Clearing site
Levelling the location of the area the Pod will go, is an important step. On flat blocks this is relatively easy but on sloping blocks it is a matter of scraping the grass or bush off the area where the Pod will go in order to be accurate for the drilling of the piers. We sometimes need to add retaining walls if there is any side cut. All is determined on plan prior to starting and the surveyor comes to mark the levels in this stage.
Pad footings
Each Pod gets a soil report to show how deep we have to drill down to hit solid ground. Usually it’s around 600mm deep but in some cases it can be 1500mm deep with 450mm wide piers. As we must hit solid ground, we have to keep drilling until we get there. This is then filled up with concrete and later the steel frame is bolted onto these piers. During this stage the concrete tank slab is poured also.
Drainage and electrical
It takes a few days for trench to be dug and connections to be made from the current residence to the secondary residence. This includes storm water, sewer, water and electrical conduit. This also may include diversions of where the current connections are to work around the Pod, each Pod has a drainage plan from a hydraulic engineer for the plumber and an electrical plan so all parties understand the scope of the work to be completed.
Steel floor frame
We use a steel floor frame that is bolted onto the concrete piers, all ticked off by a structural engineer. This process can also take a few days, it is a lot faster than a concrete slab and it also is less damaging to roots and trees if there is a significant tree we must avoid. We use the steel frame for not only the Pod but the deck and ramps as well. It is a great product to work with as you can create the most accurate level with the adjustment system it comes with. This also termite proofs our Pods.
Floor insulation & Upper frame
We use R2 batts for our floor insulation and top it with yellow tongue structure floor sheets. After this stage we then get onto erecting the upper wall frames and then ceiling frame. All are treated pine and also termite protected. You can really see the Pod coming together at this stage as the shape takes place with the external and internal walls going up. This process can take a couple of weeks as we like to make sure each section is perfect for the set of joinery and products we have going into the build.
Lock up stage
At this stage we are putting in the frames of the windows and doors. We then start installing the roof and external cladding. We use NRG green board to clad the outside of the Pod, along with the custom orb metal colourbond cladding on the back and usually one side. Once we can physically lock up your Pod, you’re at lock up stage.
Internal linings
The plumber, electrician and aircondining team come to ‘rough in’ the services into your new Pod. The carpentry straighten frames and then the certifier compelted his pre sheet inspection to ensure we can keep proceeding. We then sheeting the internal walls with gyprock, the bathroom with structural gyprock, and set it. After setting and sanding we double check to make sure it is ready for painting. At this stage the wetseal in the bathroom has usually been completed and the underfloor heating has been installed.
Painting & Tiling
We can now prepare for the rendering and wet seal for the cladding area. Windows would have already been installed and the Pod is really taking shape. The Pod is rendered with an acrylic render and then painted. This is where the tank get installed, the air-conditioning gets ready and all is prepared for the final steps during fit off. The painting and wardrobe get installed the tiling gets finalised with the splash backs and ready for the next stage being fit off and ready for practical completion.
Touch ups, flooring, timber cladding at practical completion
The final part is ‘all systems go’, bathroom fittings get installed, flooring gets installed, the decking gets completed, the front timber cladding gets installed, the whole Pod gets painted, skirting goes on and so much more. The final touches are the blinds, appliances and fly screens which we leave until the very end. If you have landscaping included, we create your final finished Pod look. Then the certifier gets to check, sign off, and provide your (COU) Certificate of Occupancy and Use for you or your tenants to move in.
