Modular retro-fit pod

Abstract

A modular bathroom pod is described which is assembled on site. It has an enclosure with a floor, ceiling and walls. At least two of the walls have a stainless-steel frame with a flush outer cladding

Description

1 9 09 9^ Field of the invention The present invention relates to a modular retro-fit pod for use in prisons and other 5 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. 10 The majority of UK prison cells do not have showers and there is a drive in the UK by the Ministry of Justice (MOJ) to increase decency in prisons and avoid communal showers. 15 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 needs to be extremely robust and 20 safe, especially where there is a risk of “smash ups”. Custodial furniture, such as beds, desks, lockers, screens and the like, may compromise 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 alia, fracturing of the medium density fibreboard (MDF) or pressure bonded resin 1 9 09 9^ materials. 5 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 10 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 15 frame with cladding, wherein the frame compromise a flush outer face; and the inner face compromising 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 fame with stainless steel 25 outer face flush in appearance. The metal frame will 1 9 09 9^ be provided with a metal outer skin, e.g. a sheet stainless 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 5 D to Cat A). Thus, the external appearance of the frame and cladding is that of a conventional wall found in most buildings, i.e. ready 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. 10 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 15 normal conditions. The 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 20 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. 25 1 9 09 9^ The inner face will generally comprise internal panels that may also be manufactured as smaller panels which are capable of being interlinked. The interlinking of the smaller panels may compromise 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 5 layperson under normal conditions. In the modular pod, one wall will define an entrance. The floor may be constructed of a cast of solid surface resin type with a prepositioned 10 fall to a drain. The dimensions of the frame will vary depending upon, inter alia, the nature of the modular pod. However, such dimensions will be well understood by the person skilled in the art. 15 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 20 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 50mm thick; or from 25 about 15 to 50 mm thick; or from about 15 to 45mm thick; or from 1 9 09 9^ about 20 to about 45mm thick; or from about 20 to 40mm thick; or from about 20 to 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, 5 acrylic polymers. A preferred material may compromise an acrylic polymer / alumina trihydrate composite, such as it available as Krion® from Porcelanosa or Corian™ from Du Pont. 10 Another example of a substrate is a high pressure laminate plate material. A particular high pressure laminate plate material may compromise a phenolic resin. A preferred material may comprise Trespa™ which is commercially available from Trespa International BV. 15 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 compromise the same resin as that used in the substrate. Thus, for example, furniture comprising a Krion® or Corian™ coating may comprise an acrylic polymer base; or furniture comprising Trespa™ may comprise a phenolic resin base. However, it is 20 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 non-degradable. Thus, the resin or polymer may comprise a natural or synthetic material 1 9 09 9^ 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 5 include, but shall not be limited to, silica polymers, and the like. The modular pod will generally include appropriately positioned plumbing, ventilation and wiring. 10 Key features of the modular bathroom pod of tire invention include: • Bespoke space savings design, built to suit existing w aste outlets and water services • Incorporates ligature-resistant MO J approved fixtures, fittings and sanitary 15 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 minimalised as far as possible. • Panels incorporate self-cleaning and purification properties when subject to 20 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). 1 9 09 9^ The modular pod is advantageous in that, inter alia, 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, 5 (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. 10 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. 15 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. 20 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 25 be lighter in weight, does not need additional components, and can be quicker to 1 9 09 9^ assemble. The solvent cementing process also avoids the stress concentrations usually found at mechanical fixings. The process gives a joint with low or zero visibility and, unlike adhesive bonding, 5 there is no additional phrase 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 10 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. 