GB2611024A - Modular retro-fit pod - Google Patents

Modular retro-fit pod Download PDF

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Publication number
GB2611024A
GB2611024A GB2113194.1A GB202113194A GB2611024A GB 2611024 A GB2611024 A GB 2611024A GB 202113194 A GB202113194 A GB 202113194A GB 2611024 A GB2611024 A GB 2611024A
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United Kingdom
Prior art keywords
pod
shower
frame
modular
handed
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Granted
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GB2113194.1A
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GB2611024B (en
GB2611024A9 (en
GB202113194D0 (en
Inventor
Noel Greenwood Jamie
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Individual
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Individual
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Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
    • A47K4/00—Combinations of baths, douches, sinks, wash-basins, closets, or urinals, not covered by a single other group of this subclass
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34869—Elements for special technical purposes, e.g. with a sanitary equipment
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0889—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
    • E04F13/0894—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections with tongue and groove connections

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Epidemiology (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Residential Or Office Buildings (AREA)

Abstract

A modular bathroom pod formed from a floor and walls, where the walls have a metal frame and cladding. The frame has a flush outer face and an inner face with a laminate substrate bonded with a solid surface resin which is secured to the metal frame with recessed mechanical fixings. The pod may have a shower, WC and basin, and the fixings may be concealed with resin pellets. The inner face may be made from smaller panels which are interlinked and may be formed by three stepped tongue and groove. The frame may have a means of securing it to a wall. A panel created from interlinked smaller panels which may be a compact grade laminate, and a method of manufacturing the modular bathroom, are also claimed.

Description

Modular Retro-fit Pod
Field of the invention
The present invention relates to a modular retro-fit pod for use in prisons and other custodial or similar establishments.
Background of the invention
The concept of a modular retro-fit pod is known and is used mainly within hotels and the like.
The majority of UK prison cells do not have showers and there is a drive in the UK by the Ministry of Justice (M0J) to increase decency in prisons and avoid communal showers.
Furthermore, in 2018 the total UK prison population was 83,618 (0.088% of the population), 79,749 men and 3,869 women In 2019 England and Wales have the largest prison population in Western Europe.
However, furniture and fittings for use in prison cells need to be extremely robust and safe, especially where there is a risk of "smash ups". Custodial furniture, such as beds, desks, lockers, screens and the like, may comprise medium density fibreboard (MDF), solid grade high pressure laminate or a plywood substrate covered with a resin material.
It is also essential that any ingress of water should be avoided which can cause, inter cilia, fracturing of the medium density fibreboard (MDF) or pressure bonded resin materials.
Therefore, the present invention provides a modular pod comprising a shower/WC/wash hand basin that can be suitably retro-fitted into a prison cell and which overcomes or mitigates the aforementioned problems and disadvantages
Summary of the Invention
The present invention provides a new and improved modular bathroom pod for use in a prison or other custodial environment.
According to one aspect of the present invention there is provided a modular bathroom pod comprising an enclosure defining a floor and walls, the walls comprising a metal frame with cladding, wherein the frame comprise a flush outer face-and the inner face comprising a laminate substrate bonded with a solid surface resin and secured to the metal frame with recessed mechanical fixings.
According to a further aspect of the invention the modular pod comprises at least a 20 shower, WC and wash hand basin. The entrance to the modular pod may be fitted with saloon style doors or a curtain secured in a way that the rail and fixings are ligature resilient.
The metal frame will generally comprise a stainless steel frame or mild steel frame with stainless steel or mild steel outer face flush in appearance. The metal frame will be provided with a metal outer skin, e.g. a sheet stainless (or mild) steel plain outer skin where visible; a compact grade laminate substrate bonded with solid surface resin internal face fixed to the frame or a thicker solid surface resin internal face without a substrate bonded to the frame (this may depend on the pod size and the nature of the prison (Cat D to Cat A). Thus, the external appearance of the frame and cladding is that of a conventional wall found in most buildings, i.eready for decoration.
There will generally be a cavity between inner and external surfaces, this cavity may desirably be substantially filled with non-combustible insulation material The solid surface resin will generally be secured to the stainless steel frame with mechanical fixings (bolts and screws) which are recessed below the resin face, or proprietary commercial adhesive, or a combination of both; and then concealed with resin pellets, thus making them invisible and inaccessible to the layperson under normal conditions.
The mild or stainless steel frame may be manufactured in such a way that they bolt together and thus smaller sections can be combined to make a larger wall. The combination of smaller sections is advantageous because, inter alia, it makes manual handling and logistics easier.
Similarly, the inner face comprising a laminate substrate bonded with a solid surface resin will generally comprise a compact grade laminate (sometimes also called solid grade laminate) substrate bonded with a solid surface resin.
The inner face will generally comprise internal panels that may also be manufactured as smaller panels which are capable of being interl nked. The interlinking of the smaller panels may comprise a three stepped tongue and groove, with the addition of a solvent weld adhesive in order to make the joint watertight and invisible to the layperson under normal conditions.
In the modular pod, one wall will define an entrance The floor may be constructed of a cast solid surface resin type with a prepositioned fall to a drain.
The dimensions of the frame will vary depending upon inter cilia, the nature of the modular pod. However, such dimensions will be well understood by the person skilled in the art.
