Modular building unit manufacturing

Abstract

A method of manufacturing a modular building unit. The method comprises constructing a floor assembly and walls extending upwardly from the floor assembly and separately constructing a ceiling assembly. The ceiling assembly includes a load transfer section configured to transfer load to the walls. The method further comprises coupling building services equipment to the ceiling assembly. Finally, the ceiling assembly is lifted onto the walls and the walls secured to the load transfer section such that the walls connect the floor and ceiling frame assemblies.

Description

MODULAR BUILDING UNIT MANUFACTURINGTECHNICAL FIELD

[0001] The present invention relates to a method of manufacturing a modular building unit as well as modular building units manufactured according to the method. The present invention also relates to services module that may be used during manufacture of a modular building unit or a modular building assembly comprising two or more modular building units.BACKGROUND

[0002] Prefabricated 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 modular building units are typically constructed to a substantially assembled form in the factory, in which they can be transported to the final location. Construction of the building can involve stacking one or more upper modular building unit on a lower such unit, so that the lower unit supports the upper unit.

[0003] Hybrid buildings have been developed by the applicant which comprise a first building section that is constructed at a final location for the building, and a second building section comprising one or more modular building units constructed in a dedicated facility, away from the final location. A hybrid building of this type can provide advantages including that: construction of the first building section is simplified, with more complex parts of the building provided in the section formed by the modular building unit(s); and the first building section can provide the primary living space in the building, without being constrained by construction and transport limitations imposed on the modular building unit(s). The hybrid buildings and associated construction techniques are disclosed in International patent publication nos. WO2022 / 243696, WO2022 / 243695, WO2022 / 243694, WO2022 / 243693, and WO2023 / 222853.

[0004] When a hybrid building is constructed there is a need to interconnect building services such as heating, ventilation, power, communications, water, and drainage, between the first (site- built) building section and the second (modular, or off-site constructed) building section (as well as between modular building units if a plurality of units is used in the construction). Such interconnections can require wires, pipes, or ducts to pass from one building section to another. Also, for fully modular buildings, there is a similar requirement for such interconnections between modular building units. Current solutions to interconnecting building services, including for fully modular buildings, often required holes or ducting to be formed through walls or floor or ceiling assemblies of the modular building unit, which can interfere with the structural integrity of those structures or otherwise impact on the building, for instance by compromising insulation or restricting architectural freedom in arranging rooms and doorways.

[0005] Furthermore, during manufacture of a modular building unit where building services are incorporated into a ceiling assembly, conventionally the services such as wires, pipes and ducts are incorporated into the ceiling assembly after the structure of the modular building unit is substantially complete. Consequently, this may involve working at height within a factory which poses a risk to personnel as well as being inefficient or making it harder to access certain areas of the ceiling assembly.

[0006] It is an aim of certain examples of the present invention to provide for improved interconnection of services within a hybrid or fully modular building.BRIEF SUMMARY OF THE INVENTION

[0007] According to a first aspect of the present invention there is provided a method of manufacturing a modular building unit, the method comprising: constructing a floor assembly and walls extending upwardly from the floor assembly; separately constructing a ceiling assembly, wherein the ceiling assembly includes a load transfer section configured to transfer load to the walls; coupling building services equipment to the ceiling assembly; and lifting the ceiling assembly onto the walls and securing the walls to the load transfer section such that the walls connect the floor and ceiling frame assemblies.

[0008] The building services equipment may be configured to form part of a building services system within a building defined in part by the modular building unit. The building services equipment may comprise one or more of: an electricity supply cable; a data cable; a cold water pipe; a hot water pipe; a drainage pipe; a gas pipe; an air ventilation duct; or an energy storage system.

[0009] Constructing the ceiling assembly may further comprise: forming a support section connected to the load transfer section within at least a portion of the ceiling assembly, the support section being configured to support at least part of the building services equipment. The support section may define a generally planar surface within a portion of the ceiling assembly. The support section may be recessed relative to an upper surface of the load transfer section. The support section may comprise joists or panelling spanning or interconnecting at least part of the load transfer section, or wherein the support section and the load transfer section are integrally formed.

[0010] The method may further comprise forming a load bearing structure over at least part of the building services equipment. At least part of the building services equipment may be sandwiched between and at least partially protected by the support section and the load bearing structure.

[0011] The method may further comprise: constructing a services module comprising building services equipment and a housing at least partially containing and / or supporting the building services equipment; and coupling the services module to the ceiling assembly. The services module may be located on or coupled to the support section.

[0012] The load transfer section may include at least one first portion and at least two second portions extending above a top surface of the first portion. The second portions may be configured to support a floor assembly of a further modular building unit stacked on top of the modular buildingunit. Each first portion of the load transfer section may be configured to form an aperture between the stacked modular building units. The building services equipment may be configured to connect through the aperture between the stacked modular building units.

[0013] The load transfer section may take the form of a structural frame, which may comprise structural (e.g. elongate) frame members. The load transfer section may take the general form of a lattice or lattice type structure. The load transfer section may comprise a lower structural member, which may define a lower surface of the load transfer section. The load transfer section may comprise an upper structural member, which may define an upper surface of the load transfer section. The load transfer section may comprise at least one connecting member, which may extend between and connect the lower structural member to the upper structural member. The lower and upper structural members, and the connecting member(s), may form sides of the structural frame. The at least one connecting member may serve for transferring loads from the upper structural member to the lower structural member, and so to the walls. The load transfer section may comprise a plurality of connecting members.

[0014] The load transfer section may comprise a plurality of generally elongate portions which may together define the load transfer section, and which may together form the structural frame. A generally elongate portion may be provided for each wall. The generally elongate portions may each be seated on a respective wall. The generally elongate portions may each be disposed transverse to (optionally substantially perpendicular to) at least one adjacent generally elongate portion. Each generally elongate portion may comprise respective lower and upper structural members, and at least one connecting member extending between and connecting the lower and upper structural members. The upper structural members of the elongate portions may together form a loop member, which may be an upper loop member. The lower structural members of the elongate portions may together form a loop member, which may be a lower loop member.

[0015] The ceiling assembly may comprise a ceiling section, which may be configured to define or support a ceiling of the modular building unit. The ceiling section may provide, define or form the support section. The ceiling section may be disposed inwardly of the load transfer section and may be connected to it. The ceiling section may comprise a lower surface, which may be disposed at a position that is lower than an upper surface of the walls.

[0016] The ceiling assembly may define a services void (which may also be referred to as a space or gap), which may be configured to receive the building services equipment. The services void may comprise an upper boundary, which may be defined or formed by a plane containing an upper surface of the load transfer section. The services void may comprise a lower boundary, which may be defined or formed by a plane containing the lower surface of the ceiling section. The services void may be defined between a plane containing the upper surface of the load transfer section, and a plane containing the lower surface of the ceiling section.

[0017] According to a second aspect of the present invention there is provided a services module for a modular building assembly, the services module comprising: building services equipment; and a housing at least partially containing the building services equipment; wherein the services moduleis configured to be received in or connected to a floor or ceiling assembly of a modular building unit forming part of the modular building assembly such that when two modular building units are stacked to form the modular building assembly, the services module is located between the two stacked modular building units.

[0018] The building services equipment may be configured to form part of a building services system within a building defined in part by the modular building unit. The building services equipment may comprise one or more of: an electricity supply cable; a data cable; a cold water pipe; a hot water pipe; a drainage pipe; a gas pipe; an air ventilation duct; and an energy storage system.

[0019] Further features of the method of the first aspect, and / or the services module of the second aspect, may be derived from the text set out elsewhere in this document.

[0020] BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Examples of the invention are further described hereinafter with reference to the accompanying drawings, in which:Fig. 1 is an isometric view of a modular building assembly comprising first and second modular building units according to an embodiment of the invention;Fig. 2 is an isometric view of the modular building assembly of Fig. 1 including cladding material covering the walls;Fig. 3 is a partial view of lower modular building unit showing the load transfer section in greater detail;Fig. 4 isolates the load transfer section of the lower modular building unit and the floor frame assembly of the upper modular building unit prior to coupling together;Figs. 5 and 6 are enlarged sections of part of Fig. 4;Figs. 7 and 8 illustrate a ceiling assembly of a modular building unit including building services equipment, with Fig. 7 shown in an exploded view;Figs. 9 to 11 are further views illustrating the provision of building services equipment within a ceiling assembly of a modular building unit;Figs. 12 and 13 illustrate a mounting member configured to couple respectively to an alignment pin and a lifting eye;Fig. 14 illustrates a lifting frame coupled to a modular building unit;Figs. 15 to 17 illustrate detail of a mounting member according to an alternative embodiment of the invention;Figs. 18 to 22 illustrate alternative forms of ceiling frame assemblies according to alternative embodiments of the invention;Figs. 23 and 24 are first and second views of part of a modular building assembly according to a further embodiment of the present invention;Fig. 25 is a perspective view of a hybrid building comprising the modular building assembly of Figs. 1 and 2, shown with an external layer of the building removed;Fig. 26 is a wire-frame isometric view of a plurality of modular building units, configured to form part of a building according to an alternative example;Figs. 27 to 29 are shown front (Fig. 27) and rear (Figs. 28, 29) isometric views of a modular building assembly in accordance with another embodiment of the invention, showing building services equipment routed through stacked modular building units of the assembly;Fig. 30 is an exploded isometric view of parts of the modular building assembly shown in Figs. 27 to 29, showing the location of various different building services and their routing throughout the modular building assembly;Fig. 31 is an isometric view of a ceiling assembly according to a further embodiment of the invention;Fig. 32 is an enlarged view of part of the ceiling assembly shown in Fig. 31 ;Fig. 32A is an isometric view showing building services equipment mounted on a panel to be fitted in the ceiling assembly of Fig. 31 ;Fig. 32B is a further enlarged view illustrating a variation of the ceiling assembly shown in Fig. 31 ;Fig. 33 is a cross-sectional front view of a modular building assembly comprising first and second modular building units, the first modular building unit comprising the ceiling assembly of Fig. 31 , the modular building assembly sectioned along line A-A of Fig. 31 ;Fig. 34 is an isometric view of a part of a modular building assembly according to a further embodiment of the invention;Fig. 35 is a cross-sectional front view of a modular building assembly comprising first and second modular building units, the first modular building unit comprising the ceiling assembly of Fig. 34, the modular building assembly sectioned along line B-B of Fig. 34;Fig. 36 illustrates a floor assembly and walls of a modular building unit during manufacturing of a modular building unit;Fig. 37 illustrates a partial ceiling assembly of a modular building unit during manufacturing of a modular building unit;Fig. 38 illustrates building services equipment to be incorporated into a ceiling assembly of a modular building unit during manufacturing of a modular building unit;Fig. 39 illustrates the partial ceiling assembly of Fig. 37 and the building services equipment of Fig. 38 coupled together to form a substantially complete ceiling assembly during manufacturing of a modular building unit;Fig. 40 illustrates the substantially complete ceiling assembly of Fig. 39 coupled to the floor assembly and walls of Fig. 36 during manufacturing of a modular building unit according to an embodiment of the invention;Fig. 41 illustrates a floor assembly, walls and a partial ceiling assembly of another modular building unit during manufacturing of a modular building unit;Fig. 42 illustrates the partial ceiling assembly of Fig. 41 and building services equipment coupled together to form a substantially complete ceiling assembly during manufacturing of a modular building unit; andFig. 43 illustrates the building services equipment of Fig. 42 prior to incorporation into the ceiling assembly.DETAILED DESCRIPTION

