Fully Integrated Sanitary Modules
BFG's systems integration capability goes far beyond composite manufacturing. We engineer and assemble complete, ready-to-install sanitary modules for high speed, intercity, commuter and metro rolling stock. Each cabin is a fully integrated system combining the composite structure with all mechanical, electrical and plumbing subsystems — tested and validated before delivery to the train builder.
OEM customers increasingly prefer a single source responsible for both the composite cabin structure and the integrated subsystems. BFG's proven track record as both a composites specialist and systems integrator uniquely positions us to deliver this complete scope, reducing interfaces, lead times and risk for our customers.
Scope of Integration
Integrated Subsystems
- Vacuum toilet systems (compact flush units, bowls, controls)
- Fresh water supply systems (tanks, pumps, plumbing, fittings)
- Waste water collection and retention systems (tanks, tank frames, piping)
- Electrical systems (lighting, sensors, control panels, wiring harnesses)
- Pneumatic systems (door actuators, flush controls)
- Automatic and hinged door systems
- Mirrors, dispensers, grab rails, baby change tables and accessories
- Heating and ventilation interfaces
Integration Engineering
Our systems integration engineering team manages the complete design and coordination of all subsystems within the cabin envelope. Using 3D CATIA modelling, we develop detailed integration drawings that define every interface point — structural mounting, electrical routing, plumbing connections and pneumatic supply — ensuring all components fit precisely within the available space and comply with the train builder's specifications.
Every integrated cabin undergoes rigorous factory acceptance testing (FAT) before shipment, including electrical continuity, leak testing of water circuits, vacuum system performance and door operation — so the module is ready for direct installation on the production line.
Cabin Configurations
Standard and Universal Cabins
- Standard WC cabins — compact modules with hinged doors for standard passenger use
- Universal (PRM) cabins — accessible modules with automatic sliding doors, larger footprint and wheelchair-compliant layouts
- Shower cabins — for long-distance and sleeper trains
- Custom configurations — bespoke layouts to match specific train geometry and operator requirements
OEM Customers
BFG is the preferred systems integration partner for the world's leading rolling stock manufacturers:
Materials & Compliance
All composite cabin structures are manufactured in fire retardant polyester or phenolic resin systems with gelcoat and paint finish, complying with the relevant fire, smoke and toxicity standards for each market:
Fire & Safety Standards
- EN 45545 (European rail fire safety)
- NF F 16-101 / NF F 16-102 (French norms)
- BS 6853 (British standard)
- DIN 5510 (German standard)
- UIC regulations for toilet cabins
Featured Projects
Explore some of our systems-integrated toilet cabin projects: