Our GRP Manufacturing Case Studies

ABI Holiday Homes is one of the UK’s leading manufacturers of premium holiday lodges, known for combining craftsmanship, comfort, and innovation in each design. Their products are built to deliver an exceptional experience for holiday park operators and owners alike.

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THE CHALLENGE

Develop accessible, seamless GRP flooring system

THE VALUE WE ADDED

Integrated design combining form, function, and efficiency

THE BENEFIT TO THE CUSTOMER

Improved quality, accessibility, and production consistency

“MPM took the project from initial concept by working closely with the ABI team and transferring the ideas right through to first off parts for approval. The project was delivered on time and kept to the agreed timescales and budget.”

Steve Collinson,
Procurement Co-ordinator ABI UK LTD

ABI’s goal was to develop a new flooring system for its premium holiday homes that improved accessibility and user comfort while maintaining a high-end aesthetic. The brief required the floor to accommodate the diverse needs of all users, including wheelchair accessibility, while also enhancing the overall design and ease of installation for ABI’s manufacturing team. The solution needed to balance style, practicality, and production efficiency — a challenge that required both technical expertise and creative design thinking.

Durham worked collaboratively with ABI’s engineering and design teams from the earliest concept stages. Together, they developed a one-piece GRP flooring system that eliminated the need for multiple assemblies and additional surface finishing. A key feature of the new design was the integration of moulded raised plinths to accommodate essential fixtures such as the WC, basin, and radiator. This innovation simplified installation, maintained consistent levels across units, and ensured a precise fit every time. To further strengthen the structure, timber rails were bonded beneath the floor, ensuring stability and flatness throughout production and use. This not only improved durability but also made the part more efficient to install, helping ABI maintain a smooth production flow.

One of the most notable achievements was the inclusion of a tile pattern directly into the mould tool at the pattern stage. By engineering the texture into the tool itself, MPM removed the need for secondary surface finishing, achieving a premium look that was both durable and easy to clean. The end product also featured integrated ramp access and improved drainage, ensuring compliance with accessibility requirements while enhancing overall user experience. The design combined strength, functionality, and elegance — all in a single, moulded GRP component.

The success of the project was built on strong communication and partnership between ABI and MPM Durham. From initial sketches through to first-off parts, both teams maintained close collaboration to meet agreed timescales and budget targets. MPM’s ability to deliver on technical design, tooling precision, and quality manufacturing helped ABI elevate their product offering, reinforcing its reputation for quality and innovation in the leisure industry.