[0022] As noted in the background section at the start of the present patent specification, for hybrid buildings and for fully modular buildings the distribution of building services from a modular building unit to a further modular building unit (or a site-built first housing section, in the case of a hybrid building) has not been satisfactorily resolved for commercially available modular building systems. Particularly, the interconnection of building services without compromising the structural integrity of a modular building unit (or compromising some other aspect of the unit such as insulation, or architectural freedom to lay out the building as so desired) remains a challenge. A building service or a building system may comprise one or more of the following: a heating or cooling system distributing heated or cooled fluids such as water or air; a hot or cold water supply system; an electrical supply system; a ventilation system distributing fresh air or extracting stale air (and optionally heating or cooling the air); a data communications system; a gas supply system; or a drainage system. Further similar systems will be apparent to the skilled person. It will be appreciated that there is a need for building services equipment to bridge the interface between a modular building unit and a further unit or site-built building section. Such building services equipment bridging the interface may comprise one or more of: an electricity supply cable; a data cable; a cold water pipe; a hot water pipe; a soil pipe; a gas pipe; or an air ventilation duct. Furthermore, there may be a need for further building service equipment to be housed within the modular building unit for forming suitable interconnections, as well as other components of building services such as connectors, manifolds, pumps, and other plant equipment.

[0023] The present inventors have identified that the problem of interconnecting building services for a modular or hybrid building may be solved through configuration of floor and / or ceiling assemblies of a modular building unit. Particularly, according to the present invention, a modular building unit comprises a floor assembly, a ceiling assembly, and one or more walls connecting the floor and ceiling assemblies. The walls may comprise one or more exterior walls effectively defining a periphery or part of the periphery of the modular building unit. As well as or instead, the walls may comprise one or more interior walls defining different rooms or portions of rooms within the modular building unit.

[0024] The configuration of ceiling and floor assemblies may be such that the ceiling assembly is relatively deep while the floor assembly is relatively shallow. This has particular benefits for hybrid and fully modular buildings including permitting floor levels for site built building sections to be matched to floor levels in modular building units. This may be achieved in part by providing insulation underneath a lower level modular building unit within the building foundation. In some cases, advantageously the ceiling assembly may be relatively thick as this can assist in providing rigidity to the modular building unit during lifting and transportation. The floor and ceiling assemblies may be configured such that at an intersection between stacked modular building units the total intersection height may be within a predetermined range, such as between 200 mm and 500 mm, optionally around 300 mm (which may be less than for conventional fully modular solutions). For the particular case of a hybrid building, this relatively shallow intersection of a floor assembly overlying a ceiling assembly of another modular building unit may advantageously match up to the ceiling section of a site built building section. For instance, an intersection height of around 300 mm may match up to a standard joist used to form the site built ceiling. One such suitable joist type is known as a posi joist formed for instance from a combination of a pair of timber members spanning a room void and a metal web interconnecting the timber members to increase their strength. Posi joists and other types of joists with an open structure are widely commercially available and will be well known to the skilled person. This permits room heights to be consistent between modular parts of the building and site built parts of the building.

[0025] The present inventors have identified that there is a synergistic solution to the provision of building services into or out of modular building units with this form of floor and ceiling assemblies. Particularly, taking the example of a modular building assembly comprising a lower modular building unit and an upper modular building unit stacked on top, the present inventors have identified that the building services interconnections can suitably be provided through the side of the intersection of the ceiling frame assembly of the lower modular building unit and the upper modular building unit. Where services connect sideways to further modular building units they may feed into similar floor and ceiling assemblies in the neighbouring building units. Where services connect sideways to a site built building section, particularly where the site built section includes a ceiling assembly such as built with posi joists, the building services may then suitably extend through that ceiling structure.

[0026] The present inventors have identified two variants of the modified floor and ceiling assembly that permit building services to extend into and out of a modular building assembly. The first variant comprises a modification to the ceiling assembly of the lower modular building unit in a stack of two units. The second variant comprises a modification to the floor assembly of the upper modular building unit in a stack of two units. In either variant the other modular building unit may have a conventional construction: that is, no particular requirements are placed on the floor or ceiling assembly that abuts the modified floor or ceiling assembly of the first modular building units. Or the other modular building unit may include similar modifications for the abutting floor or ceiling assembly for the provision of services into and out of the modular building assembly.

[0027] The modification for each variant provides for apertures opening in the side of the floor and ceiling intersection when the units are stacked. It will be appreciated that in some cases boththe respective floor and ceiling assemblies may be modified to open up such apertures. In some cases where there are more than two modular building units (such as in a fully modular building) the variant followed for different intersections of two stacked units may vary through the building. Furthermore, for instance where there are only two stacked modular building units (for instance, in a hybrid building, particularly a house) it may be that only one of the two units includes any modifications for the provision of building services: the lower or the upper unit may include no specific modifications. Furthermore, where one or the other of a floor or ceiling assembly is modified to provide for such an aperture through which building services can extend, that modified floor or ceiling assembly may further include one or more portions of a building service (such as, at a minimum, one or more pipe, wire or duct) that is pre-installed when the unit is delivered to a building site such that as the units are stacked services may be readily connected without further significant modifications to the delivered unit. The building service equipment may be physically attached or integrated into the modified floor or ceiling assembly or may be provided in a separable building services cartridge or module that connects to or at least is received by the modified floor or ceiling assembly.

[0028] In the following description the first variant (a modified ceiling assembly for a lower modular building unit in a stack of two units) is described first, whilst the second variant (a modified floor assembly for an upper modular building unit in a stack of two units) is described later on within the present patent specification.

[0029] According to the first variant of the present invention the ceiling assembly comprises a load transfer section configured to transfer load to the walls. The load transfer section is further configured to form an aperture, optionally when a further modular building unit is stacked on top. In some examples the aperture is formed through the load transfer section including at least one first portion and at least two second portions extending above a top surface of the first portion. The second portions are configured to support load stacked on top of the modular building unit, for instance a further modular building unit stacked on top of the modular building unit. The second portions may support a floor assembly of the further modular building unit. Each first portion of the load transfer section is configured to form an aperture between the stacked modular building units. That aperture is provided by the first portions being lower than the second portions. The modular building unit further comprises building services equipment coupled to or incorporated into the ceiling frame assembly; the building services equipment being configured to connect through the aperture between the stacked modular building units. The load transfer section of the ceiling assembly is defined as being that portion of the ceiling assembly that serves to transfer load from above the modular building unit to the walls of the unit (and downwards through the building). It may comprise a frame structure. It may comprise a stiffened section of the ceiling assembly that is at least partly contiguous with other portions. In some embodiments of the invention the load transfer section is configured to provide sufficient rigidity to the ceiling assembly (and hence the modular building unit as a whole) to resist bending or flexing under load (including where the unit is lifted though the ceiling assembly) and to transfer load evenly along the length of the walls. Theceiling assembly may include further parts, for instance relatively weak struts or panelling upon which building services equipment may be installed.

[0030] Turning first to Fig. 1 , there is shown an isometric view of a modular building assembly 1 comprising first and second modular building units 2, 102 according to the first variant. Modular building unit 2 is a lower or ground floor modular building unit and modular building unit 102 is an upper or first floor modular building unit. Each modular building unit 2, 102 is of generally the same construction and they are configured to be stacked (though Fig. 1 is an exploded view in which a gap 3 is shown between the modular building units 2, 102 so that details of their interconnection can be more readily seen). Corresponding features of the modular building units are given the same reference number, with those of the upper modular building unit 102 incremented by 100. Corresponding features should be considered to be generally the same except where their differences are noted. The modular building units 2, 102 are shown in the drawings with certain features removed, so that a structure of the units can be seen.

[0031] The modular building units 2, 102 comprise structural frames, indicated generally by numerals 4, 104. However, it will be appreciated that in other embodiments the structure of a modular building unit may not comprise a frame as such: it may be a frameless construction formed for instance from a panellised material such as Structurally Insulated Panels (SIPs) where strength and rigidity are provided by panels rather than a skeletal frame. The structural frames 4, 104 comprise floor assemblies 5, 105 configured to support a planar floor structure (not illustrated) within the modular building units and ceiling assemblies 6, 106 . The floor assemblies 5, 105 and the ceiling assemblies 6, 106 for each modular building unit 2, 102 are interconnected by one or more walls 7, 107 formed from a lattice of framework. Fig. 2 shows the modular building assembly1 of Fig. 1 in which upper modular building unit 102 is shown landed on lower modular building unit2 and the walls 7, 107 shown in a further constructed state in which they have been clad with sheet material 8, 108.

[0032] Numerous options for forming the structural frames 4, 104 exist. Preferred options include a metallic frame, which can be of a cold-formed metal or metal alloy (for instance light gauge steel), a hot formed metal or metal alloy (for instance hot rolled steel), or combinations of the two. A hot- formed metallic frame may provide a sufficiently rigid structure so that additional perimeter support posts and bracing struts can be dispensed with (or the number of posts / struts reduced). Other options include timber-based frames. In the illustrated embodiment however, the structural frames 4, 104 between the floor assemblies 5, 105 and the ceiling assemblies 6, 106 are formed from cold- formed steel, comprising elongate members which may be of a generally hollow box shape in crosssection, or channels having a C, L or U-shape. Connection methods for structural components of the frame can include welding (metallic frames), bonding and mechanical fixations such as nut and bolt assemblies and rivets.

[0033] As noted above, the modular building assembly 1 is formed from modular building units 2, 102 having a structural frame in which at least the floor assemblies 5, 105 and ceiling assemblies 6, 106 are formed (at least in part) from box section hot formed steel. The construction of the wallsinterconnecting the floor and ceiling assemblies is not relevant to the presently claimed invention and so will not be discussed in detail.

[0034] The ceiling assembly 6 for the lower modular building unit 2 comprises a load transfer section 9 configured to transfer load to the walls when the upper modular building unit 102 is stacked on top. The load transfer section 9 includes at least one first portion 10 and at least two second portions 11 extending above a top surface of the first portion 9. The load transfer section 9 comprises a ring beam formed from frame members of box section metal and mounting members11 (forming the second portions 11) affixed to an upper surface of the ring beam, such that the first portions 10 of the load transfer section comprise the gaps between mounting members 11 . In other embodiments of the present invention (described below) where a ceiling assembly 6, 106 or at least a load transfer section 9 of a ceiling assembly 6, 106, is formed from metal beams (including box section or I section beams) the beams may include stepped portions or cutaway portions so as to provide at least one lower part identifiable as a first portion and at least two raised up portions identifiable as second portions.

[0035] Fig. 3 is a partial view of lower modular building unit 2 showing the load transfer section 9 in greater detail. Fig. 4 isolates the load transfer section 9 of the lower modular building unit 2 and the floor assembly 105 of the upper modular building unit 102 prior to coupling together. Fig. 5 is an enlarged section of one corner of Fig. 4 showing part of the load transfer section 9 of the lower modular building unit 2 and the floor assembly 105 of the upper modular building unit 102 prior to coupling together. Fig. 6 is a similar view to Fig. 5, but with the ceiling assembly 6 of the lower modular building unit 2 and the floor assembly 105 of the upper modular building unit 102 coupled together.

[0036] It can be seen particularly from Figs. 3 and 4 that the load transfer section 9 of the lower modular building unit 2 comprises a loop member 12 extending around the periphery of the modular building unit 2 in the form of a perimeter frame and at least one support member 13 within the loop member 12. The loop member 12 may also be referred to as a ring beam. In the example presented it extends about the periphery of the modular building unit but may in some cases be slightly offset from the periphery in at least one region. The loop member 12 aligns with exterior walls of the modular building unit 7for transferring load to those walls. In the particular example of Figs. 3 and 4 the support member 13 comprises an intermediate support member extending along the length of the modular building unit 2 and spanning the loop member 12. The support member 13 aligns with an interior wall (not visible in Fig. 1) of the unit 2 for transferring load to that wall. According to one embodiment the whole of the load transfer section 9 comprising the loop member12 and the support member 13 serve to transfer a load applied to the top of the modular unit to the walls. Each support member 13 within the loop member 12 may be aligned with an interior wall of the modular building unit 2 such that all walls of the modular building unit 2 transfer load. However, the present invention is not limited to this: it may be that there is any distribution of support members within the loop member, for instance forming a lattice or ladder structure in one or more regions. The support member 13 may bisect the modular building unit 2 into equal parts or it may be offset from a central position (suitably, such that is aligns with interior walls or wall portionsdefining a stairwell (not illustrated) within the unit 2. There may be multiple such support members 13. They may in some cases form a lattice work across the ceiling assembly 6. The ceiling assembly 6 may further include other portions such as struts or joists 14 (one ofwhich is labelled in Fig. 1) which may serve to support ceiling materials within the modular building unit 2 and to support building services equipment housed within, supported on, or attached to the ceiling assembly 6 (as is described below).

[0037] Figs. 3 and 4 show mounting members 11 provided at corners of the modular building unit 2 and also at intermediate positions along the sides of the modular building unit 2. Furthermore, at least one mounting member 11 is provided along the intermediate support member 13 in a generally central position within the periphery of the modular building unit 2. There may be any number of mounting members 11 provided along the loop member 12 and each support member 13: their number and distribution being primarily dictated by the load of the upper modular building unit 102 and other building structures above (such as a roof) and the distribution of that load.

[0038] It can be seen particularly in Fig. 4 that the corresponding floor assembly 105 of the upper modular building unit 102 comprises a corresponding frame structure including a loop member 15 and an intermediate support member 16 aligned with intermediate support member 13 of the ceiling assembly 6 of the lower modular building unit 2. The effect is that the floor assembly 105 of the upper modular building unit 102 is supported not only at its sides but also at intermediate points. This distributed support enables reduction in thickness of floor assembly 105 relative to the ceiling assembly 6. In general, it may be that the ceiling assembly 6 and the floor assembly 105 overlying the ceiling assembly 6 have a similar or identical layout. However, it matters only that the floor assembly 105 includes a suitable distribution of material such that where it rests upon the mounting members 11 the floor assembly 105 provides sufficient rigidity to the floor assembly 105 and hence to the upper modular building unit 102 to reduce the risk of damage.

[0039] Furthermore, the ceiling assembly 6 of the lower modular building unit 2 is configured to provide sufficient torsional stiffness to receive effectively point loads at the location of each mounting member 11 (from the weight of the upper modular building unit 102) and to distribute that load along the length of each of the loop member 12 and each intermediate support member 13 so that the underlying walls are loaded along their length. The present inventors have identified that the ability to distribute a point loading applied to the top of a modular building unit along the length of supporting walls advantageously distributes stresses within the modular building unit.

[0040] Referring back to Fig. 2, this shows the modular building assembly of Fig. 1 including panelling applied to the structural frame. In the alternative, Fig. 2 may be considered to illustrate a modular building assembly in which the walls are formed from a panellised material such as SIPs without any underlying framework. As the present invention primarily concerns floor and ceiling assemblies, this will not be further described. It can be seen that the load transfer section of the lower modular building unit 2, and particularly the raised second portions (the mounting membersl l) preserves a series of apertures 20 on at least one side of the modular building assembly through which building services equipment 21 may extend (illustrated generically asducting and pipework). Furthermore, the raised second portions 11 of the load transfer section of the ceiling assembly 6 of the lower modular building unit 2 serve to provide a void 22 (labelled in Fig. 4) between the lower and upper modular building units 2, 102 within which further connecting building services equipment 21 can be provided. This may be coupled to the ceiling assembly 6 of the lower modular building unit 2 such that the building unit 2 is delivered to site with building services equipment 21 preinstalled, as will be described below in connection with Figs. 7 to 9. Fig. 3 shows the void 22 being defined on its lower side by ceiling panels 23 upon which building services equipment 21 can be mounted. Alternatively, the building services equipment 21 may be installed within the ceiling assembly 6 upon joists 14 as illustrated in Fig. 1 .

[0041] Turning to Fig. 5, a mounting portion 11 (that is, a raised second portion 11 of the load transfer section 9 of a ceiling assembly 6) will now be described in greater detail. The mounting member 11 may comprise a post or peg 24 and may be generally formed from metal box section of similar dimension to the loop member 12. However, there is no restriction to the shape, size, or construction of the mounting members 11 so long as they raise up the load transfer section by the required amount and provide sufficient strength to support the weight of the building above. The mounting member may be attached to the upper surface of the loop member in any convenient fashion, for instance being welded in position or affixed with bolts. An upper surface 25 of the mounting member 11 provides a support surface to bear the weight of the floor frame assembly 105 of the upper modular building unit 102 (particularly loop or outer frame member 15, or a support member 16 as the case might be). The upper surface 25 may be generally planar. Extending from the upper surface 25 there is a pin or spigot 24. The pin 24 may be tapered. The pin 24 may be removable as will be described below in connection with Figs. 12 to 17. Pin 24 serves to guide the alignment between the lower modular building unit 2 and the upper modular building unit 102 as they are stacked one on top of the other by engaging a corresponding alignment hole 26 (shown in Fig. 6) upon an underside of the floor frame assembly 105 of the upper modular building unit 102. Alignment hole 26 may extend only through a lower wall of the floor frame assembly box section, as illustrated, such that once stacked the alignment pin 24 terminates within the inside of the box section (the alignment pin 24 being shorter than the depth of the box section 15 within the floor frame assembly 105). However, in other embodiments (not illustrated) the alignment pin may be longer than the height of the box section such that the alignment pin 24 will extend fully through the box section frame of the floor assembly (not illustrated).

