GB2621254A

GB2621254A - Modular building unit, building system, building and associated methods

Info

Publication number: GB2621254A
Application number: GB2311681.7A
Authority: GB
Inventors: Lee Jones David; Ross Shenton Edward
Original assignee: Sano Development Ltd
Current assignee: Sano Development Ltd
Priority date: 2022-07-29
Filing date: 2023-07-28
Publication date: 2024-02-07
Also published as: GB202311681D0

Abstract

There are disclosed modular building units, building systems, buildings, methods of constructing a building, kits for forming a modular building unit, and methods of constructing a modular building unit of a building. One method of constructing a modular building unit (12aIV)comprises the steps of: providing a service pod (50bIV 5 ) configured to perform a service function within the building, the service pod comprising a structural frame (110bIV) having at least one load-bearing support (214); providing a roof structure (99aIV) for the modular building unit; providing a floor structure (103aIV)for the modular building unit, and connecting the service pod to the floor structure to form a modular building unit sub-assembly (200) comprising the service pod and the 10 floor structure, and then connecting the roof structure to the modular building unit sub-assembly to form the modular building unit, by connecting the roof structure to the service pod. The service pod is arranged so that the at least one load-bearing support extends between and connects the roof structure to the floor structure, structural loading being transmitted from the roof structure to the floor structure through the at least one load-bearing support.

Description

MODULAR BUILDING UNIT, BUILDING SYSTEM, BUILDING AND ASSOCIATED METHODS The present invention relates to modular building units, building systems, buildings, methods of constructing a building, kits for forming a modular building unit, and methods of constructing a modular building unit of a building.

Prefabficated buildings (also known as 'modular' buildings) are well known in the construction industry, particularly modular residential buildings such as houses, flats or apartments, and hotels. Modular buildings typically comprise a series of building units which are constructed in a factory, transported to a final location (or site) for the building, and then arranged in a predetermined configuration and coupled together to form the finished building. The building units are typically constructed to a substantially assembled form in the factory, in which they can be transported to the final location.

Residential buildings arc typically taken to be buildings in which sleeping accommodation is provided for normal residential purposes, preferably with cooking and dining facilities, and normally comprise covered or enclosed living spaces which are heated ainUor climate controlled. Residential buildings therefore corwentionally comprise sleeping accommodation; and various service facilities including ones for cooking and dining, as well as sanitary and washing facilities. Accordingly, the buildings usually include a kitchen, one or more bathroom and/or shower room, and one or more water closet (WIC). Technical areas are also provided, such as utility rooms; and cupboards, closets or other rooms which house heating equipment, water tanks and the like.

In conventional modular building construction techniques, equipment intended to provide such service facilities are typically installed in the factory. Kitchens, bathrooms and V//Cs (among other things) are therefore installed in the building units during construction, and so are pre-installed prior to transportation to the final location.

This has conventionally been achieved using standard installation techniques, and in a piecemeal fashion, by tradespeople skilled in the relevant fields. For example, kitchens are typically installed in modular building units at the factory location, using a kit of kitchen partshmiLs. This can be Lime-consuming and expensive, and can also lead to significant variations in quality, depending on the skill levels of the relevant tradespeople.

Other options include on-site installation, following transportation of the building unit to the final location, which is subject to similar disadvantages.

According to a first aspect of the present invention, there is provided a method of constructing a modular building unit configured to fonn at least part of a building, the method comprising the steps of: providing a service pod configured to perfonn a service fimetion within the building, the service pod comprising a structural frame having at least one load-bearing support; providing a roof structure for the modular building unit; providing a floor structure for the modular building unit, and: A) connecting the service pod to the floor structure to form a modular building unit sub-assembly comprising the service pod and the floor structure, and then connecting the roof structure to the modular building unit sub-assembly to fonn the modular building unit, by connecting the roof structure to the service pod; or B) connecting the service pod to the roof structure to form a modular building unit subassembly comprising the service pod and the roof structure, and then connecting the floor structure to the modular building unit sub-assembly Lo linm the modular building unit, by connecting the floor structure to the service pod; and arranging the service pod so that the at least one load-bearing support extends between and connects the roof structure to the floor structure, structural loading being transmitted from the roof structure to the floor structure through the at least one load-bearing support.

The method of the invention may offer advantages over prior modular building unit construction methods, including reduced construction times, cost savings, and reduced complexity. In particular, prior such methods typically involve the construction of a structural frame of the unit, comprising a roof frame portion, a floor frame portion, and wall frame portions extending between and connecting the roof and floor frame portions.

The wall frame portions typically comprise colunms or struts which support structural loading. A service pod could be located within an internal volume defined by the structural frame, once it has been constructed.

In the method of the invention, comiecting the roof/floor structure to the service pod of the sub-assembly, and arranging the load-bearing support of the pod so that it ex-tends between and connects the roof structure to the floor structure, may have the result that the service pod effectively provides a structural core of the modular building unit. Consequently, it may not be necessary to construct a structural frame in which to subsequently locate the service pod. Construction of the modular building unit may effectively be achieved by arranging the service pod so that it foam at least part of the load-bearing structure of the modular building unit. In addition, the construction process may be more efficient than prior methods, by avoiding a requirement to firstly construct a structural frame or the modular unit., and then to locate a service pod in its internal volume. This may be achieved by connecting the roof structure to the service pod, and arranging the load-bearing support of the service pod so that it connects the roof and floor portion and transmits structural loads to the floor structure.

Reference is made to structural loading being transmitted from the roof structure to the floor structure. 11. will be understood that this can comprise both the load of the roof structure itself, and further loads of the building which are imparted on the roof structure (e.g. by further parts of the building which rest on and/or are supported by the modular building unit, in particular its roof structure).

Reference is made to a moll structure of the modular building unit. This is intended to refer to a structure which fonns all upper extent of the unit, and which may define a ceiling of the unit. It is not necessarily intended to reler to an outer or upper structure which closes the unit relative to the building exterior (and which may weatherproof a building comprising the unit). For example, a separate roof may be provided which extends over or covers the unit and shields it from exterior weather, or a further modular building unit may be mounted or stacked upon it. It will be understood however that the roof structure could be arranged to close the unit and/or to provide a shield against exterior weather, e.g. by providing the roof structure with a suitable weatherproofing layer.

The step of connecting the roof structure to the service pod may comprising mounting the roof structure on the service pod. This may involve resting the roof structure on, or arranging it so that it is supported from or by, the service pod.

In option A), the method may comprise connecting the service pod to the floor structure, and then (i.e. subsequently) comecting the service pod to the roof structure. In option 13), the method may comprise connecting the service pod to the roof structure, and then (i.e. subsequently) connecting the service pod (with the roof structure mounted on it) to the floor structure. Connecting of the floor and roof structures may have the result that the service pod is positioned between the roof and floor structures, with the at least one load-bearing support extending between and connecting the roof structure to the floor structure.

The method ma.y comprise connecting the roof structure to the floor structure via the service pod. The method may comprise arranging the service pod so that it provides a majority (or all) of a vertical load-bearing structure for the roof structure. The method may comprise arranging the service pod so that it fauns a structural core of the modular building unit. The method may comprise arranging the service pod so that it defines a primary load-bearing path for transmitting structural loads from the roof structure to the floor structure during use of the modular building unit. The at least one load-bearing support of the service pod may form or define the primary load-hearing path.

The method may comprise positioning the at least one lead-bearing support of the service pod behveen (and optionally sandwiching it between) the roof structure and the floor structure. The method may comprise arranging the primary load-bearing path so that it defines, or resides on, a direct ancllor straight line passing from the roof structure and along/through the load-hearing support to the floor structure.

The method may comprise providing the at least one load-bearing support with an upper support surface. The method may comprise providing the at least one load-bearing support with a lower support surface. One or both of said support surfaces may be disposed transverse to, and optionally substantially perpendicular to, a main axis of the load-hearing support (which may be a vertical axis, in use). The method may comprise arranging the upper support surface so that it contacts the roof structure. The method may comprise arranging the lower support surface so that it contacts the floor structure.

The method may comprise providing a phuality of service pods, each service pod configured to perform a service function within the building. The service pods may each comprise a structural frame having at least one load-bearing support. The service pods may each form part of the sub-assembly. The method may comprise arranging each service pod so that their respective load-hearing supports extend between and connect the roof structure to the floor structure. Structural loading may be transmitted from the roof structure to the floor structure through the load-bearing supports of the service pods. The method may comprise arranging said service pods so that they together provide the majority (or all) of the vertical load-bearing structure, and/or so that they together provide the structural core, and/or so that they together define the primary load-bearing path. The method may comprise connecting at least one service pod to the floor structure, and arranging said service pod so that it is out of contact with the roof structure (i.e. said pod may not have the roof structure connected to it, in particular mounted on it). Said service pod (or at least a structural member or members of the pod) may be arranged so that it extends part way between the floor and roof structures.

The method may comprise providing the service pod structural frame with a plurality of loading-bearing supports, and arranging said supports so that they each extend between and connect the roof structure to the floor structure, and transmit structural loads.

The method may comprise the step of providing the floor structure with one of a recess and a locating member, and providing the service pod with the other one of the recess and the locating member. The recess may be shaped to receive the locating member. The step of connecting the service pod to the floor structure may comprise aligning the locating member and the recess relative to one another, and bringing the service pod and the floor structure into contact to position the locating member in the recess. The method may comprise arranging the floor structure so that it describes a min floor plane of the modular building runt. 'f he method may comprise arranging the locating member and the recess so that they cooperate to prevent relative movement between the service pod and the floor structure in at least one direction, which direction may be parallel to the main floor plane described by the floor structure.

The recess may be a lower recess, and the locating member may be a lower locating member. The lower recess may be shaped to receive the lower locating member, and may serve for locating the service pod relative to the floor structure. The method may comprise the step of providing the roof structure with one of an upper recess and an upper locating member, and providing the service pod with the other one of the upper recess and the upper locating member. The upper recess may be shaped to receive the upper locating member, and may serve for locating the service pod relative to the roof structure. The step of connecting die roof structure to die service pod may comprise aligning the upper locating member and the upper recess relative to one another, and bringing the service pod and the roof structure into contact to position the upper locating member in the upper recess. The method may comprise arranging the roof structure so that it describes a main roof plane of the modular building unit. The method may comprise arranging the upper locating member and the upper recess so that they cooperate to prevent relative movement between the service pod and the roof structure in at least one direction, which direction may be parallel to the main roof plane described by the roof structure.

The method may comprise mounting the roof structure on a top or upper part of the service pod(s).

The method may comprise providing a recess which is elongate, e.g. in the fonn of an elongate groove, channel, slot or rebate which is shaped to receive the locating member. The method may comprise providing the recess with a main axis, which may be arranged to extend in a direction that is parallel to a main plane of, or described/defined by, the floor structure (or the service pod, as appropriate). The method may comprise providing flie recess with a shape that is selected from the group comprising: generally L-shaped in cross-

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section (this may apply particularly to a rebate e.g. at or adjacent a periphery/edge of the floor structure); and generally Ikshaped in cross-section (taken in a direction perpendicular Lo the main axis, and which may apply particularly to a groove, channel or slot). The method may comprise arranging the recess and the locating member so that relative movement between them in at least one direction, and optionally in a plurality of directions, is restricted. Said direction or directions may be substantially perpendicular to the main axis. Said direction or directions may be parallel to the main plane described by the floor structure the method may comprise arranging the recess so that the locating member can be translated relative to the recess in a direction along its main axis. 't his may facilitate connection of the service pod to the floor structure (e.g. in a sliding fit relative to the floor structure), and/or adjustment of a position of file service pod relative to the floor structure.

The method may comprise arranging the recess so that the locating member can be inserted into the recess in a direction perpendicular to its main axis, and which may be a generally vertical direction (considered ill use of the unit).

The method may comprise providing the recess with a side wall which is arranged to abut the locating member.

The side wall may define an abutment stuface. The method may comprise providing the recess with first and second opposed such side walls, and positioning the locating member between said side walls. The method may comprise arranging each side wall to abut the locating member so that the locating member is captured between the side walls. This may provide a secure engagement between the service pod and the floor structure. The method may comprise providing the recess with a further wall disposed transverse (e.g. substantially perpendicular) to the side wall or walls. The further wall may be ananged so that it abuts the locating member, and/or may define an abutment surface. 'The further wall may define a base or a top of the recess, depending on whether the recess is provided by the floor structure or the service pod.

Where there is an upper recess, the method may comprise providing the upper recess with a side wall which is arranged to abut the upper locating member. The side wall may define an abutment surface. The method may comprise providing the upper recess with first and second opposed such side walls, and positioning the upper locating member between said side walls. The method may comprise arranging each side wall to abut the upper locating member so that the upper locating member is captured between the side walls. The method may comprise providing the upper recess with a further wall disposed transverse (e.g. substantially perpendicular) to the side wall or walls. The further wall may be arranged so that it abuts the upper locating member, and/or may define an abutment surface. The further wall may define a Lop or a base of the upper recess, depending on whether the upper recess is provided by the roof structure or the service pod.

The method may comprise forming the service pod structural frame from a plurality of frame members, and may comprise coupling each frame member to one or more fluffier frame member. The method may comprise arranging a frame member or the structural frame so that it delines the locating member The method may comprise arranging the locating member so that it is supported by, or so that it extends/protrudes from, a frame member of the structural frame. The frame member may be a lower frame member, which may extend in a direction substantially parallel to a floor or base of the service pod, and may be elongate. Where the locating member is provided by llie floor structure, the method may complise arranging a frame member of the structural frame so that it defines the recess. The method may comprise arranging the recess so that it is supported b so that it is defined by, a frame member of the structural frame. The frame member may be a lower frame member, which may extend in a direction substantially parallel to a floor or base of the service pod, and may be elongate.

The method may comprise arranging the locating member so that it has a side wall, which may be generally planar, and which may define all abutment surface. The method may comprise arranging the recess so that it contacts the side wall. The method may comprise =Lancing the locating member so that it has first and second such side walls. The recess may be arranged so that it contacts both of the first and second side walls. The first and second side walls may be opposed first and second side walls, and may be disposed substantially parallel to one another. The method may comprise providing the locating member with a further wall, which may extend from the side wall, and may extend beriveen the first and second side walls. The further wall may be disposed transverse to, optionally substantially perpendicular to, the side walUthe first and second side walls. The method may comprise arranging the lather wall of the locating member so that it contacts the further wall of the recess.

Where there is an upper recess, the method may comprise arranging the frame member of the structural frame so that it defines the upper locating member. The method may comprise arranging the upper locating member so that it is suppoited by, or so that it extends/protrudes from, a frame member of the structural frame. The frame member may be an upper frame member, which may extend in a direction substantially parallel to a roof or top of the service pod, and may be elongate. Where the upper locating member is provided by the roof structure, the method may comprise arranging a frame member of the structural frame so that it defines the recess. The method may comprise arranging the recess so that it is supported by, or so that it defined by, a frame member of the structural frame. 'the frame member may be an upper frame member, which may extend in a direction substantially parallel to a roof or top of the service pod, and may be elongate.

The upper recess, and the upper locating member, may have further features which conespond to those of the recess and locating member set out above, including but not restricted to side walls, first and second side walls, and Ihrther walls.

The method may comprise the step of providing the floor structure with one of a plurality of recesses and a plurality of locating members. The method may comprise providing the service pod with the other one of the plurality of recesses and the plurality of locating members. The method may comprise providing a plurality of service pods, and providing each service pod with at least one locating member, or at least one recess. The method may comprise arranging a first one of the plurality of recesses of the floor structure to receive a locating member of a first one of the service pods. The method may comprise arranging a second one of the plurality of recesses of' the floor structure to receive a locating member of a second one of the service pods The method may comprise arranging at least one recess of the floor structure to receive locating members associated with more two or more service pods. The method may comprise arranging a recess of a first one of the plurality of service pods to receive a first locating member of the floor structure. The method may comprise arranging a recess of a second one of the plurality of service pods to receive a second locating member of the floor structure.

A similar arrangement may be provided for upper recesses and upper locating members of the roof structure and service pods.

Where the recesses are elongate and/or comprise a main axis, the method may comprise arranging at least one recess so that iL is disposed generally transverse, optionally substantially perpendicular to, at least one other recess. Main axes of such recesses may be arranged so that they are disposed transverse to one another, optionally substantially peipendicular. At least one recess may be arranged to intersect at least one other recess.

The method may comprise providing a plurality of separate locating members configured to be located in a single recess. The method may comprise providing a plurality of separate locating members, and a plurality of separate recesses, each recess optionally being configured to receive a respective locating member. It will be understood that the features set out in this paragraph call apply to both lower mid upper recesses, and lower and upper locating members, where provided.

Where there are a plurality of recesses, e.g. each in the form of all elongate groove, channel, slot or rebate, the method may comprise providing at least one of the recesses with a different shape in cross-section (particularly in a direction perpendicular to a main axis of said groove, e.g. in a vertical plane) to at least one other recess. The method may comprise providing at least one recess at or adjacent an edge of the floor structure. The edge may be a peripheral edge. The method may comprise providing a recess at more than one edge of the floor structure, and optionally at each edge. The method may comprise providing at least one further recess at a position which is inboard or inward of the or an edge of the floor structure.

The method may comprise providing at least one recess at or adjacent all edge of the roof structure. The edge may be a peripheral edge. The method may comprise pmviding a recess at or adjacent more than one edge of the roof structure, and optionally at each edge. The method may comprise providing at least one Further recess at a position which is inboard or inward of the or an edge of die roof structure.

The method may comprise forming the service pod structural frame so that it comprises a plurality of lower triune members, and arranging at least some of the lower frame members so that they each define at least one locating member, or at least one recess. The method may comprise providing the structural frame with a plurality of wall frame portions, and arranging each wall frame portion transverse to one or more other wall frame portion. The method may comprise arranging each wall frame portion so that it defines a respective lower frame member.

The method may comprise Miming the service pod structural frame so that it comprises a plurality of upper frame members, and arranging at least some of the upper frame members so that they each define at least one locating member, or at least one recess. The method may comprise arranging each wall frame portion so that it defines a respective upper frame member.

