Building Innovation: How B&T Manufacturing Created a First-of-Its-Kind Floorless Bathroom Pod Solution
At B&T Manufacturing, we pride ourselves on creating tailored solutions for our clients—solutions that not only solve today’s challenges but set a new standard for what’s possible in modular construction. Over the past year, we’ve had the privilege of working closely with a developer and general contractor in Nebraska to design and deliver a unique bathroom pod system unlike anything that has been built before.
This journey wasn’t just about building pods; it was about building trust, solving complex problems, and reimagining how bathrooms can be integrated into multifamily construction.
A Partnership in Innovation
The Nebraska project is no small feat. With 117 bathrooms across six buildings, the developer needed a partner that could deliver a product that fit seamlessly into a wood-frame multifamily design. The requirements included three distinct bathroom configurations, each complete with a shower insert, toilet, vanity, mirror, and high-quality finish work.
To keep the project on schedule and within the client’s strict design parameters, the developer chose to source the materials directly, giving them greater control while allowing B&T Manufacturing to focus on precision assembly. This collaborative approach created a partnership built on communication and trust.
Our delivery plan is carefully staged: nine shipments in total, beginning with 15 bathrooms, then 10 at a time, and continuing until the full order is complete. This phased schedule ensures that the pods arrive just in time for installation, aligning with the building construction timeline.
Tackling a First-of-Its-Kind Challenge
The project’s most unique challenge—and its biggest breakthrough—was the need for a floorless bathroom pod design. Unlike conventional pods, which are built as complete modules with integrated floors, these pods had to be placed into the wood-frame structure before the concrete flooring was poured.
This meant rethinking pod construction from the ground up. Our team developed three prototype designs, testing and refining until we found a solution that could streamline both plumbing and electrical connections. Using steel frame wall studs cut with precision, the pods were engineered to align seamlessly with the building’s infrastructure.
“The floorless design wasn’t just new for us; it was new to the entire market. By taking on the challenge, B&T Manufacturing pushed modular construction into new territory, proving once again that when clients bring us their toughest problems, we deliver solutions”, said Tim Torpey, GM at B&T Manufacturing.
Looking Ahead
This week marks a milestone: the first set of 15 bathroom pods is being installed in the first building. Watching these pods slide into place is a powerful reminder of why innovation matters. Every line cut, every connection designed, and every hour spent refining prototypes has led to this moment.
As the project moves forward, B&T Manufacturing will continue delivering shipments on schedule, working closely with the developer and general contractor to ensure the final product exceeds expectations.
This commitment to efficiency is about more than speed—it’s about value. The faster pods are produced, the more quickly they can be installed on-site, ultimately accelerating the overall project schedule. And when time is money in construction, shaving hours off a project translates into real savings for our clients.
This isn’t just about building bathrooms—it’s about building smarter, faster, and with more flexibility than ever before.
Key Takeaways:
- Collaboration Drives Innovation:
When clients, contractors, and manufacturers work as true partners, even unprecedented challenges—like a floorless bathroom pod—become achievable. - Precision Matters:
From steel stud alignment to plumbing and electrical routes, success in modular construction depends on exacting detail and high-quality craftsmanship. - Efficiency is the Future:
By reducing production hours while maintaining quality, modular construction continues to deliver faster schedules and cost savings for developers.
At B&T Manufacturing, we believe every challenge is an opportunity to innovate. This Nebraska project is proof that when vision meets expertise, there are no limits to what can be built.