20 Summary of Drawings The invention will now be illustrated by way of example only and with reference to the accompanying drawings in which: Figures 1 to 6 illustrate views of a left-handed stainless steel metal framework of an 25 embodiment of a left-handed shower pod according to the present invention: Figures 7 to 12 illustrate views of a right-handed stainless steel metal framework of an embodiment of a right-handed shower pod according to the present invention; Figures 13 to 41 illustrate views of an embodiment of a left-handed shower pod according to the present invention; Figures 42 to 70 illustrate views of an embodiment of a right-handed shower pod according to the present invention. Figures 1 to 6 illustrate views of a left-handed stainless steel metal framework of an embodiment of a left-handed shower pod according to the present invention. As shown, the framework comprises frames and outer cladding. The framework also comprises an entrance opening. The frames include a base frame for a floor of the lefthanded shower pod, a top frame for a ceiling of the left-handed shower pod, and side frames for walls of the left-handed shower pod. Outer cladding is arranged on the outer side of two side frames. Outer cladding is arranged across the top and bottom of the entrance opening. Figure 1 depicts a top view of the left-handed stainless steel framework. Figures 2 and 3 depict side views of the left-handed stainless steel framework. Figures 4 and 5 depict perspective views of the left-handed stainless steel framework. Figure 6 depicts an exploded view of the left-handed stainless steel framework of the left-handed shower pod. Figures 7 to 12 illustrate views of a right-handed stainless steel metal framework of an embodiment of a right-handed shower pod according to the present invention. As shown, the framework comprises frames and outer cladding. The framework also comprises an entrance opening. Hie frames include a base frame for a floor of the right-handed shower pod, a top frame for a ceiling of the right-handed shower pod and side frames for walls of the right-handed shower pod. Outer cladding is arranged on the outer side of two side frames. Outer cladding is arranged across the top and bottom of the entrance opening. Figure 7 depicts atop view of the right-handed stainless steel 1 9 09 9^ framework. Figures 8 and 9 depict side views of the right-handed stainless steel framework. Figures 10 and 12 depict perspective views of the right-handed stainless steel framework. Figure 11 depicts an exploded view of the right-handed stainless steel framework of the right-handed shower pod. 5 Figures 13 to 42 illustrate views of an embodiment of a left-handed shower pod according to the present invention where an inner Krion resin wall panel is secured directly to a wall frame with recessed screws and an inner Krion resin ceiling panel is secured directly to a ceiling frame with recessed screws. 10 Figures 13 illustrates a view of a left-handed Krion ceiling panel of the embodiment of the left-handed shower pod according to the present invention. In this example, the ceiling panel is a 19mm thick Krion panel (2) and comprises a cut out for shower plumbing (1), and a cut out for a light (3). 15 Figure 14 illustrates a view of a left-handed shower tray base of the embodiment of the left-handed shower pod according to the present invention. In this example, the shower tray base is a 20mm thick sold grade laminate (SGL) substrate (5) and comprises a cut-out for drainage (4). 20 Figure 15 illustrates a view of a left-handed shower tray of the embodiment of the lefthanded shower pod according to the present invention. In this example, the shower tray is a 30mm thick shower tray (6) and comprises a cut out for drainage (not numbered). 25 Figures 16 to 25 illustrate views of frames of the left-handed shower pod. As shown, the left-handed shower pod comprises a side 1A, an entrance IB, a side 2, a side 3 and a side 4. Figure 16 depicts a plan view of a floor of the shower pod, showing the line of the outside edge of the base frame (7). The base frame is held together in comers with stainless steel comer plates (8). The floor includes a stainless steel floor grate (17). Figure 17 depicts a plan view of the shower pod above the entrance opening level, showing the line of the outside edge of the top frame (9). As shown, the shower pod comprises a shower head (21), resin WC (27) and resin wash hand basin with shelf over (31). Figure 18 depicts a view of a top frame for a ceiling of the left-handed shower pod, showing a removable access panel over the entrance opening (10). Figure 19 depicts a view of a base frame for a floor of the left-handed shower pod, showing a removable access panel under the entrance opening (11). The side wall 1A and entrance IB are formed by one side frame. Figures 20 and 21 respectively depict views 1 9 09 9^ A and B of a first side frame forming the side wall for side 1A and entrance IB. Figure 22 depicts a view of a second side frame forming the side wall for side 2. Figure 23 depicts a view of a third side frame forming the side wall for side 3. In this example, 2mm stainless steel plate is flush with the internal frame to form wall panels (12). Holes for sanitary ware (13, 14) will be drilled into the plate on site by others. In this example, the recommended hole sizes in the wall panels are: (A) water pipe hole 35mm dia (2off) (wallgate show 33mm dia), (B) basin fixing holes 25mm dia (3off) (wallgate show 16mm to 22mm dia), (C) waste pipe hole 80mm dia (1 off) (wallgate show 75mm) (D) push button hole 35mm dia (2off) (wallgate show 27mm to 33mm dia), (E) wall fixing hole 25mm dia (5off) (wallgate show 20mm dia). In this example, note 1. the 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 24 depicts a side view of the third side frame. Figure 25 depicts a view of a fourth side frame forming the side wall for side 4. Figure 26 illustrates a plan view of the left-handed shower pod. As shown in Figures 16 to 25, each side wall at sides 1A, 2, 3 and 4, floor and ceiling comprise a frame. As shown, the shower pod comprises rockwool firestop insulation to all inside cavities of the metal framework (15). The side wall on side 2 comprises a 304 grade 30x30 stainless steel frame with security bolts through the outside face through the frame. The exterior of the side wall on side 2 is faced with 2mm thick stainless steel sheet welded to the frame and has a smooth finish painted with magnolia satin (16). The drain in the floor includes a stainless steel floor grate (17). A ligature resistance rail and FR shower curtain (18) is arranged at entrance IB. The line of the outside edge of the shower tray is depicted (19). The exterior of the side wall on side 1A is faced with 2mm thick stainless steel sheet welded to the frame and has a smooth finish with painted magnolia satin (20). The shower pod comprises a shower head (21). As shown 1 9 09 9^ at (22) and (32), the respective outer 2mm stainless steel sheets sail over the respective frames. The frames are held together in comers with stainless steel comer plates (23, 26). The side wall of side 4 comprises an inner Krion K-life resin panel mounted on the inside of the frame of the sidewall. The frame of the side wall at side 4 comprises a 304 grade 30x30 stainless frame (25). The shower pod comprises a resin W.C (27). In this example, a service duct with hot and cold waste discharge and 5 amp fused spur is provided, the sanitary’ ware is plumbed up to existing services and the electronic control box wired into the spur (28). In side wall 3, a 2mm stainless steel plate is welded to the inside of the frame, forming a flush face and drilled to accommodate sanitary ware (29). As shown, sanitary ware is fixed through the wall (30). The shower pod comprises a resin wash hand basin with a shelf over (31). Figure 27 illustrates a sectional view through axis AA of the left-handed shower pod of Figure 26. The side walls of the left-handed shower pod comprise inner 19mm Krion resin panels mounted on frames. As shown, the side wall on side 3 and ceiling comprise inner Krion K-life panels (33). Rockwool firestop insulation is provided to the inside of metal framework of the left-handed shower pod. As shown, rockwool firestop insulation is provided to the inside of the metal framework of side wall of side 1A (34). The exterior of the side wall of side 1A is faced with 2mm thick stainless sheet welded to the frame and has a smooth finish painted with magnolia satin (35), the interior of the side wall of side 1A has a Krion K-life resin panel (36) mounted on the frame and the frame of the side wall of side 1A comprises a 30mmx30mm 304 grade stainless steel frame (37). In this example, the floor of the shower pod comprises a resin shower tray on a solid grade laminate substrate on a 304 grade stainless steel base frame (38). The shower pod comprises sanitary ware (39). Figure 28 illustrates a sectional view of a panel fixing detail for a side wall of the left handed shower pod. The side wall comprises a 30mmx30mm 304 grade stainless steel 1 9 09 9^ frame (40) fixed to a building wall. Rockwool firestop insulation (41) is arranged inside the metal framework. There is a void (42) between the frame and the building wall. A Krion K-life resin panel (43) is secured to the inside of the steel frame by a recessed stainless steel csk self-tapping screw (44). Tire screw recess is filled with a 19mm Krion pellet (45). Figure 29 illustrates a sectional view of interface details between a side wall and the floor of the left-handed shower pod, where the left-handed shower pod comprises a Krion K-life resin panel, a resin shower tray and a base frame. The side wall comprises a frame and the floor comprises a frame (46) bolted together by a M5 stainless steel round headed bolt (47). A 30mmx30mm 304 grade stainless steel frame portion (48) spaces the side wall frame and floor frame from the building wall. A 30mm Krion shower tray (49) and 20mm thick solid grade laminate substrate base (50) are mounted on the floor frame (46). The side walls of the left-handed shower pod comprise 19mm Krion resin panels. As shown, a 19mm Krion K-life resin panel (51) is secured to the inside of the side wall frame by a recessed stainless steel csk self-tapping screw with 19mm Krion pellet (52). White Arbicol 1025 anti-pick mastic (53) is located along the edge between the Krion wall panel and Krion shower tray. Figure 29 shows how a removable access panel (54) is required where the entrance opening is. 1 9 09 9^ Figure 30 illustrates a sectional view of ceiling junction details of the left-handed 5 shower pod. Hie ceiling junction is formed between a side wall and the ceiling of the left-handed shower pod. The side wall comprises a 30mmx30mm 304 grade stainless steel frame (55) that extends to the building ceiling. The ceiling comprises a 30mmx30mm 304 grade stainless steel frame (56) extending to the building wall. There is a void (57) between the ceiling frame and the building ceiling. There is a void 10 (58) between the wall frame and the building wall. Krion K-life resin panels (59) are mounted on the inside of the wall frame and the ceiling frames. As shown, the Krion ceiling panel is secured to the frame by a recessed stainless steel csk self-tapping screw with a 19 mm Krion pellet (60). White Arbicol 1025 anti-pick mastic (61) is located along the edge between the Krion wall panel and Krion ceiling panel. 