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The frame member(s) of the structural frame may be selected from the group comprising struts, columns and beams. Suitable materials for forming the structural Frame (and so the frame members) can include metals and metal alloy s (which could be hot-formed e.g. hot-rolled, or cold-fonned e.g. pressed or stamped, as well as combinations of the two). One or more frame member may define or form said load-bearing support, particularly a column or columns.

t he structural frame coukl be panelised, e.g. formed of structural insulated panels (SD's), which generally comprise a perimeter frame that would fonn said structural frame The locating member may be generally elongate, and may define a main axis. The locating member may be arranged to extend in a direction that is parallel to a main plane of or described/defmed by, the service pod (or die floor structure, as appropriate). The method may comprise arranging at least one locating member so that it is disposed generally transverse, optionally substantially perpendicular to, at least one other locating member. 't he locating member e.g. extends from a frame member of the service pod structural frame (or from a surface of die floor structure), it may take the general form of a rib, tongue or the like. Other options include a pin of e.g. cylindrical shape in cross-section, configured to engage in a recess having a matching shape The service pod and the floor structure may be connected by securing or fixing the locating member within the recess. The service pod and the roof structure may be connected by securing or fixing the upper locating member within the upper recess. Skxuring or fixing the locating member(s) may be achieved by bonding (e.g. using an adhesive), a welding process (depending on the materials used), and/or using a mechanical fixing such as one or more nut and bolt assembly, nut and threaded socket assembly, and/or screw.

The step of providing the floor structure may comprise forming a floor structural frame from a plurality of floor frame members, and may comprise coupling each floor frame member to one or more further floor frame member. The method may comprise arranging a floor frame member of the floor structural frame so that it defines the recess, or the locating member. The method may comprise arranging a floor frame member of the floor structural frame so that it defines a plurality ofrecesses, and/or a plurality of locating members. The method may comprise: arranging a first floor frame member of the floor structural frame so that it defines a first recess, or a first locating member, and arranging a further floor frame member of the floor structural frame so that it defines a further recess, or a further locating member.

The step of providing the roof structure may comprise forming a roof structural frame from a plurality of roof frame members, and may comprise coupling each roof frame member to one or more further roof frame member. The method may comprise arranging a roof frame member of the roof structural frame so that it defines the upper aress, or the upper locating member The method may comprise arranging a roof frame member of the roof structural frame so that it defines a plurality of recesses, and/or a plurality of locating members. The method may comprise arranging a first roof frame member of the roof structural frame so that it dei-ines a first recess, or a first locating member: and arranging a further roof frame member of the roof structural frame so that it defines a further recess, or a further locating member.

The frame member(s) of the Poor and/or roof structural frame may be beams. Suitable materials for lonning the floor and/or roof structural frame (and so the frame members) can include metals and metal alloys (which could be hot-formed e.g. hot-rolled, or cold-thmied e.g. pressed or stamped, as well as combinations of the two), cement based materials (e.g. a cast concrete or 3D printed concrete material), and composite materials (e.g. fibre-reinforced resin materials).

The step of providing the floor structure may comprise fanning die floor structure as a substantially continuous and/or generally planar structure. The step of providing the floor structure may comprise ananging the floor structure so that it defines an upper surface forming a floor of the modular building unit. The upper surface may be arranged to extend substantially continuously along substantially a full length, and/or across substantially a full width, of die floor structure. The floor structure may be formed as a one-piece or substantially unitary structure. The method may comprise arranging the floor structure so that the recess/locating member is integral to die floor structure. For example, die recess may be provided in the upper smface, or die locating member may extend from/proud of the upper surface. Alternatively, die recess/locating member may be provided as a separate part coupled to the floor structure.

The step of providing die roof structure may comprise forming die roof structure as a substantially continuous and/or generally planar structure. The step of providing the roof structure may comprise arranging the roof structure so that it defines a lower surface forming a roof (or ceiling) of the modular building unit. The lower surface may be arranged to extend substantially continuously along substantially a full length, and/or across substantially a full width, of die roof structure. The roof structure may be formed as a one-piece or substantially unitary structure. The method may comprise arranging the roof structure so that die recess/locating member is integral to the roof structure. For example, the recess may be provided in the lower surface, or the locating member may extend from/proud of the lower surface. Alternatively, the recess/locating member may be provided as a separate part coupled to die roof structure.

Options Rif forming said substantially continuous floor structure and/or roof structure may comprise: forming the structure(s) from a cement-based material (e.g. a cast concrete or 3D printed concrete material); forming the structure(s) from a timber or timber-based material (e.g. a cross-laminated timber construction); forming the structure(s) from a sheet of a metal or metal alloy material (e.g. by pressing or stamping in a cold-forming process); forming the structure from a composite material (e.g. a fibre-reinforced resin material). Optionally, separate generally planar members may be constructed and then connected together to form said substantially continuous/planar floor and/or root-structures.

The method may comprise sealing the service pod relative to the floor structure. This may be achieved, at least partially, by sealing the locating member relative to (e.g. within) the rmicss. Scaling may be achieved using a seal and/or a sealant material, which may be carried by at least one of the locating member and the recess, or provided on one or both of the locating member and the recess prior to connection. The method may comprise sealing the service pod relative to the roof structure. Sealing may be achieved in a similar fashion as for the floor structure.

The method may comprise providing at least one wall panel, and connecting the wall panel to one or both of the floor structure and the roof structure.

the method may comprise providing the floor structure with one of a wall panel recess and a wall panel locating member, and providing the wall panel with the other one of the wall panel recess and the wall panel locating member. The step of connecting the wall panel to the floor structure may comprise positioning the wall panel locating member in the wall panel recess. Where a recess or recesses are provided by the floor portion, said recess may be arranged to cooperate both with a service pod locating member(s) and a wall panel locating member(s). Where recesses are provided by both the service pod and the wall panel, the locating member of the floor portion may be arranged to cooperate with both of said recesses.

The wall panel recess may be a lower wall panel recess, and the wall panel locating member may be a lower wall panel locating member. The method may comprise providing the roof structure with one of an upper wall panel recess and an upper wall panel locating member, and providing the wall panel with the other one of the upper wall panel recess and the upper wall panel locating member. The step of connecting the wall panel to the roof structure may comprise positioning the upper wall panel locating member in the upper wall panel recess.

lie method may comprise arranging the wall panel so that it is at least partially load-bearing, and may comprise providing the wall panel with at least one wall load-bearing support. The method may comprise arranging the wall panel so that it extends between and connects the roof structure to the floor structure. The method may comprise arranging the wall panel so that it provides at least part of an outer wall of the modular building unit.

The method may comprise positioning at least one wall panel at or adjacent a perimeter of the modular building unit. One option for forming die wall panel may be fanning a frame structure from a plurality of frame members, and covering the frame structure with an outer and/or inner wall surface e.g. in the fonn of a plate. A frame member or members may define the locating member(s)/recess or recesses. STF's may be a particularly suitable option for the wall panel.

The method may comprise arranging the service pod so that it forms at least part of at least one external wall of the modular building unit. The method may comprise arranging at least one wall panel so that it forms at least part of a wall of the service pod.

Reference is made in options A) and B) above to the formation of a sub-assembly. The sub-assembly may fonn a part or the modular building unit which is created during the construction process, and may be separate from the roof structure/floor structure that is subsequently connected to it. The sub-assembly, and/or the roof structure/floor structure that is to be connected to it, may be independently manipulatable or movable to facilitate the construction process.

The floor structure may provide multiple connection locations for the service pod(s), for example by appropriate dimensioning or the service pods, and positioning of recesses. The floor structure may define a grid comprising grid blocks, and at least some grid blocks may be of the same size. The service pod may have a floor plan which corresponds to the size of more than one grid block, so that the pod can be located on either block, in order to provide multiple connection locations lir the pod. The service pods can be arranged so that they have floor plans which are multiples of a basic grid block. A service pod may be provided which has a floor plan that accommodates or bridges over a plurality' of grid blocks. the grid blocks may be defined by and/or bordered by various recesses of the floor structure. Grid blocks may be configured to receive service pods having different dimensions e.g. floor plans, to provide alternative connection locations for the pod(s). A service pod call be dimensioned to fit over munerous grid blocks in order to provide alternative connection locations.

According to a second aspect of the present invention, there is provided a method of constructing a modular building unit configured to form at least part of a building, the method comprising the steps of providing a service pod configured to perform a service function within the building, the service pod comprising a structural frame having at least one load-bearing support; providing a floor structure for the modular building unit; providing a roof structure for the modular building unit; providing the floor stricture with one of a receptacle and a locating member, and providing dle service pod with the other one of the receptacle and the locating member, the receptacle shaped to receive the locating 20 member; connecting the service pod to the floor structure by positioning the locating member in the receptacle; mounting the roof structure on the service pod; and arranging the service pod so that the at least one load-bearing support extends between and connects the roof structure to the floor structure, structural loading being transmitted from the roof structure to the floor structure through the at least one load-bearing support.

The method may comprise connecting the service pod to the floor structure, and then (i.e. subsequently) mounting the roof structure on the service pod. Mounting of the roof structure on the service pod may' have the result that the service pod is positioned between the roof and floor structures, with the at least one load-bearing support extending between and connecting the roof structure to the floor structure.

The method may comprise motmling are roof structure on the service pod, and then (i.e. subsequently) connecting the service pod (with the roof structure mounted on it) to the floor structure. Connecting the service pod to the floor structure may have the result that the service pod is positioned between the roof and floor structures, with the at least one load-bearing support extending between and connecting the roof structure to the floor structure.

Further features of the method of the second aspect of the invention may be derived from the text set out elsewhere in this document, particularly in or with respect to the first aspect of the invention.

According to a third aspect of the present invention, there is provided a kit configured to be assembled to form a modular building unit for a building, the kit comprising: a roof structure; and a sub-assembly comprising a floor structure and a service pod, in which the service pod is configured to perform a service function within the building and comprises a structural frame having at least one load-bearing support, and in which the service pod is connected to the floor structure to form the sub-assembly; in which the roof structure is configured to be connected to the service pod of the sub-assembly to fonn the modular building unit; and in which the service pod is configured so that, in the assembled modular building unit, the at least one load-bearing support extends between and connects the roof structure to the floor structure, and serves to transmit structural loading from the roof structure to the floor structure.

According to a fourth aspect of the present invention, there is provided a kit configured to be assembled to form a modular building unit for a building, the kit comprising: a floor structure; and a sub-assembly comprising a roof structure and a service pod, in which the service pod is configured to perfonn a service function within the building and comprises a structural frame having at least one load-bearing support, and in which the service pod is connected to the roof structure to form the sub-assembly; in which the floor structure is configured to be connected to the service pod of the sub-assembly to form the modular building tmit; and in which the service pod is configured so that, in the assembled modular building unit, the at least one load-bearing suppoit extends between and comects the roof structure to the floor structure, and serves to transmit structural loading from the roof structure to the floor structure.

According to a fifth aspect of the present invention, there is provided a modular building unit constructed according to the method of the first or second aspect of the invention.

According to a sixth aspect of the present invention, there is provided a building system comprising: a modular building unit constructed according to the method of the first or second aspect of the invention, the modular building unit being transportable to a final location for a building in a substantially assembled form; and a further building unit configured, in use, to define an internal volume which pro vides a living space within the building; in which the modular building Lmit and the further building unit are configured to be connected at the final location to define at least part of the building.

According to a seventh aspect of the present invention, there is provided a building comprising: a modular building unit constructed according to the method of the first or second aspect of the invention, the modular building unit being transportable to a final location for the building in a substantially assembled faun; and a further building unit defining an internal volume which provides a living space within the building; in which the modular building Lullt and the Further building unit are connected aL the final location to define at least part of the building.

Further features of the kits, modular building unit, building system and building of any one of the third to seventh aspects of the invention may be derived from the text set out elsewhere in this document, particularly in or with respect to the methods of the first or second aspects.

According to an eighth aspect of the present invention, there is provided a method of constructing a modular building unit configured to form at least part of a building, the method comprising the steps of: providing a service pod configured to perform a service function within the building, the service pod comprising a load-bearing structural frame; providing a floor structure for the modular building unit, and arranging the floor structure so that it desc bes a main floor plane of the modular building unit; providing the floor structure with one of a recess and a locating member, and providing the service pod with the other one of the recess and the locating member, the recess shaped to receive the locating member; connecting the service pod to the floor structure by aligning the locating member and the recess relative to one another, and bringing the service pod and the floor structure into contact to position the locating mentha in the recess; arranging the locating member and the recess so that they cooperate to prevent relative movement between the service pod and the floor structure in at least one direction which is parallel to the main floor plane described by the floor structure; and providing a roof structure for the modular building unit, and connecting the roof structure to the floor structure.

The step of providing the service pod may comprise arranging the service pod, in particular its load-bearing structural frame, so that It defines a footprint of the service pod. The footprint may he an area of (or on) the floor structure which the service pod accommodates when connected to the floor structure.

The step of arranging the locating member and the recess so that they cooperate to prevent said relative movement may comprise arranging the recess and the locating member so that they each define an abutment surface, and may comprise arranging the abutment surfaces so that they cooperate to prevent said relative movement. The abutment surfaces of at least one (and optionally both) of die recess and the locating member may be disposed within the Footprint of the service pod.

A majority (optionally all) of each of the recess and the locating member may be disposed within the footprint of the service pod, at least portions of the recess and/or locating member that mutually engage.

The recess may have a main axis, and may have a width taken in a direction that is transverse (typically perpendicular) to the main axis, and which direction may be parallel to the main floor plane. The width of the recess may be less than a width of the service pod, in particular of its load-bearing structural frame, considered in a direction parallel to the main floor plane. The width of the recess may be less than a width of the footprint.

Further features of the method of the eighth aspect of the invention may be derived from the text set out elsewhere in this document, particularly in or with respet t to the lirst or second aspects of the invention.

According to a ninth aspect of the present invention, there is provided a modular building unit configured to form at least part of a building the modular building unit comprising: a service pod configured to perfonn a service function within the building, the service pod compnsmg a structural frame having at least one load-bearing support; a floor structure; and a roof structure; in which the floor structure comprises one of a recess and a locating member, and the service pod comprises the other one of the recess and the locating member, the recess being shaped to receive the locating member; n which the service pod is connected to the floor structure with the locating member positioned in the recess; in which the roof structure is mounted on the service pod; and in which the service pod is arranged so that the at least one load-bearing support extends between and comiects the roof structure to the floor structure, structural loading during use being transmitted from the roof structure to the floor structure through the at least one load-bearing support.

According to a tenth aspect of the present invention, there is provided a building system comprising: a modular building unit according to the ninth aspect of the invention, the modular building unit being transportable to a final location for a building in a substantially assembled form; and a fiuther building unit configured, in use, to define an internal vohune which provides a living space within the building; in which the modular building unit and the further building unit are configured to be connected at the final location to define at least part of the building.

According to an eleventh aspect of the present invention, there is provided a building comprising: a modular building unit according to the ninth aspect of the invention, the modular building Lunt being transportable to a final location for the building in a substantially assembled form; and a further building unit defining an internal volume which provides a living space within the building; in which the modular building unit and the fmther building unit are connected at the final location to define at least part of the building.

Further features of the modular building unit, building system and building of any one of the ninth to eleventh aspects of the invention may be derived from the text set out elsewhere in this document, particularly in or with respect to any one or more of the first to eighth aspects.

Optional further features of any of the aspects defined above (and so of the methods, kits, modular building units, building systems and buildings) may be derived from the following text.

The service pod (or pods) may be connectable/mountable as a sell-contained structure.

The modular building unit may comprise an internal volume, and may be configured so that its internal volume communicates directly with the internal voltune of the thither building unit, to facilitate access into at least one service pod from a living space of die further building unit. The modular building imit may define a circulation space which provides access, in use, to both an internal volume of at least one self-contained service pod and the living space provided by die internal volume of the further building unit, from within die modular building unit. The internal volume of the modular building unit may define a circulation space which provides access to an intemal vohune of at least one of the self-contained service pods, ancUor at least one service pod may be accessible, in use, directly from a living space of the further building unit.

A plurality of service pods may be mounted within the internal volinne of the modular building unit as self-contained structures, each service pod providing a respective service function within die building An internal volume of the modular building unit may define a circulation space which provides access to an internal volinne of at least one of the self-contained service pods, and/or at least one service pod may be accessible directly from a living space of the further building unit.

The building systems and buildings of the present invention may provide advantages over plior modular buildings comprising a modular building unit, in which facilities such as a kitchen, bathroom and W/C are installed in the unit in a factory, prior to transportation to a final location for the building. In particular, the provision of a service pod which is a self-contained structure, mountable within the internal volume of the modular building unit, may offer advantages including: ease of instillation (and resultant construction time/cost efficiencies); reliability and repeatability of installation; and improved quality control. The at least one service pod may be constructed at a different location to the modular building unit, for example in a dedicated facility or factory. The service pod can therefore be constructed by operators skilled in El field relevant to the service function in question. This may reduce the likelihood of quality issues arising, as could occur in a factory where operators are required to install components providing multiple different service functions. Similar advantages may be achievable in comparison to services or facilities which are installed at a final location or site for the The system/building may comprise a plurality of service pods, each of which may be mountable within die internal volume of the modular building unit as self-contained structures. The service pods may each provide a different service function, in use. At least one service pod may provide a same or a similar service function to at least one other service pod. The at least one service pod may be configured, in use, to provide more than one service finiction. The service function(s) may be selected from the group comprising: an access function (e.g. betwom different floors or storeys of the building, in particular of the further building unit); a cooking, dining and/or kitchen ffinction; a sanitary function (e.g. washing/bathing, toilet); and a technical function (e.g. provision of utilities, communications, heating, ventilation).

It will be noted that the word 'storey is used throughout this document. In some territories the term 'story' has an equivalent meaning, and may be used in its place.

the at least one service pod may contain equipment/component(s) configured to peifonn the service function. the at least one service pod may contain one or more of a stairway/staircase (access function); a lift (access foil:hon): a W/C or washroom and/or a toilet facility (sanitary function); washing/bathing facilities (sanitaw function, and which may include a basin/sink, shower ancUor bath); utilities connections such as electrical power supply, gas supply, water supply, sewerage, and relevant meters (technical function); communication equipment such as data and telecommunication equipment (teclmical function); heating and/or cooling equipment (technical function); ventilation equipment (technical function, which may include mechanical ventilation and heat recovery -MV11R -equipment); washing and/or diving equipment for textile products (technical function); and water storage tank (technical function).

Where there are a plurality of service pods, at least one of the service pods may be comuuctable to at least one other service pod, which may facilitate connection/mounting of said service pods together and/or at the same time. Said comiected service pods may together form a service pod assembly.

The at least one service pod may he releasably mountable/mounted within the modular building unit. This may facilitate removal of the pod from the unit, for example for maintenance and/or replacement purposes. the pod may be readily removable for example in the event that wear and tear on the pod has degraded its appearance; if It is desired to change a decorative appearance of the pod; or to alter, improve or upgrade functional equipment provided by or within the pod. Removal may be facilitated by the arrangement of recess and locating member deschbed above.