The frame will be provided with means for securing it to a building which houses the modular pod. Thus, in use, the modular pod may be secured to the building at one or more fixing points. By way of example only, the modular pod may be adapted to be screwed or bolted to the floor or wall(s) of the prison building. It will be understood that any combination of the aforementioned fixing means and/ or fixing points.
Indeed it is preferable that more than one fixing point is used.
The thickness of the panels may vary, depending upon, inter alia, the nature of the pod being provided. For example, it may be from about 10 to about 50mm thick; or 25 from about 15 to about 50mm thick; or from about 15 to about 45mm thick; or from about 20 to about 45mm thick; or from about 20 to about 40mm thick; or from about 20 to about 35mm thick; or from about 20 to about 30mm thick; e.g. about 25mm thick.
A variety of surface coating resins may be used. Such resins include, for example, acrylic polymers.
A preferred material may comprise an acrylic polymer/ alumina trihydrate composite, such as is available as Krion0 from Porcelanosa or CorianTM from Du Pont.
Another example of a substrate is a high pressure laminate plate material. A particular high pressure laminate plate material may comprise a phenolic resin. A preferred material may comprise Trespalm which is commercially available from Trespa International BV.
A variety of waterproof resins may be utilised for the waterproof base according to this aspect of the invention. In one embodiment, the waterproof base resin will comprise the same resin as that used in the substrate. Thus, for example, furniture comprising a Krion0 or CorianTM coating may comprise an acrylic polymer base; or furniture comprising a TrespaTm may comprise a phenolic resin base. However, it is within the scope of the present invention for a different resin to be used for the waterproof base.
However, it will be understood by the person skilled in the art that any suitable thermoplastic or thermoset resin or cellulosic material may be used. The resin or polymer material should be water resistant and non-absorbent towards water and nondegradable. Thus, the resin or polymer may comprise a natural or synthetic material or a mixture of natural or synthetic material. Examples of natural materials include, but shall not be limited to, rubber based material. Examples of synthetic materials include, but shall not be limited to, silica polymers, and the like.
The modular pod will generally include appropriately positioned plumbing, ventilation and wiring.
Key features of the modular bathroom pod of the invention include: * Bespoke space saving design, built to suit existing waste outlets and water services.
* Incorporates ligature-resistant MOJ approved fixtures, fittings and sanitary ware.
* Tried and tested water resilient and fire retardant materials used throughout.
* 304 or 316 grade stainless steel framework.
* Water resilient triple lock panel joints minimal sed as far as possible.
* Panels incorporate self-cleaning and purification properties when subject to natural or artificial light * Modular construction for easy transportation and assembly on-site.
* 10 year limited warranty on all resin materials * Ligature-resistant design throughout (excluding saloon doors if fitted).
The modular pod is advantageous in that, inter cilia, it can be suitably retro-fitted into a prison cell or other custodial establishment.
The term "custodial establishment" shall include for example, prisons, police cells, (high security) mental institutions, and the like.
The watertight interlinking of smaller panels with a three stepped tongue combined with a solvent weld adhesive is novel per se.
Therefore, according to a further aspect of the invention there is provided a panel comprising a plurality of smaller interlinked panels, wherein the smaller panels are interlinked by a combination of a three stepped tongue and groove and application of a solvent weld adhesive.
In particular, the watertight interlinked panels comprise a laminate substrate bonded with a solid surface resin, e.g. a compact grade laminate substrate bonded with a solid surface resin.
Advantageously, the joints between the smaller panels are watertight.
Solvent welding refers to a process in which a solvent or solvent blend with no dissolved polymer is used to create a joint between two usually thermoplastic parts. Solvent welding and solvent cementing are simple and inexpensive processes that produce durable, hermetic joints Compared with mechanical fastening, the joint may be lighter in weight, does not need additional components, and can be quicker to
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assemble. The solvent cementing process also avoids the stress concentrations usually found at mechanical fastenings.
The process gives a joint with low or zero visibility and, unlike adhesive bonding, there is no additional phase at the joint.
Compared with most thermoplastic welding techniques, solvent cementing can be used to assemble components containing irregular joints. Solvent welding and solvent cementing can produce welds with very little or no weld flashes, giving a better appearance than the welding techniques that use heat or friction. Furthermore, compared with frictional techniques, there is no risk of producing particulate debris.
According to a further aspect of the invention there is provided a panel as herein described for use in the manufacture of a modular bathroom pod as herein described. 15 According to a further aspect of the invention there is provided a method of manufacturing a modular bathroom pod as herein described which comprises interlinking a plurality of smaller metal frames and smaller panels, wherein the smaller panels are interlinked by a combination of a three stepped tongue and groove and application of a solvent weld adhesive.
