Limbs & Things is a Bristol‑based manufacturer of medical simulation and training devices. The company has grown rapidly since its founding by medical illustrator Margot Cooper, supplying customers in 106 countries with over 100 simulation products . To support this growth, the business invested £2.2 million in a major expansion of its headquarters. The project involved refurbishing two adjacent warehouses on Days Road and Kingsland Road and linking them to the existing office to create a unified logistical, manufacturing and operational hub.
The expansion aligns with Limbs & Things’ mission of improving patient outcomes and maintaining Bristol as the centre of its global production . When the new premises officially opened in March 2026, the company celebrated an increase in production capacity and warehouse space, enabling it to scale manufacturing, reduce lead times and strengthen inventory management .
The client’s brief was to integrate two industrial units into a single, high‑functioning facility connected to the existing headquarters. Key objectives included:
Kitto Construction Ltd was appointed to design and deliver the project. The works included full refurbishment, the addition of a mezzanine floor, creation of changing rooms, stores and offices, and the construction of enclosed link structures between the units and the existing HQ to produce a fully integrated site.
The first phase focused on converting one warehouse into a dedicated goods‑in and quality‑control hub. The building was stripped back and refitted with modern receiving bays, inspection areas and integrated office spaces. To connect this facility to the existing HQ, the team designed and built a custom link bridge. Because the warehouse floors and the office were at different levels, the bridge incorporated a heavy‑duty goods lift. This ensured materials could flow smoothly into the production and storage areas without manual handling or disruption.
The second warehouse, larger than the first, was transformed into a state‑of‑the‑art manufacturing space. To maximise footprint, the team introduced a mezzanine floor. Engineers worked to minimise the number of support columns so that the ground floor remained open and flexible. New trimming areas and offices were created, and the layout was carefully coordinated to maintain clearances for oversized manufacturing machinery. The design balanced structural integrity with cost‑effective foundations to support the new mezzanine.
Installing the mezzanine imposed strict ceiling height restrictions. Limbs & Things’ manufacturing equipment is large, so meticulous spatial planning was vital to ensure machinery would fit and operate safely beneath the mezzanine. Kitto’s team collaborated with the client to map equipment footprints, adjust column positions and refine floor levels. Despite tight tolerances, the project delivered a usable layout without compromising structural safety or budget.
The integrated facility provides Limbs & Things with a unified logistical, manufacturing and operational base. The company reports that the expansion increases manufacturing capacity by around 70 per cent and expands its footprint by 50 per cent to roughly 59,000 sq ft . Warehouse capacity has also grown by about 70 per cent . This investment allows Limbs & Things to scale production, reduce lead times and improve inventory management . The new facilities enhance the working environment for staff and enable the company to pursue manufacturing excellence while keeping all production in Bristol . The expansion is expected to create up to 12 new jobs in 2026 .
Limbs & Things now supplies customers in 106 countries, and this project reinforces its commitment to Bristol as the centre of its global operations . By integrating multiple buildings and overcoming complex engineering challenges, Kitto Construction delivered a cost‑effective solution that future‑proofs the company’s growth and aligns with its mission to improve patient outcomes.
This facility expansion demonstrates how thoughtful design and strategic investment can unlock significant operational benefits. By refurbishing two warehouses, installing a mezzanine and connecting everything to the existing headquarters, Kitto Construction helped Limbs & Things dramatically expand its manufacturing and storage capacity. The project’s success supports the company’s global growth plans and enhances its ability to deliver high‑quality medical simulation products worldwide.
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