AL least parlor an external wall (lithe modular building unit may be removable and/or releasably attached to a structure of Llic unit, which may facilitate removal of the pod. The pod may be configured to be translated out of the modular building unit through an aperture created when said part of the wall is removed. The at least one service pod can optionally limn at least part ol one or more wall of the modular building unit_ The pod may be released from the unit together with (or earning) said part of the one or more wall.

The at least one service pod may be dimensioned so that it can be removed through one or more door or window of the modular building unit. One or more door or window may be releasably connected to the modular building unit in order to facilitate service pod removal. The at least one service pod may be dimensioned so that it can be removed through a doorway or walkway of the modular building unit, and/or a door or doors mounted in the doorway may be releasably mounted relative to a frame forming the doorway. Alternatively, a frame of such a door/window may be removably mounted to the modular unit, to facilitate pod removal.

Reference is made to the at least one service pod being a self-contained stnicture. This could be taken to mean that the pod: is structurally self-supporting and does not rely e.g. on the modular building mit. Ibr its structural integrity; comprises all (or substantially all) components and/or facilities necessary for it to carry out its service function (other than for example external connections to components in the modular building unit, such as sewerage connections); and/or defines a complete perimeter structure (e.g. a wall perimeter structure) of the pod, without relying on other components such as of the modular building unit.

The service pod may comprise a perimeter structure. The perimeter structure may compnse one or more wall. The service pod may comprise at least one wall, and suitably comprises a plurality of walls. At least one wall of said service pod may be defined by the modular building unit. For example, said pod may comprise two or three walls, and may be configured to be positioned within die modular building unit adjacent a wall or walls of the building unit, which may define a remaining wall or walls of the pod during use.

The service pod may define at least part of at least one wall of the modular building unit. The modular building unit may comprise a wall, which may include, or may define, an aperhue or space. Said service pod may be configured to be positioned within the internal volume of the modular building unit so that its wall closes the aperture or space. Said service pod may therefore effectively complete the wall of the modular building unit.

Att of the walls of the at least one service pod may be detailed by the pod itself.

Where there are a plurality of service pods, there may be a mixture of different wall arrangements for the pods. For example, at least one wall of one or more service pod may be defined by the modular building unit, and/or one or more pod may define at least part of at least one wall of the modular building emit Optionally, at least one service pod may define at least one wall of at least one further service pod. Thus service pods may share one or more wall.

The service pod may comprise one or more of a floor and a ceiling/roof At least one of a floor and a ceiling/roof may be provided by the modular building unit.

The service pod may define an internal volume. The internal volume may be provided by or bordered by the perimeter structure/structural frame. The service pod, in particular its internal volume, may house equipment and/or components providing the required service function, or facilitating provision of the service function. The service pod may comprise a doorway, which may provide access into the internal volume of said pod. A door may be mounted in the doorway, and may be provided integrally with the pod. At least some of the equipment.

and/or components may be mounted to one or more of a wall, a floor and a ceiling/roof of the service pod. At least some of the equipment and/or components may be mounted to the pod structural frame. The equipment/components may therefore be transportable to die final location Withill die pod.

The service pod internal volume may contain equipment/component(s) providing the required service function during use. the equipment/component(s) may be coupled to the perimeter structure/structural frame (directly or indirectly). The equipment/component(s) may be mountable within the internal volume of the modular building unit by mounting the perimeter structure/structural frame (containing said equipment) within the internal volume of the modular unit.

The service pod (or at least one service pod where there are a plurality) may define one or more mom. The service pod may define or form an enclosed space. The enclosed space may contain equipment/component(s) providing die service time-hon. The service pod may comprise a doorway or walkway winch provides access into the enclosed space.

Where there are a plurality of service pods, at least one service pod may be shaped to receive at least part of one or more other service pod, e.g. within an internal volume of said at least one service pod.

The modular building unit in particular its internal volume, may comprise or may define a circulation space/zone or transition space/zone. The circulation space may provide access, during use, to: the internal vohune of the further building unit (suitably from within die modular building mitt and/or an internal volume of the at least one self-contained service pod. The circulation space may open on to the internal volume of the further building unit, suitably via one or more doorway or walkway aperture. The doorway may be provided by the modular building runt. The circulation space may conummicate with the at least one service pod, suitably its intemal volime. Access into said service pod from the living space of die further building unit may be via the circulation space. Alternatively, said service pod (or at least one service pod where there are a plurality) may be arranged within the internal volume of the modular building unit such that the service pod communicates directly with, and/or opens directly on to, the internal vohune of the further building mit. Said pod may therefore be accessible directly from the living space of the anther building unit, without passing into the circulation space.

The modular building unit may be configured so that its internal volume conummicates directly with the internal volume of the further building unit, to facilitate access into the at least one service pod from the living space of the further building unit.

The modular building unit may have a perimeter which borders or defines a boundary of its internal volume, and the at least one service pod may be disposed within said perimeter.

Reference is made to the internal volume of the modular building unit communcating directly with the internal volume or the further building unit. The communication between the internal volumes may be such that it is possible to transit from die internal vohune of one of die modular and further building units directly into die internal volume of the other one of the modular and further building units, without having to pass through a further unit or part of the building, or to die building exterior.

The living space provided by the further building unit may form at least part of one or more room of the building. The one or more room may be selected from the group comprising: a kitchen; a dining room; a sitting or leisure room; a bedroom; and an open plan room comprising a plurality of different usage areas. The usage areas may be selected from the group comprising: a kitchen area; a dining area; and a living, sitting or leisure area. Optionally, a kitchen may be provided in the modular building unit, in particular in the or a service pod.

The further building unit may comprise a lower storey and at least one upper storey. The further building unit internal volume may define all upper living space and a lower living space, which may be defined by the upper and lower storeys respectively. Typically, the upper living space will fonn at least part of one or more bedroom, and the lower living space will fonn at least part of: a kitchen; a dining room; a living, sitting or leisure room; and/or an open plan room comprising a plurality of different usage areas of the type set out above. Depending on factors including building design and ground conditions (e.g. a slope or inclination of the land), the room or rooms provided by the upper and lower living spaces may be reversed. For example, the lower living space may provide at least part of a bedroom or bedrooms, and the upper living space may provide at least part of a kitchen, dining room and/or living room. Bedrooms could be provided in both living spaces.

Reference is made to the modular building unit being transportable to the final location in a substantially assembled form. This may be taken to mean that said unit is constmcted to a state in which: it call be transported safely (i.e. it has sufficient structural integrity/rigidity for transport purposes); minimal further work is required to be carried out on said unit in order to connect it to the further building mit; and/or minimal (optionally no) further work is required to complete a portion of the building formed by said unit. Such further work may be of a structural and/or weatherproofing nature, and may exclude work associated with a final fit-out of said unit, for example of a decorative nature (in particular the application of 'perishable' materials such as plaster/plasterboard, decorative panels and suiface finishes such as paint).

The building may be a residential building. In the context of the invention, this should be taken to mean a building in which sleeping accommodation is provided for normal residential purposes, preferably with cooking and dining facilities. Non-limiting examples of residential buildings falling within the scope of the invention include houses (detached, semi-detached, terraced and single storey/bungalow), as well as apartments and Hats. The principles of the invention may however be applicable to non-residential buildings including commercial or industrial buildings, such as offices and factories.

The building system/building may comprise a plurality of modular building units, which may be connectable or connected to define at least part of the building. The modular building units may be configured so that they can be slacked one on top or another, so that they at least partially overlap one-another. The modular building units may be stackerUstackable directly on top of one another (i.e. one resting on top of the other), so that access between the units can be achieved directly, eg_ without passing into or through any part of the further building unit. The modular building units may however be located side by side and/or at a similar level, and could be spaced apart and/or not connected. This may apply particularly to a single storey building.

The modular building units may each comprise at least one service pod, and so may each be units as defined in any or the aspects. However, at least one °tithe modular building units may be devoid of, or may not comprise, a service pod. In a stacked arrangement of modular building units, there may be a lower such unit and an upper such unit. The service pod of the lower modular building unit may provide an access function, and so may e.g. include a staircase/stairway. The upper modular building unit may comprise an opening or aperture configured to cooperate with the access function service pod, to facilitate access between internal volumes of said units via said pod.

The further building unit may also be a modular building tunt, optionally as defined in aspects of the invention.

Alternatively, the further building limit may be a non-modular building turn. The further building unit may be an on-site construction at the final location for the building. The fmther building unit may be of a construction selected from the group comprising: a blockwork/masomy construction e.g. of clay bricks and/or cement blocks; a timber frame (and blockwoik/masomy, or cladding construction); a metal frame construction (optionally comprising panels coupled to the frame, which may be composite panels comprising insulation material); a structure comprising structural insulated 'SIP' panels; a time-setting 3D printed construction e.g. of a cementitious material; and combinations thereof The further building unit may be or may comprise a kit of building materials (e.g. blocks, timber frame components, metallic structural elements) which can be used in the on-site construction of the building unit. Suitable timber frame constructions can include a stick-built construction, and a timber flame kit.

The building may be fanned entirely from the modular building unit and the anther building unit, or from a plurality of the modular building units and the further building runt. The building may comprise additional such further building units.

The modular building unit may be or may provide a first building section, the further building unit may be or may provide a second building section, and the modular and further building units may together form part of a modular building or hybrid residential building, as disclosed in the applicant's pending international patent application nos. PC1/0132022/051270, PCl/CiB2022/051271, PCl/CiB2022/051272, PC1/GB2022/051273 and PCT/FP2023/063435, the disclosures of which are incorporated herein by this reference.

Methods of constructing a building may comprise the steps of: constructing the modular building unit to a substantially assembled form at a location which is distanced from a final location for the building; transporting the modular building unit to the final location in the substantially assembled form; providing a anther building Turn at the final location, and arranging the further building min so that it defines an internal volume which provides a living space within the building during use; connecting the modular building unit with the further building unit at the final location, to define at least part of the building; and: arranging the modular building unit so that its internal volume communicates directly with the internal volume of the further building unit, to facilitate access into the at least one service pod from the living space of the further building unit; and/or arranging the modular building unit so that its internal volume defines a circulation space which provides access, during use, to both all internal volume of the at least one sell-co tamed service pod and the living space provided by the internal volume of the further building unit from within the modular building mil The method may comprise providing the modular building unit with a plurality of the service pods, each service pod configured to provide a respective service fLuiction within the building during use, and optionally: arranging the modular building unit so that its internal vohnne defines a circulation space which provides access, in use, to an internal volume of at least one of the self-contained service pods; and/or arranging at least one service pod so that it is accessible directly from the living space of the further building unit.

The modular building unit may be constructed in a factory or facility. The factory or facility location may be on a building site containing the final location for the building, but distanced from the final location. Alternatively, the factory or facility may be off-site, or away from the building site. Access to the site may then be achieved e.g. via road and/or rail transportation. It will be understood therefore that the construction location may be distanced from the final location in that the modular building unit is not constructed at the final location for the building, and requires to be transported some distance from the construction location to the final location.

The method may comprise transporting at least one further service pod to the final location and then mounting said pod within an internal volume of the unit. Alternatively, all of the service pods may be provided within the modular building unit before transportation of the modular building unit to the site.

The method may comprise connecting at least one service pod to at least one other service pod, and then connecting said service pods to the floor structure/roof structure (together and/or at the same time). The step of connecting said service pods may form a service pod assembly which is then connected to the floor structure/roof structure.

The method may comprise releasably mounting the at least one service pod within the modular building unit. The method may comprise subsequently removing the pod from the building unit and either: A) perfonning maintenance on die pod before re-mounting die pod within the internal volume; or B) transporting a replacement service pod to the final location and mounting the replacement pod within the internal volume. The maintenance may be perfonned on or off-site.

The method may comprise providing at least one service pod with one or more wall, which may be integral to the pod. All of the walls may be provided integrally to the pod. Alternatively, the method may comprise arranging the modular building unit to provide at least one wall of the pod. In another alternative, the method may comprise arranging at least one service pod so that it defines at least part of at least one wall of the modular building unit. The modular building unit may be provided with a wall including an aperture or space, and the method may comprise positioning said service pod within the internal volume of the modular building unit so that its wall closes the aperture or space. The method may comprise arranging at least one service pod so that it defmes at least one wall of at least one further service pod. The method may comprise providing the at least one service pod with one or both of a floor and a ceiling/root which may be integral to the pod. Alternatively, the method may comprise arranging the modular building unit to provide at least one of a floor and a ceiling/roo rof the at least one service pod, following mounting of the pod in the internal volume of the unit.

The method may comprise positioning equipment and/or components providing the required service Function, or facilitating provision of the service fink:don, within an internal volume defined by the service pod, suitably prior to mounting the pod within the internal volume of the modular building unit. The method may comprise mounting at least some of the equipment and/or components to one or more of a wall, a floor and a ceiling/roof of the service pod.

The step of constructing the modular building unit may comprise configuring its internal volume so that it defines a circulation space/zone or transition space/zone; which may provide access; during use: to the internal volume of the further building unit (suitably from within the modular building unit); and/or to an internal volume of the at least one self-contained service pod. The method may comprise arranging the circulation space so that it opens on to the internal volume of the fluffier building unit, suitably by providing the modular building unit with one or more doorway or other access/walkway. The method may comprise arranging the circulation space so that it communicates with the at least one service pod, suitably its internal volume. Alternatively, the step of mounting said service pod within the internal volume of the modular building unit may compiise arranging the service pod so that it comnumicates directly with, and/or opens directly on to, the internal vohune of the further building unit.

The step of constructing the modular building unit may comprise configuring its internal volume so that it communicates directly with the internal vohune of the further building unit, to facilitate access into the at least one service pod from the living space of the further building unit.

The step of providing the further building unit may comprise arranging its living space so that it forms at least part of one or more room of the building. The one or more room may be selected from the group set out above.

The step of providing the further building unit may comprise providing said unit with a lower storey and at least one upper storey, and optionally arranging said further building unit internal volume so that it defines an upper living pace and a lower living space. The upper and lower living spaces may be provided respectively by the upper and lower storeys.

The method may comprise constructing a plurality of the modular building units, transporting the modular building units to the final location, and comiecting the modular building units (suitably following transpoit to the final location) to define at least part of the building. The method may comprise stacking modular building units one on top of another. The method may comprise providing each of the modular building units with at least one self-contained service pod. in a stacked arrangement of modular building units, there may be a lower such unit and an upper such unit. The method may comprise =tuning a self-contained service pod providing an access function within an internal volume of the lower modular building unit. The method may comprise providing the upper modular building unit with an opening or aperture configured to cooperate with the service pod, to facilitate access between internal volumes of said units via said pod.

The step of providing the further building unit may comprise providing a thither building unit which is a modular building unit, optionally as defined in aspects or the invention. Alternatively, the step of providing the further building unit may comprise providing a further building unit which is a non-modular building unit. The method may comprise constructing the further building unit on-site at the final location for the building, suitably using a kit of building materials (e.g. blocks, timber frame components, metal structural elements) provided at the final location. Options for the construction of the thither building unit are set out above. The method may comprise constructing the further building mitt and then connecting the modular building unit with the further building unit. the constructing step may take place prior to transporting the modular building unit to the final location. Alternatively, the method may comprise transporting the moduktr building unit to the final location, and then constructing the further building runt, optionally using the modular building unit as a platform or support for part or parts of the further building unit.

The method may comprise at least partially enclosing an internal volume of the modular building unit with a perimeter structure.

The method may comprise providing the service pod with one or both of a floor and a ceiling/roof, which may be integral to die pod. Altonatively, the method may comprise arranging die floor and/or roof structure to respectively provide a floor and a ceiling/roof of the service pod.

The method may comprise positioning equipment and/or components providing die required service function, or facilitating provision of the service function, within an internal volume defined by the service pod, optionally prior to connecting said pod to the floor/roof structure. The method may comprise mounting at least some of the equipment and/or components to one or more of a wall, a floor and a ceiling/roof of the service pod.

The step of-at least partially enclosing the internal volume of the modular building unit with a perimeter structure may take place following comacction of the service pod to one or both of the floor and roof structures.

The step may comprise providing the modular building unit a wall structure comprising one or more perimeter wall. The step fluty comprise providing at least one doorway/walkway aperture within the wall structure, which may provide access between an exterior of the modular building unit and the internal volume of the modular building unit. The circulation space/zone (which may also be referred to as a transition space/zone) may provide access to both the internal volume of the self-contained service pod and the doorway aperture.

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a simplified perspective view of a building, comprising a modular building unit, in accordance with an embodiment of die invention; Figs. 2 and 3 arc cross-sectional plan views respectively of lower and upper storeys of the building shown in Fig. 1, illustrating certain features of the building; Figs. 4 and 5 are cross-sectional plan views respectively of lower and upper storeys of a building, comprising a modular building unit, in accordance with another embodiment of the invention; Fig. 6 is an exploded perspective view illustrating a general structure of a rust modular building unit of die building shown in Fig. 4; Fig. 7 is an exploded perspective view illustrating a general structure of a second modular building unit of the building shown in Fig. 5; Fig. 8 is a perspective view of a building, comprising a modular building unit, in accordance another embodiment of the invention, with certain features removed for ease of illustration; Figs. 9 and 10 are exploded perspective views illustrating general structures of first and second modular building units in accordance with tiuther embodiments of the invention; Fig. 11 is a perspective view illustrating a general structure of another modular building unit accordance with an embodiment of the invention; Fig. 12 is a perspective view illustrating a general structure of a further modular building unit in accordance with an embodiment of the invention; Figs. 13 and 14 are exploded perspective views of the modular building units shown inN2s. 11 and 12, respectively; Fig. 15 is an enlarged perspective view of a corner region of a floor structure, and of part of a service pod, forming part of the modular building unit shown in Fig. I 1; Fig. 16 is a view similar to Fig. 15 but drawn to a different scale, and showing only pints of the floor structure; Fig. I 7 is a perspective view of an alternative floor structure, which can Ibni, part of the modular building units; Fig. I S is a simplified exploded perspective view showing a general structure of a further modular building unit, in accordance with an embodiment of the invention; Fig. 19 is a view similar to Fig. 18 of another modular building unit in accordance with an embodiment of the 40 invention; Fig. 20 is a perspective view of an alternative floor structure, which can Conn part of the modular building units; Figs. 21, 22 and 23 are perspective views of comer regions of further floor stmctures which is are variations on that shown in Fig. 20; and figs. 24 and 25 are end views of parts of floor structures which are variations on that shown in Fig. 17, and showing parts of service pods located on the floor structures.