[0042] Referring back to Figs. 1 and 2, while the upper modular building unit 102 may have a generally similar construction to the lower modular building unit 2, where there are no further modular building units to be stacked on top, the ceiling assembly 106 of the upper modular building unit 102 may have a simplified structure without the inclusion of mounting members 11 . However, as illustrated in Fig. 2, building services equipment 21 may still be located within the ceiling frame assembly 106 of the upper modular building unit 102 and extend laterally to serve another portion of the building (or vertically into a roof space).

[0043] As illustrated in Figs. 1 , 3 and 4, the ceiling assembly 6 of the lower modular building unit 2 and particularly the load transfer section 9 comprises more than four second portions 11 (that is,the mounting members 11). These may suitably be provided at least on corners of the ceiling assembly 6 (for a rectangular modular building unit 2) but they need not be at corner locations. There may be more than two mounting members 11 on one or more side of the ceiling assembly 6 such that when the modular building units 2, 102 (and optionally further units) are stacked one side may include two or more apertures 20. This may include corner located mounting members 11 on one side and another mounting member 11 provided at an intermediate location along at least one side of the load transfer section 9. There may be any number of apertures 20 provided around the periphery of a modular building assembly 2, 102. In some cases, particularly where the load transfer section 9 is not formed from a ring beam with discrete mounting members 11 , but rather with longer second portions, some sides may not include any apertures (such as for an exterior wall of the building).

[0044] The second portions 11 , such as the mounting members 11 , may extend above the top surface of the first portion 10 (that is, above the loop member 12 and the intermediate support member 13 (such that when the modular building units 2, 102 are stacked the aperture or apertures 20 between the stacked modular building units 2, 102 has a height between 10 mm and 250 mm, optionally between 20 mm and 150 mm.

[0045] As illustrated, the ceiling assembly 6 of the lower modular building unit 2 includes a portion within the load transfer section 9 that is recessed relative to the top surface of the first portion 10 of the load transfer section 9 to form void 23, the recessed portion being configured to receive the building services equipment 21 . The recess may be no more than the height of the second portions 11 above the first portions 10 of the load transfer section 9. That is, within the loop member 12 the ceiling assembly 6 may be closed off at the level of the top surface of the loop member 12. Or, within the loop member 12, the ceiling assembly 6 may be further recessed such that between the stacked modular building units 2, 102 the void 23 containing building services equipment 21 is taller than the aperture 20 about the edge of the modular building assembly 2 through which building services equipment 21 can extend into and out of the modular building assembly 1 .

[0046] Although not specifically illustrated, it will be appreciated that where apertures 20 are formed for the modular building assembly 1 , one or more apertures 20 may be closed off for instance by a plate structure either before or after stacking the modular building units 2, 102. Where building service equipment 21 extends through an aperture 20, the closing off may preserve a smaller gap.

[0047] The distribution of building services for a modular building assembly 1 as presented above primarily concerns the lateral distribution of services through pipes, wires, and ducts (generically referred to as building services equipment) to adjacent portions of a building. It will be appreciated that for a modular building assembly 1 there is a similar need to vertically distribute building services. In some embodiments one or more modular building unit 2, 102 may include a vertical services riser that intersects the void 22 within the ceiling assembly 6, 106 housing building services. In some cases, a vertical services riser may extend between the lower modular buildingunit 2 and the upper modular building unit 102, the vertical services riser intersecting with and communicating with the services void 22 between the stacked modular building units 2, 102. As well or instead, the ceiling assemblies 6, 106 and floor assemblies 5, 105 may include a suitable opening for accessing the services void 2. For instance, for the example of Fig. 1 the floor frame assembly 105 of the upper modular building unit 102 may include an access hatch (not illustrated) enabling access to the services void 22 between the stacked units 2, 102 and the building services equipment 21 housed or otherwise attached to the ceiling assembly 6 of the lower modular building unit 2. In some cases, it may be that upon delivery to the building site the building service equipment 21 attached to the modified ceiling assembly 6 of the lower modular building unit 2 may not extend outside of the periphery of the modular building unit 2. After the units 2, 102 are stacked, services such as wires, pipes, and ducts may be inserted through the apertures 20 to a point where they align with features such as a manifold within the ceiling assembly 6. Connections may then be made through the access panel in the upper modular building unit 102.

[0048] Referring now Figs. 7 and 8, these illustrate the ceiling assembly 2 of the lower modular building unit 2 of Fig. 1 including building services equipment 21 . The structure of the ceiling assembly 6 in terms of mounting members 11 will not be described again. Fig. 7 is an exploded view showing the building services equipment 21 separated from the structural portions of the ceiling assembly 6. Fig. 8 shows the building services equipment 21 in an installed position. The building services equipment 21 includes various wires, pipes, and ducts, which are not individually identified, nor will their functions within various building services or systems be described. The building services equipment 21 may suitably be mounted on a board or panel 30 shaped to fit within the services void 22 within the ceiling frame assembly 6. In some cases, the panel 30 may be formed within the ceiling assembly and then the building services equipment 21 coupled to it in-situ. More generally, the ceiling assembly 2 may include a support section configured to support building services and defining a generally planar surface. This may be provided by joists or panelling within the structural frame. The board 30 is shown with a cutout 31 that aligns with an open portion 32 of the ceiling frame assembly 6 in one quadrant defined by the loop member 12 and the intermediate support member 13. In the completed modular building assembly 1 a staircase may be provided within the open portion 32 and so of course it is necessary that it is not occluded by building services equipment 21 . In further examples of the present invention, it may be that there may be more than one board configured to support building services equipment in different portions of the ceiling assembly 6.

[0049] In one example, panel 30 may be installed within the ceiling frame assembly 6 prior to building services equipment 21 being attached. In another example, as illustrated the panel 30 may be built up with the building services equipment 21 separately from the construction of the structural elements of the ceiling assembly 6 and then the two parts brought together as illustrated in Fig. 8. The panel 30 may be supported by struts 14. It can be seen in Fig. 8 that the building services equipment 21 , for instance a duct 33 extends to the periphery of the ceiling assembly 6 but does not extend beyond the periphery. In other cases, the building services equipment 21 may be set back from the periphery of the ceiling assembly 6 (or some combination of both). Thus, connections ofbuilding services equipment 21 may be formed at the periphery of the modular building assembly 1 once the units 2, 102 are stacked, or connections may be made within the confines of the modular building assembly 1 , such as through an access panel as noted above.

[0050] The building services equipment 21 and / or the panel 30 (if used) may be coupled to the remainder of the ceiling assembly 6 in any suitable way, such as screws, bolts, or clips. The connection may be releasable or the building services equipment 21 may be permanently installed within the ceiling assembly 6.

[0051] Referring now to Figs. 9 to 11 , these are further views illustrating the provision of building services equipment 21 within a ceiling assembly 6 of a modular building unit 2 according to other examples. Fig. 9 is generally the same as for the depiction of building services equipment 21 upon panel 30 as illustrated in Figs. 7 and 8, differing in that also a top panel 34 is provided overlaying the building services equipment 21 . Advantageously, the top panel 34 provides an upper platform within the ceiling assembly that may be walked over during manufacturing of the modular building unit during off-site manufacture (once the building services are fitted out) and once brought to the final location of the modular or hybrid building. Fig. 9 is presented in an exploded view prior to the panels 30 and 34 being brought together and optionally sealed together to form a building services cartridge or module 35. The building services cartridge or module 35 may be permanently or releasably coupled to the structural portions of the ceiling assembly 6 either during off site module manufacture or at the time of stacking up the modular building assembly.

[0052] Figs. 10 and 1 1 extend the concept of a building services equipment cartridge or module 35 of Fig. 9. The building services equipment 21 is at least partly encapsulated by housing 36 which is shaped to fit between mounting members 11 . Fig. 10 is shown in exploded form and Fig. 11 is a partial assembled view. Housing 36 may extend over the building services equipment 21 and may be coupled to a panel 30 such that the building services equipment 21 is at least partially sandwiched top and bottom. Housing 36 may include side portions 37 at least proximal to the mounting members 11 so that apertures 38 are preserved. The housing 36 in position between the mounting members 11 is overlayed with panel 39 which is shown optionally extending over the top of the mounting members 11 (with holes 40 preserved for pins or spigots 24).

[0053] In combination, building services equipment 21 , panels 30 and 39 and housing 36 (or optionally without top panel 39) may form a building services cartridge or module 35. Module 35 may be mostly or completely formed prior to coupling (releasably or permanently) to the remainder of the ceiling assembly 6.

[0054] Services module 35 is primarily described herein as being coupled to a ceiling or floor assembly of a modular building unit during manufacture of the modular building unit (for instance, in a factory). However, in other embodiments of the invention, at least one modular building unit may be delivered to a final location for a modular or hybrid building and a services module such as module 35 only connected at the final location of the modular building unit.

[0055] The housing 36 at least partially contains the building services equipment 21 . The services module 35 is configured to be received in or connected to a floor or ceiling assembly of a modular building unit, or a portion of the floor or ceiling assembly, for instance by coupling to or being received within part of a frame forming a floor or ceiling assembly. In some cases, multiple services modules 35 may be provided in different areas of a ceiling or floor assembly. When two modular building units are stacked to form the modular building assembly, services modules are located between the two stacked modular building units. In some examples, after the modular building assembly is formed then connections are made to the building services equipment 21 within the services module 35, those connections extending through the apertures previously described between the stacked modular building units. The connection points may in some cases be formed inboard of the periphery of the modular building assembly. For instance, one or more wire, pipe, or duct may be passed through an aperture and connected to the services module.

[0056] The building services equipment 21 forms part of a building services system within a resulting modular or hybrid building defined in part by the modular building unit. The building services equipment may comprise one or more of: an electricity supply cable; a data cable; a cold water pipe; a hot water pipe; a drainage pipe; a gas pipe; an air ventilation duct; or an energy storage system. For instance, the energy storage system may comprise a battery system to store electricity. Advantageously, the services void between stacked modular building units forms a suitable storage location for such a battery system.

