Build Pods draft manual by toby peterson

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DEDICATION We hope the users of this design manual will find it essential for a successful and complete integration of Pod Technology into their building project. We have listened to our customer’s questions (architects, engineers, general contractors and subcontractors) over the past 3 years and have answered them in CAD detail and/or narrative within the body of this manual. We truly appreciate and place high value on all questions in regards to our product. Acceptance of new innovations in the construction industry is slow and always comes with a perceived risk of trying something new; being the first. It’s much easier to take the path of least resistance and do it the same way as you have done it before; the status quo. This manual is dedicated to all of our customers from every AEC disciple that have embraced the POD product, concept and have persevered to use Pods on their projects; the innovators, the risk takers. The industry is stagnant and starving for innovation and advancement. Thanks for paving the way….

Special Thanks: Special thanks goes to Hornberger & Worstell Architects in San Francisco for donating their time for the development of the manual from an architect’s viewpoint. Mark Hornberger, Jack Worstell and Stephen Li all donated their time and talent towards the completion of the manual. Special thanks to Bruce Lavazzano, of Lavazzano plumbing of San Mateo for donating his time for the development of the manual from a “boots on the ground” plumbing perspective Special thanks to Charles Salter, Salter & Associates Acoustical Engineers for donating his time and talent towards the acoustical attributes of the Pod Concept. Special thanks to Kevin Menninger of Nishkian/Menninger for donating his time and talent towards the development and integration of the POD flooring system into all building structure types. Special thanks to Toby Petersen, a 4th year Cal Poly, San Luis Obispo Architectural Student for his listening, graphics and CAD skills to articulate all of our ideas into a graphic, architectural language form which became the backbone of the manual. 2

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Table Of Contents

General Overview: What are Pods? Buildpods - For Owners/Contractors/Architects Pod Design Pod Flexibility Pod Materials Pod Sustainability From Paper to Pod: Design Considerations Pod Installation Transport Considerations Integration Sequence Pod Technical Details Typical Floor Plan Layout/Plumbing Core Template Typical Pod Section Wall and Connection Details

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WHAT ARE PODS? The concept of quality, factory built assembly line products certainly isn’t new, Henry Ford did an admirable job of bringing the concept into the mainstream in the early 1900’s. In the AEC industry within the United States the concept of “factory built” components has mainly been limited to appliances, cabinets, electrical and HVAC integrated box components. In addition, there has been a tremendous advance in the development of sustainable building materials, energy monitoring and renewables in the recent wave of “green “building technologies. New technologies and ideas that improve quality/safety/schedule/price and reduce the overall embodied carbon content for a project within the built environment will win immediate acceptance within the AEC industry. So would you rather build a car in a parking lot or in factory? Unfortunately, most of the AEC industry operates under this operating principle. Bring the materials, labor, and equipment to the jobsite and then build the project in the winter and subject yourself to schedule delays, damage to finished product, labor shortages, perceived coordination, dimensional intolerance of finish tolerances, rework, punch lists, lots of CYA paperwork, and extra unnecessary but necessary costs of “building” on a jobsite. Welcome to building a car in a parking lot. A “Pod” is an assembly line, factory built room that is delivered to the jobsite in its final finished condition; much like a factory built car is delivered to a car dealership. The most popular forms of pods within the AEC industry are bathrooms and kitchens. The POD concept has been alive and well in Europe and Asia for over 20 Years. Although the US AEC industry has embraced some forms of factory Built assembly ( modular classrooms, mobile homes) the industry as a whole has been

slow to adapt to the idea of factory built units in the larger built environments of student housing, hospitality, healthcare, military and high rise residential projects. To meet the demand for the ever pressing need for greater predictability, efficiency and schedule reliability in construction, a high tech, easily deployable and dependable response is required. BuildPods LP offers an industry proven solution that meets market demands and design conditions for today’s competitive building market. Traditional means and methods of field finish construction for bathrooms and kitchens are compromised with dimensional trade intolerance, multiple punch lists, schedule and material delays and the huge inefficiencies of multiple trades working in a single area. As discussed in the previous “Build a car in a parking lot” analogy these means and methods lead to project delays and cost overruns. BuildPods provides practical, integrated solutions to the many challenges associated with field-built construction. With BuildPods factory built and building integrated PODs, every aspect of the building process can be automated in a factory environment. It is far easier to plan the work and the sequencing of materials in assembly line labor fashion in a factory built environment rather than the open and unpredictable confines of a project jobsite. BuildPods utilizes a quality-controlled, and fully integrated manufacturing process which insures the highest level of quality and dimensional consistency and accuracy.

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BUILDPODS: A PRODUCT FOR OWNERS / ARCHITECTS / GENERAL CONTRACTORS With Buildpods, you get a factory-built, quality-controlled, tested and finished room delivered to your jobsite. Every pod project is completed based on the OWNERS/ARCHITECTS design and finish specifications. Taking this into consideration, each Pod is constructed with the highest level of dimensional consistency allowing for complete integration into the building design. Pod designs are optimized and integrated into the Architects design to insure there is no compromise of loss of interior floor space. Field hook ups to the Building MEPS spine are plug and play and take only a fraction of time to complete in comparison to traditional field build construction; think of hooking up a giant dishwasher. Since the pod is delivered with exposed studs on the exterior side of the pod, there is no change to traditional wall close up and plumbing testing. No matter the type of project (housing, hospitality, healthcare) taking the rooms with the highest concentration of finish surfaces ( usually kitchens and bathrooms) out of the critical path will improve the overall schedule and put more focus of the building structure, skin and MEPS system schedule components. How much time saved will vary by project type and will translate into real $ saved on general conditions, worker parking, trade coordination, material escalation, punch lists, etc.

BuildPods is one of 3 leading manufacturer of factory built rooms in the United States approved by Turner Construction and Procurement. We differentiate ourselves from our competitors by using a fully integrated approach to incorporating the POD into the architecture without compromise in floor space and/or functionality of space. Whenever possible, we employ sustainable materials and processes that will contribute to 11 achievable LEED credits offered by the USGBC. The combined result of an integrated approach and a sustainable process is predictability in quality, cost, safety and schedule. Fragmented on-site construction of the rooms is eliminated and replaced with a 100% completed room ready for job-site fit up. BuildPods is advancing the United States built environment with and innovative and integrated approach to sustainable building that provides dramatic cost savings, faster delivery and improved quality. Quit the process of building a car in a parking lot; contact us today and find out how BuildPods can enhance your project.

