering option.

Mechanical & Electrical Services

In general terms, provision is made within the pod for all MEP services required within bathroom. All services are incorporated and terminate at an agreed location to simplify on- site connection to the main systems. This includes but is not limited to water supply pipework, drainage, soil & waste pipework, electrical wiring systems, ventilation and extract. In each case the system design is detailed within our shop drawings which are issued for sign- off and approval by the project design team and relative consultants prior to commencement of pod manufacture.

Water Supply Pipework

The UNIPODS bathroom pod will be supplied with all terminal fittings including taps, mixers, shower valves and shower heads fitted and will include all required hot & cold supply pipework. The supply is generally fed from a single pair of hot & cold manifolds. The manifolds are located at an agreed accessible location so that MEP contractor has only one hot and one cold connection to make at each pod. All required service and isolation valves can be included within the pod design dependent upon specific design constraints. UNIPODS supply a main isolation valve at inlet connection to each manifold as standard.

UNIPODS use a flexible Pex pipework system that confirms to all WRAS, BS, & EN standards for potable water. The system is installed using a pipe- in-pipe system meaning that pipe runs cast into concrete components or within wall cavities can be easily replaced should this ever be required.

Pipework installations on every pod are rigorously tested as part of the factory production quality assurance procedures. Test results for each pod are recorded and supplied with the pod as record and confirmation of testing procedure (see “Testing & Quality Control” for more details”).

It is assumed that the incoming supply system will be a nominally balanced, pressurized system set to meet the operating requirements of the specified fittings used within the pod. No allowance is made within the pod design for the provision of pressure reducing valves or flow regulators unless specifically requested.

The main contractor must ensure that the site installed plumbing installations are fully flushed out prior to making connection to the water service manifolds as any debris in the system could damage the terminal fittings within the bathroom or cause them to malfunction. Where such symptoms arise, the responsibility for failure will lie with the Main Contractor.

Drainage Systems

Soil and waste drainage pipework will be included to all appliances within the pod. Connection will be made to appliance within the pod and will include water seal/trap (where required). The drainage pipework will run to an agreed termination point for on-site connection to main system (by others). Drainage runs within the pod can be accommodated in a number of ways depending on location of appliance to be drained, required pipe dimensions and design limitations to ensure conformity with regulations.

The following methods or combination of both can be considered in each case:

Horizontal – drainage routes will run above pod floor level within the pod, penetrating pod wall to terminate at agreed location; possibly a service riser or shaft. The pipe termination will project approx 75mm beyond external face of pod wall to allow on-site connection. Pipes are generally concealed either by running within bulkheads or pipe boxing. For smaller diameters it is possible for the pipe to run within the depth of the pod wall cavity.

Vertically – drainage routes will terminate directly through the pod floor. This is done by casting a socket within the pod floor. Corresponding cut-out is required in the supporting slab below so that site connection can be made by pushing pipe up into the socket provided.

Unless stated otherwise all soil & waste drainage pipework within the pod will be solvent weld PVC & uPVC material. Fire sleeves are not fitted to waste pipework except where the provision of these has been clearly stated within our specifications and indicated on our detailed design drawings.

All drainage systems fitted within the pod are factory tested as part of our factory production quality assurance procedures. Test results for each pod are recorded and supplied with the pod as record and confirmation of testing procedure (see “Testing & Quality Control” for more details”).

The services hook-up to each bathroom requires to be undertaken in a manner that recognises the fact that termination points of pod drainage are fixed and cannot be adjusted when connecting to main system pipework. We therefore recommend use of slip couplings when connecting to horizontal drainage terminations. Failure to adopt this technique will disturb or even dislocate factory tested pipework. Should this be the case then this would invalidate any warranty and may result in cause damage to finishes and fittings.

Electrical Installations

The UNIPODS bathroom pod will be supplied as fully finished room with all specified electrical components and wiring systems complete and installed in compliance with the requiredregulatorystandards. Allrequiredwiringwillbeinplaceandterminationwillbe made at agreed location (normally junction box on pod roof or duct wall) for simple on-site connection to the main system.

The pods can be supplied with an external back-box for light switch at the entrance door however the switch-plate is supplied and installed by others on site once required finishing has been completed to the external face of the pod wall. Additional conduits and junction boxes required to serve site-installed electrical systems can be incorporated within the pod design and manufacture upon request.

Ventilation Systems

Ventilation and extract grilles can be accommodated within the pod design and installed within the pod wall or ceiling. Final connection from grille to main system would be carried out by the main contractor.

Cleaning & Protection

Once all necessary testing procedures have been satisfactorily carried out the pod receives a thorough builder’s clean prior to being wrapped ready for dispatch. All construction debris, traces of plaster and grout are removed. Protection is applied internally as necessary to avoid any damage duringtransportation. The temporary or final door is installed and secured and protection is applied as necessary. The pod is then fully wrapped in heavy duty polythene protection and is moved to storage ready for despatch to site.

Delivery

Pods are delivered on flat bed articulated lorries. The number of pods per load is dependent on the overall size and mix of pods required. The delivery programme is agreed and tailored to the exact site requirements with just-on-time deliveries and pods loaded in the sequence of intended installation.