The invention will now be illustrated by way of example only and with reference to the accompanying drawings in which: figures 1 and 2 illustrate typical illustration of left handed shower pod stainless steel 25 metal framework; figures 3 and 4 illustrate typical illustration of right handed shower pod stainless steel metal framework, figure 5 illustrates typical left-handed shower pod ceiling, base panels and shower tray; figure 6 illustrates typical left-handed shower pod frame; figure 7 illustrates typical left-handed shower pod plan; figures 8 and 9 illustrate typical left-handed shower pod sections; figures 10 and 11 illustrate typical left-handed shower pod wall panel; figure 12 illustrates typical right-handed shower pod ceiling, base panels and shower tray; figure 13 illustrates typical right-handed shower pod frame, figure 14 illustrates typical right-handed shower pod plan; figures 15 and 16 illustrate typical right-handed shower pod sections; figures 17 and 18 illustrate typical right-handed shower pod wall panel; figure 19 illustrates typical version 1 left-handed shower pod base and ceiling panels and shower tray; figure 20 illustrates typical version 1 left-handed shower pod frame; figure 21 illustrates typical version 1 left-handed shower pod plan figures 22 and 23 illustrate typical version 1 left-handed shower pod sections; figures 24 and 25 illustrate typical version 1 left-handed shower pod wall panel; figure 26 illustrates typical version 1 right-handed shower pod base, ceiling panels and shower tray; figure 27 illustrates typical version 1 right-handed shower pod frame; figure 28 illustrates typical version 1 right-handed shower pod plan; figures 29 and 30 illustrate typical version 1 right-handed shower pod sections; and figures 31 and 32 illustrate typical version 1 right-handed shower pod wall panel.
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Figures Key Figure 1 Typical illustration of left handed shower pod stainless steel metal framework.
Figure 2 Typical illustration of left handed shower pod stainless steel metal framework.
Figure 3 Typical illustration of left handed shower pod stainless steel metal framework.
Figure 4 Typical illustration of left handed shower pod stainless steel metal framework.
Figure 5 Typical illustration of left handed shower pod stainless steel metal framework.
Figure 6 Typical illustration of left handed shower pod stainless steel metal framework.
Figure 7 Typical illustration of right handed shower pod stainless steel metal framework.
Figure 8 Typical illustration of right handed shower pod stainless steel metal framework.
Figure 9 Typical illustration of right handed shower pod stainless steel metal framework.
Figure 10 Typical illustration of right handed shower pod stainless steel metal framework.
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Figure 11 Typical illustration of right handed shower pod stainless steel metal framework.
Figure 12 Typical illustration of right handed shower pod stainless steel metal framework.
Figure 13 Typical left-handed shower pod 19mm thick Krion ceiling panel with cut-outs for the shower plumbing and light.
Figure 14 Typical left-handed shower pod 20mm thick SGL shower tray substrate with a cut-out for the drainage.
Figure 15 Typical left-handed shower pod shower tray.
Figure 16 Typical left-handed shower pod frame.
Figure 17 Typical left-handed shower pod frame plan Figure 18 Typical left-handed shower pod frame plan at high level above the entrance to the pod.
Figure 19 Typical left-handed shower pod top frame.
Figure 20 Typical left-handed shower pod base frame.
Figure 21 Typical left-handed shower pod frame 1 view a Figure 22 Typical left-handed shower pod frame 1 view b.
Figure 23 Typical left-handed shower pod frame 2.
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Figure 24 Typical left-handed shower pod Recommended hole sizes in wall base frame. (A) Water pipe hole 35mm dia (2off) (wallgate show 33mm dia) (B) Basin fixing holes 25mm dia (3 off) (wallgate show 16mm to 22mm dia) (C) Waste pipe hole 80mm dia (loft) (see note 3)(wallgate show 75mm dia) (D)Push button hole 35mm dia (2off)(wallgate show 27mm to 33mm dia) (E) Wall fixing hole 25mm dia (Soft) (wallgate show 20mm dia) Note (1) Base of cistern to sit 750mm from finished floor level (top of shower tray) (2) The wall hole size specified for the waste pipe allows enough room for a pipe fall of 3 degrees (3) Fixing holes larger than 20mm dia require a larger fixing plate contact wallgate for details Figure 25 Typical left-handed shower pod frame 3 side view.
Figure 26 Typical left-handed shower pod frame 4.
Figure 27 Typical left-handed shower pod (A) Rockwool firestop insulation plan. to all inside cavities of metal framework; front 2mm stainless steel to sail over frame; existing aspirated smoke detection system to be extended by others, new pepper-pot faceplate to be incorporated into pod side panel; resin WI-LB. with shelf over; sanitary ware fixed through wall; 2mm stainless steel plate welded to inside of frame flush face and drilled to accommodate sanitary ware; service duct with hot and cold waste discharge & 5 amp fused spur, sanitary ware to be plumbed up to existing services and electronic control box wired into spur; resin WC (A*) Exterior faced with 2mm thick stainless steel sheet welded to the frame and smooth finish with painted magnolia satin.
(B) one 304 grade 30x3Ostainless steel frame for wall with security bolts through outside face through frame; exterior faced with 2mm thick stainless steel sheet welded to the frame and smooth finish with painted magnolia satin; drain; stainless steel floor grate; ligature resistant rail for shower curtain; line of outside edge of shower tray (C) 304 Grade 30x30mm stainless steel frame; Krion K-life resin panels; 12mm thick substrate; frame held together in corners with stainless steel corner plates; front
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20mm stainless steel to sail over frame; cut-out for relocation of light plate see dwg No. C2008-14.
Figure 28 Typical left-handed shower pod Note: section through a-a. Walls to be from 19mm Krion; Rockwool firestop insulation to inside of metal framework.
Rockwool firestop insulation to inside of metal framework; exterior faced with 2mm thick stainless steel sheet welded to the frame and smooth finish with painted magnolia satin; Krion K-life resin panel; 30mm x 30mm 304 grade stainless steel frame; resin shower tray on SGL substrate on 304 gare stainless steel frame; outline of resin sanitary ware.