[0057] Turning now to Figs. 12 and 13, these illustrate the mounting member 1 of Figs. 1 to 6 in alternative views to reveal further details. As noted previously, the alignment spigot or pin 24 for aligning and interconnecting the lower and upper modular building units 2, 102 may be removable. As illustrated in Fig. 12 each mounting member 11 (or at least some of the mounting members 11) includes a female threaded socket 50 and the pin 24 is generally formed as a bar with a corresponding male thread 51 at one end arranged to releasably engage the threaded socket 50. That is, when the lower modular building unit 2 has been set in position at the final location for the building, the threaded pin 24 may be screwed into position and the upper modular building unit 102 lifted into position until alignment holes 26 align with and engage the alignment pins 24.

[0058] The reason at least some of the alignment pins 24 are releasably coupled to the mounting members 11 is apparent from Fig. 13: the same threaded socket 50 may first receive a lifting eye 52 with a corresponding male screw thread 51 . The lifting eye 52 serves to lift the modular building unit 2 for transportation and positioning at the final location for the building. For this, a lifting rig 53 as illustrated in Fig. 14 is connected via wires 54 to a crane (not shown) and wires 55 to a plurality of lifting eyes 52. The lifting rig 53 serves to distribute the crane lifting force about the ceiling assembly 6 such that wires 55 connect vertically to lifting eyes 52 to avoid distortion of the ceiling frame assembly 6. It may be that not all of the mounting members 11 are provided with releasable lifting eyes 52, and some mounting members 1 1 may be provided with permanently attached alignment pins.

[0059] As noted previously, in the case of an uppermost modular building unit 102, it may be that there is no need for the load transfer section to include raised second portions (mounting members) as there is no need to preserve an aperture for the delivery of building services laterally. However, there remains a need to lift the uppermost modular building unit into position and so the ceiling frame assembly may be provided with similar lifting eyes 102 that engage threaded sockets which may be flush with a planar upper surface of the ceiling frame assembly 106.

[0060] Turning now to Figs. 15 to 17, these illustrate detail of a mounting member 11 according to an alternative embodiment of the invention. Fig. 15 is generally the same as Fig. 5 and shows an alignment pin 60 coupled to mounting member 11 . Alignment pin 60 may be releasable as for Fig.12. As for Fig. 5 the alignment pin 60 is configured to engage a corresponding alignment hole 26 within the floor frame assembly 105 of the upper modular building unit 102. However, differing from alignment pin 24, the exposed portion of alignment pin 60 includes a male screw thread 61 configured to engage a fixing nut 62 that is configured to accommodate tapered portion 63 as shown in Fig. 16. After alignment pin 60 has engaged alignment hole 26 and the floor assembly 105 of the upper modular building unit 102 is fully seated on the ceiling assembly 6 of the lower modular building 2, nut 62 may be secured to thread 61 to lock the modular building units 2, 102 together. If required, the floor frame assembly 105 of the upper modular building unit may include a cut away upper part for accessing the taper 61 to secure nut 62.

[0061] Referring now to Figs. 18 to 22, these illustrate alternative forms of ceiling assemblies 6 according to alternative embodiments of the invention. Figs. 1 to 17 have generally illustrated aspects of ceiling assemblies 2 where at least a load transfer section 9 is formed from box section metal beams. Particularly, the load transfer section 9 of the ceiling assembly 6 in those figures was in the form of a loop member 12 extending around the periphery of the modular building unit 2 and formed from frame members and optionally one or more intermediate support members 13, each formed from a box section beam formed from hot formed metal such as steel.

[0062] An alternative is for the load transfer section of a ceiling assembly to be formed from a folded or welded steel profile formed in a ring around the modular building unit. Figs. 18 to 22 illustrate various options in which a ceiling assembly may be formed from folded or welded steel profiles.

[0063] Fig. 18 shows that a portion of a load transfer section may be formed from a metal profile 70 which may suitably be formed from a single sheet of metal and folded into shape to form an inverted U shaped channel. The profile 70 has an outer flange 71 that may extend downwards over a wall of the modular building unit 2 and may be connected (for instance, welded) to the wall to brace the wall to reduce skewing under load. The outer flange 71 may extend downwards by different amounts along different wall sections. For instance, where minimal bracing is provided in a wall section, flange 71 may extend down further to provide rigidity to the wall.

[0064] Connected to outer flange 71 is an upper surface 72 and connected to the upper surface 72 is an inner flange 73 which may also be connected to the underlying wall to provide bracing. In contrast to the mounting members provided in previous embodiments of the present invention, forthe profile 70 of Fig. 18, a first (lower) portion of the load transfer section is provided by cutting away a length of the upper surface 72 and parts of the side flanges 71 and 73 as indicated at region 75. In an alternative (not illustrated) in place of a cutout, the profile may simply be shorter in region 75. Consequently, the second (raised) portions of the load transfer section are provided by adjacent intact portions of profile 70. Accordingly, when the modular building assembly is formed by stacking completed units an aperture is formed by region 75.

[0065] Fig. 19 shows the same profile 70 as Fig. 18 except that to provide the differentiation between first and second portions of the load transfer section, in place of cutout 75, there is provided one or more mounting members 76 affixed to the upper surface 72. Mounting members 76 may be generally the same as previously described for other embodiments and will not be described again, except to note that they may be of varying length along the profile 70 to define (in their gaps) apertures of different sizes.

[0066] Fig. 20 is generally the same as Fig. 19 except that profile 70 further comprises a projection 77 that may support a joist in a site built section of the building. Similarly, Fig. 21 is generally the same as Fig. 20 except that profile 70 further comprises a projection 78 that may support a joist or strut within the centre part of the ceiling assembly 6 (such as strut 14 previously described) which may in turn provide support for building services equipment 21 . It will be appreciated that a profile may include projections 77 and 78.

[0067] Further alternative profiles forming parts of a load transfer section of a ceiling assembly will be readily apparent to the skilled person.

[0068] Fig. 22 shows an alternative ceiling assembly 80 (shown partly cutaway) according to another embodiment of the invention in which load transfer sections 81 extending at least about a periphery of the ceiling assembly 6 comprise metal profiles similar to Fig. 21 except that a continuous sheet 82 extends between them in place of shortened projections 78. The sheet 82 may support building services equipment 21 , which may be provided similarly to how previously described for Figs. 7 to 11 . The ceiling assembly 80 may be formed from a single sheet of metal that is appropriately folded or stamped. Advantageously, this may allow any shape or pattern of load transfer section to be provided while provided any required support for building services equipment 21. If required, cutouts may be provided in sheet 82 to reduce weight or to provide access to building services equipment within the void formed between modular building units in a modular building assembly.

[0069] Turning now to Figs. 23 and 24, the second variant noted above will now be described. The second variant comprises a modification to the floor assembly of the upper modular building unit in a stack of two units. The modification provides for apertures opening in the side of the floor and ceiling intersection when the units are stacked. Fig. 23 shows the floor assembly 105 of an upper modular building unit 102 in a modular building assembly 1 viewed partly from underneath with building services 21 shown partially removed for clarity. Fig. 24 is the same view from above.

[0070] In substance, the modification to the floor assembly 105 for the upper modular building unit 102 is the same as the previously described alternative of a modification to the ceiling assembly 6 for the lower modular building unit 2 described in Figs. 1 to 22, so will be more briefly described. The (upper) modular building unit 102 comprises a floor assembly 105, ceiling assembly 106, and walls 107 connecting the floor and ceiling assemblies 105, 106. The ceiling assembly 106 and walls 107 are not shown in Figs. 23 and 24 but may be generally as previously described. The ceiling assembly 6 for the underlying lower modular building unit 2 (again not illustrated) may differ from that previously described by having no mounting portions 11 .

[0071] In place of the lower modular building unit having mounting portions, the floor frame assembly 105 comprises a load transfer section 90 configured to transfer load from the walls 107 to the underlying lower modular building unit 2. The load transfer section is further configured to form an aperture when a further modular building unit is stacked on top. In Figs. 23 and 24 the load transfer section comprises a frame formed from box section metal beams and including a loop member 91 and at least one intermediate support member 92. However, it will be understood that the construction of the load transfer section 90 may be of any form, including folded metal profiles similar to those illustrated in Figs. 18 to 22 (but inverted).

[0072] In some examples the load transfer section 90 includes at least one first portion and at least two second portions descending below a bottom surface of the first portion. The second portions in the example of Fig. 23 are formed from mounting members 93. Mounting members 93 serve to form an aperture when modular building units 2, 102 are stacked though which services can be connected. They may include features such as alignment pins (not illustrated) to engage the ceiling assembly of the lower modular building unit. Mounting members 93 may be formed similarly to previously described mounting members 11 . Building services equipment 21 may be permanently or releasably installed in a void formed within the floor assembly.

[0073] More generally, the second variant whereby structures of the floor frame assembly of the upper modular building unit may be considered to be an inversion of the modified ceiling frame assembly described in connection with the preceding figures and features described in connection with those figures may be provided equally for the embodiment of Figs. 23 and 24, adapted mutatis mutandis.

[0074] Referring now to Fig. 25, there is shown a perspective view of a hybrid building 200 comprising the modular building assembly 1 formed from lower modular building unit 2 and upper modular building unit 102 of Figs. 1 and 2. The hybrid building 200 is shown in Fig. 25 with an external layer removed so that a structure of the building can be seen. The hybrid building 200 may suitably be clad, for instance with bricks or blocks.

[0075] In the illustrated embodiment, the hybrid building 200 is a house, and in particular a detached house. The principles of the invention can however apply to other types of houses, including semi-detached and terraced, as well as single storey houses (bungalows). In addition, the principles of the invention can apply to other residential buildings such as flats / apartments and hotels, and indeed to non-residential buildings, for instance industrial or commercial buildings.

