Consider all the things
Optimization Time surrounding you at this moment that is
and Cost using made in a factory setting. The computer
you may be reading this on, the car you
Toilet POD drive in every day, the desk that you work
from, whether at work or home, all of these
items were manufactured in a factory. Now
imagine if all these products that make your
In the building construction industry, the
life easier were created outside in the rain,
residential sector is considered to have the
heat, and snow. Would you expect a high-
highest opportunity to implement
quality product? Would you pay a tenth of
prefabrication. Some of the benefits
the price for these products if you were told
attributed to its implementation are cost
they were made out in the rain? Probably
savings, schedule acceleration, improved
not. For a fine-tuned, high-quality product
quality and safer work environments,
you would expect it to be created in a
among others. The decision to use
climate-controlled environment with little to
prefabrication tends to be based on the
no distractions. construction, such as
unreliable sign rather than rigorous data,
bathroom pods, is completed in a factory, it
given that no formal methods are available
capitalizes on the ability to move products
to determine the impact of prefabrication on
in controlled manufacturing conditions, and
project performance outcomes. An analysis
on tight inventory control and project
was conducted on an ongoing 1,056,000
schedules. It is inherently waste-conscious
square feet residential project, with input
and can have minimum site impact if
from the major parties involved in the
delivered carefully and strategically with
prefabrication process. To determine the
respect to site constraints. Examples in
impact of prefabrication on the project,
which POD construction can be
prefabricated versus traditional site-built
incorporated into site construction include
performance outcomes were compared in
projects with tight deadlines, those built-in
terms of cost, schedule, safety, and quality.
secure environments, those were weather
Each prefabricated component was
may impede construction, and those
analysed individually, as well as the
needing repetitive interior structures. This
combined impact from all four components.
white paper focuses on the interspersion of
A cost premium of 6% over the traditional bathroom pods into traditional construction
site-built cost, as well as a schedule methods. We will discuss how to know if
reduction of 10% and over 150,000 work- bathroom pods are ideal for your project,
hours diverted from the Jobsite, were the benefits of bathroom pods., the general
among the findings from this study. A value- contractor in this project, and its
based benefit-to-cost ratio of 1.14 was subcontractors involved directly with the
estimated prefabrication scope of work, and the
evaluation method implemented has taken
to be accomplished in this project. This a value-based approach. The residential
case study shows that direct cost savings project is 1,056,000 square feet in which
are not considered to be the primary benefit cost, schedule, labour, safety and quality,
of prefabrication, but rather the indirect being some of the main performance
benefits achieved, such as schedule drivers that were available to the
savings and reduced on-site labour, which researchers, were analysed to determine
can be quite significant when quantified. actual project prefabrication performance
outcomes. The purpose of this study is to
present the combined effect of four
1. Introduction significant prefabricated components
implemented in this residential project and
compare and contrast its main performance layout would be kept to 4 walls, however up
outcomes with traditional site-built to 6 walls or more is not uncommon.
processes. Bathroom pods, in which certain
4.2 Drainage Design
value components were also analysed, and
to further extend the methods of proper It is important to reduce the number of
evaluation of such construction strategies. drainage points in the bathroom design, as
a greater number of penetrations in the slab
2. POD
increases the risk of concreting
Bathroom POD units are complete with all inaccuracies and installation errors onsite.
interior fittings and cladding, built POD in
To ensure the number of penetrations are
controlled factory settings, and delivered to
minimised efficiently, POD recommends:
the building site ready for installation and
connection. 4.2.1 Using P trap toilets and connecting
them to the stack above the slab. Exposed
3. Requirements of a good POD
pipework can be avoided by concealing it in
All bathrooms should be the same size and joinery or backing the toilet onto the riser.
shape. Any slight deviation, other than
4.2.2 Connecting basin wastes to the stack
finishes, requires a new pod template.
above ground. 40mm PVC can generally
Ensure pod sizes are reflected correctly in run a reasonable distance in the wall cavity.
the framing details.
4.2.3 Using a single strip drain servicing
The pod supplier, architect, and contractor both the shower and main bathroom area.
should perform a BIM conflict analysis to
4.3 Fixtures & Finishes
ensure there are no MEP clashes.