Figure 29 Typical left-handed shower pod Rockwool firestop insulation to panel fixing detail with void inside of metal framework; 30mm x 30mm 304 grade stainless steel frame fixed to the wall; stainless between wall and shower pod steel CSK self-tapping screw; frame, 19mm Krion pellet; Krion K-life panel.
Figure 30 Typical left-handed shower pod Note: interface detail between the panel, the shower tray and the base frame. Walls to be constructed from 19mm Krion.
Arbicol 1025 anti-pick mastic; stainless steel CSK self-tapping screw with 19mm Krion pellet; Krion K-life resin panels; 30mm Krion shower base; 20mm thick
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SGL substrate; M5 stainless steel round head bolt; 30x 30mm 304 grade stainless steel; a removable access panel is required where door opening is.
Figure 31 Typical left-handed shower pod ceiling corner junction detail with void between wall, shower pod frame and ceiling.
Figure 32 Typical left-handed shower pod A2 M10 S/Steel security bolt with nylon nut; 30 x 30mm 304 grade stainless steel frame; Arbicol 1025 corner detail with shower pod anti-pick mastic; Rockwool frame, firestop insulation to inside of metal framework; corner plate welded to /S frame to space frame off wall.
Figure 33 Typical left-handed shower pod section through entrance b-b above entrance header.
Figure 34 Typical left-handed shower pod section through entrance b-b below entrance plinth.
Figure 35 Typical left-handed shower pod section through cc ceiling frame.
Figure 36 Typical left-handed shower pod section through cc floor frame with base support foot under shower tray.
Figure 37 Typical left-handed shower pod Note wall panels plan. Panels all in one piece (19mm thick Krion)
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Panel 1 -726mm wide x 2001mm high with radius edge Panel 2-512mm wide x 2001mm high with radius edge Panel 3 - 1162mm wide x 2001mm high Panel 4 -981mm wide x 2001mm high Install order Panel 1 = 14 Panel 2 = 2nd Panel 4 = 3Id Panel 3 = 4th Ceiling last WHB; drain-shower head WC.
Figure 38 Typical left-handed shower pod Krion k-life wall panel plan view.
Figure 39 Typical left-handed shower pod Krion k-life wall panel 2 plan view.
Figure 40 Typical left-handed shower pod Krion k-life wall panel 3 plan view.
Figure 41 Typical left-handed shower pod Krion k-life wall panel 4 plan view.
Figure 42 Typical left-handed shower pod Top of shower tray (50mm above top of base frame).
Krion k-life wall panel section view detail with wall panel running up to ceiling panel above.
Figure 43 Typical right-handed shower pod SQL shower tray substrate with a cut-out for the drainage.
Figure 44 Typical right-handed shower pod
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ceiling panel with cut-outs for the shower plumbing and light.
Figure 45 Typical right-handed shower pod shower tray.
Figure 46 Typical right-handed shower pod frame plan Figure 47 Typical right-handed shower pod frame plan at high level above the entrance to the pod.
Figure 48 Typical right-handed shower pod top frame Figure 49 Typical right-handed shower pod base frame.
Figure 50 Typical right-handed shower pod frame I view a.
Figure 51 Typical right-handed shower pod frame 1 view b.
Figure 52 Typicalright-handed shower pod frame 2 Figure 53 Typical ht-handed shower pod Recommended holes sizes in wall frame 3 with WC and WHB plumbing cut-outs. (A) Water pipe hole 35mm dia (2o11) (wallgate show 33mm dia) (B) Basin fixing holes 25mm dia (3 off) (wallgate show 16mm to 22mm dia) (C) Waste pipe hole 80mm dia (loff)(see note 3) (wallgate show 75mm dia) (D)Push button hole 35mm dia (2off) (wallgate show 27mm to 33mm dia) (E) Wall fixing hole 25mm dia
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(Soil) (wallgate show 20mm dia) Note (I) Base of cistern to sit 750mm from finished floor level (top of shower tray) (2) The wall hole size specified for the waste pipe allows enough room for a pipe fall of 3 degrees (3) Fixing holes larger than 20mm dia require a larger fixing plate contact wallgate for details Figure 54 Typical right-handed shower pod frame 3 side view.
Figure 55 Typicalright-handed shower pod frame 4.
Figure 56 Typical right-handed shower pod plan comprising of a shower tray with stainless steel floor grate. (A) Exterior faced with 2mm thick stainless steel sheet welded to the frame and smooth finish with painted magnolia satin.
(A*) Sanitary ware fixed through wall; 2mm stainless steel plate welded to inside of frame flush face and drilled to accommodate sanitary ware; service duct with hot and cold waste discharge & 5 amp fused spur; sanitary ware to be plumbed up to existing services and electronic control box wired into spur; resin WC.
(B) Line of outside edge of shower tray, ligature resistant rail and FR
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shower curtain, stainless steel floor grate; exterior faced with 2mm thick stainless steel welded to the frame and smooth finish with painted magnolia satin; one 304 Grade 30 x 30 stainless steel frame for wall with security bolts through outside face through frame; Rockwool firestop insulation to all inside cavities of metal framework; front 2mm stainless steel to sail over frame, existing aspirated smoke detection system to be extended by others; new pepper-pot face plate to be incorporated into pod side panels -details to be confirmed; resin WI-IB with shelf over.
