2011 Bathroom POD Product Guide

2011 Bathroom POD Product Guide
AmeriPod Guide Table of Contents
1) Overview – pgs 3-4
2) Prototyping with AmeriPod – pg 5
3) 3D/4D Design – pg 6
4) POD Fabrication – pg 7
5) MEP Assemblies – pgs 8-13
6) POD Subflooring – pg 14
7) Testing & Inspection – pg 15
8) POD Transportation & Delivery – pgs 16-17
9) Staging & Installation Guide – pgs 18-19
1) AmeriPod Product Overview
What is a POD?
A POD is a modular building component that’s fabricated
off-site in a controlled factory environment for use in a
traditionally constructed building. PODs are transported to
construction sites as fully finished, furnished, & functioning
units, ready for client use upon installation. PODs are a
greener, more convenient alternative to conventional
construction offering a significant benefit to any project
schedule & LEED status.
Not all PODs are created equal though. AmeriPod utilizes
the latest developments in the modular & conventional
construction industries to create a POD that is higher
quality & more sustainable than any other fabricator in the
industry. AmeriPod is the only POD manufacturer to offer a
completely welded 18 gauge metal framing system, giving
our units superior strength & durability. Through extensive
research & development, AmeriPod has designed a high
performance waterproofing & tiling assembly that assures
our PODs arrive on site with a flawless, water-tight finish.
AmeriPod’s mass-customization manufacturing process
allows us to create PODs for bathrooms, kitchens, exam
rooms, or any other repetitive room unit. PODs are
fabricated to the exact design specifications required by
our clients without any limitations. PODs are brought onto
the site as plug & play units that require only simple MEP
connections to the project’s conventional building systems
for installation.
AmeriPod units are fabricated in our South Plainfield, New
Jersey manufacturing facility using a lean manufacturing
production line which creates a high-precision, high quality
product that cannot be duplicated using conventional
construction methods on-site.
AmeriPod units are compliant with the International Building Code, Uniform Plumbing
Code and the National Electric Code. AmeriPod units can also be built to any
international standards. Units fall under CSI Code #134200 for Building Modules.
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The most commonly used POD in building applications are bathroom PODs due to
the high volume and repetition of units commonly found projects.
What items can be included in an AmeriPod bathroom?
Lighting Fixtures
Electrical Outlets
Switches
Exhaust Fans
Mirrors
Medicine Cabinets
Illuminated Mirrors
Plumbing Fixtures
Faucets
Mixing Valves
Traps
Trap Covers
Shower Valves
Shower Fixtures
Hand Showers
Rainshower Fixtures
Vanity Countertops
Quartz, Granite,
Corian
Vanity Bases
Laminated, Oak,
Decorative
Floor Drains
Linear Trench Drains
Shower Drains
Tub Drains
Walk-In Showers
Bathtubs
Shower Curbs
Surrounds
Glass Enclosures
Recessed or Surface
Mounted Accessories:
Toilet Paper Holders
Towel Bars
Soap Dishes
Robe Hooks
Paper Towel Dispensers
Soap Dispensers
Additional Options:
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Fire Strobes & Alarms
Sloped Tile Flooring
Nurse Call Boxes
Hand Dryers
Heat Lamps
Sliding Doors
Storage Niches
Linen Closets
Glass Shower Doors
Patient Lift Tracks
Bariatric Rated
Accessories
Doors
Door Frames
Door Hardware
Transoms
All Floor, Wall & Ceiling Finishes:
Porcelain & Ceramic Tile
Engineered Stone
Epoxy Flooring
Vinyl Wallcovering
Paint
Grab Bars
Shower Seats
ADA Accessories
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2) Prototyping With AmeriPod
Prior to any scaled fabrication, AmeriPod will produce a full functioning prototype of
your project’s bathroom as a POD unit. This prototype can be delivered directly to
the client and their design team for review.