The math is simple and the benefits are clear. Build Pods offers a higher quality product at competitive prices in a shorter, PREDICABLE time frame than traditional field built Construction. BuildPods integrated system approach for factory built rooms is ideally suited to meet the following traditional and emerging projects with repetitive “Pod” elements: •Housing (Student, Senior, Affordable, Luxury- Pod bathrooms & Kitchens) •Healthcare (patient rooms, patient bathrooms, exam rooms) •Hospitality (guest bathrooms) •Military Housing (BEQ, residential base housing- overseas and domestic) 7

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BUILDPOD DESIGN

THE BUILDPOD ADVANTAGE: DESIGN Now that you understand what pod construction is, let us tell you what buildpods offers. Buildpods provides distinct advantages to several aspects in your project including:

Flexible Deisgn Integrated Design Quality Materials Quality Construction Cost Savings

Integrated Pod

Build Pod

Flexible Design: The buildpod is meant to be a custom module that is deisgned by the owner and architect. Whatever the floor plan or character, you have the flexibility to design it into a pod. The buildpod envelope is optimized in order to maximize the interior usable space and amenities that the architect has programmed into the design. We will help you develop a modular unit that meets your programmatic, operational and aesthetic needs. Working in a design-assist fashion, Build Pods will work closely with the project team to insure the architect’s design intent is enhanced through the process. Throughout the POD design process, the overall efficiency and ergonomics of the space are optimized for the end user while the spines of the building (especially plumbing) don’t compromise the overall POD space planning. Please see the case study buildpod designs for the Hospitality, Military Housing and Health Care markets starting on page 16.

Integrated design of build pods take up less floor space giving you more unit area.

Area Difference = 7% (6.4 ft2) (.6 m2) Saved usable space in each unit using an integrated Pod

Non-Integrated Pod

Design Integration: BuildPods insures an integrated design with the Owners/ Architects space planning requirements. Common walls will not be doubled up for the sake of the pod; floor space is always a premium no matter what type of project you are building. Our integrated approach carefully considers space requirements first and foremost and integrates the pod into the space without compromise. Building code considerations also come into effect during the process. BuildPods will work with the Architect’s team to insure that the Pod design is optimum from a space planning perspective; all constraints (code & comfort) being considered.

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Other Pods

Larger pod footprint affects door clearances.

Other Pods

THE BUILDPOD ADVANTAGE: QUALITY MATERIALS AND CONSTRUCTION Buildpods provids factory fit quality and tolerance in the most critical, high use end user areas within any project; bathrooms and kitchens. Optimization of finish layout and placement reduces the need for cutting and modification of finish materials due to field inaccuracies and tolerances in level, plumb and line. Dimensional accuracy is superior when compared to what is achievable in traditional field built construction

THE BUILDPOD ADVANTAGE: COST SAVINGS Direct cost of pod end product may be cost neutral or lower than traditional means. See the cost analysis on the following page for a recent hospital project where the projected savings to the project was approximately 22%. For larger projects Manufacturer direct supply agreements can also contribute to savings. A breakdown of the possible savings is illustrated in the table below.

When performing a cost analysis on PODs vs traditional methods, itâ&#x20AC;&#x2122;s important to include savings on soft and hard cost items directly related to earlier completion (project general conditions, escalation, interest carry on construction loans). The project owner/client/developer should also consider the net cost benefit of getting the project to market sooner; project schedule is more predicable by using pods thus revenue for the project is collected earlier.

SAMPLE BUILD PODS FINANCIAL SAVINGS MODEL: OSHPD Hospital - California 288 Patient Bathrooms Build Pods Saves 22% over traditional field built bathrooms. Traditional Construction

Where are we saving?

Build Pods Cost Savings

Escalation Savings - Build Bathroom 12 months early

Productivity Savings - Less trade congestion on tower floors

Punch list/Trade Damage Savings

12% Direct Cost Savings 2%

* Completed by Herrerro Boldt Project team , MEPS trade partners and Build Pods Lp.

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Project General Conditions Savings * Soft cost savings and ability to open Hospital 2-4 weeks earlier not shown but should be anticipated in the overall Hospital proforma

SAMPLE BUILD PODS FINANCIAL SAVINGS MODEL: OSHPD Hospital - California Project: Location: General Contractor: Approximate Project Value: Prevailing Wage: Bathroom Quantity Bathroom Configuration/Location

Description

HospitalͲ OSHPD Downtown San Francisco, California Herrero Boldt $ 1,000,000,000 $99.50 Blended rate for all tradesͲUnion Wages in field and Factory 288 each Back to BackͲAdjacent to exterior Skin System StatusͲ Quo Field Built

Factory Built Pod Assembly Notes

Preconstruction WorkͲ Pods Shop drawings/Detailing Project Management Factory Supervision & Overhead Mock upsͲ Architectural Mock upsͲFabrication OSHPDͲ Shake table mock up OSHPDͲ Shake table testing OSHPDͲ Factory Inspections OSHPDͲField inspectionsͲ Tie in Structural engineering Fees Protection of work Removal of Protective wrap Structural work Structural Steel/Concrete work Erect Pods Exterior Enclosure Interiors Pods Sink vanity & Counter Door Drywall/Metal Studs Ceramic TileͲ FloorsͲMud set Ceramic TileͲ Walls Painted Ceilings Toilet Accessories Shower curtain & rack Fire Protection Mechanical Plumbing Electrical

see below 144,000 576,000 5,173,344 494,208 1,244,160 15,120 1,008,000 57,600 115,200 125,000 12,221,653 540,000

Subtotal Direct Costs:

22,546,285 19,928,574

General Requirements General Conditions Savings Man lift Duration Savings Tower Crane Extended Time Trade Congestion Savings @ Tower Level Punch List/Trade Damage Savings Parking Savings Subtotal General Requirements Savings: Estimated escalation savings Labor Material Subtotal Escalation Savings:

N/A N/A N/A N/A 65,000 N/A N/A N/A N/A N/A N/A 288,000 N/A

123,000 148,000 393,000 175,000 65,000 130,000 65,000 40,000 87,000 144,000 32,000 19,000 85,000

Integration work with Project Team Detailing/Shop drawings/Material/Submittals Project Management for 2.5 yearsͲ OSHPD Supervision of General Contractors Union Trades in Factory Project Requirement Coordination Mock up with MEPS Subcontractors Per OSHPD Per OSHPD 3rd Party Special Inspections Site inspection of Pod Tie ins to MEPS systems Misc Fees for POD integration into structure Pods are factory sealedͲ protection of in place work is minimal Removal by General Contractor

479,000 152,248 Pod design included structural floor system; added amount for Pods 279,360 Pods erected with Structural Steel Frame; includes added crane & erection time N/A 545,000 Misc labor costs for working around PODs @ exterior aluminum framing system Ͳ 12,089,180 included included 1,787,904 included included included included included included 63,000 3,505,882 included

Factory Built and delivered price using UNION labor and specified finishes

Metal Stud/Drywall integration around Pod

Sprinkler head and branch Line included in POD Register included in Pod price Vertical riser piping and infrastructure for pod connection All in wall electrical included within pod; precut whips included to J box.

(250,000) Although structural schedule is longer by 2 weeks; 4 weeks are saved in project schedule. (50,000) 1/2 month of man lift savings 105,000 Added tower crane time during steel erection. (800,000) 8,000 man hours saved at tower levels due to less trade congestion (216,000) Pods are preͲpunched at factory (300,000) 12,000 man days saved at $25/dayͲ less trips to jobsite 0 (1,511,000)

(308,000) $22M= cost of traditional built bathroom; pre built ;12 month savings (440,000) $22M= cost of traditional built bathroom; pre built ;12 month savings 0 (748,000) Ͳ

GRANDTOTAL: $/BATHROOM: TOTAL SAVINGS TO PROJECT SAVINGS/BATHROOM % SAVINGS PER BATHROOM

$ 22,546,285 $ 17,669,574 $ 78,286 $ 61,353 $ 4,876,711 $ 16,933 22%

* Study completed by Herrerro/Bolt Project Team including MEPS trade partners and Build Pods LP

THE BUILDPOD ADVANTAGE: SUSTAINABILITY By the very nature of the factory built process; Pods are natural fit for the green building process. Through the factory built process “natural” green benefits are achieved at every process step in the assembly line: •Less Construction Waste in factory when compared to jobsite •Less trips by workers and material delivery operations equals less carbon emitted into atmosphere; less embodied carbon content for the project.

LIGHTING CONTROL - Occupancy Sensors - LED and CFL Fixtures - Dimmers - LEED Credits EQ 6.1

RAPIDLY RENEWABLE MATERIALS - Cabinetry - Flooring - Insulation - LEED Credit MR6

REGIONAL MATERIALS - Fabricated and assembled locally within a 500 mile radius - LEED Credit MR 5.1 and 5.2

INNOVATION IN DESIGN - By Nature, Pods are innovative - LEED Credit ID1.1 - 1.4

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As specified by the Owner, Architect, Pods can be designed to incorporate sustainable materials and practices as determined by various agencies: •United States Green Building Council- USGBC Pods can contribute up to 11 LEED credits www.usgbc.com •Green Guide for Healthcare- GGHC www.gghc.org •International Green Construction Code- IGCC www.iccsafe.org •Green Globe Certification : GGC www.greenglobecertification.com

INDOOR AIR QUALITY -Offgassing of products occur before pod is delivered to jobsite. - Low VOC Emitting Materials can be specified - LEED Credits EQ3.1, EQ3.2, EQ4.1 and EQ 4.2

WATER EFFICIENCY - Dual Flush Toilet - Low-Flow Shower Head - Can be plumbed for Grey Water system - Low Flow Sink Faucet - LEED Credits: WE2, WE3.1 and WE 3.2

RECYCLED CONTENT - All Finish Surfaces can be specified for rapidly renewable or recycled content: - Floor Tile - Walls - Wall Coverings - Countertops - Cabinets - LEED Credits MR4.1 and MR 4.2

ACHIEVABLE LEED CREDITS USING BUILDPODS TECHNOLOGY WE2 - Water Efficiency - Innovative Wastewater Technologies

EQ3.1 - Construction IAQ Management Plan - During Construction

Owner may specify high efficiency plumbing fixtures and consider a gray water system to reduce wastewater volumes; ideas that can be easily implemented into the POD framework.

Since PODs are delivered to the jobsite in a factory sealed envelope, material pollutant sources are controlled and contamination pathways are interrupted. By nature, POD construction sequences installation to avoid contamination of absorptive materials such as insulation, gypsum board and ceramic tile cutting. PODs can be easily written and implemented into any Construction IAQ plan and help achieve a LEED credit in this category.

WE3.1, 3.2 - Water Use Reduction - 20%, 30% Owner may specify high efficiency plumbing fixtures and occupancy sensors to reduce potable water demand; ideas that can be easily implemented into the POD framework. POD bathrooms will be a significant contribution towards achieving this LEED credit. MR4.1, 4.2 - Recycled Content - 10%/20% (post consumer + Â˝ pre consumer) Owner may specify recycled content materials and identify material suppliers that can achieve this goal. There are emerging technologies in ceramic tile and drywall industries that can contribute towards this LEED credit. Metal studs, metal decking, misc iron and concrete all have a recycled component; all of which are components of the standard POD platform and chassis. MR5.1, 5.2 - Regional Materials - 10%/20% processed & manufactured regionally

EQ3.2 - Construction IAQ Management Plan - Before Occupancy Since PODs are delivered to the jobsite ahead of a normal construction sequence, off gassing of POD materials occurs earlier, thus contributing towards a cleaner result for air quality testing. EQ4.1, 4.2 - Low Emitting Materials - Adhesives, sealants, paints, coatings Owner may specify low emitting primers, paint, caulking and waterproofing systems within the interior of the POD that can help contribute to the LEED point for this credit. EQ6.1 - Controlability of Systems - Lighting

Owner may specify building products, materials and manufactured assemblies to be manufactured within 500 miles of the project site. Our factory, located within the San Francisco greater bay area, will be able to serve most of Ownerâ&#x20AC;&#x2122;s market within California. PODs manufactured from this location will contribute towards achieving this LEED credit for the project.