(C) 12mm thick SGL substrate; Krion K-life resin panels; 304 grade 30 x 30mm stainless steel frame; frame held together in corners with stainless steel corner plates.
Figure 57 Typical right-handed shower pod Outline of resin sanitary ware; section through a-a Krion K-life resin panels; Rockwool firestop insulation to inside of metal framework; exterior faced with 2mm thick stainless steel sheet welded to the frame and smooth finish with painted magnolia satin; 30mm x 30mm 304 grade stainless steel
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frame; resin shower tray on SGL substrate on 304 grade stainless steel frame.
Figure 58 Typical right-handed shower pod Stainless steel CSK self-tapping panel fixing detail with void screw; Rockwool firestop between wall and shower pod insulation to inside of metal frame. framework; 30mm x 30mm 304 grade stainless steel frame fixed to the wall; 19mm Krion pellet; Krion K-life resin panel.
Figure 59 Typical right-handed shower pod interface detail between the resin panel, the resin shower tray and the base frame. 30 x 30mm grade S/S frame to space frame off wall; Arbicol 1025 anti-pick mastic; stainless steel SK self-tapping screw with 19mm Krion pellet; Krion IC-life panels; 30mm Krion shower base; 20mm thick SGL substrate; 30x 30mm 304 grade stainless steel frame; M5 stainless steel round head bolt.
Figure 60 Typical right-handed shower pod 30 x 30mm 304mm grade S/S frame to space frame off wall; ceiling junction detail with void void between wall and pod; between wall and shower pod frame and ceiling and shower pod frame and resin panels. Arbicol 1025 anti-pick mastic; Krion K-life resin panels; stainless steel CSK self-tapping screw with 19mm Krion pellet; 30mm x 30mm 304 grade stainless steel frame.
figure 61 Typical right-handed shower pod A2 M10 S/Steel security bolt with corner detail with shower pod nylon nut; 30 x 30mm 304 grade frame offset by corner plate. stainless steel frame; Arbicol 1025 anti-pick mastic; Rockwool firestop insulation to inside of
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metal framework; corner plate welded to frame; 30 x 30mm 304mm grade S/S frame to space frame of wall; corner plate stainless steel figure 62 Typical right-handed shower pod section through entrance b-b above Stainless steel frame; Arbicol 1025 entrance header with removable anti-pick mastic; stainless steel access panel. outer skin.
figure 63 Typical right-handed shower pod section through entrance b-b below entrance plinth Arbicol 1025 anti-pick mastic; A2 MI0 round head security bolt with nylon nut; stainless steel outer skin; stainless steel frame.
figure 64 Typical right-handed shower pod section through c-c ceiling frame.
figure 65 Typical right-handed shower pod section through c-c floor frame with base support foot under shower tray.
figure 66 Typical right-handed shower pod wall panels plan Drain; WI-TB; shower head & WC Note Panels all in one piece (19mm thick Krion) Panel 1 -726mm wide x 2001 mm high with radius edge Panel 2-512mm wide x 2001 mm high with radius edge Panel 3 -1162mm wide x 2001 mm high Panel 4 -981mm w de x 2001 mm
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Install order Panel 1 = 1 si Panel 2 = 2nd Panel 4 = 3'd Panel 3 = 4th Ceiling last figure 67 Typical right-handed shower pod wall panel 1 plan view with radius edge.
figure 68 Typical right-handed shower pod wall panel 2 plan view with radius edge.
figure 69 Typical right-handed shower pod wall panel 3 plan view.
figure 70 Typical right-handed shower pod wall panel 4 plan view.
figure 71 Typical right-handed shower pod wall panel section view detail with wall panel running up to ceiling panel above.
figure 72 Typical version 1 left-handed shower pod ceiling panel with cutouts for shower plumbing and light.
figure 73 Typical version 1 left-handed shower pod shower tray with cutout for drainage.
figure 74 Typical version 1 left-handed shower pod ceiling panel with cutouts for the shower plumbing and light.
figure 75 Typical version 1 left-handed
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shower pod shower tray.
figure 76 Typical version 1 left-handed shower pod frame plan.
figure 77 Typical version 1 left-handed shower pod frame plan.
figure 78 Typical version 1 left-handed shower pod top frame.
figure 79 Typical version 1 left-handed shower pod base frame.
figure 80 Typical version 1 left-handed shower pod frame I view a.
figure 81 Typical version 1 left-handed shower pod frame 1 view b.
figure 82 Typical version 1 left-handed shower pod frame 2.
figure 83 Typical version 1 left-handed Recommended hole sizes in wall shower pod frame 3 with W C and WHB plumbing cut-outs. (A) Water pipe hole 33mm dia (2off) (B) Basin fixing holes 16mm dia to 22mm dia (3 off) (C) Waste pipe hole 75mm dia (loll) (see Note 2) (D) Push button hole 27mm to 33mm (2off) Note Base of cistern to sit 750mm from finished floor level (top of shower tray).
figure 84 Typical version 1 left-handed shower pod frame 3 side view.
figure 85 Typical version 1 left-handed
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shower pod frame 4.
figure 86 Typical version I left-handed (A) Resin WC; service duct with shower pod plan comprising of a hot and cold waste discharge & 5 shower tray. amp fused spur; sanitary ware to be plumbed up to existing service and electronic control box wired into spur; 2mm stainless steel plate welded to inside of frame flush face and drilled to accommodate sanitary ware, sanitary ware fixed through wall, resin WHB with shelf over, existing aspirated smoke detection system to be extended by others; new pepper-pot face plate to be incorporated into pod side panel -details to be confirmed; Rockwool firestop insulation to all inside cavities of metal framework front 2mm stainless steel sail over frame; one 304grade 30 x 30stainless steel frame for wall with security bolts through outside face through frame; exterior faced with 2mm thick stainless steel sheet welded to the frame and smooth finish with painted magnolia satin.