The prototype POD serves the following purposes:
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Up close review of room layout, finishes, & fixtures
Coordination of MEP connections from actual model
Verification of design’s code compliances
Review of quality standards
Education of local inspectors
Coordination with on-site installers
This upfront effort ensures all members of the project team have a chance to view &
touch the project’s actual bathroom unit prior to full scale construction. This
coordination opportunity eliminates the coordination & fabrication wastes typical in
conventional construction.
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3) 3D/4D Design
AmeriPod utilizes state-of-the-art design software including Revit (Architectural, MEP,
& Structural) & Navisworks. AmeriPod will create an interactive 3D model of the POD
units, allowing them to be used a design tool to be coordinated into the building
construction documents.
Design tools like Navisworks allow us to take the 3D model one step further to create
a 4D BIM model of the POD units, where time is the 4th dimension. This model is
extremely useful as a coordination tool in planning the staging & installation of all the
units once on site. This method allows the construction manager & supporting
contractors to visualize the delivery & placement sequence, allowing all trades to
collaborate for a more efficient logistics plan.
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4) POD Fabrication
AmeriPod utilizes lean manufacturing methods tailored for mass production our POD
units. In our 120,000 SF factory, AmeriPod bathrooms move down a production line as
they are constructed, similar to a car assembly line. At each station AmeriPod
craftsmen perform their standardized work tasks before the PODs move down the line
to the next station.
All of the tools & materials needed are located at each station and are constantly
monitored & restocked when necessary. Feeder lines supply each station with the
necessary material while installers focus on quality of construction at each point in
the assembly line. These lean manufacturing methods reduce waste & increases
productivity as PODs can move down the production line without stopping or
waiting.
Conditioned Area For POD Finishes
Phase 1
Once Wrapping is
Complete, PODs are
Loaded For Transportation
Phase 4
Phase 2
Phase 5
Phase 3
Phase 6
Phase 1 – Welded 18 GA Wall & Ceiling Panels Assembled w Subflooring
Phase 2 – Rough Plumbing & Electrical Work Performed
Phase 3 – Sheetrock & Cutouts
Phase 4 – Tape & Spackle, Waterproofing, Priming, & Tiling Performed
Phase 5 – All Fixtures, Accessories & Door/Hardware Installed
Phase 6 – Final Paint Coat & Grouting Applied, POD Wrapped For Shipment
AmeriPod also uses 4D line simulation software to determine station time, staffing
needs, material flow, & feeder locations. This eliminates inefficiencies and optimizes
POD construction ensuring a reliable production schedule.
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5) Plumbing Connection Overview
AmeriPod bathrooms have the same plumbing as a conventionally built bathroom,
just constructed in a different approach. In an effort to minimize the amount of work
that needs to be done on site, AmeriPod bathrooms are typically designed so that
just a single point of connection is required for the waste, vent, & supply piping tie-ins
to the main building system. Plumbing details are coordinated between AmeriPod,
the architect & mechanical contractor in order to ensure ease of installation. In the
field the mechanical contractor makes final connections to the main building
systems.
Bathroom Waste & Vent
Risers Integrated Into
POD Design
Insulated Copper Supply
Piping For Bathroom
Fixtures
Waste & Vent Piping
Field Connection of POD
Waste Piping To Risers In
Chase Location
Waste/Vent Risers Left
4”-6” Above Track For
Field Tie-Ins
Just like conventional construction, bathroom fixtures will outlet into waste & vent
piping stacks for tie-in to the main building system. AmeriPod bathrooms can be
designed to either incorporate these stacks into the POD design as shown above on
the left, or they can be constructed entirely in the field in an organized chase
location. When riser piping is included in the POD design, tie-ins will be made through
cored holes in the framing track. If riser piping is assembled in a chase location, POD
waste & vent piping will be routed for single points of connection as shown above on
the right.
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Where floor outlet fixtures or drains are specified, on the floor below branch lines are
hung in place to prepare for tie-ins to the main building risers. Ground floor units will
be hooked up in the same fashion; only the piping will be sleeved and boxed out to
allow for final adjustments, similar to conventional construction.
To avoid construction of branch lines in the field or if clearances do not allow for the
installation of branch piping, back outlet plumbing fixtures can be utilized. This allows
for all waste & vent branch piping to be included in the POD design.