Owner may specify occupancy sensors in all POD bathrooms as a sub component of the building lighting control system that can help contribute to the LEED point for this credit.

MR6 - Rapidly Renewable Materials - 2.5% of total value of all building materials

By nature, the POD product is unique and innovative by design. The design approach and strategies used in POD construction can be categorized as exceptional performance in the LEED rating system.

Although this credit is difficult to achieve, Owner may specify bamboo or wheat board cabinetry, linoleum flooring, and cotton batt insulation for POD construction. Selection of materials must be balanced with first cost and life cycle costs.

ID1.1, 1.4 - Innovation

ID2 - LEED Accredited Professional - BuildPods By selecting BuildPods as a factory built bathroom supplier and a principal participant of the building team, this LEED credit will be achievable for any new project Owner decides to build. 50% of our founding members are LEED Accredited Professionals. 15

Corridor Side

B Mechanical Shaft 2

Overall Pod Length

Pod w/ Tub

Pod w/ Shower (Optional Accessible Design)

5 10

Unit Side

Overall Pod Width

Floor Plan: Typical back-to-back pod bathroom

DESIGN FLEXIBILITY FOR ANY MARKET Hospitality: The Guestroom Bath The hospitality market is a prime candidate for implementing the Buildpodâ&#x20AC;&#x2122;s concept. Whether for the high end luxury market or for the economic budget traveler, a hotel guestroom program provides the perfect frame work for incorporating well-built, durable, repetitive modular units. Buildpods provides a flexible and scalable design structure that can accommodate custom layout designs that fit your needs. Every pod is designed to be durable, easy to maintain and seamless with the rest of the building design. Whether the countertop will made from Italian marble or a laminate veneer, finish materials are installed per your specifications. Pods can even be built for ADA accessibility when specified. 16

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Optional removable ceilings alow relxibility of finishes and installation sequence. The following case study offers a pair of typical hotel guestroom bath layouts in a back-to-back orientation. Using a shared shaft offers additional time and cost savings during construction. Pods for various other markets have been developed and share very similar detailing as is shown here. Further construction assembly and integration details can be found at the back of the manual in the Technical Details section.

1 8

10 4

Section a-a: Back to Back units

LEGEND 1 Full height Tile Walls

2 Shower/Tub Enclosure and Fixtures 3

Mirror

4 Dual Flush Toilet 5 Built-In Millwork / Glass Storage Unit 6 Removable Ceiling / Plenumn (Optional)

7 2

7 Custom Vanity and Countertop 8 Decorative Light Fixtures

Section B-B: Typical pod bathroom

9 Barn Door 17

10 Towel Bars and Other Misc Accessories C

Floor Plan: Typical back-to-back pod bathroom

DESIGN FLEXIBILITY FOR ANY MARKET US Military Housing: BEQ (Bachelor Enlisted Quarters) The very nature of the military barracks style housing or permanent base housing is another natural fit for the POD product. As our men and women depart and arrive back from their missions, temporary and permanent housing will be required at home and abroad. The BEQ ( Bachelor Enlisted Quarters are simple, repetitive structures that are a perfect match for the POD concept. Structures are typically load bearing block wall and metal decking with concrete fill for the floor assembly. Top down placement of the pods ( for plumbing hookup) is required if load bearing party and corridor walls are to remain interrupted ( floor to deck). Combination BEQ PODS ( Bathroom and 18

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small kitchen) can also be designed per the specifications of the Military entity soliciting the proposal for the project. For larger projects abroad, an onsite factory assembly process can be implemented when the use of local labor forces is required. Please review our transportation section of the manual for limitations of shipping PODS in standard shipping containers.

Section a-a: Back to Back units

Section B-B: Typical pod bathroom 19

Floor Plan: Typical back-to-back pod bathroom

DESIGN FLEXIBILITY FOR ANY MARKET Health Care: Patient Care rooms With the continual rise of healthcare costs; the life cycle costs of hospital operations are subject to an increased amount of scrutiny from the government, healthcare providers and the patients; the general public. There are many forms of reform; but the one that touches our AEC industry the most is the first cost and life cycle costs of designing and building a hospital. As an example, it takes about 8 years to design and build a hospital. Just factoring in escalation for 8 years in the first cost can be a challenge to get the project to pencil in current $. Plus, there is still allot of unpredictability of where health care reform will end up.

Some of the larger Health care providers have recognized that they need to build a better mouse trap; one that is very predictable and provides better patient care at an overall lower

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cost. Most have developed or are in the midst of developing standardized patient room layouts and floor plans that are â&#x20AC;&#x153;cookie cutterâ&#x20AC;? type and are thus very predictable in schedule and cost. BuildPods fits the bill for this order. Hospital Pods can be delivered in a variety of layouts and configurations; the most common being back to back units. Pods can include structural floors or can be configured to set in a slab depression depending upon shower drain requirements. In a hospital, first cost savings can be substantial compared to traditional means. Please see our cost comparison section of this manual for an example cost savings.

Section a-a: Back to Back units

Section B-B: Typical pod bathroom 21

POD WIDTH

8” CLR BOTTOM OF SLAB TO TOP OF POD

FUTURE UNIT

F.F.

9’-2” FLR. TO FLR.

F.F.

8’-0" MAX POD HT.

BuildPod

7’-6” INTERIOR CLG. HT.

8” SLAB

FUTURE CORRIDOR

Typical Concrete Structure Diagram for Residential / Hospitality (Dimensions vary based on project and are shown for reference only)

FUTURE UNIT

F.F.

FUTURE CORRIDOR

Typical Steel Frame Structure Diagram for Residential / Hospitality (Dimensions vary based on project and are shown for reference only)

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10’-4” FLR. TO FLR.

F.F.

8’-0" MAX POD HT.

9’-6” BED/UNIT

BuildPod

7’-6” INTERIOR CLG. HT.