15 Figure 31 illustrates a sectional view of comer details of the left-handed shower pod. The comer is formed between two side walls of the left-handed shower pod. Each side wall comprises a 30mmx30mm 304 grade stainless steel frame. Rockwool firestop insulation is mounted to inside of the metal framework (62). A 30mmx30mm 304 20 grade stainless steel frame portion (63) spaces one of the side wall frames from the building wall. A comer plate (64) is welded to the side wall frames at welding joints (65) and secured by an A2 M10 stainless security bolt with nyloc nut (66). Krion panels (67) are mounted on the inside of the wall frames using recessed screws. White Arbicol 1025 anti-pick mastic (68) is located along the edge between the Krion wall 25 panels. Figure 32 illustrates a sectional view through axis BB above the entrance of the lefthanded shower pod. The ceiling comprises a stainless steel frame (69) and an inner 1 9 09 9^ 19mm Krion panel (70). Rockwool firestop insulation is provided inside the metal framework. A removable front access panel (71) extends between the ceiling frame and the ceiling. The removable front access panel is secured using M6 button head security bolts (A2 stainless steel). 5 Figure 33 illustrates a sectional view through axis BB below the entrance of the lefthanded shower pod. The floor comprises a 30mm stainless steel frame (72), 20mm solid grade laminate substrate (73) and 30mm shower tray (74). Rockwool firestop insulation is provided inside the metal framework. A removable front access panel 10 (75) extends between the floor frame and the floor. The removable front access panel allows for access to drains is secured using M6 button head security bolts (A2 stainless steel). A contrast nosing (76) is mounted atop the access panel. White Arbicol 1025 anti-pick mastic (77) is located along the edge between the contrast nosing and the shower tray. 15 Figure 34 illustrates a sectional view through axis CC at the ceiling of the left-handed shower pod. The side wall extends to the ceiling and comprises a frame, a stainless steel outer skin (78) and an inner 19mm Krion panel (79). The ceiling comprises a stainless steel frame (80) and an inner 19mm Krion panel (81). The wall frame and 20 ceiling frame are bolted together. Rockwool firestop insulation is provided inside the metal framework. White Arbicol 1025 anti-pick mastic (82) is located along the edge between the inner wall Krion panel and inner ceiling Krion panel. Figure 35 illustrates a sectional view through axis CC at the floor of the left-handed 25 shower pod. The side wall extends to the floor and comprises a frame (83), a stainless steel outer skin (84) and an inner 19mm Krion panel. The floor comprises a stainless steel frame (85), solid grade laminate substrate base (86) and a shower tray (87). The wall frame and floor frame are bolted together by a bolt with a nyloc nut (88). Rockwool firestop insulation is provided inside the metal framework. Support feet (89) are arranged between the floor frame and the floor as required to avoid the frame and feet near shower tray drain. White Arbicol 1025 anti-pick mastic (90) is located along the edge between the inner wall Krion panel and shower tray. Figures 36 to 41 illustrate views of the inner wall panels of the left-handed shower pod. The inner wall panels are one piece and comprise 19mm Krion panels. Figure 36 depicts a plan view of tire left-handed shower pod where a first inner panel is arranged on the inside of the first side wall on the first side 1, a second inner panel is arranged on the inside of the second side wall on the second side 2, a third inner panel is 1 9 09 9^ arranged on the inside of the third side wall on the third side 3, and a fourth inner panel is arranged on the inside of the fourth side wall on the fourth side 4. In this example, the first inner panel and second inner panel have radius comer edges (91) at the entrance. Figure 37 depicts apian view of the first inner panel having the radius comer edge (R6). The first inner panel is 726mm wide, 200mm high with the radius edge to face the entrance. Figure 38 depicts a plan view of the second inner panel having a radius comer edge (R6). The second inner panel is 512mm wide, 2001mm high with the radius edge to face the entrance. Figure 39 depicts a plan view of the third inner panel that is 1162mm wide and 2001mm high. Figure 40 depicts a plan view of the fourth inner panel that is 981mm wide and 2001mm high. Figure 41 depicts a side view of the inner wall panel (92) where it extends to the ceiling panel (93).The top of the shower tray is 50mm above the top of the base frame When installing the inner panels, the first inner panel is installed first, second inner panel is installed second, third inner panel is installed third, fourth inner panel is installed fourth, and ceiling inner panel is installed last after the inner wall panels. Figures 42 to 70 illustrate views of an embodiment of a right-handed shower pod according to the present invention where an inner Krion resin wall panel is secured 1 9 09 9^ directly to a wall frame with recessed screws and an inner Krion resin ceiling panel is secured directly to a ceiling frame with recessed screws. Figures 42 illustrates a view of a right-handed Krion ceiling panel of the embodiment 5 of the right-handed shower pod according to the present invention. In this example, the ceiling panel is a 19mm thick Krion panel (95) comprising a cut out for shower plumbing (94) and a cut out for a light (96). Figure 43 illustrates a view of a right-handed shower tray base of the embodiment of 10 the right-handed shower pod according to the present invention. In this example, the shower tray base is a 20mm thick solid grade laminate (SGL) substrate (98) and comprises a cut-out for drainage (97). Figure 44 illustrates a view of a right-handed shower tray of the embodiment of the 15 right-handed shower pod according to the present invention. In this example, the shower tray is a 30mm thick shower tray (99) and comprises a cut out for drainage (not numbered) and. Figures 45 to 54 illustrate views of