Turning firstly to Fig. 1, there is shown a simplified perspective view of a building 10, comprising a modular building unit 12a, in accordance with an embodiment of the invention. The building 10 can be considered to be a modular or hybrid building, comprising the modular building unit 12a and a further building unit 14, the units being connected together to form at least part of the building. The modular building unit 12a and the further building unit 14 may respectively define first and second sections of the building 10, which in the illustrated embodiment takes the form of a static residential building or domestic dwelling, in particular a detached house.

The modular or hybrid building 10 of the invention is of the general type disclosed in the applicant s pending International patent application nos. PCT/GB2022/051270, PCT/GB2022/051271, PCT/GB20221051272, PCT/GB2022/051273 and PCT/EP2023/063435, the disclosures of which are incorporated herein by this reference. General features of the building 10 are as follows.

The second building section provided by the further building unit 14 is, in the illustrated embodiment, an on-site construction at a final, fixed, on-site location for the building 10. The second building section can take the form of a dock, to which the first building section provided by the modular building unit I 2a may he docked, installed, connected, or attached. The final, fixed, on-site location may he determined by construction plans and fixed by virtue of building foundations. The tenn "on-site location" is used to refer to the building site, which will be understood to refer to the immediate proximity of the building 10 and the entire building site, including a housing estate, on which the building is to be built. Tt will be understood that the site may be a large building/ construction site comprising a plurality of plots, the final location for the building 10 being provided by one of said plots. The first building section provided by the modular building unit 12a can take the form of a module which is dockable, installable, connectable, or attachable to another building section, particularly to a second building section in the form of a dock.

in the illustrated embodiment, the second building section provided by the further building unit 14 is configured to receive the first building section provided by the modular building unit 12a. The modular building unit 12a is connected to and received by the further building unit 14 at the final location of the building 10, to provide the building at the final, fixed, on-site location. During construction of the second building section at the on-site location, the second building section is preconfigured to receive the first building section. That is, the second building section is constructed with the knowledge and design that a first building section is to be subsequently connected, and the second building section is thus preconfigured for connection and receipt of the first building section. This could relate to the shaping of the second building section, through to sealing and connection features. In a variation, the modular building unit I 2a may be transported to the final location and positioned on site, and the further building unit 14 subsequently constructed and connected to the modular building unit.

The first building section provided by the modular building unit I 2a is transportable to the final location in a substantially assembled fonn. This may be taken to mean that the unit 12a is constructed to a state in which: it can be transported safely (i.e. it has sufficient structural integrity/rigidity for transport purposes); minimal further work is required to be carried out on the modular unit in order to connect it to the further building unit 14; and/or minimal (optionally no) further work is required to complete a portion of the building formed by the modular unit. Such further work may be of a structural and/or weatherproofing nature, and may exclude work associated with a final fit-out of said unit, for example of a decorative nature (in particular the application of perishable' materials such as plaster/plasterboard, decorative panels and surface finishes such as paint).

The second building section provided by the further building unit 14, in the illustrated embodiment, can be configured to removably receive the first building section provided by the modular building unit 12a. That is, the second building section can be configured to receive the first building section in a receivable manner such that the second building section can be removed, if and when desired, to facilitate replacement and/or modification of the second building section. The first building section provided by the modular building unit 12a is portable, in a form to be connected to and received by the second building section provided by the further building unit 14.

The second building section provided by the further building unit 14 is configured to receive the first building section provided by the modular building unit 12a, so that the first and second building sections may be connected. The first building section and the second building section may be provided with male-female structures, for facilitating the connection, or guiding the connection. This might also facilitate an at least partial sealing of or between the second building section and the first building section. In another example, the first building section might closely abut against the second building section, and there may be no male-female structures. This might also facilitate an at least partial sealing of or between the second building section and the first building section.

Fig. 2 and 3 will now be referred to, which are more detailed cross-sectional plan views respectively of lower and upper storeys of the building 10 shown in Fig. 1, illustrating certain further features of the building.

The further building unit 14 can be of any suitable construction, including hut not limited to: a blockwork/masomy construction e.g. of clay bricks and/or cement blocks; a timber frame and blockwork/masonry construction; a timber frame and cladding construction; a metal frame construction (optionally comprising panels coupled to the frame, which may be composite panels comprising insulation material); a structure comprising structural insulated 'SIP panels; a time-setting 3D printed construction e.g. of a cementitious material; and combinations thereof The further building unit 14 can be constructed from a kit of building materials (e.g. blocks, timber frame components, metal structural elements) provided at the building site. Suitable timber frame constructions can include a stick-built construction, and a timber frame kit.

The building 10 in-fact comprises the modular building unit I 2a, and a further modular building unit 12b, which is stacked on Lop of the unit I 2a. The modular building units I2a and 12b are connected together. Stacking of the modular building units 12a and 12b typically occurs at the [Mal location, which facilitates handling and transportation. The modular building units 12a and 12b are of like construction, and configured to connect with the further building unit 14 to form the completed building 10. The modular building units 12a and 12b are stacked directly on top of one another (that is with the upper unit 12b resting on top of the lower unit 12a).

Access between the units 12a, b can therefore be achieved directly, without having to pass into or through any part of the further building unit 14.

As explained in detail in the applicant's pending International patent applications mentioned above, the modular building units 12a and 12b provide a number of functions in the completed hybrid/modular building 10. These include that the modular building unit 12a includes a stairway or staircase 18 which provides access anchor an access route between a lower storey 20 and an upper storey 22 of the further building unit 14, as indicated by the arrow 23 in Fig. 1.

In addition, and referring to Fig. 2 showing the lower storey 20, the modular building unit 12a comprises a front or main doorway 24 into the building 10, which provides access and/or an access route (indicated by the anew 26 in the drawing) between an exterior 84 of the building 10 and an interior of the building, in particular of the further building unit 14.

Still further, and referring to Fie 3 showing the upper storey 22, the modular building unit 12b provides access and/or an access route between individual rooms or areas within the further building unit 14, including rooms/areas which cannot be accessed solely from within the further building Imit. This is indicated by the arrow 28 in Fig. 3. Access in this instance is provided between a master bedroom 30 and further bedrooms 32 and 34 in the further building section 14.

As can be seen in Figs. 2 and 3, the modular building units 12a and 12b define circulation spaces/zones (or transition spaces/zones) which provide for the required access/access mutes speci lied above. Two such circulation spaces are shown in broken outline in the drawings, and indicated by reference numerals 36 and 38. The circulation spaces 36 and 38 encompass and/or are provided by a hallway 40, the staircase 18 and a landing 42. The hallway 40 and staircase 18 are provided in or by the lower modular building unit I8a, and the landing 42 by the upper modular building mit 18b stacked on the mitt 18a. The upper modular building unit 18b includes a stairway aperture or opening 44 which communicates with the staircase 18, to Ilicilitate movement between the building units 18a and 18b (and so between the lower and upper storeys 20 and 22 of the further building unit 14).

As mentioned above, the modular building 10 comprises the modular building units I 2a and 12b, and the further building unit 14 (which is typically an on-site construction). Reference will be made mainly to the modular building unit 12a. The modular building unit 12b is of similar construction, and it will be understood that the discussion of the unit I 2a applies equally to the unit 12b. Accordingly, only substantive differences between the modular building units I 2a and 12b will be described. The invention also encompasses a modular building system which is used to fonn the modular building 10 The features of the modular building system will be evident from the following discussion.

The modular building unit 12a defines an internal volume 46, and is transportable to the final location for the building 10 in the substantially assembled form ShOW11 in the drawings. The blither building unit 14 is configured, in use, to define an internal volume 48 which provides a living space 49 within the building 10. The living space 49 defines various rooms and/or areas of the building 10. These include an open-plan room providing a kitchen area 64, dining area 65, living area 67 and leisure area 69 in the lower storey 20, and the bedrooms 30 to 34 in the upper storey 22. The living space 49 which is provided therefore includes a lower living space part in the lower storey 20, and an upper living space part in the upper storey 22.

The internal volume 46 of the modular building unit 12a communicates directly with the internal volume 48 of the further building unit 14. The comimmication is such that it is possible to transit from the internal vohune 46 or 48 of one of the modular and further building units 12a and 14 directly into the internal volume of the other one of the modular and further building units, without having to pass through a further imit or part of the building 10, or to the building exterior 84.

The building 10 also comprises at least one service pod which call be mountable within the internal volume of the modular building unit I 2a/b" and can be provided as a self-contained structure. In the illustrated embodiment, the building 10 comprises a plurality of such service pods, which are each given the reference muneral 50, together with a respective suffix a, b, c etc. The service pods 50, in use, each provide a service function within the building 10, as will be described below. I,ike components of the service pods 50 share the same rellirence numeral, but are indicated by the relevant suffix.

The communication between the internal volume 46 of the modular building unit I 2a and the internal volume 48 of the further building unit 14 can Ihciliiate access into the at least one service pod 50 from the living space 49 of the further building unit. In addition, the circulation space 40 defined by the internal volume 46 of the modular building unit 12a can provide access, in use, to both an internal volume 52 of the service pod 50" and the living space 49 provided by the internal volume 48 of the further building unit 14, from within the modular building unit 12a.

The hybrid or modular building 10 of the invention may provide advantages over prior modular buildings comprising a modular building unit, in which components of facilities such as a kitchen, bathroom and WIC or washroom are installed in the unit in a factory, prior to transportation to a final location for the building In particular, the provision of a service pod 50 which is a self-contained starchily, mountable within the internal volume 46 of the modular building unit I 2a, offers advantages including: ease of installation (and resultant construction Lime/cost efficiencies); reliability and repeatability o [installation; and improved quality control. The service pod 50 can be constructed at a different location to the modular building unit 12a, for example in a dedicated facility or factory. The service pod 50 can therefore he constructed by operators skilled in a field relevant to the service function in question. This may reduce the likelihood of quality issues arising, as could occur in a factory where operators are required to install components providing multiple different service functions. Similar advantages may be achievable in comparison to components of facilities which are installed at a final location or site for a building.

As mentioned above, the building 10 comprises a plurality of service pods 50, each of which can be momitable within the internal volume 46 of the modular building unit 12a, suitably as self-contained structures. In the case of the modular building unit 12a, there are four such service pods 50a to 50d, which each provide a different service fimction during use. A wide range of different service functions can be provided, which may be selected from the group comprising: an access function (e.g. between different storeys 20 and 22 of the building 10, in particular of its further building unit 14); a cooking, dining and/or kitchen function; a sanitary filiation (e.g. washing/bathing and/or toilet); and a technical function (e.g. provision of utilities, communications, healing, ventilation).

In the illustrated embodiment, the service pods 50a to 50d of the modular building unit 12a respectively provide all access function (pod 50a), a sanitary function (pod Sob), and teclmical functions (pods 50c and 50d). The service pods 50a to 50d contain equipment or components which are configured to perform the required service function. The service pods 50a to 50d call each be positioned on a floor 47 of the modular building unit 12a, so that they are suppoited by the floor, and in prefeired embodiments that will be described below, the pods are each connected to a floor structure of the unit.

The pod 50a, which provides an access filiation, contains the stairway 18 that provides access between the lower and upper modular building units 12a, hand so the access between the different storeys 20 and 22 of the building unit 14 (as indicated by the anow 23). It will be understood that this could similarly be achieved via a lift (not shown) or other suitable access equipment.

The pod 50b, which provides a sanitary function (functioning as a WIC orwashroom), contains a toilet 54 and a sink 56.

The pod 50c, which provides a technical function, can contain a wide range of different equipment, including utilities connections such as electrical power supply, gas supply, water supply, sewerage connections, and relevant meters; communication equipment such as data and telecommunication equipment; heating and/or cooling equipment; ventilation equipment which may include mechanical ventilation and heat recovery (MVHR) equipment white goods such as washing and/or drying equipment for textile products; and a water storage tank. In the illustrated embodiment, the pod 50c contains a boiler or heating/cooling unit 58, MVEIR control equipment 60 and utilities connections 62 (e.g. for electric and water supplies terminated in the pod).

The pod 50c effectively acts as a services hub, providing services into the further building unit 14 (and so the building 10).

The pod 50d also provides a technical function, functioning as a utility room for the kitchen area 64 provided in the open-plan living space 49 (defined by the internal volume dit (tithe further building unit 14). The pod 50d con ains a sink 66 and 'white goods' type equipment such as a washer/diver 68.

In a similar fashion, the modular building unit 12b comprises service pods 50e and 50f, which provide sanitary functions. The service pod 50e functions as a bathroom, containing a bath 70, shower cubicle 72, toilet 74 and sink 76. The service pod 50f functions as an ensuite for the master bedroom 30, and contains a shower cubicle 78, toilet 80 and sink 82. The service pods 50e and 50f can each be positioned on a floor 53 of the modular building unit 1214 so that they are supported by the floor, but again, in prefened embodiments are each connected to a floor structure of the unit.

As can be seen from Figs. 2 and 3, the service pods 50a and 50b each open on to (and so communicate with) the circulation space 36. Access into the pods 50a, 1, from within the living space 49 of the further building unit 14 (and indeed from within the modular building unit 12a itself) is therefore provided via die circulation space 36. The service pod 50d in contrast opens directly on to the living space 49 of the further modular building unit 14, and so effectively provides direct access from the living space into the pod, without passing into die circulation space 36 of the modular building unit 12a. The service pod 50d therefore communicates directly with, and/or opens directly on to, an internal volume 48 of the further building unit 14.

The service pod 50c opens to the building exterior 84, via access doors 86. This facilitates access to the equipment within the pod 50c without requiring entry into the main part of the building 10, for example by skilled tradespeople or meter readers In a variation however, the pod 50c may additionally or alternatively be accessible from within the modular building unit 12a, or the further building mid 14.

in a similar fashion, the service pod 50e in the second modular building runt 121) opens on to (and so communicates with) the circulation space 38. Access into the pod 50e from within the bedrooms 30, 32 or 34 of the further building unit 14 (and indeed from within the modular building unit 12h itself) is therefore provided via the circulation space 38. The service pod 501 in contrast opens directly on to the master bedroom 30, and so effectively provides direct access from the bedroom into the pod.

One or more (tithe service pods 50a to 501 can he arranged so that they are releasably mounted within the respective internal volumes 46,51 of the modular building units 12a, b. This facilitates removal of the pods from the units, for example for maintenance and/or replacement purpose* The pods 50a to 501 may be removable, for example in the event that wear and tear on a pod has degraded its appearance; if it is desired to change a decorative appearance of a pod; or to alter, improve or upgrade functional equipment provided by or within a pod Further features of the modular building units and modular buildings of the invention will be described with renrence to a further embodiment shown in Figs. 4 to 7. In these drawings. Figs. 4 and 5 are cross-sectional plan views respectively of lower and upper storeys of a further building 10, comprising a modular building mit I 2a'/1 2b', in accordance with another embodiment of the invention. Fig. 6 is an exploded perspective view illustrating a general structure of a lint modular building unit I 2a' of the building 10' shown in Fig. 4. Fig. 7 is an exploded perspective view illustrating El general structure of a second moduku-building unit 12b' of the building 10' shown in Fig. 5. Upper struchual parts of the modular building units 12a'112 b' have been removed in Figs. 6 and 7, to facilitate illustration and understanding of the invention. Like components of the building 10' with the building 10 shown in Figs. 1 to 3 share the same reference munerals, with the addition of the suffix '. Only substantive differences or additional features in comparison to the building 10 will be described.

Preferred embodfinents of modular building units are shown in Figs. 11 to 25 and \yin be described below. The preferred modular building units can have any of the further features of the modular building units described elsewhere in this doctunent, as shown for example in Figs. 1 to 10. 'f his applies particularly to internal volume communication and circulation space concepts described herein. The prefened modular building units can fonn part of a building system/building as described in this doctunent and shown in the drawings, particularly Figs. 1 to Sand Fig. 8.

Thus tuning to Figs. 4 and 5, the building 10' again takes the form of a residential building, in this instance a semi-detached house sharing an internal wall 88 with an adjacent such house. Parts of back 90 and front 92 walls of the adjacent house are shown in the drawing. It will be understood however that the building may be a detached house like that shown in Fig. 1. The building 10' comprises the modular building units 12a' and 12tic and a further building unit 14'. The modular building units 12a' and 121): are stackod in the same way as the units 12a and 121) (as shown in Fig. 1), and connected to the further building unit 14' which is again an on-site construction at a final, fixed, on-site location In the building 10'.

As can be seen from Fig. 6, the modular building unit 12a' comprises a structural frame or core structure, indicated generally by numeral 94, which provides structural support during use of the unit (as well as during transportation and handling). The structural frame 94 is a perimeter frame, generally defining a perimeter of the modular building unit I 2a'. The structural frame 94 comprises a plurality of frame components which are interconnected to tionri the frame. The drawing shows side roof beams 96a and 1), which are connected to end roof beams 98a and b to form a top or roof frame portion/structure 99 of the frame 94. A floor franc portion/structure of the frame 94 similarly comprises side and end floor frame beams, one side floor beam 100 and one end floor beam 102 being shown. The floor frame portion is indicated by numeral I 03. The roof and floor frame portions 99 and 103 are connected together by comer posts or cohmms 104a to 104d, to form a wall structure comprising side wall frame portions I 06a, b and end wall frame portions I nla, b. As will be described below however, in prefened embodiments a service pod (or pods) soy es for connecting the floor and roof frame structures.

It will be understood that further frame components (not shown) may he provided defining any one or more of the roof, floor and/or wall frame portions 99, 103, 106a/b and I 08a/b. in particular, floor joists are provided which extend between and are connected to the side floor beams 100 of the floor frame portion 103. Roof joists are provided which extend between and are connected to the side roof beams 96a, h of the roof frame portion 99. A roof structure comprising such joists has been removed from the part or the drawing showing the modular unit 12a', to facilitate illustration and Luiderstanding (as have roof frame components of the pods 50a1/50b' shown located in the modular unit). The wall frame portions 106a, b and 108a, b may comprise bracing members such as struts, beams or columns which provide additional structural strength, and/or define a structure of the wall frame portions. For example, additional columns may extend between and be comiected to side floor beams 100 and side roof beams 96a, it as well as between end floor beams 102 and end roof beams 98a, b.

Transverse bracing struts may extend between adjacent columns.