4.3.1 Floor & Wall Finishes
Factor in site storage options and
installation paths for the pods during The most economical linings include pre-
preconstruction planning. Consider issues finished wall panels such as Compact
related to access to each floor level to allow Laminate. All of the POD standard finishes
rigging of the pods. such as tiles, natural stone, vinyl, Laminam,
and Kerlite offer the highest standard of
Designers should consider the interface
quality to the bathroom pod’s finish. Painted
between the top of the pod and the ceiling
plasterboard is an option, however full
structure to avoid any gaps or misalignment
height tile or vinyl combined with a pre-
of utilities.
finished ceiling increases the level of quality
Make sure all necessary connection points and performance.
are accessible from the outside.
4.3.1.1Tapware and Sanitaryware POD can
Once installed, ensure the pod is squared source any specified items through a
and plumbed. strong, national network of suppliers.
4. Construction Activities with POD
4.3.1.2 Electrical Fixtures Any standard
4.1 Size & Shape electrical fixtures can be specified.
To enable easy manufacturing, delivery
and installation, Inter-pod recommends that 4.4 Door & Door Jambs
the internal bathroom dimensions are no POD bathrooms can be fitted with most
greater than 2.3m wide by 3.0m long types of steel, aluminium and timber door
internally. Larger sizes can be jambs. Generally, steel is recommended for
unaccommodated if required. Minimising its superior strength. The jamb profile and
complexity is also key. Ideally the bathroom header height are matched to other jambs
that have been used in the project. The All electrical points are wired back to a
external faces of the jamb and door have single connection point. These can be
the first and second coat of paint applied, terminated at a junction box for connection
with the final coat by site painter in order to by the site electrician, or supplied with a tail
ensure a perfect colour match, in long enough to reach the closest power
comparison to nearby doors. source. Additional points can be roughed-in
if there are other electrical fixtures to be
4.5 Concrete Finish
attached to the external pod walls.
It is very important to achieve a high-quality Electrical fixtures within the pod can also be
concrete finish in areas where the bathroom integrated with external switches as
pods will be installed. POD bathrooms rely required.
on a flat and level finish for efficient
installation. For best results, the following
tolerances should be specified: 5. Pre & Post activates majors
5.1 Slab Penetrations
4.5.1 For pod installation without additional
packers or levelling, slab variation must be Slab penetrations must be cast with a high
no greater than 3mm over the entire level of accuracy to ensure the waste
bathroom area with no localised high spots. connection spigots are not damaged during
installation. POD provides a template for
4.5.2 For pod installation with packers,
each bathroom type to assist with the layout
variations of up to 15mm can be
and verification of penetration and setdown
accommodated.
positions.
Variation of greater than 15mm will require
5.2 External Lining
additional slab treatment such as topping or
grinding. Note that the finished threshold POD uses a 64mm stud to minimise any
height will increase if excessive packing is lost space in the pod walls. The external
required at the door area. Communication wall studs are left exposed and are lined
with all subcontractors across the project is onsite to ensure a seamless finish with the
critical, as the concrete finish was not as adjoining walls. See wall details on page 12
important in the wet areas of a traditionally for more information.
built bathroom because the tile bed covered
5.3 Weight Loadings
imperfections.
The weight of a POD bathroom pod is
generally the same as the weight of a
4.6 Plumbing traditional, site-built bathroom. For a more
accurate estimate please contact POD.
Plumbing connections are provided with
standard DN15 or DN20 threaded 5.4 Ceiling Heights
connections, or plain pipe ends.
Ceiling heights should be considered to
Connections include hot and cold water,
ensure the pod can be manoeuvred into
along with optional greywater. Connection
position. Allow for the internal bathroom
point locations are specified by the builder,
height to be a minimum of 300mm less than
generally during the design and
slab to the structural ceiling.
development phase. Where the bathroom
adjoins a kitchen or laundry area, additional 5.5 Waste Connections
plumbing points can be roughed-in to
minimise additional plumbing on site. Most POD bathrooms are supplied with a
DN100 DWV pipe waste connection spigot
4.6 Electrical protruding through the base of the pod.
Connection is made by the site plumber.