[0076] The hybrid building 200 comprises a first building section 201 and a second building section 202. The first building section 201 is an on-site construction at a final location 203 for the building, and is generally L-shaped in plan-view (although not restricted to that shape). The second building section 202 comprises the modular building units 2, 102. The modular building units 2, 102 are constructed to a substantially assembled form away from the final location 203, for example in a dedicated factory or facility. The modular building units 2, 102 are transported to the final location 203 in a substantially assembled form, and arranged to form at least part of the second building section 202. In the illustrated embodiment, the second building section 202 is effectively formed by the modular building assembly 1. As explained in detail in International patent publication nos.WO2022 / 243696, WO2022 / 243695, WO2022 / 243694, WO2022 / 243693, and WO2023 / 222853 (the disclosures of which are incorporated herein by this reference), the hybrid building 200 is formed by connecting the first and second building sections 201 and 202 together at the final location 203.

[0077] As can be seen from Fig. 25, the second building section 202 fits with the generally L- shaped first building section 201 in order to form a building having a generally rectangular shape in plan-view. Other shapes are of course possible. The modular building units 2, 102 can have any suitable dimensions, with the proviso that it will generally be required to be transported for instance by road or rail from the factory to the final location 203. Although the illustrated modular building units 2, 102 extend only part way between the front and back of the building 200, other units according to the invention may extend the full length of the building, and so may for instance have a greater length dimension.

[0078] In a variation on the illustrated embodiment, the building may be a modular building 210 comprising a plurality of modular building units which form all (or at least a majority) of an internal volume of the building. This is illustrated in Fig. 26, which is a wire-frame isometric view of a plurality of modular building assemblies, configured to form part of a building 210. The building 210 comprises a plurality of modular building units 2, 102, at least one of which is a modular building unit according to the invention. In a particularly preferred option, all of the modular building units are units according to the invention.

[0079] The modular building units are arranged in modular building assemblies 1 stacked as discussed above in relation to the modular building assembly 1 . Thus, each modular building assembly 1 comprises a lower modular building unit 2 and an upper modular building unit 102 stacked on the lower unit 2. The modular building assemblies 1 or in turn the modular building units 2, 102 define the entire internal volume of the building 210, with the exception of an upper or outer roof of the building (not shown), which may be formed at a final location for the building, or formed as a modular (transportable) structure.

[0080] Turning now to Figs. 27 to 29, there are shown front (Fig. 27) and rear (Figs. 28, 29) isometric views of a modular building assembly 1 a in accordance with another embodiment of the invention, showing building services equipment routed through stacked modular building units 2a and 102a of the assembly. Like components of the assembly 1 a with the assembly 1 of Figs. 1 to 26 share the same reference numerals, with the addition of the suffix ‘a’.

[0081] In this embodiment, the modular building units 2a and 102a are typically longer than the units 2 and 102, being intended to extend from the front to the back e.g. of the hybrid building 200 shown in Fig. 25. Reference will be made to the building 200 for simplicity, the modular building assembly 1 a then being provided in place of the assembly 1 . Of course, the modular building assembly 1 a could equally form part of the fully modular building 210 shown in Fig. 26. The general construction of the modular building units 2a and 102a is the same as for the modular building units 2 and 102, and so will not be described again. Reference is therefore made to the text above, including the discussion of alternative options for the modular building unit constructions.

[0082] Fig. 27 shows a water heater 212, and a ventilation system in the form of an MVHR (mechanical ventilation and heat recovery) system 214, both of which are located in the lower modular building unit 2a. A fresh air inlet 216 and a stale air outlet 218 each extend through a services void 22a between the stacked modular building units 2a, 102a before passing downwardly to the MVHR system 214. Following the principes outlined above, the services void 22a can be formed in a ceiling assembly 6a of the lower modular building unit 2a, or a floor assembly 105a of the upper modular building unit 102a. The fresh air inlet 216 serves for supplying fresh air to the MVHR system 214 for distribution throughout the building 1 a, whilst the stale air outlet 218 serves for exhausting stale internal air drawn from within the building by the MVHR system to the building exterior.

[0083] Fresh air is supplied to a lower storey living space area or areas of the building 1 a via a supply duct 220, which may serve e.g. a lounge or sitting room. Stale air is withdrawn from lower storey living space areas via extract ducts 222 and 224, which may serve e.g. a kitchen and a washroom / WC. The supply and extract ducts 220-224 all extend through the services void 22a into the first building section 201 , or to a location within the lower modular building unit 2a. It will be understood that the living space areas may be provided in the first building section 201 , a second building section defined by the modular building assembly 1 a, or jointly by the two building sections

[0084] Fresh air is supplied to upper storey living space areas of the building 1 a via supply ducts 226, 228 and 230, which may serve e.g. separate bedrooms provided at least partly in the first building section 201 . Stale air is withdrawn from an upper storey living space area or areas by an extract duct 232, which may serve e.g. a bathroom provided in the upper modular building unit 10a. The supply and extract ducts 226-232 all pass upwardly through the services void 22a via a services riser whose general location is indicated at 234 in the drawing, before passing into and along a services void 236 provided by a ceiling assembly 106a of the upper modular building unit 102a.

[0085] Fig. 28 shows a network of cold and hot water pipes extending through the modular building assembly 1 a, some of which extend on into and supply the first building section 201 . A cold water mains supply pipe is shown at 238, extending into the lower modular building unit 2a. This provides all water supply requirements for the building 200, including for drinking, heating and bathing purposes, and so feeds the water heater 212 (not shown in Fig. 28).

[0086] Cold water supply pipes 240 and 242, and hot water supply pipes 244 and 246, extend upwardly to a manifold (indicated generally at 248) which is located in the services void 22a, via a services riser whose location is indicated generally at 250. From there, cold and hot water is supplied to a variety of end use points within the building 200 (in both lower and upper storeys), via a network of cold and hot water pipes. These end use points can include space heaters (e.g. radiators), as well as cold and hot water supplies servicing living space areas throughout the building 200. Cold and hot water end use points can include taps / faucets and toilet feeds, for example in kitchen, washroom / WC and utility room living space areas in a lower storey, and bathroom and ensuite living space areas in an upper storey. Space heaters can of course be provided throughout the living space areas of the building, and are typically connected in a closed loop to radiator supply and return pipes. The cold and hot water pipes will not be discussed in detail, but for general understanding, cold water supply pipes (and optionally space heater return pipes) are indicated with numeral 252, and hot water supply pipes with the numeral 254.

[0087] Fig. 29 shows the location of a bathroom 256 in the upper modular building unit 102a, and a washroom / WC 258 in the lower modular building unit 2a. The drawing also shows the location and routing of soil / waste pipes which serve equipment in the bathroom 256 and the washroom 258. These include a bathroom soil pipe 260 (which connects to bath 262, sink 264 and toilet 266 waste water outlets), and washroom soil pipes 268, 269 (which connect respectively to sink 270 and toilet 272 waste water / waste outlets). A further soil pipe 274 is shown which can connect e.g. to a sink in a kitchen area of the first building section 201 . These soil pipes 260, 268, 269 and 274 all connect to a main soil pipe 276 which passes downwardly through a foundation of the building 200 to a main sewer (not shown). The main soil pipe 276 extends up through the lower modular building unit 2a to services void 22a, for connection with the bathroom soil pipe 260, which extends along the services void 22a to the main soil pipe 276.

[0088] Electrical wires / cables (not shown) are routed in much the same way as the water pipes 252 and 254, into the lower modular building unit 2a, and from there into the services void 22a before being routed into the upper modular building unit 102a, and indeed the first building section 201.

[0089] Fig. 30 is now referred to, which is an exploded isometric view of parts of the modular building assembly 1a, taken from the front, and showing the location of the various different services discussed above in relation to Figs. 27 to 29, and their routing throughout the modular building assembly 1a and the building 200. Viewing from the bottom up, the drawing shows a floor assembly 5a of the lower modular building unit 2a with lower parts of walls 7a connected it; a ceiling assembly 6a of the lower modular building unit, with upper parts of the walls 7a connected to it; and a ceiling assembly 106a of the upper modular building unit 102a with parts of walls 107a connected to it. Parts of the various services shown in Figs. 27-29 and located in the floor assembly 5a, and ceiling assemblies 6a and 106a discussed above are identified in the drawing.

[0090] Turning now to Fig. 31 , there is shown an isometric view of a ceiling assembly 6b according to a further embodiment of the invention. Fig. 32 is also referred to, which is an enlargedview of part of the ceiling assembly 6b (taken from a different angle), and Fig. 33, which is a cross- sectional front view of a modular building assembly 1 b comprising first and second modular building units 2b and 102b, sectioned about line A-A in Fig. 31. The first modular building unit 2b comprises the ceiling assembly 6b. Like components of the modular building assembly 1 b (including the ceiling assembly 6b) with the modular building assembly 1 share the same reference numerals, with the addition of the suffix ‘b’.

[0091] The ceiling assembly 6b comprises a load transfer section 9b, which takes the form of a structural frame, specifically of a lattice or lattice type structure. The structural frame 9b comprises elongate structural frame members, comprising a lower structural member in the form of a beam 278, an upper structural member also in the form of a beam 280, and at least one connecting member, which extends between and connects the lower structural member to the upper structural member. In the illustrated embodiment, the structural frame 9b comprises a plurality of connecting members in the form of struts 282, disposed generally perpendicular to the lower and upper structural members 278 and 280, and a plurality of transverse bracing members 284 disposed at a non-perpendicular angle relative to the lower and upper structural members 278 and 280 (suitably at an angle other than 90°, for example between perhaps 20° and about 45°).