frames of the right-handed shower pod. As shown, 20 the right-handed shower pod comprises a side 1A, an entrance IB, a side 2, a side 3 and a side 4. Figure 45 depicts a plan view of a floor of the shower pod, showing the line of the outside edge of the base frame (100). The base frame is held together in comers with stainless steel comer plates (101). The floor includes a stainless steel floor grate (17). Figure 46 depicts a plan view of the shower pod above the entrance 25 opening level, showing the line of the outside edge of the top frame (102). As shown, the shower pod comprises a shower head (21), resin WC (27) and a resin wash hand basin with a shelf over (31). Figure 47 depicts a view of a top frame for a ceiling of the right-handed shower pod, showing a removable access panel over the entrance 1 9 09 9^ opening (103). Figure 48 depicts a view of a base frame for a floor of the right-handed shower pod, showing a removable access panel under the entrance opening (104). The side wall 1A and entrance IB are formed by one side frame. Figures 49 and 50 respectively depict views A and B of a first side frame forming the side wall for side 5 1A and entrance IB. Figure 51 depicts a view of a second side frame forming the side wall for side 2. Figure 52 depicts a view of a third side frame forming the side wall for side 3. In this example, 2mm stainless steel plate is flush with the internal frame to form wall panels (105). Holes for sanitary ware (106, 107) will be drilled into the plate on site by others. In this example, the recommended hole sizes in the wall panels are: 10 (A) water pipe hole 35mm dia (2off) (wallgate show 33mm dia), (B) basin fixing holes 25mm dia (3off) (wallgate show 16mm to 22mm dia), (C) w aste pipe hole 80mm dia (loff) (wallgate show 75mm) (D) push button hole 35mm dia (2off) (wallgate show 27mm to 33mm dia), (E) wall fixing hole 25mm dia (5ofi) (wallgate show 20mm dia). In this example, note 1. the base of cistem to sit 750mm from finished floor level (top 15 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 53 depicts a side view of the third side frame. Figure 54 depicts a view of a fourth side frame forming the side wall for side 4. 20 Figure 55 illustrates a plan view of the right-handed shower pod. As shown in Figures 45 to 54, each side wall at sides 1A, 2, 3 and 4, floor and ceiling comprise a frame. As shown, the shower pod comprises rockwool firestop insulation to all inside cavities of the metal framework (108). Hie side wall on side 2 comprises a 304 grade 30x30 stainless steel frame with security bolts through the outside face through the frame. 25 The exterior of the side wall on side 2 is faced with 2mm thick stainless steel sheet welded to the frame and has a smooth finish painted with magnolia satin (109). The drain in the floor includes a stainless steel floor grate (17). A ligature resistance rail and FR shower curtain (110) is arranged at entrance IB. The line of the outside edge 1 9 09 9^ of the shower tray is depicted (111). The exterior of the side wall on side 1A is faced with 2mm thick stainless steel sheet welded to the frame and has a smooth finish with painted magnolia satin (112). The shower pod comprises a shower head (21). As shown at (113) and (121), the respective outer 2mm stainless steel sheets sail over the 5 respective frames. The frames are held together in comers with stainless steel comer plates (114, 117). The side wall of side 4 comprises an inner Krion K-life resin panel (115) mounted on the inside of the frame of the sidewall. The frame of the side wall at side 4 comprises a 304 grade 30x30 stainless frame (116). The shower pod comprises a resin W.C (27). In this example, a service duct with hot and cold waste 10 discharge and 5 amp fused spur is provided, the sanitary ware is plumbed up to existing services and the electronic control box wired into the spur (118). In side wall 3, a 2mm stainless steel plate is welded to the inside of the frame, forming a flush face and drilled to accommodate sanitary ware (119). As shown, sanitary ware is fixed through the wall (120). The shower pod comprises a resin wash hand basin with a shelf over (31). 15 Figure 56 illustrates a sectional view through axis AA of the right-handed shower pod of Figure 55. Tire side walls of the right-handed shower pod comprise inner 19mm Krion resin panels mounted on frames. As shown, the side wall on side 3 and ceiling comprise inner Krion K-life inner panels (122). Rockwool firestop insulation is 20 provided to the inside of metal framework of the right-handed shower pod. As shown, rockwool firestop insulation is provided to the inside of the metal framework of side wall of side 1A (123). The exterior of the side wall of side 1A is faced with 2mm thick stainless sheet welded to the frame and has a smooth finish painted with magnolia satin (124), the interior of the side wall of side 1A has a Krion K-life resin panel (125) 25 mounted on the frame and the frame of the side wall of side 1A comprises a 30mmx30mm 304 grade stainless steel frame (126). In this example, the floor of the shower pod comprises a resin shower tray on a solid grade laminate substrate on a 304 grade stainless steel base frame (127). The shower pod comprises sanitary ware (128). Figure 57 illustrates a sectional view of a panel fixing detail for a side wall of the right 1 9 09 9^ handed shower pod. The side wall comprises a 30mmx30mm 304 grade stainless steel frame (129) fixed to a building wall. Rockwool firestop insulation (130) is arranged 5 inside the metal framework. There is a void (131) between the frame and the building wall. A Knon K-life resin panel (132) is secured to the inside of the steel frame by a recessed stainless steel csk self-tapping screw (133). The screw recess is filled with a 19mm Krion pellet (134). 