Composite Enclosure System Bathroom Pod

Main Content

  • 1. Bathroom Pod classification
  • 2. Composite enclosure system bathroom pod introduction
  • 3. Comparison between composite enclosure system bathroom pod and traditional bathroom
  • 4. Comparison between composite enclosure system bathroom pod and SMC bathroom pod
  • 5. Composite enclosure system bathroom pod case study

1. Bathroom Pod classification

  • Composite enclosure system bathroom pod (European style)
  • SMC bathroom pod (Japanese style)
  • Gypsum board + LGS system bathroom pod
  • Prefabricated panel system bathroom pod
  • Aluminum and glass system bathroom pod

1.1 Composite enclosure system bathroom pod (European style)

The Composite enclosure system bathroom pod was started from 1950s, which was derived from the bathroom pod of luxury cruise ships in Finland to the bathroom pod system within the building. Up to now, in the past 70 years, Europe and the United States have adopted composite panels as non-load-bearing independent walls, with good strength and rigidity, and fire resistance, sound insulation and bearing capacity are in line with the international civil building wall standards.

1.2 SMC bathroom pod (Japanese style)

The SMC system bathroom pod was innovated by the Japanese in the 1970s and which was consist of SMC materials in Japan. Until toady is more than 40 years, the SMC system bathroom pod must build a wall to the outside of the bathroom pod to withstand the strength and rigidity of the SMC.

2. Composite enclosure system bathroom pod introduction

  • Bathroom pod structure
  • Bathroom pod installation process
  • Connection work of the bathroom pod to the others
  • Bathroom pod test
  • Precautions for the usage of the bathroom pod
  • Construction conditions of the bathroom pod

2.1 Bathroom pod structure

Composite enclosure system bathroom pod

Internal diagram of the bathroom pod module (eight parts)

The bathroom pod are designed modular and prefabricated within the factory. It is divided into eight modules and the assembly efficient is very high.

bathroom pod
bathroom pod

Bathroom pod finished picture

The bathroom pod is fully prefabricated and produced in factory assemble line. The onsite installation method can be lifting installation or part assembly installation, and the installation efficiency is greatly improved.

Base tray material

Steel base tray

Steel base tray

The steel base tray is made of hot-rolled steel plate + cement mortar + 2 layers of waterproof treatment + tile (anti-slip).

The steel base is formed by integral bending, the joint seam is complete penetration welded, and the interior and exterior are rust-proof treated to ensure good waterproof effect.

The shapes, colors and patterns can be customized.

Steel base tray drawing

Steel base tray drawing

FRP base tray

FRP base tray

The FRP base tray is produced by one-time molding, and there is no leakage problem which is easily caused in the traditional bathroom.

The finish is integrated with the main material, and the surface is smooth and easy to clean. At the same time, tiles can be used on the surface, which will achieve better effect.

Good strength and light weight, it is only 50% weight of the steel base tray.

FRP base tray drawing

FRP base tray drawing

Ceiling, enclosure wall structure material

Aluminum honeycomb composite panel

Main material:Aluminum honeycomb/rock wool composite material

Rock wool panel
Aluminum honeycomb panel
Connection method - male and female plug-in

Connection method – male and female plug-in

Galvanized steel plate + aluminum honeycomb / rock wool + galvanized steel plate with PVC film combined into composite material, with waterproof, A-level fireproof effect.

The connection between the panels is the male and female plug-in type, good waterproof effect.

Base tray,wall panel and ceiling assembly

pod assembly

Steel base tray wall panel elevation node

pod assembly

FRP base tray wall panel elevation node

Ceiling, wall surface finish material

Finish material type Wall surface Ceiling surface Effect
PVC/PET film
Mosaic
Tile
Marble
Glass

PVC/PET film on the surface of the steel plate is a kind of decorative material and a variety of patterns and surface effects can be selected. At the same time, according to the requirements of users,the traditional decorative materials such as mosaic, tile, marble and glass can be selected to achieve better interior effects.