The frame components are typically of a metallic material, which may be a metal or metal alloy such as aluminium or steel. The frame components are suitably of a cold-fonned (e.g. rolled or pressed) metallic material, which may be a metal or metal alloy such as aluminnun or steel. As is well-known, cold-formed metallic frame components of this type are typically constructed from thin flat plates (e.g. around 3mat thick), and are fonned into channel or box-section shapes which provide structural rigidity and resist applied loading. At least some frame components could however be of a hot-formed (e.g. hot-rolled) material such as steel, particularly frame components of or forming a main perimeter part of the structure, including for example the roof beams 96a/b and 98a/b, the floor beams 100 and 102, and the columns 104a to d. Timber and timber-based materials (e.g. composite wood materials such as plywood) may also he capable of being employed.

In the illustrated embodiment, the modular building unit 12a' again comprises a plurality of service pods, two shown and given the numerals 50a' and 5011'. As mentioned above, Fig. 6 is an exploded perspective view, which also shows the service pods 50a' mid 50b' separately or removed from an internal volume 46' of the building unit 12a' (or prior to mmmting in the building ma). The pod 50a' provides an access function, housing a stairway 18'. The pod 5011' provides a sanitary function (functioning as a W/C or washroom), housing a toilet 54' and a sink 56'. Further service pods can be provided in the modular building unit 12a', including a technical pod 50ct mid a utility pod 50d'. The utility pod 50d' may be located within, or may effectively form part of, the access pod 50a'.

The service pods 50a' and 50b' may each be releasably connectable to the structural frame 94 of the building unit 12a', so that the pods can be releasably momited within the internal vohune 46 of the building unit. Connecting the service pods 50a' and 50b' to the structural frame 94 provides structural benefits during use of the modular building -Lunt 12a'. In particular, the pods 50a' mid 50b provide structural support to the building unit 12a', specifically to its structural frame 94. The pods 50a' and 50b' arc effectively integrated into the structural frame 94, and thereby providc the structural support The service pods 50a' and Sob' are typically coimected to at least one frame component of the stmctural frame 94, optionally to a plurality of frame components. Releasable connections (not shown), such as nut-and-bolt assemblies, may he used to connect the pods 50al and 50b to the frame 94. However, other options can include clamps, a friction fit, a snap-lock arnmgement latching pins and indeed any other releasable connection.

The service pods 50a' and 50b1 comprise respective structural frames 110a and 110b, which are each connectable to the structural frame 94 of the modular building unit I 2a'. The structural frames II 0a/b define perimeter structures of the pods 50a' and 501)', providing structural integrity to the pods: during use; during transport to the manufacturing facility for the modular building unit 12a'; and during handling of the pods e.g. for mounting them within the internal volume 46.

Referring for example to the service pod 50a1, and in a similar fashion to the structural frame 94 of the building unit 12a', the structural flame 110a of the pod compfises a plurality of frame components which are interconnected to Ram the pod frame. Side roof beams 112 and 114 are connected to end roof beams 116 and 118 to form a top or roof frame portion 120 of the frame 110a. A floor frame portion 122 comprises side and end floor frame beams, one side floor beam 124 being shown, and two end floor beams 126 and 128. The roof and floor frame portions are cmmected together by collier posts or columns 130, 132, 134 and 136. The frame components are again typically of a cold-fomied metallic material, such as ahuninium or steel, although use of a hot-formed material such as steel is an option (or indeed limber/timber-based materials).

The service pod 50a' defines an internal volume 137, which is bordered by the perimeter structure of the frame 94. The stairway 18' is positioned within the internal voltune 137, and is suitably comiected to the frame 94.

For example, the stairway 18' may also be of a metallic material (suitably the same material as the frame 94), and connected to the frame by welding or bonding. However, other options include releasable connectors of the type described elsewhere in this document, which may facilitate maintenance and/or replacement of the stairway Ig' whilst permitting reuse of other parts such as the frame 1 I Oa. Additional options for connecting the stairway lfd to the pod 50a' (and indeed other equipment/components to different pods) includes securing the stairway 18' directly to one or more of a floor, roof or a wall/walls of the pod. The latter may be a particular option where structural panels are used to form walls of the pods, as will be discussed below. in another variation, the stairway 18' may be provided as a pod which does not comprise a structural frame, the stairway optionally being directly connected to the structural frame 94 of the modular building unit 12a'.

The perimeter structure defined by the structural frame 110a of the service pod 50a' comprises one or more wall, and in the illustrated embodiment comprises end wall 138, side wall 140 and end wall 142. A second side 144 is open, providing access to the stairway 18'. All of the walls 138, 140 and 142 of the service pod 50a' are defined by the pod itself. in a variation however, at least one (il-the walls 138, 140 and 142 may be delined by the modular building -Lunt 12a', in particular by the side or end wall portions 106a/b and 108a/b of the building unit in the case of the service pod 50a, the side wall portion 106a of the building unit 12a' may provide the pod wall 140, and the end wall portion 108b of the building unit may provide the pod wall 142. Ananging the building unit end wall portion I 08b so that it provides the pod wall 142 may facilitate the provision of a utility compartment or area 146 in the service pod 50a1, as shown in the plan view of Fig. 4, so that the pod provides multiple service functions.

The service pod 50b' is of similar structure to the service pod 50a', and, will not he described in detail here. Again, the pod 50b' itself may provide all of its walls, or the building unit 12a' may provide one or more of the walls. In a variation, service pods provided adjacently in the building unit 12a' may share one or more internal wall. For example, in the illustrated building unit I 2a', the service pods 50a' and 50b are adjacent within the unit, and the end wall 138 of the pod 50a' may provide an end wall of the pod 50b'.

The modular building unit 12a' comprises a front doorway 24', with a door 148 mounted in a door frame 150 positioned in the doorway. The door frame 150 is secured to the structural frame 94, to provide a stable mounting for the door 148. The building unit 12a' also comprises internal doorways or tvalkways 152 and 153, which provide access between a lower storey 20' of the further building unit 14a and the modular building unit 12a, and so to the service pods 50a' and 50b' (and thus the stairway 18' and the WIC facilities in the pod Sob'). In a similar fashion to the modular building unit 12a of Figs. 1 to 3, the building unit 12a' defines a circulation space 36' which facilitates the movement between the modular building unit and the further building rmit 14'.

The modular building unit 12b' is of a similar construction to the building unit 12a' and so will only be briefly described. The building unit 12b' comprises a structural frame 154, which is similar to the frame 94 of the building unit 12a'. Service pods 50es and 501 may each be releasably mounted within an internal volume 51' of the building unit l2 h'. and are secured to the frame 154. The pods 50e' and 501 both provide sanitary functions.

The service pod 50e' functions as a bathroom, containing a bath 70', toilet 74' and sink 76'. The service pod 501 functions as an ensuite for a master bedroom 30', and contains a shower cubicle 75', toilet 80' and sink 82'. Fig. 7, similar to Fig. 6, again shows roof structure of the modular unit 12b' removed, as well as roof frame components of the pods 50e7501 shown located in the modular unit).

The modular building unit I2b' comprises Ibur internal doorways or walkways 156, 158, 160 and 162, which provide access between an upper storey 22' of the further building unit 14a and the modular building -unit 12b', and so to the service pods 50e' and 50f (and thus the stairway 18' and the sanitary facilities in the pods). Specifically, the doorway 156 provides access from the master bedroom 30' into the ensuite pod 501', whilst the doorways 158, 160 and 162 provide access respectively between the modular building unit 12b' and the master bedroom 30', a second bedroom 32' and a third bedroom 34'. In a similar fashion to the modular building unit 12b of Figs. 1 to 3, the building unit 12b' defines a circulation space 38' which facilitates the movement between the modular building unit and the further building unit 14'.

in the illustrated embodiment, wall structures of the first and second modular building units I 2a' and 12b' are both panellised. For example and referring to Fig. 6, externally facing walls of the unit 12a' comprise insulated panels which are connected to the structural Frame 94 The panels have a weather-proof external surface, three being identified in the drawing and given the reference numerals 164a to 164c. Internal walls also comprise panels connected to the frame 94. A plurality of such panels can be seen in the drawing, one of which has been identified with the numeral 166.

Wall structures of the various service pods 50a' to 5011 are similarly panellised, as can be seen in Figs. 6 and 7. For example and referring to the sanitary pod 50IY, side walls 168 and 170 (considered relative to a direction of entry into the pod), and end walls 170 and 172, are formed from a plurality of panels, one of which has been identified with the numeral 176. The panels forming the side walls 168, 170 and the end wall 174 are each connected to the pod structural frame I 101). Bracing or mounting struts or the frame 110b, e.g. as shown at 177 in Fig. 6, serve for connecting the panels 168 and 170 to the frame. Similar such struts for the pod 5017 frame 110f can be seen in Fig. 7, indicated at 179. In the illustrated embodiment, the end wall 172 of the pod Sob' is provided by the modular building unit 12W itself, and so by panels forming a wall of the unit (connected to the mit frame 94). In a variation however, the pod end wall 172 may be formed by integral pod panels.

It may be desirable to arrange one or more of the service pods 50a' to 50e' of the modular building units 12a' and 121Y to provide at least part of one or more wall of the respective building unit. This may be particularly useful where relatively complex internal wall finishings are required in the pods, for example tiled surfaces on walls of the W/C pod 50bc bathroom pod 50e and/or ensuitc pod 501.

Taking the W/C pod Sob' as an example, it may be desirable to provide the side walls 168, 170 and end wall 172 with tiled internal surfaces (facing into the internal volume of the pod). The side wall portion 106a of the modular building unit 12a' may have all aperture or opening (not shown) where the end wall 172 of die pod Sob' is located. The pod end wall 172 may be arranged to close the aperture in the side wall portion 106a once installed, and may fonn part of the external surface structure of the modular building unit 12a'. This may provide the advantages that a double wall can be avoided (as would be the case where the modular building unit 12a' and pod Sob' each define respective overlapping wall structures), and that the relevant wall surfaces can be tiled prior to installation of the pod (avoiding a requirement to tile after installation, as may be necessary where the modular building unit I 2a' provides the pod end wall 172).

At least one of the service pods 50al to 50e' may be connectable to at least one other service pod. This may facilitate mounting of the service pods within the Internal volume of the respective modular building unit 12a', 12W together and/or at the same time. This may apply particularly to service pods which are positioned adjacent one-another when mounted within the modular building unit 12a'/12b'. For example, the pods 50a: and 50b' may be connected prior to installation within the internal volume 46' of the modular building unit I 2a1. The connected service pods 50a' and 50b' may together limn a service pod assembly which is mountable within the internal volume of the modular building unit. Connecting the service pods 50a' and Sob' in this way may facilitate or streamline the installation process for the pods.

The service pods 50a' and 50b' may be comiected by joining their structural frames 110a and 1 lob together, for example by welding, or using releasable connectors such as nut and bolt assemblies (or other such options discussed elsewhere in this document). Providing a releasable connection may facilitate maintenance and/or replacement of a selected one of the pods.

Reference is made to the various service pods 50 disclosed herein being self-contained structures. This could be taken to mean that the pods 50: are structurally sell-supporting arid do not rely e.g. on the modular building units 12 for their structural integrity; comprise all (or substantially all) components and/or facilities RCCOSSary for them to carry out their service function (other than for example external connections to components in the modular building units 12, such as sewerage connections); and/or define a complete perimeter (e.g. a wall perimeter) of the pods 50; without relying on other components such as of the modular building units 12.

A preferred constmction method for the modular building 10' (which applies also to the building 10) involves constructing the modular building units 12a' mid 12b' to substantially assembled fonns at a location which is distanced from a final location for the modular building, suitably in a dedicated factory or facility. The self-contained service pods 50a to 50f are mounted within the internal volumes 46' and 51' of the modular building units 12a' and 12b' at the factory. The assembled units 12a' and 12b' can then be transported to the final location in preparation for connection to the further building unit 14'.

The further building unit 14' is constructed at the final location; typically employing a construction method involving blocks, timber frame, panels etc. as described above. Transport of the modular building units 12a' and 12b' to the fmal location will typically take place only after the further building unit 14' has been constructed to a state in which it is ready to be connected to the modular units. This avoids a requirement to store the modular units 12a' and 12b' on-site for lengthy periods whilst the further building unit 14' is constructed.

In a variation, the modular building units 12a' and 12b' may be transported to the final location and positioned on site, and the further building unit 14' subsequently constructed mid comiected to the modular building units. The further building unit 14 may be constructed using the modular building units 12a' and 12b' as a platfonn or support for part or parts of the further building unit.

The modular building units 12a' and 12b' are typically transported to the final location in a disconnected state, suitably on a loin/ or truck trailer. The first (or lower) modular building unit I 2a' is located on a prepared foundation or plattimn located adjacent the further building unit 14', as shown in Fig. 2, and connected to the further building unit. 't he second (or upper) modular building unit 12b' is then positioned on top of the lower unit I 2a (i.e. stacked); and also connected to the further building unit 14'. The upper modular building unit 12b' can be configured to provide an upper or outer roof for the stacked modular building units, which is sealed relative to the further building imit 14' to prevent water ingress. A similar such roof 178 is shown on the building 10 in Fig. 1. Any necessary final fitting-out work can then be carried out to complete the building 10'.

A construction method for the modular building unit 12a' (which also applies to the other building unit 12b', as well as the units I 2a and 12b) can comprise the Ibllowing steps.

The method firstly comprises constructing the structural frame 94 describing the internal volume 46' of the modular building unit 12a', suitably in an off-site factory or facility as explained above. The service pods 50a" to 50d' are typically constructed in specialised facilities and transported to the factory for installation in the modular building unit I 2a'. It will be understood however that the service pods 50a' to 50d' may be constructed at the same factory as the modular building unit 12at The service pods 50a' to 50d' are then positioned within the internal volume of the modular building unit 12a' and commuted to the structural frame 94 as described above. The service pods 50a' to 50d' may be lowered into the building unit frame 94 from above, but could be translated in from the side, for example on rollers or skids (not shown).

the internal volume 46' of the modular building imit 12a' is then at least partially enclosed with a perimeter structure, which is provided by the walls 106a/b and 108ani. hi the illustrated embodiment, this involves cmmecting the various panels 164 to the frame 94. In a variation however, the perimeter structure may be formed prior to instillation of the pods 50a' to 50d' within the building unit 12a'. This may apply particularly where the pods 50a' to 50d' are to be lowered in. As explained above, the service pods 50a' to 50d' comprise structural frames (e.g. the frames 110a/b), and the method suitably comprises connecting the structural frames of the service pods to the structural frame 94 of the modular building unit 12a'. This construction process may be particularly suited to mass-production of the modular building units in a factory location, for example on an assembly line.

Tinning now to fig. 8, there is shown a perspective view of a further building 10", comprising modular building units 12a"/12b", in accordance with another embodiment of the invention. The building 10" takes the forin of a detached house. Certain features of the building 10" have been removed, for ease of illustration. Like components of the building 10" with the building 10 shown in Figs. 1 to 3 share the same reference munerals, with the addition of the suffix ". Only substantive differences or additional features in comparison to the building 10 will be described.

The modular building units I 2a" and 121)" are of like construction to the modular units I 2a' and I 21)' of the building I Oa', and will not be described again. The building 10" differs primarily in that it is a fully modular structure, constituted from the modular building units 12a" and 12b", and fiuther modular building units 12c and 12d. The modular building unit I 2c is a lower unit, and the modular building unit I 2d an upper unit that is stacked on the lower unit I 2c, in the same way as the units I 2b" and I 2a". The modular building mits 12a" and 12b" can be considered to form a first section of the building 10", and the units 12c and 12d a further (second) section 14" of the building. The modular building units I 2a", I 2h", 12c and I 2d each extend a full depth of the building (from front to back) and together form the internal volume of the building 10". It will be understood however that other arrangements of modular units are possible (e.g. different numbers of modular units, and/or different orientations of modular units).

The building 10" also differs in that it includes a roof structure 180 that overlies both the imst building section provided by the stacked modular units 12a"/121r, and the second building section 14". The roof I SO ties the first building section 12a"/12b" relative to the further section 14", to provide structural rigidity to the constructed building 10". The roof 150 is supported by and connected to both of the building sections 12a"/12b" and 14", but can be arranged to be supported by or from one of the building sections and arranged to extend over the other section. The roof 180' comprises a plurality of roof trusses, one of which is shown and indicated by numeral 182. The roof trusses 182 are each supported by and connected to the building sections, and 1brined of any suitable material, including hut not restricted to wood and wood-based products/composites, and cold-formed metal (e.g. LOSE). An external surface 184 of the constructed building 10" is finished in any suitable way, e.g. by cladding it with decorative weatherproofing panels (not shown), or forming an outer skin of brick/blockwork (and optional cementitious render).

the building 10" also differs in that parts of side walls oldie modular units 12 a"/12b" are removable, to allow access to the interior of the units. Specifically, die lower modular unit 12a" has a side wall 106a", and a part of die sidewall is removable to form an aperture 185. Similarly, die upper modular unit 12b" has a side wall 106b"" and a part of the sidewall is removable to form an aperture 187. This can be achieved by releasably attaching said parts of the sidewalls 106a7106b" to structure of die units, particularly their structural frames (not shown). This facilitates removal of one or more service pod from within the modular units 12a"/12b", e.g. for maintenance or replacement, as described elsewhere in this document. The pods (not shown) are configured to be translated out of the modular writs 12a712b" though the apertures 185/187. In a variation, service pods can be arranged to fonn the removable portions of the external walls 106a"/106b" which effectively close the apertures 185/187. The pods may therefore be released from the modular units together with (or carrying) said pails of the walls.

It will be understood that the ability to remove such wall 106a/1 06b" portions to form the apertures 185/187 will require access to the removable wall portions in the constructed building 10". This can suitably be achieved by arranging the modular units 12a"/121)" so that they themselves form the outermost surface of the building, or e.g. by cladding the external surface 184 (at least in the region of the modular units) with removable panels or the like.

in a further variation, service pods may be dimensioned so that they can be removed through one or more door or window of the modular building units 12a" and/or 12h", or one or more door or window may he releasably connected to the or a modular building unit in order to facilitate service pod removal. For example, pods may be dimensioned so that they can be removed through a doorway 189 of the modular building unit I2a", and/or a door or doors 191a/b mounted in the doorway may be releasably mounted relative to a frame 193 forming the doorway. Alternatively, the frame 193 itself may be removably mounted to the modular unit I 2a "to facilitate pod removal.

In yet another variation, the building 10" could be a hybrid construction of the type shown in Figs. 1 to 5, and the modular building units I 2a" and I2b" may only extend part way from front to hack of the building. The further building section 14" may thus be constructed on site, and may be generally L-shaped. In this variation, other portions of the modular unit walls I 06a"/I06b" shown in Fig.£1 may be removable, to facilitate service pod removal.

Turning now to Figs. 9 and 10, there are shown exploded perspective views illustrating general structures of first 12ar" and second 121)": modular building units in accordance with further embodiments of the invention. The modular units 12a"7121)" can form part of any one of the buildings 10 to 10" shown in Figs. Ito 8. like components of the modular units 12a'"/I 21am with the modular units I 2a/I 21) shown in Figs. 1 to 3 share the same reference numerals, with the addition of the suffix ". Only substantive differences or additional features in comparison to the building 10 will be described.

the modular units 12a"712b:" differ primarily in terms of their internal layout, plus the shapes and locations of service pods provided in the modular units. The modular unit 12a"' shown in Fig. 9 is a lower modular unit and the modular unit 12b"' shown in Fig. 10 is an upper modular unit that is stacked on the lower unit in the constructed building.

Service pods 50a1", 50b" and 50d" are mountable within an internal volume 46" of the lower modular building unit 12a" (suitably as self-contained structures), and respectively provide access, sanitary and teclmical fruictions in the building. Thus pod 50a" contains a staircase 18"; pod 501)" a toilet 54" and sink 56T: and pod 50c1" a washer/drier 68" and hot water storage tank 186. The access pod 50aT is located in all area 188 in the modular unit vohune 46T, and the sanitary pod 501)" in an area 190. The sanitary pod 50b" is effectively located partly underneath the staircase 18". and so partly in the area 188, extending into a space or recess 192 of the access pod 50a". A doorway 194 providing access into the sanitary pod Sob" is defined by the pod itself, but a door 195 located in the doorway is shown in file modular unit 12a".

't he modular unit 12a" includes a recessed area 196 which, in use, is intended to form part of a room pfimarily defined by the further building section, e.g. a living room. 'Ibis can assist in meeting particular planning requirements whilst optimising the equipment provided in the modular unit. hi a variation that is not shown in the drawings, the sanitary pod 501):" could be shaped to fit in the area 190, and the teclmical pod Sod" could be shaped to fit in the area 188.

A service pod 50e" is nip-tunable within an internal volume 48" of the upper modular building unit 12bl" as a self-contained structure, and provides a sanitary function. Thus pod 50e" contains a bath 70T, toilet 74" and sink 76m. The sanitary pod SOc'' is located in an area 198 in the modular unit 12bm, and provides the primary bathing facility in the building as there is no ensuite pod in this embodiment (sec pod 5017 in Fig. 7). A utility cupboard is also provided in the modular unit 121)T, in this case as a pod 50g containing e.g. ventilation equipment (such as a MVHR unit -not shown), although may not be provided in pod limn. For example, a housing could be positioned in the internal volume 48" and the MVHR equipment subsequently fitted in the housing.

Taming now to Figs. 11 and 12, there are shown perspective views of further modular building units, constructed in a method according to a preferred embodiment of the invention, the modular building units indicated by numerals 12aly and 12bT. Like components of the modular building units 12a1" and 12b1" with the modular units shown in Figs. 1 to 10 share the same reference numerals, together with the suffix Only substantive differences or additional features will be described. As explained above, the modular building units 12aw and 12bw call fonn part of any of the buildings shown and described in this document, and so for example the buildings le to ID" of Figs. 1 to 5 and S. The modular building unit I 2a'v again forms a lower such unit, and the modular building unit I 21)" an upper such unit which is stacked on the lower unit (e.g. as shown in Fig. 8). The following discussion will focus on the structure of the lower modular building unit 12a". It will be understood however that the upper modular building unit I 21i'v is of a similar construction.

Fig. 13 is an exploded perspective view of the modular building unit 12a" shown in Fig. 11, and will also be referred to. The modular building unit 12a" comprises a roof structure 99a1v, a floor stucture 103a1, and a service pod 50a" configured to perfonn a service function within the building. In this embodiment, the service famction is an access fmiction, the service pod 50a" containing a stairway or staircase 18'. The service pod 18' comprises a structural frame 110a Iv having at least one load-bearing support in the form of a support wall or panel 199 (which will be described in more detail below).

The method of constructing the modular building unit 12a Iv generally comprises the following steps. The service pod 50a" is connected to the floor structure 103a to fonn a modular building turn sub-assembly 200 comprising the service pod and the floor structure. The roof structure 99a IV is then connected to the sub-assembly 200 to form the modular building unit 12a", by connecting the roof structure to the service pod 50a". In an alternative approach, the service pod 50a " is connected to the roof structure 99a Iv to form a modular building unit sub-assembly 202 comprising the service pod and the roof structure. The floor structure 103a TV is then connected to the modular building unit sub-202 assembly to form the modular building unit 12a tv, by connecting the floor structure to the service pod 50a ". In both approaches however, the service pod 50a TV is arranged so that its load-bearing support 199 extends between and connects the roof structure 103a " to the floor structure 99a", structural loading being transmitted from the roof structure to the floor structure through the load-bearing suppoit.

The method of the invention may offer advantages over prior modular building unit construction methods, including reduced construction times, cost savings, and reduced complexity. In the method of the invention, connecting the roof/floor structures 99a" and 103a" to the service pod 50a" of the sub-assembly 200/202, and arranging the load-hearing support 199 of the pod so that it extends between and connecLs the roof structure to the floor structure, has the result that the service pod effectively provides a structural core of the modular building unit 12a". The service pod 50a" forms at least part of the load-hearing structure of the modular building unit. The construction process may be more efficient than prior methods, by avoiding a requirement to firstly construct a structural frame of the modular unit, and then to locale a service pod in its internal volume. This is achieved by connecting the roof structure 99arv to the service pod 50a'v, and arranging the load-bearing support 199 of the service pod so that it connects the roof 99a" and floor 103aw structures and transmits structural loads to the floor structure. The step of connecting the roof structure 99a' to the service pod 50a' comprises mounting the roof structure on the service pod. This involves resting the roof structure 99a" on, or arnanging it so that it is supported from or by, the service pod 50aw.

Reference is made to structural loading being transmitted from the roof stucture to the floor stmcture. It will be understood that this can comprise both the load of the roof struchur 99a" itself, and further loads of the building which are imparted on the roof structure (e.g. by further parts of the building 10, 10' or 10" which rest on and/or are supported by the modular building unit. 12a", in particular its roof structure).

Reference is made to a roof structure 99a" of the modular building unit 12a". This is intended to refer to a structure which fonns an upper extent of the unit, and which may define a ceiling of the unit. it is not necessarily intended to refer to an outer or upper structure which closes the modular building unit 12aw relative to die building exterior (and which may weatherproof a building 10, 10' or 10" comprising the unit). For example, a separate building roof structure may be provided which extends over or covers the modular building unit 12 aw and shields it from exterior weather (for example the roof structure 180 shown in Fig. 8), or a!anther modular building unit may be mounted or stacked upon it (as is the case here, with the upper modular building unit 121)"). It will be understood however that the roof structure 99a1" could be arranged to close the unit 12aw and/or to provide a shield against exterior weather, e.g. by providing the roof structure with a suitable weatherproofing layer (not shown).

In the first option outlined above, the method comprises connecting die service pod 50a" to the floor structure 103aw, and then (i.e. subsequently) connecting the service pod to the roof structure 99alv. In the second option, the method comprises connecting die service pod 50aw to the roof structure 99a", and then (i.e. subsequently) comiecting the service pod (with the roof structure mounted on it) to the floor structure 103aw. Connecting of the floor 103a" and roof 99a" structures has the result that the service pod 50a" is positioned between the roof and floor structures, with the load-bearing support 199 extending between and comiecting the roof structure to the floor structure.

The method effectively involves comiecting the roof structure 99aw to the floor structure 103aw via the service pod 50a". The service pod 50a" provides a majority (or all) of a vertical load-bearing structure for the roof structure 99a", and may be considered to limn a structural core of the modular building unit 12a". The service pod 50aw effectively defines a primary load-bearing path 204 (Fig. 11) for transmitting structural loads from the roof structure 99a" to the floor structure 103a" during use of the modular building unit. As can be seen from the drawing, the load-hearing support 199 of the service pod 50a" limns or defines the primary load-bearing path. The construction method effectively comprises positioning the load-bearing support 199 of the service pod.50a." between (and suitably sandwiching it between) the roof structure 99aw and the floor structure 103a1".

The primary load-bearing path 204 defines, or resides on, a direct and/or straight line 206 passing from the roof structure 99a' and alongAhrough the load-bearing support 199 to the floor structure 103aw. The load-bearing support 199 comprises an upper support surface 208 which contacts the roof structure 99aw, and a lower support surface 210 which contacts the lloor structure 103a". The support surfaces 208 and 210 are disposed transverse to, and in particular substantially perpendicular to, a main axis of the load-bearing support (which is a vertical axis), also indicated by the line 206 in Fig. II As can be seen from the drawings, the modular building unit 12a" comprises a plurality of service pods 50a1", 50b" and 50c', each service pod configured to perform a service function within the building. In this case, the further pod 50b" provides a sanitary function (acting as a WC/washroom), and the pod 50cw provides a technical function (acting as a utility room, containing e.g. a washer drier 68w). The further service pods 501)" and 50c" comprise respective structural dames I 10bw and I I ()chi, each having a respective at least one load-bearing support in the font) of support walls or panels 212, 214.

The service pods 50a w to 50c w all fonn pan of the sub-assembly 200/202, and so are connected to the floor structure 103a or roof structure 99a prior to connection of the other one of the roof and floor structures, to form the modular building unit 12aw. 'f he load-bearing supports 212 awl 214 of the service pods Sob' and 50cw similarly extend between and cormect the roof structure 99a Iv to the floor structure 103a ". Structural loading is therefore transmitted from die roof structure 99a to the floor structure 103d \I through die load-bearing supports 199, 212 and 214 of all the service pods 50a IVto 50c IV. The service pods 50a w to 50c Iv therefore together provide a majority (and in embodiments can provide all) of the vertical load-bearing structure, together provide the structural core, and together define primary load-bearing paths from die roof structure 99a' to the floor structure 103a1' . In a variation which is not shown in Figs. 12 and 13, at least one service pod may be connected to the floor structure 103a Iv, and arranged so that it is out of contact with the roof structure 99a Iv (i.e. said pod may not have the roof structure connected to it, in particular mounted on it). Said service pod (or at least a structural member or members of the pod) may be arranged so that it extends part way between the floor and roof structures. An example of this could be the service pod 50g shown in Fig. 10.

In the embodiment shown in Figs. 11 and 13, the service pod 50a " to 50c " structural frames 110a " to 110c w comprise a plurality of loading-bearing supports, each arranged so that they extend between and connect the roof structure 99a " to the floor structure 103a Iv, and so that they transmit structural loads. In more detail, the service pod 50a w comprises the support panel 199 (which itself comprises corner support posts or columns 130" and I 32" , as well as a centre post or column 133), and a further support post or column 216 that is separate from the panel 199. The service pod 50bIv comprises the support panel 212 (which itself comprises corner support posts or columns I 30" and 132w as well as intermediate posts 222), and further support panels 224 and 226. The support panel 224 shares the comer post 2I8 of the panel 212, and has a further comer post 228 and centre post 230. the support panel 226 shares the corner post 228 of the panel 224, and has a further corner post 232 and centre posts (not shown). The service pod 50c " is similar, having support panels 236 and 23g, comprising comer and support posts that will not be further described.

The upper modular building unit 12b w is of similar construction and will only be described briefly, with reibrence also to Fig. 14, which is an exploded view similar to Fig. I 3. The unit I 21) "comprises a roof structure 99b w, a floor structure 103b w and a service pod 50e1" which provides a sanitary fimetion (in this case defining a bathroom). Again the service pod 50e" can be connected to the floor structure I 03b "to limn a subassembly 200b to which the roof structure 99b can subsequently be connected (by connecting die service pod 50e w with the roof structure). Alternatively, the service pod 50e w can be connected to the roof structure 99h w to form a sub-assembly 202b to which the floor structure 103b w can subsequently be connected (by connecting the service pod 50e Iv with the floor structure). The service pod 50e comprises load-bearing support panels 238, 240, 242 and 244. These comprise support columns/posts, e.g. the panel 238 comprises corner posts 240 and 242, and an intermediate support post 244. The support panels 240 In 244 are similar and will not be described.

The mechanism by which the support pods are connected to the roof and Poor structures will now be described, with reference primarily to the modular building unit 12a and to its service pod 50c ". The connection is achieved by providing the floor structure 103a" with one of a recess and a locating member, and providing the service pod 50c IV with the other one of the recess and the locating member. The recess is shaped to receive the locating member. In the illustrated embodiment, the floor shucture 103a IV comprises a recess 246, and the service pod 50c comprises a locating member 248, in this case defined by its support panel 236. This is best shown in Fig. 15, which is an enlarged perspective view of a collier region of the floor structure 103a v where it is connected to the service pod 50c Ty.

As will be described in more detail below, the locating member is defined by a frame member 248 of the support panel 236 which forms part of the service pod structural flame 110c". The frame member 248 is a bottom frame member, and is shown in broken outline in Fie. 15. The frame member 248 takes the form of a beam which extends between and connects collier support posts of the panel 236 (one shown and given the muneral 250). The frame member 248 extends in a direction substantially parallel to a floor or base of the service pod, and is elongate. The frame member 248 is generally C or U-shaped, as is the comer post 250, side walls 252 and 254 of the comer post shown in the drawing.

Connection of the service pod 50civ to the floor structure 103a1v involves aligning the locating member (beam 248) and the recess 246 relative to one another, and bringing the service pod and the floor structure into contact to position the locating member in the recess. The floor structure 103a." describes a main floor plane of the modular building unit I 2a1t', part of which is shown in broken outline in Fig. 15 and given the numeral 256. The locating member 248 and the recess 246 cooperate to prevent relative movement between the service pod 50cw and the floor structure 103a." in at least one direction, which direction is parallel to the main floor plane 256. In the illustrated embodiment, movement in first and second such directions A and B is prevented, as indicated by the arrows in Fig. 15.

In the illustrated embodiment, the recess 246 is a lower recess, and the locating member 248 is a lower locating member, the lower recess being shaped to receive the lower locating member, and serving for locating the service pod 50c" relative to the floor stmcture 103a". A fin-tiler, upper recess is also provided, and a corresponding upper locating member. Specifically, the roof structure 99a1'! is provided with one of all upper recess and an upper locating member, and the service pod 50c' with the other one of the upper recess and the upper locating member. In the illustrated embodiment, the roof structure 99a" comprises an upper recess 258, and the service pod 50c TV comprises an upper locating member shaped to receive the upper locating member. The upper recess is defined by a frame member of its support panel 236 which forms part of the service pod structural frame 110cw. The frame member is a top frame member 260, and takes the form of a beam which extends between and connects the comer support post 248 of the panel 236 with a similar such support post (not shown) at the other end of the panel. This arrangement of recess 258 and locating member 260 serves for locating the service pod 50c w relative to the roof structure 99a w.

Connection of the roof structure 99a Iv to the service pod 50c " again involves aligning the upper locating member 260 and the upper recess 258 relative to one another, and bringing the service pod and the roof structure into contact, to position the upper locating member in the upper recess. This will typically involve lowering the roof structure 99a1" on to the top of the service pod 50c". The roof structure 99a" describes a main roof plane of the modular building unit 12a w, part of which is shown in fig. 13 and indicated by numeral 262. The upper locating member 260 and the upper recess 258 cooperate to prevent relative movement between the service pod 50c" and the roof structure 99a' in at least one direction, which direction is parallel to the main roof plane 262.

In the illustrated embodiment, movement in the same first and second directions A and B shown in Fig. 15 is prevented.

Returning to the lower recess 246, it can be seen that the recess is elongate, and takes the fonn of a groove, channel or slot. Other options, which will be described below, include a rebate. The recess 246 has a main axis, which is shown in the enlarged perspective view of the floor structure 11113 am shown in Fig. 16. The recess 246 extends in a direction that is parallel to the main plane 256 described by the floor structure 103aw (or by the service pod 50vw, where the recess is defined by the pod). The recess 246 is generally U-shaped in cross-section, taken in a direction perpendicular to the main axis 246. When the locating member 248 is positioned in the recess 246 as shown in Fig. 15, relative nwvement between the locating member and the recess, in the plurality of directions discussed above, is restricted. However, the locating member 248 can be translated relative to the recess 246, in a direction along its main axis 264. 'Ibis may facilitate connection of the service pod 50c" to the floor structure, e.g. in a sliding fit relative to the floor structure, and/or adjustment of a position of the service pod relative to the floor or roof structures. The U-shape of the recess 246, opening in a vertical direction, does however have the result that the locating member 248 can be inserted into the recess in a direction perpendicular to its main axis, in particular a generally vertical direction (considered in use of the unit I 2a").

The recess 246 has a side wall 266 which is arranged to abut the locating member 248, and which defines an abutment surface. In the case of the U-shaped recess 246 however, the side wall 266 is a first side wall, and the recess also has a second opposed (and generally parallel) side wall 268 which similarly defines an abutment surface. In use, the locating member 248 is positioned between the side walls 266 and 268, as shown in Fig. 15, the side walls abutting the locating member so that it is captured between the side walls. This provides a secure engagement between the service pod and the floor structure. The recess also comprises a further wall 270 disposed transverse, in this case perpendicular, to the side walls 266 and 268. The fiuther wall 270 is arranged so that it also abuts the locating member 248 when positioned in the recess, and again defines an abutment surface. The thither wall 270 forms a base of the recess 246, since it is provided by the floor structure In the case where the recess is provided by the service pod 50cw (and the locating member by the floor structure 103a" ), the recess would effectively be inverted and so the further wall would form a top of the recess.

The upper recess 258 similarly comprises first and second opposed side walls 272 and 274, with a further wall 276 disposed perpendicular to the side walls. Each wall defines an abutment. surface, the locating member 260 being captured in the recess 258 in the same way as the lower locating member 248 in the lower recess 246. In this case, the further wall 276 defines a top of the upper recess 258, but could form a base if the upper recess is instead provided by the service pod 50c1'.

