Offsite Manufacture

Steel-framed Bathroom Pods

Apart from pods specified as floorless or thin-floored, a welded steel box section base frame is used, of a size and design specific to that pod footprint and weight.

This box section base frame is boarded with 18mm tongue and groove exterior grade WBP plywood.

This rigid base then forms a stable platform for the pod, not only through the manufacturing process, but also during transport, installation and thereafter.

Wall frames are manufactured in-house from cold rolled galvanised steel 'C' section. 

These steel wall frames are then double lined with 11mm OSB 3 and 12.5mm moisture resistant plasterboard. Self-tapping screws are used to fix both layers of sheet material to the inside of the frame.

Almost all Offsite Solutions bathroom pods, whether GRP or Steel frame, are fitted with a GRP Composite ceiling panel which greatly enhances both the appearance and durability of the unit being robust, water proof and easy-clean.

When completed the carcass provides an optimum balance of durability and weight, offering efficiencies in transportation of ease of manoeuvrability.

GRP Composite Bathroom Pods

Our steel-framed pods use a welded steel box section base frame. The moulded GRP composite floor, wall and ceiling panels are then fixed to this base.

We only use premium quality marine grade and WRAS approved resins and gelcoats to make our GRP composite panels. 

All our wall and ceiling panels contain a Honeycomb Polypropylene core which significantly improves rigidity, is fully waterproof and not susceptible to delamination.

The pod exterior is fitted with horizontal strengthening battens and adjustable lightweight steel rails to facilitate dry lining fixing.

Our method of construction results in pod walls and doors which are plumb, meaning that integration of the pod is uncomplicated, allowing the use of standard door sets, without further work on-site.

Demountable GRP Pods for Projects with Restricted Access

Our award-winning demountable pod solution uses a unique sectional design where the shower tray forms part of the floor and the wall panels create the shower enclosure.

Features include:

• Completely vertical pod walls with 90° corners so integration is very simple because there are no tapered walls
• Panel sizes are specially designed following a site survey to ensure full access for installation is achievable
• Pre-drilled holes for sanitaryware minimises work on site. Only the shower door needs to be fitted
• A wide range of wall finishes – tile effect, matt, gloss and feature recesses.

Steel Fabrication

In 2019, we acquired Taylor & Kilduff, a steel fabrication business. The company had a long history of supplying steel base frames to Offsite Solutions, which spans more than 15 years. It fabricates around 10,000 units a year for all types and variations of our steel-framed bathroom pods, as well as other steel components.

By bringing the manufacture of base frames for steel-framed pods in-house, our customers benefit from complete security of supply. Their team has also leverages significant expertise in steel fabrication. This is particularly valuable to accelerate the development and prototyping of new products.

Production Process

Once the pod carcass is in a rigid state it is moved to the fit out lines where the various finishing processes are carried out under rigorous quality controlled conditions: taping, tanking, tiling, first fix, painting, second fix, cleaning and final testing.

Specialist operatives are responsible for each different process ensuring every function is completed to an excellent standard.

The plumbing system used on most units is the Uponor multilayer composite (MLC) pipe with brass & PPSU press fittings. This pipe has a five layer composite structure of longitudinally soldered aluminium with an inner and outer layer of high temperature-resistant polyethylene permanently bonded together by intermediate adhesive layers. This combines the advantages of a metal and plastic pipe and eliminates the disadvantages of both materials. The aluminium core prevents oxygen ingress, reduces heat-expansion and gives form-stability for easy and safe installation. Connections are made using the patented Uponor press system and produces permanent watertight press, clamp and compression connections. Potentially complicated connections such as welding or soldering are not necessary. The longevity of this system has been tested and confirmed by numerous certification bodies across Europe.

Each pod is accompanied by its own specific set of quality control documents with pods checked at every stage during the process to ensure that any defects are picked up swiftly and resolved prior to the pod moving further along the production line.

This production process is extremely efficient enabling high volume production and advanced quality control.