Water Supply Connections
AmeriPod bathrooms include all water supply lines for the sink, toilet, & shower
fixtures. Single points of connection for the hot water & cold water supply lines are
coordinated with the site plumber for POD installation. The supply branch lines are
typically located above the POD ceiling or in the main building riser for single point
connections.
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Supply lines are pressure tested at AmeriPod’s factory. Copper piping or PEX is used
for hot/cold water lines depending on code requirements. All copper supply lines
are insulated and secured as per code requirements within the POD wall framing.
Additional piping for the rough-in of fixtures on the outside of the POD unit can also
be factory installed for additional plug-and-play installations in the field. This would
allow any sinks, kitchen appliances, or washing machines to be installed with minimal
labor in the field. AmeriPod can also rough-in additional receptacles or low voltage
boxes on the exterior of the bathroom for added efficiency in the field electrical
work.
Washer Box
Mechanically
Fastened To
Welded Stud Wall
Panels On Outside
of Bathroom
Cast Iron Waste/Vent
Outlet For Washing
Machine Unit
Copper Hot/Cold
Water Supply
Piping Tied Into
Washer Box
Washer Box Prepared
On Exterior of POD For
Plug-and-Play
Connection of
Appliance In The Field
AmeriPod bathrooms can utilize any type of piping to meet the project’s local code
requirements including:
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Copper – Type L or Type M
Cast Iron – Double Hub / No Hub Connections
PEX
ABS
PVC/CPVC
Rain Water Reclamation Piping
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AmeriPod bathrooms can adapt to any project’s layout & plumbing specifications
with minimal change to the conventional design. Typically through coordination, just
a single point connection can be made for the following plumbing assemblies:
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Hot Water Supply
Cold Water Supply
Waste/Vent Connection For Lavatory/Toilet Fixtures
Waste/Vent Connection For Tub/Shower Fixtures
Hot Water & Cold
Water Branch Lines
Above POD Constructed
Conventionally
Single Point Connection
For POD CW To Supply
Branch Lines
Single Point Connection
For POD HW To Supply
Branch Lines
Waste Outlet For
Shower/Tub Drain To
Be Tied Into Waste/Vent
Risers
Waste/Vent Plumbing
Lines For Toilet &
Lavatory Fixtures
Waste/Vent Plumbing
Risers Constructed
Conventionally
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6) Electrical Overview
AmeriPod bathrooms include all of the lighting fixtures, switches, & receptacles found
in any regular bathroom unit, each wired for simple plug & play connections. Once
field connections are made, all lighting fixtures & receptacles will be immediately
ready for tenant use. Besides receptacle boxes, AmeriPod can also provide rough-in
for any low-voltage electrical devices such as fire alarms, strobes, nurse call boxes,
and intercoms.
A typical AmeriPod bathroom runs on two circuits and requires only two points of
connection for the on-site electrical contractor; one for the unit’s lighting fixtures and
one for its GFI receptacle. Connections are made at an accessible point above the
POD ceiling in a junction box ready for tie-in by the on-site electrical contractor.
Pulled Wiring For POD
Lighting Housed In An
Accessible Junction Box
For Tie-In
Pulled Wiring For GFCI Receptacle
Housed In An Accessible Junction
Box For Tie-In
Empty Junction Boxes & Conduit
Furnished For Low Voltage Specialty
Devices, Ready For Wire Pulls
AmeriPod accommodates any electrical rough in or receptacle installation on the
exterior of the Bathroom PODS for site installed electrical work, e.g. a duplex
receptacle is specified to be installed on the exterior wall of our POD.
All circuits, lighting, and receptacles are tested in our factory prior to delivery to site.
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7) HVAC Overview
AmeriPod bathrooms are furnished with either an exhaust fan or supply/return grilles
for ventilation depending on the project’s MEP design.
Exhaust fans are typically ceiling mounted, but can be also wall mounted when
dealing with restricting ceiling heights. Fans are secured to the panels & tied into the
bathroom lighting controls for use by the client once POD installation is complete.