10 Figure 58 illustrates a sectional view of interface details between a side wall and the floor of the right-handed shower pod, where the right-handed shower pod comprises a Krion K-life resin panel, a resin shower tray and a base frame. The side wall comprises a frame and the floor comprises a frame (135) bolted together by a M5 stainless steel round headed bolt (136). A 30mmx30mm 304 grade stainless steel 15 frame portion (137) spaces the side wall frame and floor frame from the building wall. A 30mm Krion shower tray (138) and a 20mm thick solid grade laminate substrate base (139) are mounted on the floor frame (135). The side walls of the right-handed shower pod comprise 19mm Krion resin panels. As shown, a 19mm Krion K-life resin panel (140) is secured to the inside of the side wall frame by a recessed stainless steel 20 csk self-tapping screw with 19mm Krion pellet (141). White Arbicol 1025 anti-pick mastic (142) is located along the edge between the Krion wall panel and Krion shower tray. Figure 29 shows how a removable access panel (143) is required where the entrance opening is. 25 Figure 59 illustrates a sectional view of ceiling junction details of the right-handed shower pod. Tire ceiling junction is formed between a side wall and the ceiling of the right-handed shower pod. The side wall comprises a 30mmx30mm 304 grade stainless steel frame (144) that extends to the building ceiling. The ceiling comprises a 30mmx30mm 304 grade stainless steel frame (145) extending to the building wall. There is a void (146) between the ceiling frame and the building ceiling. There is a 1 9 09 9^ void (147) between the wall frame and the building wall. Krion K-life resin panels (148) are mounted on the inside of the wall frame and the ceiling frames. As shown, 5 the Krion ceiling panel is secured to the frame by a recessed stainless steel csk self tapping screw with a 19 mm Krion pellet (149). White Arbicol 1025 anti-pick mastic (150) is located along the edge between the Krion wall panel and Krion ceiling panel. Figure 60 illustrates a sectional view of comer details of the right-handed shower pod. 10 The comer is formed between two side walls of the right-handed shower pod. Each side wall comprises a 30mmx30mm 304 grade stainless steel frame. Rockwool firestop insulation is mounted to inside of the metal framework (151). A 30mmx30mm 304 grade stainless steel frame portion (152) spaces one of the side wall frames from the building wall. A comer plate (153) is welded to the side wall frames at welding 15 joints (154) and secured by an A2 M10 stainless security bolt with nyloc nut (155). Krion panels (156) are mounted on the inside ofthe wall frames using recessed screws. White Arbicol 1025 anti-pick mastic (157) is located along the edge between the Krion wall panel and Krion ceiling panel. 20 Figure 61 illustrates a sectional view through axis BB above the entrance of the right- handed shower pod. The ceiling comprises a stainless steel frame (158) and an inner 19mm Krion panel (159). Rockwool firestop insulation is provided inside the metal framework. A removable front access panel (160) extends between the ceiling frame and the ceiling. The removable front access panel is secured using M6 button head 25 security bolts (A2 stainless steel). Figure 62 illustrates a sectional view through axis BB below the entrance of the right-handed shower pod. Ure floor comprises a 30mm stainless steel frame (161), 20mm solid grade laminate substrate (162) and 30mm shower tray (163). Rockwool firestop insulation is provided inside the metal framework. A removable front access panel (164) extends between the floor frame and the floor. The removable front access panel allows for access to drains is secured using M6 button head security bolts (A2 stainless steel). A contrast nosing (165) is mounted atop the access panel. White Arbicol 1025 anti-pick mastic (166) is located along the edge between the contrast nosing and the shower tray. Figure 63 illustrates a sectional view through axis CC at the ceiling of the right-handed shower pod. The side wall extends to the ceiling and comprises a frame, a stainless 1 9 09 9^ steel outer skin (167) and an inner 19mm Krion panel (168). The ceiling comprises a stainless steel frame (169) and an inner 19mm Krion panel (170). The wall frame and ceiling frame are bolted together. Rockwool firestop insulation is provided inside the metal framework. White Arbicol 1025 anti-pick mastic (171) is located along the edge between the inner wall Krion panel and inner ceiling Krion panel. Figure 64 illustrates a sectional view through axis CC at the floor of the right-handed shower pod. Hie side wall extends to the floor and comprises a frame (172), a stainless steel outer skin (173) and an inner 19mm Krion panel. The floor comprises a stainless steel frame (174), solid grade laminate substrate base (175) and a shower tray (176). The wall frame and floor frame are bolted together by a bolt with a nyloc nut (177). Rockwool firestop insulation is provided inside the metal framework. Support feet (178) are arranged between the floor frame and the floor as required to avoid the frame and feet near shower tray drain. White Arbicol 1025 anti-pick mastic (179) is located along the edge between the inner wall Krion panel and shower tray. Figures 65 to 70 illustrate views of the inner wall panels of the right-handed shower pod. The inner wall panels are one piece and comprise 19mm Krion panels. Figure 36 depicts a plan view of the right-handed shower pod where a first inner panel is arranged on the inside of the