[0092] The lower structural member 278 defines a lower surface 286 of the load transfer section 9b, whilst the upper structural member 280 defines an upper surface 288. The lower and upper structural members 278 and 280, and the connecting members 282 and 284, effectively form sides of the structural frame 9b. The connecting members 282 and 284 serve for transferring loads from the upper structural member 280 to the lower structural member 278, and so to walls 7b of the lower modular building unit 2b. In a second option that will be described below, a floor assembly for the upper modular building unit 102b can be provided having the same general structure as the ceiling assembly 6b, in which situation the load transfer section serves for transferring loads to the walls 7b of the lower modular building unit 2b.

[0093] The load transfer section 9b comprises a plurality of generally elongate portions which together define the load transfer section, and which may together form the structural frame. In the illustrated embodiment, the load transfer section 9b has a generally quadrilateral shape in plan view (generally rectangular), comprising left and right elongate portions 290 and 292, and front and back elongate portions 294 and 296. The number of generally elongate portions generally corresponds to the number of walls 7b of the modular building unit 2b. The elongate portions 290-296 are each generally aligned with a respective wall 7b, so that they are in substantially the same plane. Each elongate portion 290-296 is seated on a respective wall 7b, and arranged so that it is disposed transverse to (suitably substantially perpendicular) the adjacent elongate portion (or have a wall seated on them in the second option described above). Each of the generally elongate portions 290-296 comprises respective lower and upper structural members 278 and 280, and connecting members 282, 284. The upper structural members 280 of the elongate portions 290-296 together form an upper loop member 12b of the load transfer section 9b, whilst the lower structural members 278 together form a lower loop member 12b' of the load transfer section.

[0094] In this embodiment, the load transfer section 9b is configured to provide a plurality of apertures 20b through which building services equipment can pass. This is illustrated in Fig. 32, where it can be seen for example that an aperture 20b is sized so that a ventilation conduit (e.g. 220b) can pass through it. This facilitates connection of building services equipment (indicated generally by numeral 21 b in Fig. 31) located within a services void 22b between the stacked modular building units 2b, 102b into a first building section of a building comprising the modular building assembly 1 b (e.g. first building section 201 of building 200), as well as into the lower and upper modular building units themselves (and / or items / equipment contained within them). The building services equipment 21 b will not be described in further detail, but can comprise any of the options discussed above.

[0095] The building services equipment 21 b can thus be accommodated within the services void 22b, and connected through the apertures 20b, without requiring that the equipment pass generally downwardly into the lower modular building unit 2b, or generally upwardly into the upper modular building unit 102b stacked or seated on the lower unit (save where it is specifically desired to supply building services into / through the lower unit, or into / through the upper unit).

[0096] The apertures 20b are defined by or between structural members of the structural frame 9b, specifically between at least some of the lower and upper structural members 278, 280 and the connecting members 282, 284. Referring for example to the aperture 20b labelled in Fig. 32, the aperture is defined between and / or bordered by the upper beam 280, the transverse bracing member 284, and the strut 282. A further aperture, labelled 20b' for the purpose of this discussion, is defined between and / or bordered by the lower beam 278, another transverse bracing member 284, and another strut 282. A series of the apertures 20b are defined around a perimeter of the structural frame 9b, as can be seen particularly in Fig. 31 .

[0097] The lower surface 286 defined by the load transfer section 9b is seated on upper surfaces 298 of the walls 7b, as best shown in Fig. 33. The load transfer section 9b also comprises an upper surface 300, which supports the upper modular building unit 102b, specifically a floor assembly 105b of the upper unit. The load transfer section 9b is of a first height Hi , which is defined between the upper and lower surfaces 300, 298, and which is typically in the range of about 200mm to about 300mm. A height Hi in the region of about 250mm to about 260mm may be preferred.

[0098] The ceiling assembly 6b also comprises a ceiling section 302, which is configured to define or support a ceiling 304 of the modular building unit 2b. In this embodiment, the ceiling section 302 comprises a lower surface 306 which supports a series of generally planar ceiling components in the form of ceiling panels (one shown in Fig. 33 and given the numeral 308), which are configured to form the ceiling 304. The panels 308 are connected to the ceiling section 302, arranged below the lower surface 306.

[0099] The lower surface 306 of the ceiling section 302 is provided lowermost of the ceiling section, and defines a lower extent of the ceiling section. The ceiling section 302 comprises a plurality of lower surface portions which together make up the lower surface. In the illustrated embodiment, the ceiling section 302 comprises a plurality of resilient mounting bars by which theceiling 304 is mounted to the ceiling section. Fig. 33 shows one such resilient mounting bar 310, which comprises a lower surface defining a lower surface portion 312 that, together with other such mounting bars (not shown), form the lower surface 306. The resilient mounting bars 310 are of a type known in the industry, and have a generally corrugated mounting part defining the lower surface portion 312, which provides a sound absorption / deadening function to reduce transmission of vibrations (and so sound) through the ceiling 304 between the stacked modular building units 2b, 102b.

[0100] The ceiling section 302 is disposed inwardly of the load transfer section 9b and is connected to it. The ceiling section lower surface 306 is disposed at a position that is lower than the upper surface 298 of the walls 7b, as can be seen in Fig. 33. The ceiling assembly 302 effectively defines the services void 22b, the void comprising an upper boundary which is defined or formed by a plane 314 containing the upper surface 300 of the load transfer section 9b, and a lower boundary which is defined or formed by a plane 316 containing the lower surface 306 of the ceiling section 302. The services void 22b has a second height H2 which is greater than the height Hi of the load transfer section 9b. The second height H2 is typically in the range of about 250mm to about 350mm. A second height H2 in the region of about 275mm to about 295mm may be preferred.

[0101] The ceiling section 302 comprises an upper surface 318 which is disposed at a position that is lower than the upper surface 300 of the load transfer section 9b. The ceiling section 302 is of a third height H3 which is defined between the upper and lower surfaces 318, 306 of the ceiling section. The height H3 of the ceiling section 302 is less than both the first and second heights Hi and H2, and may be in the range of about 70mm to about 100mm. A third height H3 in the region of about 75mm to about 95mm may be preferred. Where the ceiling section 302 itself defines the ceiling 308, the lower surface 306 which defines a boundary of the service void 22b may be formed by an upper face of the ceiling. A maximum height H4 of the apertures 20b is dictated by structural features of the ceiling assembly 6b (including the heights H1 H2 and H3), and dimensions of structural members 278-284, but may be in the region of about 120mm to about 175mm, with a dimension of perhaps 150mm to 160mm being preferred. Of course, the structural members forming the apertures include the transverse bracing members 224. These bracing members 224 extend between the upper and lower structural members 280 and 278 at the angle shown in the drawings, and so do limit the height of the aperture towards their ends adjacent the upper structural members. An aperture 20b having such a maximum height H4 may however be sufficient to accommodate most or all different types of services (e.g. pipes or conduits) likely to be positioned in the space 22b.

[0102] The ceiling section 302 depends from the load transfer section 9b, so that the ceiling section overlaps a top part of the walls 7b defining the upper surface 298, the top part taking the form of a top frame member or beam 319 of the wall. The load transfer section 9b forms an outer part of the ceiling assembly, defining an outer perimeter 320 of the ceiling assembly 6b. The load transfer section 9b effectively comprises a perimeter structure, which is defined by the various elongate portions 290-296 forming its structural frame, and which may extend around a perimeter of the modular building unit 2b. The ceiling section 302 forms an inner part of the ceiling assembly 6b,and is disposed inwardly of the load transfer section 9b, within its outer perimeter 320. The load transfer section 9b also defines an inner perimeter 322, and the ceiling section 302 is positioned within the inner perimeter. The ceiling section 302 extends below the load transfer section 9b within the inner perimeter 322.

[0103] The ceiling section 302 also comprises a perimeter structure 324 (Fig. 32), which defines an outer perimeter 326 of the ceiling section. The perimeter structure 324 is connected to the load transfer section 9b, in particular to lower structural members 278 of some of its generally elongate portions 290-296. The load transfer section 9b additionally comprises a plurality of bracing portions (also referred to as support members) extending between opposed pairs of the generally elongate portions, three such bracing portions 328, 330 and 332 shown.

[0104] The bracing portions 328-332 are of similar construction to the elongate portions 290-296, and will not be described here. The bracing portions 328-332, in a similar fashion to the support members 13 described above, can be aligned e.g. with internal walls of the modular building unit 2b, or other structural features, and can be arranged to transfer at least part of a load applied to the top of the modular unit to the walls. The ceiling assembly 6b includes other portions such as struts or joists 14b, which again may serve to support ceiling materials within the modular building unit 2b, and to support building services equipment 21 b housed within, supported on, or attached to the ceiling assembly 6b.

[0105] The perimeter structure 324 can be connected to one of more of these bracing portions 328-332, and in the illustrated embodiment is connected to the bracing portion 328. The ceiling section perimeter structure 324 takes the form of a structural frame, and may comprise structural (e.g. elongate) frame members 334 (Fig. 33) defining the frame, and having the resilient bars 310 defining the lower surface 306 coupled to them (although could alternatively themselves form the lower surface).

[0106] In the illustrated embodiment, the ceiling section 302 comprises a plurality of subsections which together form the ceiling section. These are shown in Figs. 31 and given the numerals 336, 338, 340 and 342. Each subsection 336-342 forms a portion of the ceiling section 302, and has its own perimeter structure as described above. The ceiling subsections 336-342 can each be independently or separately connected to the load transfer section 9b during construction of the ceiling assembly 6b. The load transfer section 9b defines separate zones or spaces, each configured to receive one of the ceiling subsections 336-342. These zones are defined by or between two or more of the elongate portions 290-296, and one or more of the bracing portions 328-332. Referring for example to the subsection 336, a zone 344 is defined by the side portions 290 and 292, the end portion 294 and the bracing portion 328.