Fan boxes are placed at an accessible location for tie-in into the main building
system with a simple flex duct connection.
Installed Exhaust
Fan, Tied Into POD
Switch, Ready For
Connection
Grilles are installed into the unit’s drywall ceiling with mounting brackets. Similar to
exhaust fans, grilles are placed at an accessible location for tie-in into the main
building system. Hard or flex ductwork is connected to the grille piece in the field by
the on-site mechanical contractor.
Typically only a single connection is required by on-site HVAC contractor to tie the
bathroom POD into the main building system.
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8) POD Subflooring
The only element of AmeriPod’s bathroom design that differs from conventional
construction lies in the POD subflooring. In order to fully enclose & finish our bathroom
POD structure for delivery & installation on-site, AmeriPod utilizes a thin-set plastic
composite honeycomb flooring system. Including a typical porcelain tile finish,
AmeriPod’s floor is only 1-1/4” thick, however still provides the strength & stability to
withstand transportation & handling in the field.
Since this composite honeycomb flooring system is so thin, AmeriPod bathroom PODS
typically do not require any type of slab recess for installation in the field. AmeriPod
bathrooms come furnished with a 1” custom door threshold that can create a
transition to comply with ADA requirements for most flooring types.
AmeriPod bathrooms can also provide a number of alternate assemblies for its
flooring design in order to conform to any project’s specifications. Our plastic
composite flooring system can be slopped to drain towards a center set or linear
trench drain.
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9) Testing & Inspection
AmeriPod bathrooms are factory tested & inspector friendly. From the onset of any
project, AmeriPod’s primary focus is quality construction & code compliance.
Prior to mass fabrication, AmeriPod will review shop drawings & submittals with local
inspectors to ensure officials are familiar with our product. Delivery & installation
logistics will also be reviewed so an inspection strategy can be developed.
During mass fabrication, PODs will be subject to a strict QA/QC inspection process
along each step of the production line. Inspection stickers are used to document the
process and are filled out by station supervisors. No POD can move onto the next
step of the production process without passing the QC inspection at the station prior.
AmeriPod utilizes an independent third party inspection agency to oversee the
QA/QC process & testing of the POD units.
Before shipment of a POD unit, AmeriPod will perform a final QA/QC inspection & test
the unit’s plumbing & electrical systems. Pressure tests will be performed on plumbing
supply lines, while air leakage tests will be performed on the waste/vent lines. All light
fixtures, switches, & receptacles will be tested to ensure they are all wired correctly
and ready for tenant use once hookups are complete.
Once POD units are staged in the building in a watertight area, protective wrapping
for POD shipment can be removed for field inspections to be performed. POD
framing on the exterior is open for inspections by the building department. Test
balloons can be placed on the fixture traps for pressure tests to be performed by the
local plumbing inspectors.
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10)
Transportation and Delivery
Depending on the project location & size of the bathroom units, AmeriPod can
transport PODs to the jobsite in a variety of methods:
Box-Truck
For projects relatively local to AmeriPod’s factory location in South Plainfield, NJ, the
preferred method of shipment is via an enclosed box truck. This method is both
economical & protects the PODs from the environment during shipment. PODs are
sealed in a medium gauged wrapping to protect the unit from construction activities
& movement of the unit in & out of the truck unit.
In order to ship via box truck the maximum POD Dimensions with wrapping and
blocking cannot exceed the following dimensions:
Gross Width = 96" (8'-0")
Gross Height = 102" (8'-6")
Depending on the length of the POD designed, 4-8 PODS can fit in a single truckload.
Flatbed Trucking
If your project’s bathroom exceeds
the maximum dimensions allowed by
a box truck, AmeriPod can also ship
units via flatbed trailer. Flatbed trailers
have less restricting dimensions and
can be specialized to allow for
shipment of units up to 8’-6” in width
and 10’-6” in height.
When shipping via flatbed trailer,
PODs will be covered with a heavier
gauge wrapping than needed in a
protected box truck to keep the units
safe from the elements.
AmeriPod performs a route survey &
logistics plan prior to mass production
of units to determine the best means
of transporting & delivering PODs.