first side wall on the first side 1, a second inner panel is 1 9 09 9^ arranged on the inside of the second side wall on the second side 2, a third inner panel is arranged on the inside of the third side wall on the third side 3, and a fourth inner 5 panel is arranged on the inside of the fourth side wall on the fourth side 4. In this example, the first inner panel and second inner panel have radius comer edges (180) at the entrance. Figure 37 depicts a plan view of the first inner panel having the radius comer edge (R6). The first inner panel is 726mm wide, 200mm high with the radius edge to face the entrance. Figure 38 depicts a plan view of the second inner panel 10 having a radius comer edge (R6). Hie second inner panel is 512mm wide, 2001mm high with the radius edge to face the entrance. Figure 39 depicts a plan view of the third inner panel that is 1162mm wide and 2001mm high. Figure 40 depicts a plan view of the fourth inner panel that is 981mm wide and 2001mm high. Figure 41 depicts a side view of the inner wall panel (181) where it extends to the ceiling panel 15 (182).The top of the shower tray is 50mm above the top of the base frame When installing the inner panels, the first inner panel is installed first, second inner panel is installed second, third inner panel is installed third, fourth inner panel is installed fourth, and ceiling inner panel is installed last after the inner wall panels. Optional embodiments of the invention are described in the clauses below: 20 Clause 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. 25 Clause 2. A modular bathroom pod according to clause 1 wherein the modular pod comprises at least a shower, WC and wash hand basin. 1 9 09 9^ Clause 3. A modular bathroom pod according to any one of clauses 1 or 2 wherein the metal frame is a stainless steel frame. Clause 4. A modular bathroom pod according to any one of the preceding clauses 5 wherein the stainless steel frame comprises a stainless steel outer face flush in appearance. Clause 5. A modular bathroom pod according to any one of the preceding clauses wherein the solid surface resin is generally secured to the stainless steel frame with 10 mechanical fixings (bolts and screws) which are recessed below the resin face, or proprietary commercial adhesive, or combination of both. Clause 6. A modular bathroom pod according to clause 5 wherein the mechanical fixings are concealed in resin pellets. 15 Clause 7. A modular bathroom pod according to any one of the preceding clauses wherein the 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. 20 Clause 8. A modular bathroom pod according to any one of the preceding clauses 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. 25 Clause 9. A modular bathroom pod according to any of the preceding clauses wherein the inner face generally comprises internal panels that may also be manufactured as smaller panels which are capable of being interlinked. Clause 10. A modular bathroom pod according to clause 9 wherein the interlinking of the smaller panels comprises three stepped tongue and groove, with the addition of a 1 9 09 9^ solvent weld adhesive. 5 Clause 11. A modular bathroom pod according to clause 10 wherein the j oint between the interlinked smaller panels is watertight. Clause 12. A modular bathroom pod according to any one of the preceding clauses wherein one wall of the modular defines an entrance. 10 Clause 13. A modular bathroom pod according to any one of the preceding clauses wherein the frame is provided with means for securing it to a building which houses the modular pod. 15 Clause 14. A modular bathroom pod according to clause 13 wherein the modular pod is adapted to be screwed or bolted to the floor or wall(s) of the prison building. Clause 15. A modular bathroom pod according to any one of the preceding clauses wherein the resin includes acrylic polymers. 20 Clause 16. A modular bathroom pod according to any one of the preceding clauses wherein the resin is an acrylic polymer / alumina trihydrate composite, such as is available as Corian™ from Du Pont. 25 Clause 17. A modular bathroom pod according to any of the preceding clauses wherein the resin is a high pressure laminate plate material. Clause 18. A modular bathroom pod according to clause 17 wherein the high pressure 1 9 09 9^ laminate plate material comprises a phenolic resin, such as Trespa™ which is commercially available from Trespa International BV. 5 Clause 19. A modular bathroom pod according to any one of the preceding clauses wherein the resin is a waterproof resin. Clause 20. A modular bathroom pod according to any one of the preceding clauses wherein the modular pod includes appropriately positioned plumbing and wiring. 10 Clause 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. 15 Clause 22. A panel according to clause 21 wherein the interlinked panels comprise a laminate bonded with a solid surface resin, e.g. a compact granted laminate substrate bonded with a solid surface resin. Clause 23. A panel according to clause 21 or 22 where the joints between the smaller 20 panels are watertight. Clause 24. A panel according to any one of clauses 21 to 23 for use in the manufacture of a modular bathroom pod according to clause 1. 25 Clause 25. A method of manufacturing a modular bathroom pod according to clause 1 which comprises interlinking a plurality of smaller metal frames and smaller panels, wherein the smaller panels are interlinked in combination of a three stepped tongue and groove and application of a solvent weld adhesive. Clause 26. A modular bathroom pod, panel or method as herein described with 5 reference to the accompanying description and figures. 10 15 LD Cd 20 25 30 35 40 45