(A*) Exterior faced with 2mm thick stainless steel sheet welded to the frame and smooth finish with painted magnolia satin.
(B) Stainless steel floor grate; ligature resistant rail and FR
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shower curtain; line of outside edge of shower tray.
(C) Frame held together in corners with stainless steel corner plates; 304 grade 30x3Omm stainless steel frame; Krion K-life resin panels; 12mm thick SGL substrate; front 2mm stainless steel to sail over frame; cut-out for relocation of existing switch and light plate.
figure 87 Typical version 1 left-handed Resin shower tray on SGL shower pod section through a-a. substrate on 304 grade stainless steel frame; 30mm x 30mm 304 grade stainless steel frame; Krion K-life panel; exterior faced with 2mm thick stainless steel sheet welded to the frame and smooth finish with pained magnolia satin; Rockwool firestop insulation to inside of metal framework; 12mm thick substrate; Krion K-life resin panels; resin sanitary ware.
figure 88 Typical version 1 left-handed Void between wall and pod; shower pod panel with void stainless steel CSK self-tapping between wall and shower pod screw; 12mm Krion pellet; frame. Rockwool firestop insulation to inside of metal framework; 30mm x 30mm 304 grade stainless steel frame fixed to the wall; 12mm thick SGK substrate.
figure 89 Typical version 1 left-handed 30mm x 30mm 304mm grade S/S frame to space frame off wall; shower pod interface detail between the panel, the shower tray and the Arbicol 1025 anti-pick mastic;
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base frame, stainless steel CSK self-tapping screw with 12mm Krion pellet; Krion K-life resin panels; 30mm Krion shower base; 20mm thick SGL substrate; 30x 30mm 304 grade stainless steel frame; M5 stainless steel round head bolt; removable access panel is required where door opening is.
figure 90 Typical version 1 left-handed 30 x 30mm 304mm grade S/S frame to space frame off wall; shower pod ceiling junction detail with void between wall and shower pod frame and ceiling and shower pod frame void between wall and pod; Arbicol 1025 anti-pick mastic; stainless steel CSK self-tapping screw with 12mm Krion pellet; Krion K-life resin panels, 12mm thick substrate; 30mm x 30mm 304 grade stainless steel frame.
figure 91 Typical version 1 left-handed A2 M10 S/Steel security bolt with shower pod corner detail with nylon nut; 30x 30mm 304 grade shower pod frame offset and fixed with stainless steel corner plate. stainless steel frame; Arbicol 1025 anti-pick mastic; Rockwool firestop insulation to inside of metal framework; corner plate welded to frame; 30x 30mm 304mm grade S/S frame to space frame off wall.
figure 92 Typical version 1 left-handed shower pod section through entrance b-b above entrance header.
figure 93 Typical version 1 left-handed shower pod section through entrance b-b below entrance plinth.
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figure 94 Typical version 1 left-handed shower pod section through c-c ceiling frame.
figure 95 Typical version 1 left-handed shower pod section through c-c floor frame with base support foot under shower tray.
figure 96 Typical version 1 left-handed WHB, drain, shower head & WC.
shower pod wall panels plan with radius edges to panels 1 and 2.
figure 97 Typical version 1 left-handed shower pod wall panel 1 plan view with radius edge.
figure 98 Typical version 1 left-handed shower pod and wall panel 2 plan view with radius edge figure 99 Typical version 1 left-handed shower pod and wall panel 3 plan view.
figure 100 Typical version 1 left-handed shower pod and wall panel 4 plan view.
figure 101 Typical version 1 left-handed shower pod and wall panels 3 and 4 section view.
figure 102 Typical version 1 right-handed shower pod shower tray with cutout for drainage figure 103 Typical version 1 right-handed shower pod ceiling panel with cutouts for shower plumbing and light.
figure 104 Typical version 1 right-handed shower pod shower tray.
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figure 105 Typical version 1 right-handed shower pod ceiling panel with cutouts for the shower plumbing and light.
figure 106 Typical version 1 right-handed shower pod frame plan.
figure 107 Typical version 1 right-handed shower pod frame plan at high level above the entrance to the pod.
figure 108 Typical version 1 right-handed shower pod top frame.
figure 109 Typical version 1 right-handed shower pod base frame.
figure 110 Typical version 1 right-handed shower pod frame 1 view a.
figure 111 Typical version 1 right-handed shower pod frame 1 view b.
figure 112 Typical version 1 right-handed shower pod frame 2.
figure 113 Typical version 1 right-handed Recommended hole sizes in wall shower pod frame 3 with W.0 and WHB plumbing cut-outs. (A) Water pipe hole 33mm dia (2off) (B) Basin fixing holes 16mm dia to 22mm dia (3ofl) (C) Waste pipe hole 75mm dia (loft) (see Note 2) (D) Push button hole 27mm to 33mm (2off) Note Base of cistern to sit 750mm from finished floor level (top of shower tray).