12” CLR BOTTOM OF BEAM TO TOP OF POD 12” TYP. BEAM DEPTH 4” SLAB (CONC ON MTL DECK

POD WIDTH

FROM PAPER TO POD: ADDITIONAL DESIGN CONSIDERATIONS When incorporating Buildpods into your project there are several factors in addition to finishes and aesthetics that your design should consider prior to fabrication:

Building Structure

MEP Penetrations and Shaft Locations

BuildPods are designed for installation in many different building structures,including wood, light-gauge steel,structural concrete, pre-cast concrete, and structural steel. The building structure is usually erected prior to the pod placement. Where it makes sense to do so in structural steel buildings, pods can be erected concurrent with steel erection provide they have an integral structural floor system (optional with buildpods designs). Make sure the buildpods are coordinated to fit and positioned within the structural system. Clearance beneath beams and other structural elements should be considered when designing your pod. Buildpods can be designed to work within tight floor-to-floor heights, as allowable by code, helping you maximize the number of floors within the allowable building height.

Buildpod Size Your Pod design can be of any size and shape. Since pods are factory built, they will be transported, hosited and positioned into place. Shipping and trucking rates vary based on the size of the cargo. Although not limited, Buildpods recommends the following starting design criteria as guidelines to maintain cost effective pod design. Pod Width

8’-6”

Pod Depth

7’-6 to12’-0”

Pod Height

8’-0” (7’-6” interior height) height varies based on building type

Optimizing utility connections and risers is a standard design guideline in any design. The same applies to prefabricated bathrooms. Consolidating utility connections to a set of shared risers minimizes coordination, field hook up labor and materials. Providing back-to-back bathroom configurations for the pods will add to the cost savings. Buildpods will provide a template for all plumbing riser and required pod floor penetrations. For and example, see page ___ for a template. If designed properly, these factors will help you optimize your cost savings when integrating Buildpods. Our team is available every step of the design process to make sure that your Buildpod design considers these factors and will integrate into your building as effectively as possible. The tables on the following pages outline some of basic design criteria for different building structures and applicable markets for Buildpods pre-fabricated bathrooms.

FROM PAPER TO POD: DESIGN CONSIDERATIONS BY BUILDING TYPE

HOSPITALITY BUILDINGS Floor Floor Floor Assembly Assembly Assembly STC Thickness Rating rating

Structural System

IBC

Domestic Container Finish Shipping Shipping Ceiling Max Pod Max Pod Height Height Height

Notes

Structural Concrete Structural Steel

9’-00” 10’-4”

8” 24”

8’-4” 8’-4”

7’-10” 7’-10”

7’-6” 7’-6”

Conxtech

9’-10”

18”

8’-4”

8’-00”

7’-6”

Assume 16” Deep beams; 1 1/2” B deck ; 2 1/2”lightweight concrete fill;1 1/2 Resiliant Channel + 5/8” rock; Height governed by trucking regulations.

Wood Frame

10’-2”

18”

8’-8”

8’-00”

7’-6”

Load Bearing Metal Studs

10’-2”

18”

8’-8”

8’-00”

7’-6”

Assume 12” TGI joists ; 1 1/4”T&G ; 2”gypcrete;1 1/2” Resiliant Channel + 2 layers 5/8” rock; Height governed by trucking regulations. Assume 12” metal joists ; 1 1/4”T&G ; 2”gypcrete;1 1/2” Resiliant Channel + 2 layers 5/8” rock; Height governed by trucking regulations.

Assume 16” Deep beams; 1/2” fireproofing; 1 1/2” B deck ; 2 1/2”lightweight concrete fill;1 1/2 Resiliant Channel + 5/8” rock; Height governed by trucking regulations

RESIDENTIAL Floor Floor Floor Assembly Assembly Assembly STC Thickness Rating rating

Structural System

IBC

Domestic Container Finish Shipping Shipping Ceiling Max Pod Max Pod Height Height Height

Structural Concrete Conxtech

9’-00” 9’-10”

8” 18”

8’-4” 8’-4”

7’-10” 8’-00”

7’-6” 7’-6”

Wood Frame

10’-2”

18”

8’-8”

8’-00”

7’-6”

Load Bearing Metal Studs

10’-2”

18”

8’-8”

8’-00”

7’-6”

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Notes Assume 16” Deep beams; 1 1/2” B deck ; 2 1/2”lightweight concrete fill;1 1/2 Resiliant Channel + 5/8” rock; Height governed by trucking regulations. Assume 12” TGI joists ; 1 1/4”T&G ; 2”gypcrete;1 1/2” Resiliant Channel + 2 layers 5/8” rock; Height governed by trucking regulations. Assume 12” metal joists ; 1 1/4”T&G ; 2”gypcrete;1 1/2” Resiliant Channel + 2 layers 5/8” rock; Height governed by trucking regulations.

MILITARY HOUSING ( BEQ) Floor Floor Floor Assembly Assembly Assembly STC Thickness Rating rating

Structural System

IBC

Domestic Container Finish Shipping Shipping Ceiling Max Pod Max Pod Height Height Height

Structural Concrete Conxtech

9’-00” 10’-2”

8” 18”

8’-4” 8’-4”

7’-10” 8’-00”

7’-6” 7’-6”

Wood Frame

10’-2”

18”

8’-8”

8’-00”

7’-6”

Load Bearing Metal Studs

10’-2”

18”

8’-8”

8’-00”

7’-6”

Structural Block Wall with Metal decking

HOSPITAL

Floor Assembly Thickness

Structural System

Floor

Domestic Container IBC Finish Shipping Shipping Building Ceiling Max Pod Max Pod Type Height Height Height

Notes

Structural Concrete 15’-00”

10”

9’-00”

8’-00”

7’-6”

POD Height Governed by Shipping regulations

Structural Steel

15’-00”

38”

8’-4”

7’-10”

7’-6”

Assume 30” Deep beams; 3” Metal deck; 3 Concrete fill; 2” Fireproofing; POD Height governed by trucking regulations

Conxtech

15’-00”

38”

8’-4”

8’-00”

7’-6”

Assume 30” Deep beams; 3” Metal deck; 3 Concrete fill; 2” Fireproofing; POD Height governed by trucking regulations

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POD INSTALLATION

FROM THE FACTORY TO THE SITE : TRANSPORT All Buildpod pods are manufactured in a controlled factory environment to ensure high quality construction in each pod. The pods are built, tested, inspected and even punch listed prior to delivery to your job site. This allows for better quality construction, higher finishing standards and improved dimensional accuracy and tolerances. With Buildpods, you get a bathroom superior to a traditional field built product. After inspection approval, each pod is secured to cargo pallet for shipping purposes and then wrapped for protection during storage, delivery and placement. Pods can be shipped anywhere throughout the North America and even overseas. Every pod project is designed with the shipping restrictions in mind. Typically, for domestic projects, pods will be transported onto an air-ride suspension equipped long-bed truck. Shipping containers will be used for overseas projects. For some projects, depending on scale and location, it may be more cost effective to establish an on-site pod factory. The following tables represent some of the shipping restrictions for domestic trucking and overseas shipping to consider.