Claims

12 09 241. A modular bathroom pod having a modular construction assembled on-site in a custodial establishment, the modular bathroom pod comprising:5 an enclosure defining a floor, a ceiling and walls,wherein at least two of the walls comprises:a wall stainless steel frame with an outer cladding, wherein the outer cladding comprises stainless steel sheet and wherein the outer cladding forms a flush outer wall face; and10 a wall inner panel, wherein the wall inner panel comprises a solid surface resin, wherein the inner wall panel forms an inner wall face, and wherein the wall inner panel is secured to the wall frame with mechanical fixings recessed below the resin face;wherein the ceiling comprises:a ceiling stainless steel frame; and15 a ceiling inner panel, wherein the ceiling inner panel comprises a solid surface resin,wherein the ceiling inner panel forms an inner ceiling face, and wherein the ceiling inner panel is secured to the ceiling frame with mechanical fixings recessed below the resin face.20 2. A modular bathroom pod according to claim 1 wherein the modular podcomprises at least a shower, WC and wash hand basin.

3. A modular bathroom pod according to any one of the preceding claims wherein the sold surface resin is substantially secured to the stainless steel frame witha combination of mechanical fixings which are recessed below the resin face and a proprietary commercial adhesive.12 09 244. A modular bathroom pod according to claim 1 or 3 wherein the mechanical 5 fixings are concealed with resin pellets.

5. A modular bathroom pod according to any one of the preceding claims wherein the wall inner panel comprises a plurality of inner panel sections interlinked on-site to form the wall inner panel.

106. A modular bathroom pod according to claim 5 wherein each joint between the interlinked inner panel sections comprises a three stepped tongue and groove with the addition of a solvent weld adhesive.15 7. A modular bathroom pod according to claim 6 wherein the j oint between theinterlinked inner panel sections is watertight.

8. A modular bathroom pod according to any one of the preceding claims wherein one wall of the modular bathroom pod defines an entrance.

209. A modular bathroom pod according to any one of the preceding claims wherein the wall frame comprises fixing means for securing it to the custodial establishment which houses the modular bathroom pod.12 09 2410. A modular bathroom pod according to claim 9 wherein the modular bathroom pod comprises fixing means and fixing points to screw or bolt the modular bathroom pod to the floor or wall(s) of the custodial establishment.5 11. A modular bathroom pod according to any one of the preceding claimswherein the resin of the wall inner panel and the resin of the ceiling inner panel comprises acrylic polymers.

12. A modular bathroom pod according to any one of the preceding claims 10 wherein the resin of the wall inner panel and the resin of the ceiling inner panel is anacrylic polymer / alumina trihydrate composite.

13. A modular bathroom pod according to any one of the preceding claims wherein the resin of the wall inner panel and the resin of ceiling inner panel is a 15 waterproof resin.

14. A modular bathroom pod according to any one of the preceding claims wherein the modular bathroom pod comprises ventilation, plumbing and wiring.20 15. A modular bathroom pod according to any one of the preceding claims,wherein the wall frame comprises a plurality of wall frame sections connected together to form the wall frame.

16. A modular bathroom pod according to claim 1 or 3 wherein the mechanical 25 fixings comprises bolts and screws.12 09 2417. A modular bathroom pod kit to assemble on-site at a custodial establishment, the kit comprising:a first wall stainless steel frame with a first wall outer cladding, wherein the first wall5 outer cladding comprises stainless steel plate forming a first flush outer wall face ofthe modular bathroom pod;a first wall inner panel, wherein the first wall inner panel comprises a solid surface resin, wherein the first wall inner panel is securable to the first wall stainless steel frame on-site forming a first inner wall face of the modular bathroom pod and wherein10 the first wall inner panel is securable to the first wall stainless steel frame with mechanical fixings recessed below the solid surface resin face;a second wall stainless steel frame with a second wall outer cladding, wherein the second wall outer cladding comprises stainless steel plate forming a second flush outer wall face of the modular bathroom pod;15 a second wall inner panel, wherein the second wall inner panel comprises a solidsurface resin, wherein the second wall inner panel is securable to the second wall stainless steel frame on-site forming a second inner wall face of the modular bathroom pod and wherein the second wall inner panel is securable to the first wall stainless steel frame with mechanical fixings recessed below the solid surface resin face;20 a ceiling stainless steel frame; anda ceiling inner panel, wherein the ceiling inner panel comprises a solid surface resin, wherein the ceiling inner panel is securable to the ceiling frame on-site forming an inner ceiling face of the modular bathroom pod, and wherein the ceiling inner panel is securable to the ceiling frame on-site with mechanical fixings recessed below the resin25 face.

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