Installation

There are a wide range of options available in terms of how the pods are physically lifted, manoeuvred and located within the building structure. The method selected for any given project will be dependent on many factors with consideration given to type of structure, number of stories, method and sequence of construction etc. In general terms there are two main types of installation; Horizontal or Vertical

Horizontal Installation

For horizontal installation the pod is craned from the delivery vehicle and is normally landed on a platform at the intended installation level. From here the pod is wheeled horizontally through an opening in the side of the structure and into the building. This is by far the most common method and the one typically used in multi-storey construction projects allowing the main concrete structure to proceed in the traditional manor with pods being installed slightly later in process once formwork for floor above as been removed. The platform will typically be a cantilever type or can also be formed by scaffold where practicable and overall storey heights allow.

In some cases it may also be possible to use a specially designed lifting cage or cradle that is used to lift the pod to the desired level. The cage is then strapped to the building and the pod is wheeled out and into the building.

On low-rise projects and lower floors of multi-storey constructions it may also be possible for pods to be lifted to opening on intended installation floor by use of a fork-lift or telescopic handler.

Vertical installation

Vertical installation is based on pods being craned from delivery vehicle directly into their final location on the intended installation floor. Traditional insitu cast structures will not allow this type of installation as the pod would disrupt the formwork required for casting the slab/floor above. However this does provide a very quick and practical option in low-rise structures using pre-cast floor elements or complete pre-cast concrete structures where the pods are delivered an installed on just-in- time floor by floor basis in conjunction with erection of the pre- cast concrete element erection.

In all cases, once installed the pods are typically installed on a minimum of 4 No levelling points where loads will be transferred to the building structure. The overall weight of a bathroom pod is fully dependant on the project specific design and selection of finishes. However in general terms we present the following typical approximate loadings:

• 900 Kg/m2 for a concrete pod (concrete floor and walls)
• 450 Kg/m2 for a lightweight steel pod (concrete floor and lightweight steel walls)

The building structure into which the pod will be installed or sit upon must be suitably designed to accept the resultant pod loading as well as live loading during pod transfer across the slab.

Lifting

The pod is supplied with 4 No lifting points. The lifting points are formed with full height zinc plated steel threaded rods. The rods are mechanically secured to inserts cast into the concrete pod floor and terminate at high level with threaded sleeve connection to receive wire rope lifting eyelets. Threaded sleeves and wire rope lifting eyelets are certified to suit pod loading and are supplied by UNIPODS complete with necessary test certification. Pods should be lifted using minimum 6m chains or slings. These are supplied by the main contractor.

Where UNIPODS carry out the installation we will include for plant and machinery required for manoeuvring pods across slab however we would expect main contractor to provide use of site tower crane or mobile crane as necessary in line with agreed installation programme.

Snagging Process & Handover

Bathroom pods are delivered to site with the pod door locked and secure. UNIPODS retain the key to the pod door and the pods should not be opened without UNIPODS being in attendance. A programme of joint inspections is agreed whereby a representative of UNIPODS along with representative from main contractor will jointly open and inspect each pod. A simple pre-prepared check sheet is used to carry out a series of simple checks for completeness and quality of finish in each and every pod. Any deficiencies, missing items or damage is noted and responsibility for ratification agreed and programme of works agreed. The keys to each pod are handed over to the main contractor following this joint inspection. At this point the condition of the pod is accepted in line with the completed joint inspection check sheet and responsibility for any further damage or missing items passes to the main contractor.

Service & Commissioning Process

UNIPODS site representatives attend site to carry out commissioning of our pods. The is only carried out once all mains connections (water & electrical supplies) have been made and are fully functional and at full working pressure. It is imperative that all site installed supply pipework is fully flushed prior to connection being made to pod manifold.

Once this stage has been achieved UNIPODS representative will attend site and will turn pods on by opening isolation valve at manifold inlet connection. A function test will be carried out to ensure systems are operating correctly.

UNIPODS provide a 10 year warranty on the pod structure. We also pass on all manufacturers’ warranties for products and materials used within the construction and fit- out of the pod.

On a project by project basis we will commit to a maintenance and defects liability period (typically 12 months from practical completion).

In addition to the above UNIPODS LLC carry general liability insurance.

Facts & Figures

UNIPODS purpose-built bathroom pod manufacturing facility is located in Al Ghail within the emirate of Ras Al Khaimah, United Arab Emirates.

Our facility includes:

• Main production hall & store, 13,000m2, housing two 2 5t overhead cranes
• Casting hall including batching plant, 4200m2, with two.5t overhead cranes
• Designated on-site storage area for completed pods totalling 7000m2
• Kitchen factory, 4000m2, housing most technologically advanced kitchen
• manufacturing capability in the middle east / gulf region
• Overall site of 100,000m2 leaving space for future expansion plans

Capacity / Output

On single standard shift we have capacity to manufacture over 10,000 pods per annum. This equates to approximately 200 completed bathroom pods per week.

People & Experience

The UNIPODS management team is highly experienced in the off-site construction industry with a strong track record in managing leading bathroom pod manufacturing companies in the UK and Scandinavia. Design, production, technical and management team members have been handpicked from leading European Off-site Construction Technology companies and bring with them a wealth of experience and knowledge. The team is complemented by a number of key people who have extensive and in-depth knowledge and experience of the UAE and Gulf Region Construction Market.