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Train
For projects that are distant to AmeriPod’s South Plainfield facility or near a rail line,
PODs can also be shipped to the job site via train car. Our 120,000 SF facility is
conveniently located adjacent to a major line connected to New York City’s rail
system. From there PODs can be shipped to any location around the country.
Rail cars come in a variety of sizes for POD shipment and are a greener & more
economical method of transportation, particularly for distant project locations. Train
cars can typically carry more POD units than a regular box truck and leave much less
of a carbon footprint than shipment of the units over the road.
Bathrooms will arrive on site according to a pre-determined delivery schedule
designed to fit the needs of your project. PODS can be delivered all at once or
phased to be delivered as needed on a floor by floor or section by section basis.
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11)
Staging
AmeriPod bathrooms arrive on-site ready for staging directly from its delivery vehicle.
Depending on the project’s structural system & number of stories, bathroom units are
designed for top picking, side loading, or lifting into the building’s footprint.
AmeriPod will provide all equipment to prepare the units for staging; including all
lifting lugs, custom cradles for side loading, spreader bars, & adjustable casters.
Typically AmeriPod will utilize the project’s crane or lull to load bathroom units into the
building.
AmeriPod bathrooms are sealed with an industrial resin shrink wrap in our factory prior
to shipment. This wrap creates a water-tight barrier that protects the unit from any
damage during transportation or from surrounding construction activities once on
site. To prevent moisture from building on the inside of the POD once wrapped,
passive vents are installed onto the outside of the shrink wrapping, allowing the unit
to breathe and stay wrapped for a longer period of time.
Bathroom PODS are staged in the building at coordinated areas and can remain
there until plumbing & mechanical risers are complete and ready for POD tie-ins.
Adjustable casters allow the PODs to be relocated as needed to stay out of the way
of surrounding construction activities.
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12)
POD Installation / Final Connections
AmeriPod bathrooms are plug-and-play units, which makes installation similar to
hooking up a major appliance. Once units are set into place, only simple MEP
connections are required to make AmeriPod bathrooms a fully integrated part of
your building. AmeriPod units are typically designed to allow the room to remain
closed & locked during POD installation to protect interior finishes.
Step 1: Preparations are made to the floor slab to accommodate POD installation.
AmeriPod will provide a custom template for each bathroom layout to identify core
locations in the field. This template is a quick and extremely accurate way to
determine where floor outlets will be located underneath each bathroom unit. All
necessary leveling, access lines, & slab penetrations are to be provided by others,
unless specified otherwise, before PODs can be placed into their final location.
Step 2: Plumbing & mechanical risers are constructed as usual. All branch lines
outside of the bathroom area are also typically constructed. On the floor below the
cored holes, waste pipes are hung in place to prepare for POD connection. Ground
floor units will be hooked up in the same way, only the piping will be sleeved to allow
for final adjustments similar to convention construction.
Step 3: AmeriPod bathrooms are now ready to be set in place. A clean, clear, & level
path must be provided to for POD installation. The resin shrink wrapping is removed at
the bottom of the POD and the unit is rolled into its final location where cores have
already been made. AmeriPod will provide adjustable casters for moving POD units
into their final location. Casters are cranked down to lower the POD onto the slab.
Step 4: Once the bathroom is set, casters are removed and the POD is mechanically
fastened to the floor slab just like a piece of conventional framing track.
Step 5: All POD plumbing supply & waste lines are connected to the main building
system. Typically water supply connection points are made at a single accessible
point above the POD unit, while waste outlet connections are made from the floor
below or in a coordinated chase location.
Step 6: HVAC, & electrical hook-ups are made at an accessible, coordinated point
above the bathroom unit according to the site construction schedule.
Finishing The Exterior: AmeriPod units are delivered to the job site as open
construction, however once all MEP connections have been made & inspections are
completed, the exterior of the unit can be sheetrocked, taped, & finished like any
conventionally built room. Knee walls are constructed by the on-site carpenter where
required to complete fire-rated partitions to the bottom of slab above.
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