Modular building unit, building system, building and associated methods

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 ( 12 a IV ) comprises the steps of: providing a service pod ( 50 b IV ) configured to perform a service function within the building, the service pod comprising a structural frame ( 110 b IV ) having at least one load-bearing support ( 214 ); providing a roof structure ( 99 a IV ) for the modular building unit; providing a floor structure ( 103 a IV ) 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 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.

1 . 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 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 form 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 sub-assembly 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 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.   
     
     
         2 - 4 . (canceled) 
     
     
         5 . The method as claimed in  claim 1 , 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 . The method as claimed in  claim 1 , comprising sandwiching the at least one load-bearing support of the service pod between the roof structure and the floor structure. 
     
     
         7 . The method as claimed in  claim 1 , comprising providing a plurality of service pods, each service pod configured to perform a service function within the building, and arranging each service pod so that it comprises a structural frame having at least one load-bearing support which extends between and connects the roof structure 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. 
     
     
         8 . (canceled) 
     
     
         9 . The method as claimed in  claim 1 , 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 structure.   
     
     
         10 . (canceled) 
     
     
         11 . The method as claimed in  claim 9 , 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 the floor structure; and   the method further comprises 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 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 is parallel to a main roof plane described by the roof structure.   
     
     
         12 - 13 . (anceled) 
     
     
         14 . The method as claimed in  claim 9 , 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 - 16 . (canceled) 
     
     
         17 . The method as claimed in  claim 9 , comprising providing the recess with a side wall which is arranged to abut the locating member;
 optionally comprising providing the recess with first and second opposed side walls. and positioning the locating member between said side walls.   
     
     
         18 - 19 . (canceled) 
     
     
         20 . The method as claimed in  claim 9 , comprising:
 forming the service pod structural frame from a plurality of frame members, and coupling each frame member to one or more further 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 from a frame member of the structural frame.   
     
     
         21 . (canceled) 
     
     
         22 . The method as claimed in  claim 17 , comprising arranging the locating member so that it has first and second side walls which are each generally planar and which define an abutment surface, and arranging the recess so that it contacts both of the first and second side walls;
 optionally comprising arranging the first and second side walls of the recess so that they are disposed substantially parallel to one another and spaced apart to define the recess between them.   
     
     
         23 - 24 . (canceled) 
     
     
         25 . The method as claimed in  claim 9 , comprising:
 providing the floor structure with a plurality of recesses;   providing a plurality of service pods, and providing each service pod with a the plurality of locating members;   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.   
     
     
         26 - 27 . (canceled) 
     
     
         28 . The method as claimed in  claim 9 , comprising arranging at least one recess of the floor structure to receive locating members associated with more two or more service pods. 
     
     
         29 - 32 . (canceled) 
     
     
         33 . The method as claimed in  claim 9 , comprising forming the service pod structural frame so that it comprises a plurality of lower frame 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;
 optionally 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.   
     
     
         34 . (canceled) 
     
     
         35 . The method as claimed in  claim 9 , 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;
 optionally 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 further recess or a further locating member. 
     
     
         36 . (canceled) 
     
     
         37 . The method as claimed in  claim 9 , comprising forming the floor structure as a substantially continuous, generally planar structure defining an upper surface forming 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 . (canceled) 
     
     
         39 . The method as claimed in  claim 1 , 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 connecting the wall panel to the floor structure comprise positioning the wall panel locating member in the wall panel recess.   
     
     
         40 . (canceled) 
     
     
         41 . The method as claimed in  claim 1 , comprising arranging the service pod so that it forms at least part of at least one external wall of the modular building unit. 
     
     
         42 . The method as claimed in  claim 39 , comprising arranging at least one wall panel so that it forms at least part of a wall of the service pod. 
     
     
         43 . The method as claimed in  claim 1 , comprising providing a plurality of service pods, and arranging the floor structure so that it provides multiple connection locations for the service pods;
 optionally comprising arranging the 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 the 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.   
     
     
         44 - 47 . (canceled) 
     
     
         48 . 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 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 structure to the floor structure, and serves to transmit structural loading from the roof structure to the floor structure.   
     
     
         49 . 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 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 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 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.   
     
     
         50 . A modular building unit constructed according to the method of  claim 1 . 
     
     
         51 . A building system comprising:
 a modular building unit constructed according to the method of  claim 1 , 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  claim 1 , 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 define at least part of the building.   
     
     
         53 - 58 . (canceled)