Foot-Pump Hand-Wash Station

Double-jerry (clean/gray) + foot bellows + lead-free copper spigot + soap clip + towel bar. Built to be refilled, cleaned, and moved—no power, no problem.

What you get

Hands-free water flow via foot pump.
Clean water jerry feeds a **lead-free** copper spigot.
Sink area drains to a separate gray-water jerry.
Soap clip + towel bar on a compact frame.

Use only safe, lead-free components for any wetted parts (NSF/ANSI 61; “lead-free” under the SDWA). Sanitize containers before use. Wash ≥20 seconds. (sources)

Target spec

Flow	Comfortable 0.5–2.0 L/min by foot; marine pumps can do 15 L/min max—throttle with stroke rate.
Capacity	Clean: 20 L (5.3 gal). Gray: 20 L.
Footprint	~60×40 cm base, < 1 m tall.
Service	Bleach-sanitize containers/lines at setup and weekly.

Bill of Materials (buy list)

Clean jerry can (food-grade)	1× 20 L (HDPE, narrow neck + cap) marked “POTABLE”.
Gray jerry can	1× 20 L (HDPE) marked “GRAY”.
Foot bellows pump	1× manual galley foot pump (e.g., Whale Gusher GP0550 or Seaflo foot pump). Spec: self-priming, run-dry OK, ~4 GPM max.
Hose (potable-rated)	3–4 m of 1/2″ ID reinforced clear PVC or braided hose, NSF/ANSI 61.
Bulkhead fittings	2× 1/2″ bulkhead tank fittings (one for clean pickup, one for gray drain). Choose lead-free/NSF materials.
Check valves	2× 1/2″ inline, for inlet and outlet (prevents backflow/cross-contam).
Copper spigot	3/8″ or 1/2″ lead-free copper tube bent to gooseneck + 1/4-turn lead-free ball valve; 3D-print/metal clamp to frame.
Frame	18 mm plywood base + 20×20 mm aluminum extrusion (or 2×2 lumber) for upright; anti-tip feet.
Soap clip	Spring clamp or 3D-printed holster screwed to upright.
Towel bar	30–40 cm stainless rod + two clamps (or a small grab bar).
Hose hardware	Stainless hose clamps, Teflon tape, ferrules, grommets, labels.
Optional	Small basin or funnel under spigot, 3/4″ drain hose to gray jerry bulkhead; rubber feet; strap set for transport.

Lead-free wetted components per SDWA; look for NSF/ANSI 61 certification on valves/fittings/hoses. See sources.

Tools

Drill + step bit (for bulkheads) Deburring tool Tubing cutter Bender (for copper) Screwdrivers/wrench set Marker & labels

Printable Diagram

Blue hose: clean pickup → pump. Green: pump → spigot. Magenta: basin/funnel drain → gray jerry.

Assembly (step-by-step)

Sanitize containers. Wash with soap and water. Sanitize inside: 1 tsp bleach / quart (or 5 mL per 1 L). Cap, shake 30 s, drain; let air-dry or rinse with safe water. Label CLEAN vs GRAY. (CDC procedure)
Prep bulkheads. Mark the CLEAN jerry’s side for a 1/2″ bulkhead near the base (pickup). Drill with a step bit; deburr. Install the **lead-free** bulkhead with gasket inside. Repeat on the GRAY jerry (top or shoulder) for the drain inlet.
Pickup tube. Inside CLEAN jerry, attach short 1/2″ hose to the bulkhead, weighted end a few cm above the bottom (avoids sediment). Outside, add a check valve (flow arrow toward pump).
Mount the pump. Bolt the foot pump to the base front edge; keep ports accessible. Many marine foot pumps are **self-priming** and run dry. Follow the pump’s flow arrow and port sizes.
Plumb inlet/outlet. CLEAN bulkhead → hose → check valve → pump inlet. Pump outlet → hose → a second check valve → copper spigot valve → bent copper gooseneck over your basin/funnel.
Gray drain. Under the spigot, place a funnel/basin. Hose from its bottom → GRAY bulkhead (top). Inside gray jerry, run the hose down so it doesn’t splash.
Frame & fixtures. Screw upright to base; add towel bar ~110–120 cm high. Add soap clip at hand height. Add grommets where hoses pass through wood/metal.
Vent & caps. Leave CLEAN jerry vent slightly open while in use (or add a vented cap). Keep GRAY jerry capped except for the drain tube to control odor/splash.
Leak test. Fill CLEAN jerry with safe water. Prime pump with a few strokes until water flows at the spigot. Check all joints; snug clamps—not gorilla-tight.
Label. Big, waterproof labels: CLEAN WATER ONLY (date) and GRAY WATER – DO NOT DRINK. Add arrows on hoses for flow.

