Efficient high-volume production process with advanced quality control
From pod carcass to final fit-out
Offsite Solutions manufactures bathroom pods in a controlled UK factory environment, with capacity to deliver thousands of units each year. Our production lines are tailored to support both GRP and steel-framed pods, with dedicated areas for carcass assembly, fit-out and final testing.
Every pod is built to specification, using tested construction methods that ensure structural integrity, visual consistency and ease of installation on site.
Steel-framed bathroom pod construction
Stable, repeatable and built to last
Steel-framed bathroom pods are built on an in-house manufactured welded steel box section base, boarded with 18mm tongue-and-groove WBP plywood. This wall structure creates an incredibly robust detail which has been structurally tested and fully complies with all requirements for future adaptability under Part M and the addition of grab rails.
Walls are formed from cold-rolled galvanised steel ‘C’ sections, double-lined internally with lightweight cement board. Self-tapping screws are used to fix both layers securely, creating a strong, layered enclosure.
All steel-frame pods have a cement board ceiling which is bonded to a galvanised C section ceiling frame which eliminates the risk of screw heads popping during transit or on site.
GRP composite construction
Lightweight, waterproof and engineered for easy installation
Our GRP composite pods are made with marine-grade, WRAS-approved gelcoats and resins. The walls and ceiling panels include a honeycomb polypropylene core, making the structure fully waterproof, rigid and protected from delamination.
The pods are fitted with strengthening battens and gypliner brackets when requested to support dry lining on site. As the GRP panels are plumb and corners are set at 90°, integration is straightforward, and standard door sets can be used without modification.
Demountable pods for restricted access
Sectional GRP pods for refurbishment and constrained projects
Our award-winning demountable GRP pods are designed for buildings where space or access makes full pod installation difficult. These units are manufactured in sections, with the shower tray forming part of the floor and wall panels creating the enclosure.
Following a detailed site survey, panels are sized to ensure safe, easy access through existing openings. Sanitaryware fixings are pre-drilled to reduce on-site time – only the shower door is installed during final assembly.
This innovation was recognised with a Highly Commended award for Product Innovation at the Offsite Construction Awards.
In-house steel fabrication
Securing supply and accelerating product development
In 2019, Offsite Solutions acquired Taylor & Kilduff, a steel fabrication business with a 15-year history of supplying our base frames, as well as mezzanine floors, staircases and custom components. This acquisition brought fabrication fully in-house, securing control over quality and lead times.
The Taylor & Kilduff team fabricates around 10,000 steel units annually. This internal capability allows us to prototype quickly and adapt to client needs without delay.
Finishing and fit-out
Pods move through dedicated production lines
Once the carcass is completed, each pod moves through a tightly controlled fit-out process. Every step – from tanking and tiling to painting, wiring and plumbing – is completed by specialist operatives under supervision.
This system supports consistent output, even at high volume, and allows us to manage complex specifications with full control over finish and sequencing.
Plumbing system installation
Tested materials, watertight fittings
For hot and cold pipework, Offsite Solutions use Uponor MLCP (multi-layer composite pipe), which is a press fit system offering a 25 year guarantee on the pipework and fittings. Its five-layer bonded structure reduces heat expansion, prevents oxygen ingress and maintains form stability.
Press-fit connections eliminate the need for welding or soldering, making installation safer and more efficient. The system’s longevity and reliability have been verified by multiple certification bodies across Europe.
We use high quality Polypipe terrain waste pipes and consumables to provide a complete system under warranty from the supplier.
Built-in quality control
Checked at every stage of production
Each pod is assigned its own set of quality control documents and is checked at every stage of manufacture. This allows any issues to be identified and resolved immediately, preventing delays later in the process.
By maintaining consistent inspections from carcass to completion, we ensure every pod that leaves our facility meets our standards for finish, functionality and durability.
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