54'-0"MAX

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DOMESTIC SHIPPING (IMPERIAL UNITS) POD MAX WIDTH IN FEET* MAXLOAD LENGTH IN FEET: ALLOWANCE FOR SPACE BETWEEN PODS (for dunnage): OVERALL POD LENGTH IN FEET:

8’-6” 54’-0” 6” 7’

7’-6”

8’

8’-6”

MAXIMUM POD QUANTITY- ONE 7 6 6 6 TRUCK: *Width Limitations: - Standard permit: POD assumed to be under 8’-6” out to out dimension - Width over 8’-6” under 12’-00” extra permits required for each state - Width over 12’-00” to 14’-00” pilot car required - Width over 14’-00” highway patrol escorts and pilot car required

9’

9’-6”

10’

10’-6”

11’

11’-6”

12’

12’-6”

DOMESTIC SHIPPING (METRIC UNITS) POD MAX WIDTH IN MM*

2,591

MAXLOAD LENGTH IN MM: 16,459 ALLOWANCE FOR SPACE BETWEEN 152 PODS IN MM (for dunnage): OVERALL POD LENGTH IN MM:

2,134

mm mm mm 2,286 2,438 2,591 2,743 2,896 3,048 3,200 3,353 3,505 3,658 3,810

MAXIMUM POD QUANTITY- ONE 7 6 6 6 5 TRUCK: *Width Limitations: - Standard permit: POD assumed to be under 2,590 mm out to out dimension. - Width over 2,590 mm under 3,658 mm extra permits required for each state - Width over 3,658mm to 4,267 mm pilot car required - Width over 4,267 mm highway patrol escorts and pilot car required

54'-0" MAX

FROM THE FACTORY TO THE SITE : TRANSPORT

OVERSEAS SHIPPING (IMPERIAL UNITS) POD MAX WIDTH IN FEET: MAXLOAD LENGTH IN FEET: ALLOWANCE FOR SPACE BETWEEN PODS:

7’-9” 38’-0” 6”

OVERALL POD LENGTH IN FEET:

7.5

8.5

9.5

10.5

11.5

12.5

MAXIMUM POD QUANTITY- ONE CONTAINER:

OVERSEAS SHIPPING (METRIC UNITS) 2,387 MAXLOAD LENGTH IN MM: 11,582 POD MAX WIDTH IN MM:

ALLOWANCE FOR SPACE BETWEEN PODS IN MM: OVERALL POD LENGTH IN MM: MAXIMUM POD QUANTITY- ONE CONTAINER:

152 2,134

mm mm mm 2,286 2,438 2,591 2,743 2,896 3,048 3,200 3,353 3,505 3,658 3,810

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TYPICAL INSTALLATION PROCESS Buildpods 7 Steps Although a new process to most general contractors, incoporating a buildpod into your project is easy. The pod concept is designed to deliver a fully finished bathroom that can be folded into the rest of the construction sequence. Since the Buildpod comes to your site, packaged and ready for placement, the general contractor can install them into the building immediately. For ever buildpod installation, the sequence can be summarized in 7 simple steps:

1. Layout Coordination 2. Pod Placement 3. Connecting the Pod 4. Inspection 5. Integration into Wall System 6. Close the Building Envelope 7. Repeat The following pages describe these steps in detail and illustrates a typical buildpod installation process. To help understand what is required for the installation, the graphics have been color coded to highlight what is provided by Buildpods and what is provided by the general contractor. Further detail is provided in our technical package at the back of this manual. The Buildpods team will work with you to understand how the pod will fit the building type and construction sequence. The following table below, gives you a general idea of when the pod should be integrating into the building based on construction type.

Pod Installation Guidelines ERECT WITH STRUCTURE

STRUCTURE Concrete

ERECT BEFORE BUILDING SKIN

Yes

Steel

Optional structural floor

Yes

ConXtech

Optional structural floor

Yes

Wood

Yes

Load Bearing Metal Stud

Yes

Structural Block with Metal Deck

Yes

INTEGRATING BUILDPODS INTO YOUR BUILDING: THE 7 STEPS IN DETAIL 1. LAYOUT COORINDATION: As Buildpod assembles each modular bathroom/ kitchenette in a factory, the infrastructure for the building is being erected at the job site. As each structural floor is constructed, block outs and cores for the mechanical, plumbing, sprinkler risers and drains can be coordinated and planned out on the job site using a project specific Buildpods layout template (provided by Buildpods). Depending on the construction schedule, the pods can be delivered to the site for installation as each floor is completed, or prior to the building envelope is started. The pod can also be stored on site till it is ready to be hoisted into place 2. POD PLACEMENT: Each pod is wrapped in protective covering after being tested and inspected in the factory prior to delivery. All finishes, fixtures, accessories and utility branch supply and waste lines are completely installed in the pod upon delivery. A Buildpods “kit of parts” is provided for the general contractor which includes items for pod integration such as, an acoustic sound pad, factory-cut plumbing connections, pre-cut electrical whip (optional) and pre-cut metal stud and track connections.

• Larger sizes can be accomodated but accrue additional shipping fees. • Pod erection sequence varies depending on strucutre type and schedule requirements of general contractor/owner.

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The pod is delivered ready to be integrated into the building structure. First, using air sled equipment, the pod is properly positioned over a pre-cut acoustic membrane and lowered to match the block-outs and cores pre-set using the Buildpods template.