Referring again to Fig. 13, it call be seen that the floor structure frame 103a" takes the general faun of a frame, and is constructed from a plurality of floor frame members, each floor frame member coupled to one or more further floor frame member. In the illustrated embodiment, the floor frame 103a" comprises a perimeter frame defined by main beams 278 and 280 extending in a length direction of the frame, and cross beams 282 and 284 which extend between and connect the main beams. An intermediate main beam 286 also extends in the length direction and is positioned between the two perimeter frame main beams 278 and 280, and intermediate cross beams, in the form of joists 288 to 294, extend across the floor frame 1030 and connect the various main beams together. The main beam 278 is shaped to define the recess 246 (but in the variation explained above, could be arranged to defme the locating member). As can be seen from the drawings, the various beams 278 to 294 each define a recess, which can receive a respective locating member of one or more service pod. This provides for connection of the various SCIViCe pods 50a" to 50c1"to the floor structure 103aIv. Each recess has die general structure explained above in relation to the recess 246, and engage their locating members in the same way.

lie roof structure 99a" similarly takes the general form of a frame, comprising a perimeter frame formed from main beams 296 and 298, plus cross beams 300 and 302. An intermediate main beam 304 also extends along the roof frame 99a", and cross beams 306 to 310 comiect the main beams. The main beam 296 defines the recess 258, and each further beam again defines a recess, for receiving locating members of one or more service pod 50aR" to 50c". The roof structure frame 99a" is effectively similar to the floor structure frame 103a", hut inverted so that its U-shaped recesses face generally downward, to receive the locating members at the tops of the service pods.

Suitable materials for forming the various floor and/or roof structural frame beams can include metals and metal alloys (which could be hot-formed e.g. hot-rolled, or cold-formed e.g. pressed or stamped, as well as combinations 0)' the two), cement. based materials (e.g. a cast concrete or 3D printed concrete material), and composite materials (e.g. fibre-reinforced resin materials).

Referring again to the lower locating member 248, the locating member has a side wall 312, which is generally planar, and defines all abutment surface. The lower recess 246 is arranged so that it contacts the side wall 312.

The locating member 248 ill fact comprises a second opposed side wall 314, disposed generally parallel to the first side wall 312, and also defming an abutnent surface. The side walls 266 and 268 of the recess 246 are arranged so that they respectively contact the first and second side wall 312 and 314 of the locating member 248. The locating member comprises a further wall 316, which extends between the first and second side walls 312 and 314. The thriller wall 316 is disposed transverse to, in particularly substantially perpendicular to, the side walls 312 and 314, and arranged so that it contacts the further wall 270 of the recess 246. This can be achieved by limning the locating member 248 from a [1-shaped section facing generally upwardly, or alternatively as a hollow box section.

Referring again to the service pod 50c", the pod structural frame 110c" is constructed from a plurality of frame members, which form the various panels 214,236 and 238. Some of the service pods, in particular the pod 50a, comprise other structural supports such as the post 216. Frame members forming the structural frame 1100' are coupled to one or more further frame member, and various frame members are arranged so that they define locating members. In the case of the service pod 5001, a further locating member is defined by a lower frame member 318 of its support panel 238, and engages in a recess 320 defined by the main beam 286 of the floor structure 103a1". hi this way, the service pod 50c" can be arranged so that it can be translated (or slid) along the floor structure 103aw into its final position tin the direction of the arrow C in Fig. 11), or its position adjusted if required. Typically however the service pod 50cw will be lowered into position, and an additional locating member(s) provided to restrict its movement also in the direction C and 1), for example by providing a locating member engaging in a channel defined by the floor cross beam 288.

Similarly in the case of die roof structure 99aw a further locating member is defined by an upper frame member 322 of its support panel 238, and engages in a recess 324 defined by die main beam 304 of the roof structure. This similarly facilitates translation of the service pod 50c' relative to the roof structure 99a" into its final position (again in the direction of the arrow C in Fig. 11), or for its to be position adjusted if required. Typically however the roof structure 99aw will be lowered into position on the service pod 50cw, and an additional locating member(s) provided to restrict its movement also in the direction C, for example by providing a locating member (not shown) engaging in a charmel defined by the roof cross beam 306.

it will be understood that each of the further service pods 50a" and 50bw are similarly arranged, in terms of recesses and locating members, which will not be described in detail. Each service pod 50aw to 50cw may be provided with at least one locating member (or at least one recess), shaped to engage in one of the plurality of recesses defined by the various beams 278 to 294 of the floor structure 103a". A similar arrangement may he provided for upper recesses and upper locating members of the roof structure 99a my and the service pods 50aw to 50cw.

The service pods 50aw to 50cw may be connected to the floor structure 103 and/or the roof structure 99a w by securing or fixing the locating member(s) within the recess or recess. Thus referring for example to the service pod 501)w, securing or fixing of its locating member 248 in the floor section recess 246 may he achieved by bonding (e.g. using an adhesive), a welding process (depending on the materials used), ancUor using a mechanical fixing such as one or more nut and bolt assembly, nut and threaded socket assembly, and/or screw.

The service pods 50aw to 50cw may be sealed relative to the floor structure 103 and/or the roof structure 99a ". Thus referring for example to the service pod Sob', securing or fixing of its locating member 248 in the floor section recess 246 by sealing the locating member relative to (e.g. within) die recess. Sealing may be achieved using a seal and/or a sealant material (not shown), which may be carried by at least one of the locating member 24g and the recess 246, or provided on one or both of the locating member and the recess prior to connection. It may be preferred to provide a seal around an entire perimeter of both the floor and roof of each service pod 50aR to 50cR, particularly at edges which are adjacent a perimeter of the modular building unit I 2a R, and/or which Ibnn part of the perimeter. This may help to weatheiproof the modular building unit 12a w, and to resist cold air ingress/heat loss.

It will be understood that the foregoing discussion applies equally to the upper modular building unit 12b including the structure of the service pod 511k w; and the way in which it is comiected and sealed to the floor structure 103b Iv and roof structure 99b of the upper mit.

Turning now to Fig. 17, there is shown a perspective view of an alternative floor structure 103v, which can fonn the floor structure for the modular building units 12a Iv and/or 12b Iv. As will be appreciated from the following discussion, the roof structures 99aW and 99b1 of the modular units 12a1" and 12b Iv can be constructed in the same way.

In this embodiment, the floor structure 103v is formed as a substantially continuous, generally planar structure; which defines all upper surface 326 forming a floor of the modular building unit (and which can be covered e.g. with a decorative and/or structural floor covering). The upper surface 326 extends substantially continuously along a length and width of the floor structure 103v. This can be achieved by forming the floor structure 103v as a one-piece or substantially unitary structure which integrally comprises one or more recess (or locating member, as appropriate) ill the upper surface 326. In the illustrated embodiment, recesses 328 and 330 in the fonn of rebates are provided at first and second sides 332 and 334 of the floor structure 103v. Similar rebates 336 and 338 are provided at first and second ends 340 and 342 of the floor structure 103v. The rebates.328, 330 and 336, 338 are all generally 1.-shaped in cross-section. Further recesses 344 and 346 are provided which extend between the two sides 332 and 334, and a recess 348 extends part-way along a length of the floor structure 103' from the end 342. These recesses 344 to 348 all take the form of channels; slots or grooves; and are generally U-shaped in cross-section.

Fig. IS shows, in highly schematic fonn, a further modular building unit I 2by incorporating the floor structure 103v, and illustrates the way in which exemplary service pods 50ev and 501' are connected to the floor structure. In this case, the service pod 50ev can form e.g. a bathroom pod; and the pod 50fv an ensuite pod, hence the structure can apply particularly to an upper modular building unit such as the unit 12bR described above (although it is not restricted to this). The service pods 50ev and 501R are of similar construction to the pods 50a1' to 50e1' described above, and will not be discussed thither in detail. The pods 50ey and 50r each sit on the floor structure 103v, and are connected to the floor structure by engagement of locating members defined by the pods within various ones of the recesses 328; 330 and 336, 338 and/or 344 to 348.

Considering the service pod 50ev for example; one or more support panel 238v to 244" is arranged to defme a lower locating member; provided e.g. by lower frame members (not shown) of the panels. In the illustrated example, each panel 238' to 244v defines a respective lower locating member, two shown and indicated generally by numerals 350 and 352. The locating member 350 o Oho panel 231Iv locates in the rebate 326. The locating member (not shown) of the panel 240v locates in the rebate 328. The locating member (not shown) of the panel 242v locates in the channel 344. The locating member 352 of the panel 244v locates in the rebate 330.

This provides secure connection of the service pod 50c' to the floor structure 103 v, and resists relative movement between the pod and the floor stmclure in numerous directions (in the plane parallel to the floor nuface 326). The service pod 50f ' is similarly arranged, with locating members of the pod positioned in the rebates 328 and 338, and chmmels 346 and 348.

A roof structure 99 v can be provided which is a simple planar sheet (without any recesses), and can be secured to the tops of the service pods 50e" and 50f" in any suitable fashion, e.g. by bonding, welding and/or using mechanical fixings. It will be understood however that the roof structure 99 v may be of similar shape and construction to the floor structure 103 v, and may essentially be an inverted or mirror image of the floor structure.

As can be seen in Fig. 18, the floor structure 103 v can provide multiple connection locations for the service pods 50ev and 50t1', for example by appropriate dimensioning of the service pods, and positioning of the recesses 328, 330, 336, 338 and 344 to 348. In particular, the floor structure 103v defines a grid comprising grid blocks which are of the same size, two such grid blocks 354 and 356 being shown in the drawing. The service pod 50fv has a floor plan which corresponds to the size of the grid blocks 354 and 356 so that the pod can be located on/over either block, in order to provide multiple connection locations for the pod.

The service pods can also be arranged so that they have floor plans which are multiples of a basic grid block, which may be that of the blocks 354 and 356. For example, an alternative service pod 50f " may be provided (see Fig. 19) and which has a floor plan that accommodates or bridges over both of the grid blocks 354 and 356.

Further grid blocks 358 and 360 are defined by the upper surface 326 of the floor structure 103 v, the grid blocks being defined by and/or bordered by various recesses of the floor structure 103 v. These can also receive the service pod 50I", to provide alternative connection locations for the pod. In a similar way, the service pod 50ev can be dimensioned to fit over numerous grid blocks in order to provide alternative comection locations.

A grid block 362 is shaped to receive the service pod 50ev, hut the pod can be dimensioned to fit over the two grid blocks 358 and 360. To facilitate this, the service pod 50ev has a floor plan which is effinively twice that of the pod 50f v (twice the width and twice the length), whilst the service pod 50f VI has a floor plan which is effectively twice that of the service pod 501v (again twice the width and twice the length). It will be understood that numerous options exist and that the specific grid arrangement and service pod sizes/shapes should not be viewed as rest:di:dive.

Options for fining the substantially continuous floor structure l03v (and/or the roof structure 99v) compise: forming the structure(s) from a cement-based material (e.g. a cast concrete or 3D printed concrete material); forming the stmcture(s) from a timber or timber-based material (e.g. a cross-laminated timber -CLT -construction); forming the structure(s) from a sheet of a metal or metal alloy material (e.g. by pressing or stamping in a cold-forming process); forming the structure from a composite material (e.g. a fibre-reinforced resin material). Optionally, separate generally planar members may be constructed and then connected together to form said substantially continuous/planar floor and/or roof structures.

A cold-formed metal or metal alloy material may however he a particularly suitable option for the floor structure 103v, for example stamped from a thin sheet (of perhaps 3 to 5mm thickness) of a steel or aluminium material. this will typically be required to be positioned on a concrete fmmdation/platform (or other suitable structure) providing structural support during use. Options including GUI and cement-based Will likely have a greater depth, e.g. as in the alternative floor structure 103' shown in the perspective view of Fig. 20. Floor structures constructed in this way will typically have a uniform flat bottom surface (not shown).

limning now to Fig. 21, there is shown a perspective view of a corner region of a thither floor structure 103" which is a variation on that shown in Fig. 20. In this embodiment, a recess in the form of an elongate U-shaped groove 328" is provided at a side 332 of the floor structure 103, instead of an L-shaped rebate. In addition, a locating member 364 is provided which extends or protrudes from a frame member 366 of a pod support panel 240" forming part of its structural frame (not shown). The locating member 364 takes the form of an elongate rib, tongue or tab extending from a bottom of the frame member 366, along substantially an entire length of the frame member. A similar mangement may be provided for any one of the floor structures discussed above, and/or for the roof structures if desired. Accordingly, the illustrated example is not limited to the solid floor type structure 103' shown in Figs. 20 and 21.

t wiling now to Fig. 22, there is shown a perspective view of a comer region of a further floor structure 103 VITT which is a variation on that shown in Fig. 20. In this embodiment, a recess in the foim of an elongate groove 32gv" is again provided at a side 3321" of the floor structure 1031". In this embodiment, a locating member 364v" is provided which again extends or protrudes from a frame member 366V" of a pod support panel 24O' forming pait of its structural frame (not shown). The locating member 364vm in this embodiment again takes the form of an elongate rib, tongue or tab extending from a bottom of the frame member 366, but only extends part way along a length of the frame member, to form a short rib, tongue or tab. The recess 3281" is similarly shorter, shaped to acconunockile the locating member 3641'. Once again, a similar arrangement may be provided for any one of the floor structures discussed above, and/or for the roof structures if desired.

Accordingly, the illustrated example is not limited to the solid floor type structure 103 v shown in Figs. 20 and 21 Turning now to Fig. 23, there is shown a perspective view of a comer region of a further floor structure 103" which is a variation on that shown in Fig. 20. In this embodiment, a recess in the form of an elongate groove 32fl" is again provided at a side 332" of the floor structure I 03rx. In this embodiment, a locating member 364" is provided which again extends or protrudes from a frame member 366n of a pod support panel 240" forming part of its structural frame (not shown). The locating member 364" in this embodiment takes the form of an elongate rib tongue or tab extending from a bottom of the frame member 366, but only extends part way along a length of the frame member, to fonn a short rib. One or more further similar locating members are however provided, one shown and given the numeral 368. Tn this instance, the recess 328xm is shaped to accommodate both of the locating members 364 pc-and 368 (and optionally further such members if provided). Once again, a similar arrangement may be provided for any one of the floor structures discussed above, and/or for the roof structures if desired. Accordingly, the illustrated example is not limited to the solid floor type structure 103 Vn shown in Figs. 20 and 21.

Taming now to Fig. 24, there is shown an end view of part of a floor structure 103' which is a variation on that shown in Fig. 17, and showing part of a service pod 50cx located on the floor structure. hi this instance, a locating member is provided by the floor structure, whilst a frame member of the service pod 50cx is arranged to define a recess. In the illustrated embodiment, three such locating members 370, 372 and 374 are provided, formed integrally with the floor structure 103x (e.g. by stamping from a sheet of metal or metal alloy). hi this instance, the recess is supported by, or defined by, a frame member of the service pod 50cx structural frame. Specifically, a lower frame member 248x of a pod support panel 236x, and a lower frame member 318x of a pod support panel 238x each define a recess. Referring to the lower frame member 248x, this is achieved by providing die fame member with elongate extensions which form side walls 260 and 268x that receive the locating member 370. Once again, a similar arrangement may be provided for any one of the floor structures discussed above, and/or for die roof structures if desired. Accordingly, other floor structures disclosed herein may be arranged to provide the locating member(s), e.g. frame members of the floor structure frame 103aw of Figs.11 and 13. Here and elsewhere, file recess may be provided as a separate component which is coupled to the pod frame member, e.g. an elongate bracket may be shaped to fonn the side walls 266x and 268x, and may be connected to the frame member 248 x.

The locating members discussed above are each generally elongate, and define a main axis. The locating members are arranged to extend in a direction that is parallel to a main plane of or described/defined by, the service pod (or the floor structure, as appropriate). One or more of the locating members are disposed generally transverse, particularly substantially perpendicular to, at least one other locating member. The locating member e.g. extends from a frame member of the service pod structural frame (or from a surface of the floor structure), and may take the general form of a rib, tongue or the like. Other options include a pin of e.g. cylindrical shape in cross-section, configured to engage in a recess having a matching shape.

This option is illustrated in Fig. 25, which is an end view of part of a floor structure 103' which is a variation on that shown in Fig. 17, and showing part of a service pod 50cxl located on the floor structure. hi this case, the floor structure 103m defines recesses in the form of generally cylindrical (and smooth-walled) bores or sockets 376 and 378 (which can be closed or open ended). The bores 376 and 378 are shaped to nreive locating members in die form of cylindrical pins 380 and 382, defined by a lower frame member 384 of a structural frame I 10ex' of the service pod 50cm. Other arrangements are of course possible, including different shapes of pins and bores. Indeed, particularly for thin-walled floor structures such as the floor structures 103a" and 103x, simple apertures may suffice for receiving and engaging the locating pins 380, 382.

Returning again to Fig. 13, an optional further feature of the modular building unit 12aw will now be described, which can apply also to any of the further modular building units disclosed herein. As shown in the drawing, the modular building unit 12aw comprises at least one wall panel which is connected to one or both of the floor structure and the roof structure. Tn the illustrated embodiment, two such wall panels 386 and 388 are shown.

the wall panels 386 and 388 are each arranged to define locating members like those of the service pods described above. The illustrated wall panels 366 and 368 typically comprise structural frames (not shown), like for example the support panel 214 of the service pod 50cw shown in Fig. 13. the wall panel 366 comprises a lower frame member, whose location is indicated in broken outline by the muneral 390. The wall panel 368 includes a similar such lower frame member 392. These wall panels 386 and 388 are each connected to the floor structure 103a1" by positioning their respective locating members 390 and 392 in a wall panel recess defined by the floor structure. In this instance, the recess 394 (also shown in Fig. 16) is defined by the floor structure main side beam 280, and can additionally or alternatively receive a locating member of a service pod. Once again, this may be reversed so that the wall panel defines a recess for receiving a locating member of the floor portion. In a similar fashion, the wall panels 386 and 388 may each comprise an upper wall panel locating member, for connecting the wall panels to the roof structure 99aw. Again, the locating members may be provided by structural frame members of the panels, upper such members 396 and 398 shown in the drawing. These engage in a recess 400 defined by a main side frame member 298 of the roof portion 99a1".

'f he wall panels 386 and 388 can each be arranged so that they are at least partially load-bearing, and so the wall panels may comprise at least one wall load-hearing support. The wall panels 368 and 368 form internal walls within a building containing the modular building unit 12a", but wall panels can be arranged to provide at least part of an outer wall of the modular building unit. This is shown in relation to the upper modular building unit 2htv in Fig. 14, wall panels 402 and 404 forming external walls in the assembled building.

As can be seen, all of the wall panels 386, 388 and 402, 404 are provided at or adjacent a perimeter of the modular building units I 2atv and 12bw. One option for forming the wall panels is to form a frame structure from a plurality of frame members, before covering the frame structure with an outer and/or inner wall surface e.g. in the form of a plate. Sli's may be a particularly suitable option for the wall panels.

The present invention additionally relates to a kit configured to be assembled to form a modular building unit for a building. Referring to the embodiment of Fig. 11 and 13, the kit can comprise the roof structure 99aw and the sub-assembly 200 (comprising the floor structure 103a" and one or more of the service pods 50a1t' to 50c"). Another such kit can comprise the floor structure I 03alv and the sub-assembly 202 (comprising the roof structure 99a' and one or more of the service pods 50ary to 50c").

