Prefab Toilet Block - Floor, walls & Roof from panels: -

A). Labor team for Installation: - 1 skilled train worker + 2 unskilled workers.

B). Tools for Installation: -

1. Drilling machine (¾ inch Dia.) with different types of Drills & Boring tool.
2. Circular saw cutting machine with 120mm blade diameter. (similar to Tile cutting machine).
3. Mild Steel Pipe of 2 inch Dia. approx. about 30 / 36 inch long for lifting of panels.
4. 2 Tire trolley – for shifting of panels.
5. Special designed steel crowbar for Raising Wall panel vertically for aligning.
6. Complete Tool kit, Nylon string, Sprite liquid level ruler 600mm long, measuring tape.
7. Plastering Trowels etc.

C). Consumable per Toilet block Unit: -

1. U shape 12.7mm dia. steel bar for locking 2 panels as shown – 3 - 4 nos.
2. Inserting Timber/ wooden wedges for locking of panels - 10- 15 Nos.
3. Cement motor + Birla wall putty for Finishing of wall+ Grout material
4. Optional-Fiber glass mesh tape.
5. Optional - Mild steel Galvanized brackets ‘L’ shaped to be screwed at the corners – 3 - 6 nos.
6. Screw with plugs – 12 – 15 nos.
7. Necessary Paint.

Method to construct Toilet block – Please refer various pictures & video for assemble given on website

1. Level & compact the land where toilet block is to be fitted & make all the other necessary arrangements before Toilet blocks floor, wall & roof is being assembled / constructed.
2. Cut out pocket & Hole for air vent pipe between 2 panels as per dimension of ceramic Toilet pan.
3. Mark out the center line of different walls & door of Toilet in reference with toilet pan.
4. Move the 1St panels into position for installation with the help of pipe & trolley. Prior to surface grouting the joints the surface receiving the grout is washed thoroughly, the grout is mixed & applied properly.
5. Apply Surface grout on the bottom & on one face of panel to be erected vertically.
6. Move 2nd panels right angle to 1st panels as above.
7. Use crow bar, Sprite liquid level & Timber wedges to align the wall Panel with each other.
8. Drill, plug & screw at various points of panels to hold them to each other in Right-angle position.
9. Move 3rd panel in line with 2nd panel & lock them each other in Tongue & groove of it and align the panel to make a wall. Cementations jointing compound is applied between abutting panels in the tongue or groove of panel & at the bottom of panel.
10. Similarly fix all the remaining panels to make walls of Toilet block.
11. For further locking & holding of panels to each other make use of Cavity Anchors “U” in shape to be fitted in the cores on the top of panel & ‘L’ at the corners of walls at top & bottom.
12. After installation of walls, services like electrical wiring, plumbing & other services etc. can be concealed within the core of the Hollow core wall panel.
13. Finish jointing area with fibre glass mesh & Cementations jointing compound to avoid cracks at joints.
14. Place top Roof panel on the wall by interlocking them in Tongue & groove & place fibre glass mesh on the Jointing area & Cementations jointing compound to seal the gap if any.
15. Now fill cement motor in the gaps at Top & bottom of each panel.
16. Ventilation can be provided by Cutting / Slitting required size pocket on the walls of the Toilet Blocks
17. Check all the Walls & then plaster & level it with skim coat of Birla white putty cement.
18. Soak pit tank & necessary steps for Toilet block can also be made from same panel by cutting them as per requirement.
19. After Correction & inspection is done take-up Toilet for door fitting etc. & then for painting as required.

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