1. Layout Coordination

2. Placement

POD READY TO INSTALL

SANITARY RISER HW RISER CW RISER VENT RISER

AIRSLED MOVING EQUIPMENT PROVIDED BY BUILD PODS OPTIONAL CEILING PANELS REMOVED

BUILDPODS PROVIDED TEMPLATE 33 Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed

TYPICAL INSTALLATION PROCESS Integrating Buildpods into your Building 3. CONNECTING THE POD: After placement, Buildpods or the general contractor secures the pod to the structural floor slab using traditional attachments. From the pod or room below, horizontal branch plumbing lines are connected to the main supply, waste and vent risers by the contractor. The electrical system is completely pre-wired, including a pre-cut whip connected into a sub-panel or J-box by the electrical contractor. Ceiling fans are integrated into the pod and only require flex connections back to the duct in the shaft. An optional removable ceiling panel system in every pod allows for full access to the MEP lines for installation and future maintenance. 4. INSPECTION The pod is “pre-rocked” on the interior side with GP Densglas (or similar) and is open to the other (shaft, unit, and corridor) sides. Once the MEP connections are completed and fire sealed, the systems are ready for local building inspectors to review the installation. 5. INTEGRATION INTO WALL SYSTEM After inspection is complete, the pods can be “closed up” on all sides. Each Buildpod is specifically designed to facilitate the proper rated construction as required . The wall construction will continue to the underside of the structural slab. In most cases, the general contractor will only need to provide insulation and apply a layer of gypsum board to each wall to complete its rated construction. MEP penetrations will be sealed as required. For additional information, a series of typical details can be referenced on page ____

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3. CONNECTING THE POD 4. INSPECTION

Concurrent Installation of Pod Above Can Start

5. INTEGRATION INTO WALL SYSTEM: Framing

5. INTEGRATION INTO WALL SYSTEM: Gypsum Wall Board

Continued Work Above

35 Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed

TYPICAL INSTALLATION PROCESS Integrating Buildpods into your Building 6. CLOSE THE BUILDING ENVELOPE After the exterior pod walls have been inserted, framed and rocked, the building envelope and the rest of the unit are finished out with less trade congestion. The pod is now a fully finished bathroom unit integrated seamlessly into the building; the door is locked and controlled by the general contractor. Pods can be integrated into each completed structural floor slab as the building structure continues to rise, maximizing efficiency and shortening the project schedule.

7. REPEAT FOR THE NEXT POD There are various ways to install a Buildpod bathroom. Depending on the building type and structure and the schedule, pods can be integrated several floors at a time, using top down, while the building is being erected and others. See the table on the adjacent page for a brief overview. Buildpods will guide you through the process and you can select the best means to incoporate a Buildpod into your next project.

6. CLOSE THE BUILDING ENVELOPE 7. REPEAT FOR THE NEXT POD

POD READY TO INSTALL

BUILDING ENCLOSURE FOLLOWS POD INSTALLATION

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Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed

General Notes: 1. Due to shipping, pod positioning and waste line connections, the toilet, although included, will not come preinstalled.

The pod construction will be designed and incorporated at the factory for each layout. The rated construction required may vary based on local building codes and wall-to-wall conditions.

Please review our detail library on page ______

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TECHNICAL DETAILS

Pod Unit

Corridor

Mech Shaft

Pod Unit

Unit

Corridor

Pod B

1-hour wall Build Pods provided

Shaft Unit Pod A

2-hour wall

Build Pods provided, Contractor installed Contractor provided, Contractor installed 40

typical pod wall construction plan

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non-rated Diagram: Rated Wall Construction

Rated wall infill beyond (contractor provided)

Unit Dwelling

contractor to provide 2-hour rated shaft wall

Pod Unit

Mech Shaft

Corridor

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed

typical pod section C

varies

2” cw 6” toilet

18” @ ada compliant guestrooms

6” trench drain

6” cw

2” hw

2” cw

hw cw 6” hwr

4”

Shaft

hw cw

2” hw

2” cw

6” hw

6” tub

hw/cw stubs by build pods; field connection to risers by contractor

6” toilet

factory cut plumbing waste lines, tie in by contractor 18” @ ada compliant guestrooms

2” cw

varies

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed

• Contractors have option to can deck prior to concrete pour OR cure deck after concrete pour (concrete fill over metal deck). • Can sizes are actual size; for piping size see plumbing isometric. Plumbing risers by contractor associated fire caulking.

coring/can template for MEP penetrations

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waste varies 2”-3” pipe

sh 2”

tub

waste varies average 2”-4” pipe

2”

4” 3”

3” 2” 3”

3” vent varies 2”-3” pipe

vent varies average 3”-4” pipe

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed

plumbing isometric diagram

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This technical detail package illustrates the materials involved in integrating a Buildpod into your building. Color coded drawings have been provided highlighting materials that are either: -Buildpod Installed -Provided by Buildpods, Contractor Installed -Contractor Installed

Materials List 1

¾” Composite Ductal Concrete Floor

3/8” Ceramic Tile over Thinset Latex Mortar (as specified) or Marble Stone over Reinforced Mortar Bed (as specified)

8” Reinforced Concrete Structural Slab

Reinforced Concrete Decking

Double Stud Curb Form, welded to sheet metal

12ga Sheet Metal

Galvalume Tube (or similar)

Carpet Pad and Finish Carpet

Pre-Cut 1/8” Acoustical Mat

Waterproof Membrane

Custom Cast Iron Floor Drain (Trench Drain where shown)

5/8” Coated Glass Mat Gypsum Backer Board

5/8” Type-X Gypsum Board

1” Shaft Wall Liner

Metal Stud Framing (20ga Dimpled Studs, 16” o.c.)

Continuous Ledger

Sheet Metal Backing

Batt Insulation (Contractor Provided) Note: Furnished and installed by contractor prior to positioning of pod.)