Use lead-free and potable-rated components in the clean-water path; verify NSF/ANSI 61 and “lead-free” per SDWA on valves/fittings/hoses.

Operation (no nonsense)

Wash technique: Wet → soap → scrub **≥20 s** (backs, between fingers, under nails) → rinse → dry on clean towel. Post a “20-second” reminder.
Pumping: Gentle, rhythmic foot strokes (think 0.5–1.5 L/min). You don’t need full 4 GPM; you’re not pressure-washing your hands.
Refill & rotate: Keep a second CLEAN jerry ready. Swap when low. Cap tightly when transporting.
Gray disposal: Empty into sanitary sewer or as local rules allow—never into storm drains or waterways.

Maintenance & sanitation

Daily: Rinse the basin/funnel and spigot tip. Wipe the towel bar. Swap towels.
Weekly or on changeover: Bleach-sanitize both jerries and the clean-side hose/pump path (same CDC ratio; circulate for 30–60 s; drain; air-dry or rinse with safe water).
Storage: Keep containers cool, out of direct sun, away from chemicals/fuels.

Hazards & how to dodge them

Lead/brass risk: Some brass fittings contain lead; choose **lead-free** components certified for drinking water contact.
Cross-contamination: Always use check valves and keep CLEAN and GRAY hoses distinct. Don’t dip hands or tools into the CLEAN jerry.
Stability: Strap jerries to the frame. Add rubber feet. Keep the pump area dry to avoid slips.
Disposal: Follow local rules. Don’t dump gray water into storm drains or sensitive areas.

Performance quick-math

Total clean water (L) Flow (L/min) Scrub time (s)

Water per wash (L)	—
Hands per tank (est.)	—
Run time at set flow	—

Tip: teach “wet-stop-soap-scrub-rinse” to cut waste. Pulsed flow = big savings.

Troubleshooting

No prime	Check inlet check valve orientation, air leaks at bulkhead/barbs, and that the CLEAN vent is open.
Weak flow	Kinked hose; clogged spigot screen; foot strokes too short; try raising flow to ~1 L/min.
Backflow into clean	Outlet check valve missing or reversed—fix immediately.
Leaks	Deburr holes; snug clamps; replace gaskets; don’t overtighten plastic bulkheads.

Sources & Standards

Handwashing method (≥20 s): CDC “Clean Hands” steps. cdc.gov
Sanitize containers (bleach ratios): CDC emergency water supply guidance; 1 tsp/quart (5 mL/L), 30 s contact. cdc.gov and cdc.gov WASH
Safe storage containers (narrow neck, covered): CDC WASH safe storage page. cdc.gov
Lead-free & NSF/ANSI 61: EPA SDWA “lead-free” definition; NSF/ANSI 61 overview. epa.gov • nsf.org
Foot pump specs: Whale Gusher Mk3 (~4 GPM) and Seaflo foot/diaphragm pump manuals. defender.com • seaflo.com PDF
Handwashing station design references: UNICEF facility worksheet & “tippy tap” guides (for placement & user flow ideas). unicef.org • cdc.gov tippy tap
Gray water & storm drains: EPA stormwater pages (don’t dump to storm drains; follow local regs). epa.gov

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