figure 114 Typical version 1 right-handed
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shower pod frame 3 side view.
figure 115 Typical version 1 right-handed shower pod frame 4.
figure 116 Typical version 1 right-handed (A) Resin WC; service duct with shower pod plan comprising of a hot and cold waste discharge & 5 shower tray held together in corners amp fused spur; sanitary ware to with corner plates. be plumbed up to existing services and an electronic control box wired into spur; 2mm stainless steel plate welded to inside of frame flush face and drilled to accommodate sanitary ware; sanitary ware fixed through wall; resin WITB with shelf over; existing aspirated smoke detection system to be extended by others; new pepper-pot face plate to be incorporated into pod side panel -details to be confirmed; Rockwool firestop insulation to all inside cavities of metal framework front 2mm stainless steel sail over frame; one 304grade 30 x 30stainless steel frame for wall with security bolts through outside face through frame, exterior faced with 2mm thick stainless steel sheet welded to the frame and smooth finish with painted magnolia satin.
(A*) Exterior faced with 2mm thick stainless steel sheet welded to the frame and smooth finish
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with painted magnolia satin.
(B) Stainless steel floor grate; ligature resistant rail and FR shower curtain; line of outside edge of shower tray.
(C) Frame held together in comers with stainless steel comer plates; 304 grade 30x3Omm stainless steel frame; Krion K-life resin panels; 12mm thick SGL substrate; front 2mm stainless steel to sail over frame; cut-out for relocation of existing switch and light plate.
figure 117 Typical version 1 right-handed Outline of resin sanitary ware; shower pod section through a-a. 12mmm thick SGL substrate; Krion K-life resin panels; Rockwool firestop insulation inside of metal framework; exterior faced with 2mm thick stainless steel sheet welded to the frame and smooth finish with painted magnolia satin. Note
Walls to be constructed from 12mm SGL faced with 12mm Krion.
Rockwool firestop insulation to inside of metal framework.
figure 118 Typical version 1 right-handed Void between wall and pod; shower pod panel fixing detail with stainless steel CSK self-tapping void between wall and shower pod screw; Rockwool firestop frame. insulation to inside of metal
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framework; 30mm x 30mm 304 grade stainless steel frame fixed to the wall; 12mm Krion pellet; Krion K-life resin panel; 12mm thick SGL substrate.
figure 119 Typical version 1 right-handed 30x 30mm 304mm grade S/S shower pod interface detail between the panel, the shower tray and the base frame, frame to space frame off wall; Arbicol 1025 anti-pick mastic; stainless steel CSK self-tapping screw with 12mm Krion pellet; Krion K-life resin panels; 30mm Krion shower base; 20mm thick SGL substrate; 30x 30mm 304 grade stainless steel frame; M5 stainless steel round head bolt.
figure 120 Typical version 1 right-handed 30x 30mm grade S/S frame to shower pod ceiling junction detail with void between wall and shower pod frame and ceiling and shower pod frame. space frame off wall; void between wall and pod; Arbicol 1025 anti-pick mastic; 12mm thick SGL substrate; 30mm x 30mm 304 grade stainless steel frame; Krion K-life resin panels; stainless steel CSK self-tapping screw with 12mm Krion pellet.
figure 121 Typical version 1 right-handed A2 M10 S/Steel security bolt with shower pod corner detail with nylon nut; 30 x 30mm 304 grade shower pod frame, stainless steel frame; Arbicol 1025 anti-pick mastic; Rockwool firestop insulation to inside of metal framework; corner plate welded to frame; 30 x 30mm 304mm grade S/S frame to space frame off wall.
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figure 122 Typical version 1 right-handed shower pod section through entrance b-b above entrance header with removable access panel.
figure 123 Typical version 1 right-handed shower pod section through entrance b-b below entrance plinth.
figure 124 Typical version 1 right-handed shower pod section through c-c ceiling frame.
figure 125 Typical version 1 right-handed shower pod section through c-c floor frame with base support foot under shower tray.
figure 126 Typical version 1 right-handed shower pod wall panels plan with radius edges to panels 1 and 2.
figure 127 Typical version 1 right-handed shower pod wall panel 1 plan view with radius edge.
figure 128 Typical version 1 right-handed shower pod wall panel 2 plan view with radius edge.
figure 129 Typical version 1 right-handed shower pod wall panel 3 plan view.
figure 130 Typical version 1 right-handed shower pod wall panel 4 plan view.
figure 131 Typical version 1 right-handed shower pod wall panels 3 and 4 section view.

Claims (5)

  1. Claims 1. A modular bathroom pod comprising an enclosure defining a floor and walls, the walls comprising a metal frame with cladding, wherein the frame comprise a flush outer face; and the inner face comprising a laminate substrate bonded with a solid surface resin and secured to the metal frame with recessed mechanical fixings.
  2. A modular bathroom pod according to claim I wherein the modular pod comprises at least a shower, WC and wash hand basin.
  3. A modular bathroom pod according to any one of claims I_ or 2 wherein the metal frame is a stainless steel frame.
  4. 4. A modular bathroom pod according to any one of the preceding claims wherein the stainless steel frame comprises a stainless steel outer face flush in appearance.