Compressed Mineral Wool Batt Insulation or approved Firestop System

Continuous Flexible Acoustical Sealant (both sides)

Continuous Fire Stop Sealant (both sides) at rated partitions

Door Frame / Trim

Solid Stone or Tile Threshold

Cast Iron Tub (as specified by Architect)

3/8” Tempered Glass Shower/Tub Enclosure (optional)

Removable Ceiling Panels (Optional)

Vented Ceiling Track

2-hour rated shaft wall

Mechanical Shaft

2-hour rated shaft wall (Recommended STC Rating 50-54)

Shower Valve

Typical 15

2-Layers 12

12 18

Pod Shower

1-hour rated partition (Recommended STC Rating 50-54)

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed 46

detail a: pod wall at mech shaft and shower valve (plan view)

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Pod B

Plumbing Chase

13 2-Layers 19

2x Mtl Clips

Mechanical Shaft 18 12 1-hour rated chase partition (Recommended STC Rating 50-54)

2-hour rated shaft wall (Recommended STC Rating 50-54)

Typical 15

Pod A 2-Layers 12

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed

detail b: pod wall shaft infill at back-to-back pod (plan view) C

Unit B 13

Plumbing Chase

2x Mtl Clips

19 1-hour rated partition (Recommended STC Rating 50-54) 15

Unit A 12 Optional Built-in Shelving

Pod A

detail c: pod wall infill back to back pod wall connection (plan view)

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Pod

1-hour rated partition (Recommended STC Rating 50-54) 18

Corridor

1-hour rated partition (Recommended STC Rating 50-54)

Unit

Set back of partition varies based on floor plans

detail d: wall construction @ corridor (plan view) C

partition wall, (rated where req’d) (Recmd STC Rating 50-54) 2 10 12

Pod Shower

Unit / Corridor 18

coved base

13 base as specified

concrete fill sloped to drain

1 6

overlap waterproof membrane min 6”

15 7 20 21

slope to drain 1/4” per foot min.

9 3 or 4

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed 50

detail e: section at shower trench drain

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2 10 12 20 16 17

24 2-layers

6 9

15 7 21

3 or 4

15 Pre-Cut Metal Tracks provided by Buildpods installed by contractor

18 13 2-layers 14

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed

detail f: detail at tub drain C

Pre-Cut Metal Tracks provided by Buildpods but installed by contractor

3 or 4 21 18 15

2-layers 13

14 27 26

Mechanical Shaft

2 10

Pod

2-layers 12 partition wall, (rated where reqâ&#x20AC;&#x2122;d) (Recmd STC Rating 50-54)

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed 52

detail g: section at typical 2-hour rated wall w/ removable ceiling

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Pod 2

1-hour rated partition wall, (Recommended STC Rating 50-54) 18

12 15

Corridor

7 21

1 6

3 or 4

Pre-Cut Metal Tracks provided by Buildpods but installed by contractor

Pod

1-hour rated partition wall, (Recommended STC Rating 50-54)

Corridor

ceiling where occurs

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed

detail h: 1-hr rated interior wall C

Pod

2-hour rated shaft wall, (Recommended STC Rating 50-54)

2 12 2-layers 15

18 14

7 21

1 6

3 or 4

18 13

2-layers

Pod ceiling where occurs

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed 54

detail i: section at 2-hr shaft podwall

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14 15

Pre-Cut Metal Tracks provided by Buildpods but installed by contractor

2-hour rated shaft wall, (Recommended STC Rating 50-54)

Pod

Pod Plumbing Chase 1-hour rated chase partition (Recommended STC Rating 50-54)

2 12 15

Plumbing risers, where occur. Set by contractor prior to placement of pods.

7 1 6 9

3 or 4

21 15

18 13

Pre-Cut Metal Tracks provided by Buildpods but installed by contractor

1-hour rated chase partition (Recommended STC Rating 50-54)

ceiling where occurs

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed

detail j: plumbing chase wall section at back-to-back pods C

Pod Shower

2-hour rated partition wall, (Recommended STC Rating 50-54)

2 12 2-layers

overlap waterproof membrane min 6â&#x20AC;?

15 7 1 6 9

Mechanical Shaft

slope to drain 1/4â&#x20AC;? per foot min.

3 or 4

21 2-hour rated partition wall, (Recommended STC Rating 50-54)

Pre-Cut Metal Tracks provided by Buildpods but installed by contractor

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed 56

detail K: finished floor shower detail

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ceiling where occurs

Pod Shower 25 5 2 10 conc fill sloped to drain 1 6

extend waterproofing min 6â&#x20AC;? beyond shower

slope to drain 1/4â&#x20AC;? per foot min.

3 or 4

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed

detail L: shower curb detail C

Pod

1-hour rated partition wall, (Recommended STC Rating 50-54)

12 15

Corridor

7 21

1 6

19 15

sheet metal plate covering min 2 flutes

18 13

21 1-hour rated partition wall, (Recommended STC Rating 50-54)

Pre-Cut Metal Tracks provided by Buildpods but installed by contractor

Pod ceiling where occurs

Build Pods provided Build Pods provided, Contractor installed Contractor provided, Contractor installed 58

detail M: 1-hr rated wall at metal deck paralell with flute

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Corridor

Pod

1-hour rated partition wall, (Recommended STC Rating 50-54)

12 15

Corridor

7 21

1 6

13 18 2

Pod

21 15

Pre-Cut Metal Tracks provided by Buildpods but installed by contractor

1-hour rated partition wall, (Recommended STC Rating 50-54)

Corridor

ceiling where occurs

detail N: 1-hr rated wall - metal deck perpandicular to flutes C

Pod

Unit

6 9

3/4â&#x20AC;? Slab Depression by contractor

detail O: depressed slab threshhold detail - concrete slab

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Pod

Unit

detail P: composite ductal threshold - concrete slab C

Pod

Unit

6 9

3/4â&#x20AC;? Slab Depression by contractor

detail Q: depressed slab threshhold detail - depressed metal deck

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Pod

Unit

Leveling compound feathered up to be leveled threshold.

6 9

detail R: threshhold detail - metal deck C

Pod

Unit

6 9

detail S: threshhold detail - metal joists floor assembly

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Pod

Unit

6 9

detail T: threshhold detail - wood joists floor assembly C

For More Information Visit our Website www.buildpods.com Contact: Buildpods 24493 Clawiter Road Hayward, CA 94545 Phone: Fax: Email:

415-269-9207 510-264-1181 info@buildpods.com

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