FRP base tray + PVC wall panel structure waterproof treatment

pod waterproof treatment

Waterproof treatment at the joint area between the wall and base tray

  • The bottom of the wall is plug-in connected with the base tray, which have a certain ability of waterproof function.
  • The contact surface of base tray and bottom side of wall is sealed with sealing glue.
pod waterproof treatment

Waterproof treatment at the connection area between the wall panels

  • The connection between wall panels are plug-in type, which have a certain ability of waterproof function.
  • The gap between the walls are sealed with sealing glue.

Steel base tray + tile wall structure waterproof treatment

bathroom waterproof treatment
pod waterproof treatment
waterproof elevation diagram

waterproof elevation diagram

bathroom waterproof

real photo for reference

2.2 Bathroom pod installation process

Assembly onsite(loose parts)

  • Bathroom pod delivered to the site.
  • Wall panel, ceiling installation.
  • Sanitary ware installation.
  • Pipe and power connection.
  • Window trim installation.
  • Door trim installation.
  • Customer acceptance.
bathroom parts

Parts arrived at the construction site

bathroom parts

Base tray dispackaged

bathroom pod installation
bathroom pod installation

Bathroom pod wall panel installation

bathroom pod installation
bathroom pod installation

Bathroom pod ceiling installaltion

Sanitary ware installation
Sanitary ware installation

Sanitary ware installation

Hardware installation
Hardware installation
Hardware installation
Hardware installation

Hardware installation

bathroom installation
bathroom installation

Installation completed – test water, test electric, clean

Pre-assembled in factory,lifting onsite(prefabricated)

  • Bathroom pod lifting.
  • Bathroom pod moved to the position.
  • Unit protection.
  • Window installation.
  • Pipe and power connection.
  • External partition wall installation.
  • Test water, test electric, clean
Bathroom pod transportation

Bathroom pod transportation

Bathroom pod lifting

Bathroom pod lifting

Bathroom pod protection
Bathroom pod lifting

Bathroom pod lifting

Bathroom pod moved to the position

Bathroom pod moved to the position

Bathroom pod protection

Bathroom pod protection

Bathroom movement

Bathroom moving

Bathroom pod partition wall LGS installation

Bathroom pod partition wall LGS installation

bathroom in the position

Bathroom in position

Bathroom pod partition wall diagram

Bathroom pod partition wall diagram

  • Since the bathroom pod enclosure itself can be the partition wall, when construct the inner partition wall, the LGS can be installed on the outside of the bathroom pod wall, and then attach the CCA board to form the partition wall.
bathroom pod partition wall

The effect of CCA wall board after plastering

Bathroom pod internal effect
Bathroom pod internal effect
Bathroom pod internal effect

Real bathroom pod internal photo

2.3 Connection to other structures

Connection introduction between base tray and structural descend floor

Connection method between base tray and structural descend floor

  • H is the distance from the finished building surface to the structural descend floor surface.
  • H1 is the thickness of the building finish.
  • H2 is the depth of the structural descend.
  • For the bathroom pod with H value = 300mm; structure descend depth H2 = H-H1 (H2 = 300-H1). H=300mm is suitable for wall drain toilets and floor drain toilets.
  • For the bathroom pod with H value = 200mm; structure descend depth H2 = H-H1 (H2 = 200-H1). H=200mm is suitable for wall drain toilets.
Hot and cold water supply pipe connection

Hot and cold water supply pipe connection

  • The hot and cold water pipes are connected above the ceiling.
  • The 1/2 female connectors or PPR connectors with ID.20mm should be reserved by contractor.
  • The bathroom pod PPR hot and cold water pipe with OD.20mm.
Hot and cold water supply pipe connection
Introduction of the connection between bathroom pod and window

Introduction of the connection between bathroom pod and window

  • Window frame of different materials.
  • Tiles
  • Marbles
Introduction of the bathroom pod drainage system connection
Introduction of the bathroom pod drainage system connection

Introduction of the bathroom pod drainage system connection

  • Two drainage pipes, one from the toilet(The basin waste water is collected into the toilet drain pipe); the other is from the floor drain.
  • The toilet is wall drainage.