For low profile bathroom floors, the floor Weather:
waste is connected by way of a glue joint
As the major parts of construction are
through an oversized fire collar or a
carried out in a factory, POD don’t run the
Smartseal connection cast into the slab.
risk of being rained off. Vandalism too is far
Where the bathroom floor depth is not an
less of a problem.
issue, the floor waste can exit from the side
of the pod to facilitate connection above the Health, safety and quality:
slab.
Factory conditions allow for far greater
5.6 Fire Sprinklers control and improvement of all three
compared with the traditional building site.
Fire sprinklers are generally fitted by other
trades to avoid compliance issues. POD Environmentally friendly:
provides penetration and the required
blocking in the ceiling to facilitate easy POD are more energy-efficient, create less
installation of fire sprinklers onsite. waste and increase the use of sustainable
Optionally, fire sprinklers can be supplied materials. There is also a reduction in the
by the fire services contractor for fitment in carbon footprint of the build as fewer people
a POD bathroom for inspection and are travelling to and from the site.
certification by the site fire services Community friendly:
contractor.
Traditional builds traditionally create more
5.7 Ventilation noise, traffic, mess and disruption.
A POD generally supplies the register in the Affordable living:
ceiling and enough flexible duct to connect
to the fan or ventilation duct. Fan units and Once completed, POD cost less to live in –
connections are performed by the site’s they’re cheaper to heat and maintain, eg no
mechanical contractor. Other ventilation repainting or surface repairs are required.
systems, such as hard ducts, can be
Adaptable:
accommodated where required.
POD can be easily expanded, relocated or
6. Comparison with Conventional
reused.
Construction
7. Challenges
The below shows the relative comparison
between the POD and the conventional Access:
system. The comparison is made on the
As they come ready to put in place, POD
factors such as speed of construction,
construction requires careful consideration
quality of construction and safety.
to be given to access for delivery, not just
Time: the site itself but approaching roads.
On average, a POD is constructed 50% Change:
quicker than one using the traditional
Traditional building methods allow for late
method, resulting in an earlier return on
changes in design to be made, whereas
investment.
POD construction is less likely to be able to
Budget: factor this in and requires client sign-off far
earlier.
POD can be more affordable than site-built
buildings. Shorter build time tends to mean Rigorous planning:
significant cost savings. Also, there are no
dead spots in the process of waiting for
materials.
The logistics of individual POD assembly of Bahrain is booming for New Year, The of
demand far more rigorous planning to new innovative ways in the construction
ensure a project goes smoothly. industry is also increasing day by day. POD
construction of bathrooms, prefabricated
8. Cost Comparison
formwork used for construction of stairs,
Cost other elements of infrastructure, and other
time taking activities are going to take place
The estimated cost per bathrooms POD construction to save time and money.
for onsite construction was BHD The case study presented examines POD
construction application applied to the
19,00. Total Estimated cost of construction of high specification bathrooms
for the construction of a prestigious project.
389 Bathrooms is BHD 739,100
The client required a high specification of
finishes and fittings and it was deemed that
The utilized cost for POD a POD manufactured solution would
provide assurance in relation to the
construction of the bathroom was BHD programme, quality and cost of the
1368. Total utilized cost of 389 construction. One mock-up was carried out
to construct one bathroom onsite as well as
bathrooms AED 532,152. By POD.
doing POD construction we
saved 28% of the cost.
Conclusion:
POD construction is gaining
9. Comparison based on the time popularity because of time-saving, cost-
Work cycle saving and improving Quality. The rise is
Estimated time for onsite still lower than the desired; the industry
construction of 389 bathrooms was would have liked to have seen. By widely
182 days to complete the job displaying the impact that new POD
technology can have on the wider world,
With POD construction, we finished our job many companies are making innovations
73 days before which shows that 40% of and improvements in POD construction
time was saved. resulting in ease of construction by
achieving Time, Cost, Quality and Safety at
A CASE STUDY OF THE - Hotel Project the same time. Companies have been able
The cost of the project is a BHD to promote these new methods to the
13,744,921.00 million Lump-sum three-star boardroom with more confidence.
hotels. The duration of the project is
425days.
The building consists of a basement + G.F
+8+GYM+Roof in the heart of Bahrain. The
hotel has 10 structural
levels with 389 rooms and consists of a
conference room, private dining space,
breakout space, and hotel restaurant (with
kitchen and beer cellar) and staff
areas/offices. As the Construction industry