  5. 5. A modular bathroom pod according to any one of the preceding claims wherein the solid surface resin is generally secured to the stainless steel frame with mechanical fixings (bolts and screws) which are recessed below the resin face, or proprietary commercial adhesive, or a combination of both A modular bathroom pod according to claim 5 wherein the mechanical fixings are concealed with resin pellets.7. A modular bathroom pod according to any one of the preceding claims wherein the mild or stainless steel frame is manufactured in such a way that they bolt together and thus smaller sections can be combined to make a larger wall.8. A modular bathroom pod according to any one of the preceding claims wherein the inner face comprising a laminate substrate bonded with a solid surface resin generally comprises a compact grade laminate substrate bonded with a solid surface resin.9. A modular bathroom pod according to any one of the preceding claims wherein the inner face generally comprises internal panels that may also be manufactured as smaller panels which are capable of being interlinked.A modular bathroom pod according to claim 9 wherein the interlinking of the smaller panels comprises a three stepped tongue and groove, with the addition of a solvent weld adhesive.II. A modular bathroom pod according to claim 10 wherein the joint between the interlinked smaller panels is watertight.12 A modular bathroom pod according to any one of the preceding claims wherein one wall of the modular defines an entrance 13. A modular bathroom pod according to any one of the preceding claims wherein the frame is provided with means for securing it to a building which houses the modular pod.14. A modular bathroom pod according to claim 13 wherein the modular pod is adapted to be screwed or bolted to the floor or wall(s) of the prison building.15. A modular bathroom pod according to any one of the preceding claims wherein the resin includes acrylic polymers.16. A modular bathroom pod according to any one of the preceding claims wherein the resin is an acrylic polymer/ alumina trihydrate composite, such as is available as ConanTM from Du Pont.17. A modular bathroom pod according to any one of the preceding claims wherein the resin is a high pressure laminate plate material.18. A modular bathroom pod according to claim 17 wherein the high pressure laminate plate material comprises a phenolic resin, such as TrespaTm which is commercially available from Trespa International BV.19. A modular bathroom pod according to any one of the preceding claims wherein the resin is a waterproof resin.20. A modular bathroom pod according to any one of the preceding claims wherein the modular pod includes appropriately positioned plumbing and wiring.21 A panel comprising a plurality of smaller interlinked panels, wherein the smaller panels are interlinked by a combination of a three stepped tongue and groove and application of a solvent weld adhesive.22. A panel according to claim 21 wherein the interlinked panels comprise a laminate substrate bonded with a solid surface resin, e.g. a compact grade laminate substrate bonded with a solid surface resin.23. A panel according to claims 21 or 22 wherein the joints between the smaller panels are watertight.24. A panel according to any one of claims 21 to 23 for use in the manufacture of a modular bathroom pod according to claim 1 25. A method of manufacturing a modular bathroom pod according to claim 1 which comprises interlinking a plurality of smaller metal frames and smaller panels, wherein the smaller panels are interlinked by a combination of a three stepped tongue and groove and application of a solvent weld adhesive 26. A modular bathroom pod, panel or a method as herein described with reference to the accompanying description and figures.0635P.GB1Spec(3)
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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3745733A (en) * 1972-04-13 1973-07-17 R Litvin Panel construction for modular bathrooms
FR2297292A1 (en) * 1975-01-07 1976-08-06 Texunion Prefabricated shower, basin and toilet cubicle - is glass fibre reinforced polyester laminate sections
GB1492999A (en) * 1974-08-12 1977-11-23 Twellose Industrie Plastics Bv Building construction and wall panel for such constructio
ES1027515U (en) * 1993-12-01 1994-09-01 Dominguez Jose Ramon Alonso Modular prefabricated bathrooms and toilets bearing metal structure tailored to the construction industry. (Machine-translation by Google Translate, not legally binding)
JPH0941552A (en) * 1995-08-03 1997-02-10 Matsushita Electric Ind Co Ltd Bathroom unit
ES1039836U (en) * 1998-04-13 1999-01-16 Hevia Alvarez Francisco J Modulo applicable toilet in prisons. (Machine-translation by Google Translate, not legally binding)

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3745733A (en) * 1972-04-13 1973-07-17 R Litvin Panel construction for modular bathrooms
GB1492999A (en) * 1974-08-12 1977-11-23 Twellose Industrie Plastics Bv Building construction and wall panel for such constructio
FR2297292A1 (en) * 1975-01-07 1976-08-06 Texunion Prefabricated shower, basin and toilet cubicle - is glass fibre reinforced polyester laminate sections
ES1027515U (en) * 1993-12-01 1994-09-01 Dominguez Jose Ramon Alonso Modular prefabricated bathrooms and toilets bearing metal structure tailored to the construction industry. (Machine-translation by Google Translate, not legally binding)
JPH0941552A (en) * 1995-08-03 1997-02-10 Matsushita Electric Ind Co Ltd Bathroom unit
ES1039836U (en) * 1998-04-13 1999-01-16 Hevia Alvarez Francisco J Modulo applicable toilet in prisons. (Machine-translation by Google Translate, not legally binding)

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
CORIAN INSTALLATION INSTRUCTION *

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GB2611024A9 (en) 2023-04-19
GB202014540D0 (en) 2020-10-28
GB202113194D0 (en) 2021-10-27

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