Bathroom pod exterior partition wall construction method

Type Wall finish surface
treatment
Effect
50MM
wall panel – bathroom pod exterior wall
PVC/PET Bathroom pod exterior partition wall
LGS + CCA board Plaster/painting Bathroom pod exterior partition wall

Bathroom pod exterior partition wall

Lightweight
cement foam board
Plaster/painting Bathroom pod exterior partition wall
Wall brick Plaster/painting Bathroom pod exterior partition wall
Bathroom pod exterior partition wall construction method
Bathroom pod exterior partition wall construction method
Bathroom pod exterior partition wall construction method
Bathroom pod exterior partition wall construction method

3. Comparison between composite enclosure system bathroom pod and traditional bathroom

Item Bathroom pod Traditional bathroom
Product quality Factory prefabricated production, strict factory quality assurance
system, product quality guaranteed
It is hard to ensure the personal skills and responsibility of the on-site construction personnel, and the quality is difficult to guarantee.
Installation efficiency Assemble onsite:completed
by 2 workers in 6 hours;
Lift installation:completed
by 2 workers in 2 hours;
It will take around 11 worker day to complete a normal bathroom.
Environmental protection 1.No construction waste is generated on site, and it is green and environmentally
friendly;
2.dry construction, no need to use water;
Wet construction method is easy to
generate construction waste, and the water consumption is large.
Construction management Short time, small number of worker, less cross-work, easy to manage Many workers, long time, difficult to manage
Drainage method Same floor drainage method can be adopted,which will be no effect to the residents down floors. Different floor drainage method, easy to generate drainage noise to residents down floors.
Anti-leakage One-time base tray forming technology,no-leakage Easy to cause leakage
Combustion performance Class A non-combustible material Class A non-combustible material
Sound insulation value 33-40dB 39dB
Cost effective 1.Material cost is slightly higher;
2.Low on-site management costs;
3.Low maintenance costs;
4.Wall thickness is 30-70mm, the room usage area is increased.
1.material costs are slightly lower;
2.On-site management costs are high and onsite management is more difficult;
3.Higher maintenance costs;
4.Wall thickness is normally 120mm

4. Comparison between composite enclosure system bathroom pod and SMC bathroom pod

Item Composite enclosure system bathroom pod SMC bathroom pod
Product stability Good rigidity, very stable Poor rigidity, easy to feel vibration
Finishing effect Can be applied to a variety of interior materials such as tiles, PVC, mosaics, etc. wall material with surface finish integration
Connect with the main building Descend floor needed, no need to connect with the main building Descend floor needed, and connected to the building wall with connectors
Effective usage area The thickness of the partition wall
between the bathroom pod and the room can be reduced to 100mm,which can increase the room area.
The space between the bathroom pod wall and the building wall is 120mm on one side, which will cause a certain waste of space.
Construction method Lift installation or on-site assembly, dry construction On-site assembly, dry construction
Base tray technology One-time base tray forming technology,no-leakage One-time base tray forming technology,no-leakage
Combustion performance Class A non-combustible material Class A non-combustible material
Sound insulation value 33-40dB Sound insulation is very poor (about 20dB)
Order requirement Independent of molds, large quantities or in small batches available, and can be customized. High mold cost and minimum order
quantity required

5. Composite enclosure system bathroom pod case study

Residential series

Residential series

Wall: Tile

Floor: Non-slip tile

Base tray: Steel base tray

Residential series

Wall: Tile

Floor: Non-slip tile

Base tray: Steel base tray

Apartment series

Apartment series

Wall: PVC

Floor: FRP

Base tray:FRP

Apartment series

Wall: PVC

Floor: Non-slip floor tile

Base tray:FRP

Hotel series

Hotel series

Wall surface: PVC

Floor: floor tile

Base tray: steel base tray

Hotel series

Wall : glass surface

Floor: non-slip floor tile

Base tray: steel base tray

Hotel series

Wall surface: PVC

Floor: floor tile

Base tray: steel base tray

Hotel series

Wall: latex paint + tile

Floor: non-slip floor tile

Base tray: steel base tray