Referring to the modular building units l2aTV and 12bw of Figs. 11 to 14, the service pods, in particular their load-hearing structural frames, may define a footprint of the service pod. Considering the service pod 50e ", the footprint is indicated in broken outline and given the muneral 406, and is generally equivalent to an area of (or on) the floor structure 103b" which the service pod 50e Iv accommodates when connected to the floor structure.

As discussed above, locating members and recesses of the service pods and the floor structure (and if applicable, the roof stmcture) are arranged so that they each define an abutment surlitce. Such surfaces are described above in relation to the modular building unit 12a w, in particular its service pod 50c Ty and its floor structure 103a Ty. The pod locating member abutment surfaces defined by side walls 312 and 314, and the floor structure recess abutment surfaces defined by side walls 266 and 268, are referred to. At least one (and optionally both) of the recess abutment surfaces 266/268, and at least one (and optionally both) of the locating member abutment smfaces 312/314, may be disposed within the footprint of the service pod. This may facilitate connection of the service pod 50c' to the floor structure 103aft and/or the roof structure 99aTv, and potentially adjustment of a position of the pod relative to one or both of the floor and roof structures. It may be particularly prefened to arrange a majority (and optionally all) of each of the recess and the locating member, at least where they mutually engage, within the footprint of the service pod.

Various modifications may be made to the foregoing without departing from the spirit or scope of the present thvention.

For example, at least one service pod may be configured, in use, to provide more than one service function.

The further building unit may itself be of a modular construction, configured to be constructed off-site and transported to the final location for connection with the modular building unit housing the one or more service pod. The further building unit may therefore be of like construction to the modular building unit housing said service pod. further building unit may similarly house one or more service pod. More than one further building unit may be provided.

The building may comprise any suitable number of the modular building units, and may for example comprise more than two such units. The further building unit itself may be made up or constructed from a plurality of sub-units or sub-structures.

Non-limiting examples of residential buildings falling with the scope of the invention include houses (detached, semi-detached, terraced and single storey/bungalow), as well as apartments and flats. The principles of the invention may however be applicable to non-residential buildings including commercial or industrial buildings, such as offices and factories.

Where the building comprises a plurality of modular building units, the units may be located side by side and/or at a similar level, and could be spaced apart and/or not connected. This may apply particularly to a single storey Service pods arc disclosed which are accessible: from a circulation space within the modular building unit; directly from a living space/internal volume of the further building unit; and without having to pass into or through the further building unit (e.g. from the building exterior). It will be understood that, where there are a plurality of service pods, any desirable range of access options may be provided for the pods, selected from the range disclosed in this document. The selection may depend on factors including the respective service to be provided by the pods.

Further aspects and/or embodiments of the invention may combine the features of one or more aspect and/or embodiment disclosed in this document Accordingly, such further aspects and/or embodiments may comprise one or more feature selected from one or more aspect or embodiment of the invention disclosed in this document.

Unless explicitly implied by context or stated in the document, the features of ally method or process disclosed in this document need not necessarily be performed in the precise order set out in the relevant text and/or drawings. Accordingly, any method or process disclosed in this document may be capable of being performed ill an order other than that specifically set out in the relevant text/drawings, if chmunstances permit.

Features disclosed in this document (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving die same, equivalent or similar purpose, unless expressly stated otherwise. Accordingly, features disclosed in this document may represent only one example of a generic series of equivalent or similar features.

Claims

CLAIMS1. A method of constructing a modular building unit configured to form at least part of a building, the method comprising the steps of: providing a service pod configured to perform a service function within the building, the service pod comprising a structural frame having at least one load-bearing support; providing a roof structure for the modular building unit; providing a floor structure for the modular building unit, and: A) connecting fith service pod to die floor structure to fonn a modular building milt sub-assembly comprising the service pod and the floor structure, and then connecting the roof structure to the modular building unit sub-assembly to thim the modular building unit, by connecting die roof structure to the service pod; or B1 coimecting the service pod to the roof structure to form a modular building unit subassembly comprising the service pod and the roof structure, and then connecting the floor structure to the modular building unit sub-assembly to form the modular building Ina, by connecting the floor structure to the service pod; and arranging the service pod so that the at least one load-bearing support extends between and connects die roof structure to the floor stucture, structural loading being transmitted from the roof snucture to the floor structure through the at least one load-hearing support.
2. A method as claimed in claim 1, in which the step of connecting the roof structure to the service pod comprises mounting the roof structure on the service pod.
3. A method as claimed in either of claims 1 or 2, comprising arranging the service pod so that it provides a majority of a vertical load-hearing structure for the roof structure.
4. A method as claimed in any preceding claim, comprising arranging the service pod so that it forms a structural core or the modular building unit.
5 A method as claimed in any preceding claim, comprising arranging the service pod so that it defines a primary load-bearing path for transmitting structural loads from the roof structure to the Floor structure during use of the modular building unit, the at least one load-bearing support of the service pod defining the primary load-bearing path and the primary load-bearing path residing on a direct line passing from the roof structure along the load-bearing support to the floor structure.
6. A method as claimed in any preceding claim, comprising sandwiching the at least one load-bearing support of die service pod between the roof structure and die floor structure.
7. A method as claimed in any preceding claim, comprising providing a plurality of service pods, each service pod configured to pedonn a service function within die building, and arranging each service pod so dint It comprises a structural frame having at least one load-bearing support which extends behveen and connects the roof stmcture to the floor structure, so that structural loading is transmitted from the roof structure to the floor structure through the load-bearing supports of all of the service pods.
S. A method as claimed in claim 7, comprising arranging each service pod so that it forms part of the sub-assembly.
9. A method as claimed in any preceding claim, comprising: providing the floor structure with one of a recess and a locating member, and providing the service pod with the other one of the recess and the locating member, the recess being shaped to receive the locating member; and arranging the locating member and the recess so that they cooperate to prevent relative movement between the service pod and the floor structure in at least one direction, which direction is parallel to a main floor plane described by the floor struchne.
10. A method as claimed in claim 9, in which the step of connecting the service pod to the floor structure comprises aligning die locating member and the recess relative to one another, and bringing the service pod and the floor structure into contact to position the locating member in the recess.
11. A method as claimed in either of claims 9 or 10, in which: the recess is a lower recess, the locating member is a lower locating member, the lower recess is shaped to receive the lower locating member and serves for locating the service pod relative to die floor structure; and the method comprises the further step of providing the roof structure with one of an upper recess and an upper locating member, and providing the service pod with the other one of the upper recess and the upper locating member, the upper recess shaped to receive the upper locating member; and arranging die upper locating member and die upper recess so that they cooperate to prevent relative movement between the service pod and the roof structure in at least one direction, which direction is parallel to a main roof plane described by the roof structure.
12. A method as claimed in claim I I in which the step of connecting the roof structure to the service pod comprises aligning the upper locating member and the upper recess relative to one another, and bringing the service pod and the roof structure into contact to position the upper locating member in the upper recess.
13. A method as claimed in any preceding claim, comprising mounting the roofstructure on a top part of the service pod.
14. A method as claimed in any one of claims 9 to 13, in which the recess is elongate and comprises a main axis arranged to extend in a direction that is parallel to a main plane of the floor structure, and in Which the method comprises arranging the recess so that the locating member can be translated relative to the recess in a direction along its main axis 15. A method as claimed in any one of claims 9 to 13, comprising pmviding a plurality ofrecesses, and providing the recesses with a shape selected from the group comprising: generally L-shaped in cross-section; and generally U-shaped in cross-section.16. A method as claimed in any one of claims 9 to 15, comprising arranging the recess so that the locating member call be inserted into the recess in a generally vertical direction.17. A method as claimed in ally one of claims 9 to 16, comprising providing the recess with a side wall which is arranged to abut the locating member.18. A method as claimed ill claim 17, comprising providing the recess with first and second opposed side walls, and positioning the locating member between said side walls.19. A method as claimed in either of claims 17 or 18, comprising providing the recess with a further wall disposed transverse to the side wall or walls, and arranging the further wall so that it abuts the locating member.20. A method as claimed ill any preceding claim, comprising: forming the service pod structural frame from a plurality of frame members, and coupling each frame member to one or more thither frame member; and arranging a frame member of the structural frame so that it defines the locating member; or arranging the locating member so that it is supported by and extends item a flame member of the structural frame.21. A method as claimed in any one of claims 9 to 20, comprising: arranging the locating member so that it has a side wall which is generally planar and which defines an abutment surface; and arranging the recess so that it contacts the side wall.22. A method as claimed in claim 21, when dependent on claim IX. comprising arranging the locating member so that it has lirst and second side walls, and arranging the recess so that it contacts both ot. the first and second side walls.23. A method as claimed in claim 22, in which the first and second side walls are arranged so that they are disposed substantially parallel to one another and spaced apart to define the recess between them.24. A method as claimed in any one of claims 21 to 23, when dependent on claim 19, comprising providing the locating member with a further wall which extends from the side wall, and arranging the further wall so that it is disposed transverse to the side wall and contacts the further wall of the recess.25. A method as claimed in any one of claims 9 to 24, comprising: providing the floor structure with one or a plurality of recesses and a plurality of locating members; and providing the service pod with the other one of the plurality of recesses and the plurality of locating members.26. A method as claimed in claim 25, comprising providing a plurality of service pods, and providing each service pod with at least one locating member, or at least one recess.27. A method as claimed in claim 26, comprising: arranging a first one of the plurality of recesses of the floor structure to receive a locating member of a first one of the service pods; and arranging a second one of the plurality of recesses of the floor structure to receive a locating member of a second one of the service pods.28. A method as claimed in either of claims 26 or 27, comprising arranging at least one recess of the floor structure to receive locating members associated with more two or more service pods.29. A method as claimed in claim 26, comprising: arranging a recess of a first one of the plurality of service pods to receive a first locating member of the floor structure; and arranging a recess of a second one of the plurality of service pods to receive a second locating member of the floor structure.30. A method as claimed in any one of claims 9 to 29, comprising providing elongate recesses having a main axis, and arranging at least one recess so that its main axis is disposed generally transverse to the main axis of at least one other recess.31. A method as claimed in any one of claims 9 to 30, comprising: providing a plurality of separate locating members configured to be located in a single recess; and/or providing a plurality of separate locating members, and a plurality of separate recesses, and configuring each recess to receive a respective locating member.32. A method as claimed in any one of claims 25 to 31, comprising providing at least one of the recesses with a different shape in cross-section relative to at least one other recess.31 A method as claimed in any one or claims 9 to 32, comprising forming the service pod structural frame so that it comprises a plurality of lower frame members, and ananging at least some of the lower frame members so that they each define at least one locating member, or at least one recess.34. A method as claimed in claim 33, comprising providing the structural frame with a plurality of wall frame portions, and arranging each wall frame portion transverse to one or more other wall frame portion, and arranging each wall frame portion so that it defines a respective lower frame member.35. A method as claimed in any preceding claim, comprising forming a floor structural frame from a plurality of floor frame members, and each floor frame member coupled to one or more further floor frame member, and arranging a floor frame member of the floor structural frame so that it defines the recess or the locating member.36. A method as claimed in claim 35, comprising: arranging a first floor frame member of the floor structural frame so that it defines a first recess or a first locating member; and arranging a further floor frame member of the floor structural frame so that it defines a fmther recess or a fluffier locating member.37. A method as claimed in any one of claim 9 to 34, comprising forming the floor structure as a substantially continuous, generally planar structure defining an upper surface fanning a floor of the modular building unit, and arranging the floor structure so that the recess or the locating member is integral to the floor structure.38. A method as claimed in any one of claims 9 to 37, comprising sealing the service pod relative to the floor structure, by sealing the locating member within the recess.39. A method as claimed in any preceding claim, comprising providing at least one wall panel, and connecting the wall panel to the floor structure and the roof structure; arranging the wall panel so that it is at least partially load-bearing, and so that it comprises at least one wall load-bearing support; arranging the wall panel so that it extends between and connects the roof structure to the floor structure; and providing the floor structure with one of a wall panel recess and a wall panel locating member, and providing the wall panel with the other one of the wall panel recess and the wall panel locating member, and in which the step of connecting the wall panel to the floor structure comprise positioning the wall panel locating member in the wall panel recess.40. A method as claimed in claim 39, comprising arranging a recess provided by the floor portion so that it cooperates both NNith a service pod locating member and a wall panel locating member.41. A method as claimed in any preceding claim, comprising airangmg the service pod so that it fonns at least part of at least one external wall of the modular building unit.42. A method as claimed in either of claims 39 or 40, comprising arranging at least one wall panel so that it forms aL least part of a wall ()Lille service pod.43. A method as claimed in any preceding claim, comprising providing a plurality of service pods, and arranging the Poor structure so that it provides multiple connection locations for the service pods.44. A method as claimed in claim 43, comprising arranging die floor structure so that it defines a grid comprising grid blocks which receive the service pods, at least some grid blocks being of the same size, and providing die service pod with a floor plan which corresponds to the size of more than one grid block so that the pod can be located on a plurality of the grid blocks, in order to provide the multiple connection locations.45. A method of constructing a nodular building unit configured to form at least part of a building, die method comprising the steps of providing a service pod configured to perform a service functionwithin die building, the service pod comprising a stmclual frame having at least one load-bearing support providing a floor stmcture for the modular building unit; providing a roof structure for die modular building unit; providing the floor stmcture with one of a receptacle and a locating member, and providing die service pod with the other one of the receptacle and the locating member, the receptacle shaped to receive the locating 20 member; connecting the service pod to the floor structure by positioning the locating member in the receptacle; mounting die roof structure on the service pod; and arranging die service pod so that the at least one load-bearing support extends between and connects the roof stmcture to the floor structure, structural loading being transmitted from the roof structure to the floor structure through the at least one load-bearing support.46. A method as claimed in claim 45, comprising connecting the service pod to the floor structure, and then MO LM brIg e roof structure on the service pod.47. A method as claimed in claim 45, comprising mounting the roof structure on the service pod, and then connecting the service pod to the floor structure.48. A kit configured to be assembled to form a modular building mut for building, the kit comprising: a roof structure; and a sub-assembly comprising a floor structure and a service pod, in which the service pod is configured to perfonn a service function within the building and comprises a structural frame having at least one load-bearing support, and in which die service pod is connected to the floor structure to fonn the sub-assembly; in which the roof structure is configured to be connected to the service pod of the sub-assembly to form the modular building unit and in which the service pod is configured so that, in the assembled modular building unit, the at least one load-bearing support extends between and connects the roof stritcture to the floor structure, and serves to transmit structural loading from the roof structure to the floor structure.49. A kit configured to he assembled to form a modular building unit for a building, the kit comprising: a floor structure; and a sub-assembly comprising a roof structure and a service pod, in which the service pod is configured to perfonn a service function within the building and comprises a structural frame having at least one load-bearing support, and in which the service pod is connected to the roof structure to form the sub-assembly; in which the floor structure is configured to be connected to the service pod of the sub-assembly to form the modular building imit, and in which the service pod is configured so that, in the assembled modular building unit, the at least one load-bearing support extends between and connects the roof structure to the floor structure, and serves to transmit structural loading from the roof structure to the floor structure.50. A modular building unit constructed according to the method of any one of claims 1 to 47.51. A building system comprising: a modular building runt constructed according to the method of any one of claims 1 to 47, the modular building unit being transportable to a final location for a building in a substantially assembled form; and a further building unit configured, in use, to define an internal volume which provides a living space within the building; in which the modular building unit and the further building unit are configured to be connected at the final location to define at least part of the building.52. A building comprising: a modular building unit constructed according to the method of any one of claims 1 to 47, the modular building unit being transportable to a final location Ibr the building in a substantially assembled fonn; and a further building unit defining an internal volume which provides a living space within the building; in which the modular building unit and the further building unit are connected at the final location to define at least part of the building.53. A method of constructing a modular building tun configured to form at least part of a building, the method comprising the steps providing a service pod configured to perfonn a service fiumction within thte building, the service pod comprising a load-bearing structural Frame; providing a floor structure for the modular building unit, and ananging the floor structure so that it describes a main floor plane of the modular building unit; providing the floor structure with one of a recess and a locating member, and providing the service pod with the other one of the recess and the locating member, the recess shaped to receive the locating member; connecting the service pod to the floor structure by aligning the locating member and the recess relative Lo one another, and bringing the SC-Vice pod and the Poor structure into contact to position the locating member in the recess; arranging the locating member and the recess so that they cooperate to prevent relative movement between the service pod and the floor structure in at least one direction which is parallel to the main floor plane described by the floor structure; and providing a roof stnicture for the modular building unit, and connecting the roof structure to the floor structure.54. A method as claimed in claim 53, comprising arranging the service pod load-hearing structural frmne so that it defines a footprint of the service pod, and in which the step of arranging the locating member and the recess so that they cooperate to prevent said relative movement comprises: arranging the recess and the locating member so that they each define an abutment surface; arranging the abutment surfaces so that they cooperate to prevent said relative movement; and positioning the abutment surfaces of at least one of the recess and the locating member within the footprint of the service pod.55. A method as claimed in either of claims 53 or 54, in which the recess has a main axis and a width taken in a direction that is transverse to the main axis and parallel to the main floor plane, and arranging the recess so that the width of the recess is less than a width of the service pod.56. A modular building unit configured to form at least pail of a building, the modular building unit comprising: a service pod configured to perform a service function within the building, the service pod comprising a structural frame having at least one load-bearing support; a floor structure; and a roof structure; in which the Floor structure comprises one of a recess and a locating member, and the service pod comprises the other one of the recess and the locating member, the recess being shaped to receive the locating member; in which the service pod is connected to the floor structure with the locating member positioned in the recess; in which the roof structure is mounted on the service pod; and in which the service pod is arranged so that the aL least one load-hearing support extends between and connects the roof structure to the floor structure, structural loading during use being transmitted from the roof stmcture to the floor structure through the at least one load-bearing support 57. A building system comprising: a modular building unit according to claim 56, the modular building unit being transportable to a final location for a building in a substantially assembled form; and a further building unit configured, in use to define an internal volume which provides a living space within the building; in which the modular building unit and the further building unit are configured to be connected at the final location to define at least part of the building.58. A building comprising: a modular building unit according to claim 56, the modular building unit being transportable to a final location for the building in a substantially assembled form; and a further building unit defining an internal volume which provides a living space within the building; in which the modular building unit and the further building unit are connected at the final location to defme at least part of the building.