[0107] One or more of the subsections 336-342 can include building services equipment 21 b, and the building services equipment of each such subsection may suitably be mounted on a respective board or panel shaped to fit within the services void 22b within the respective zone, e.g. zone 344. This is in a corresponding fashion to the panel 30 referred to above. Any of the options for providing the building services equipment 21b outlined for Figs. 1 to 26 can be employed.

[0108] Referring to Fig. 32A for example, there is shown building services equipment 21 b mounted on a panel 30b. The services shown include portions of main air inlet and exhaust pipes 261 b, 218b; air supply 220b and extract ducts 222b, 224b; hot and cold water pipes 252b, 254b; data cable 345; and electrical power cable 347. The panel 30b can be mounted in the ceiling section 302 carrying the various services 21 b; mounted in the ceiling section prior to connection of the services. This can be before or after connection of the ceiling section 302 to the load transfer section 9b. a top panel 34 is provided overlaying the building services equipment 21 . As in Fig. 9, the drawing is presented in an exploded view prior to the panel 30b and a top panel 34b (which provides an upper platform within the ceiling assembly) being brought together and optionally sealed together to form a building services cartridge or module 35b. Side portions 37 (which may take the form of walls that can be partial and / or comprise apertures through which services can pass) are shown and extend between the top and bottom panels 34b, 30b. Again, the building services cartridge or module 35b may be permanently or releasably coupled to the structural portions of the ceiling assembly 6b either during off site module manufacture or at the time of stacking up the modular building assembly.

[0109] Where there are a plurality of ceiling subsections 336-342, the subsections may be configured to cooperate for the provision / routing of services within the void 22b (each subsection defining part of the void). As shown in Fig. 32A, each subsection may contain / support a part or parts of the service equipment 21 b which requires to be connected to a further part or parts contained / supported by another subsection. For example, the ventilation supply and extract ducts 216b and 218b pass along a length of the ceiling assembly 6b through the subsections 338 and 336. The ducts may be connected up following positioning of the building services equipment within the subsections (either in cartridge / module form, or separately as discussed above). This may involve the use of connectors at junctions or intersections between portions of the services provided in each subsection. See for example connector 343 which serves for connecting portions of the extract duct 216b provided in the subsections 340 and 338. It will be understood that each ceiling subsection 336-342 may comprise or accommodate respective panels 30b, 34b.

[0110] In a variation which is illustrated in the further enlarged view of the ceiling assembly 6b shown in Fig. 32B, at least one aperture 20b' can be provided without the transverse bracing member 284, so that the aperture is defined between (or bordered by) the upper structural member 280, an adjacent pair of the struts 282, and the lower structural member 278. This may provide a larger aperture, having the maximum height He along its entire width, between the adjacent struts 222. This can be of use e.g. where the aperture is required to accommodate larger service equipment such as the ventilation supply pipes 220b, 222b.

[0111] Fig. 33 additionally shows part of the first building section 201 connected to the modular building assembly 1 b, specifically one of a plurality of joists 346 which extend between at least one side of the modular building unit / assembly and a wall of the first building section to support an upper floor 348 of the first building section. Acoustic and / or thermal insulation is provided, including in the walls 7b (and load transfer section 9b) and 107b, and in the void 22b as indicated at 353 and 355 in Fig. 33. It will be understood that the insulation 353, where provided, will be fitted around services,and may be dispensed with depending on factors including the number and dimensions of services passing through the aperture(s) 20b. The maximum height H of the aperture 20b is of course less than the height H2 of the space 22b. The aperture 20b may be partially occluded by the insulation 355, although again the insulation 355 may be dispensed with, or a height of the insulation in the region of the aperture (through which services pass) may be reduced.

[0112] The floor assembly 105b may be of a hot-formed metallic material as discussed above, and may have a height H5 in a range of about 50mm to about 75mm, with around 50mm being a preferred option. A total height of the ceiling assembly 6b of the lower modular building unit 2b and the floor assembly 105b of the upper modular building unit 102b may be between approximately 300 mm and approximately 500 mm, optionally between approximately 300 mm and approximately 400 mm, and optionally approximately 350 mm. The total height may be a sum of the heights H2 and H5. A total height of the load transfer section 9b and the floor assembly 105b, may be between approximately 250mm to 370mm. The total height may be a sum of the heights Hi and H5.

[0113] Construction options for the ceiling assembly 6b, in particular its structural frame (comprising the load transfer section 9a and the ceiling section 302) can comprise any of the options discussed elsewhere in this document. Construction options can therefore include cold- formed (e.g. folded) metallic members, such as of a light gauge steel material (forming a light gauge steel frame or LGSF).

[0114] Referring now to Fig. 34, a second variant based on the structure shown and described in Figs. 31 to 33 will now be described. The second variant comprises a modification to the floor assembly of the upper modular building unit in a stack of two units as shown in Fig. 1 . Fig. 34 is an isometric view from below of a floor assembly 105c. Fig. 35 is also referred to, which is a cross- sectional front view of a modular building assembly 1 c comprising first and second modular building units 2c and 102c, sectioned about line B-B in Fig. 34. The second modular building unit 102c comprises the floor assembly 105c. Like components of the modular building assembly 1c (including the floor assembly 105c) with the modular building assemblies described above share the same reference numerals with the suffix ‘c’.

[0115] The (upper) modular building unit 102c comprises the floor assembly 105c, a ceiling assembly similar to the ceiling assembly 106, and walls 107 connecting the floor and ceiling assemblies. The ceiling assembly 106 is not shown in Figs. 34 and 35, however that and the walls 107 are generally as previously described. A ceiling assembly 6c for the underlying lower modular building unit 2c may differ from that previously described by having no mounting portions 11 . The ceiling assembly 6c generally may have a simpler form, comprising for example a frame structure of the type described in relation to the ceiling assembly 6, but without the raised second portions 11 .

[0116] The floor assembly 105c of the upper modular building unit 102c is generally of a latticetype, as described above in relation to the ceiling assembly 6b. A load transfer portion 9c of the floor assembly 105c is therefore of similar construction to the load transfer portion 9b, and configured to transfer load from walls 107c of the upper unit 102c to the underlying lower modular building unit 2c (specifically its ceiling assembly 6c).

[0117] The load transfer section 9c therefore takes the form of a structural frame comprising left and right elongate portions 290c and 292c, and front and back elongate portions 294c and 296c. The elongate portions 290c-296c are each generally aligned with a respective wall 107c, so that they are in substantially the same plane. Each wall 107c is seated on a respective elongate portion 290c-296c. Each of the generally elongate portions 290c-296c comprises respective lower and upper structural members 278c and 280c, and connecting members 282c, 284c.

[0118] The load transfer section 9c provides a plurality of apertures 20c through which building services equipment (indicated generally by numeral 21 c) located within a services void 22c between the stacked modular building units 2c, 102c can pass into a first building section of a building comprising the modular building assembly 1 c (e.g. first building section 201 of building 200), as well as into the lower and upper modular building units themselves (and / or items / equipment contained within them).

[0119] A lower surface 286c defined by the load transfer section 9c is seated on an upper surface 350 of the lower unit ceiling assembly 6c, as best shown in Fig. 35. The load transfer section 9c also comprises an upper surface 300c, which supports the walls 107c of the upper modular building unit 102c. A floor structure 352 comprises a series of floor panels (one shown and given the numeral 354). The floor panels 354 are positioned on the upper structural members 280c of the floor assembly 105c, and joists connected to the upper members 280c (one shown and given the numeral 356). The panels 354 define a floor for the upper modular building unit 102c. In this embodiment, the structure of the ceiling assembly 105c which supports the floor panels 354 forming the upper module floor structure 352 is essentially flush with the upper support surface 300c for the walls 107c.

[0120] A ceiling 304c is provided in the lower modular building unit 2c, and is defined by ceiling panels (one shown and given numeral 308c) connected to a loop member 12c of the lower unit ceiling assembly 6c, and joists 358 connected to the loop member. Joists 346 (one shown) of the first building section 201 extend between at least one side of the modular building unit / assembly and a wall of the first building section to support an upper floor 348 of the first building section. The floor assembly 105c is in many ways an inverted version of the ceiling assembly 6b (save that it does not comprise its ceiling section 302), and so reference is made to the discussion above for a full understanding of its features. This includes of the building services equipment 21 c and its method of mounting the services within the services void 22c.

[0121] Turning now to Figs.36 to 40, a method of manufacturing a modular building unit 3000 according to an embodiment of the invention will now be described. The complete modular building unit 3000 is shown in Fig. 40 and portions of the modular building unit 3000 during various manufacturing steps are shown in Figs. 36 to 39. In particular, modular building unit 3000 is a ground floor modular building unit upon which a first floor modular building unit is to be stacked.

[0122] As noted in the background section conventional approaches to constructing a modular building unit generally involve substantially constructing the frame of the modular building unit including a floor assembly, walls, and ceiling assembly. Where building services are to be installedwithin the structure of the ceiling assembly, generally this requires working at height, with the attendant inconvenience and risk that this involves. According to the present invention, instead the ceiling assembly may be separately kitted out with building services prior to being lifted and installed upon the walls of the modular building unit. For instance, a frame of a ceiling assembly may be separately constructed and kitted out at ground level. The frame may comprise a load transfer section for instance as previously described in connection with Fig .1 to 8. Building services equipment may be installed coupled to, within or connected to the load transfer section.

[0123] The method of manufacturing a modular building unit begins with constructing a partial modular building unit comprising a floor assembly 3001 and walls 3002 extending upwardly from the floor assembly as illustrated in Fig. 36. The walls 3002 in the example of Fig. 36 including both external walls 3003 and internal walls 3004 and included associated features such as doors 3005. The partial assembly of floor assembly 3001 and walls 3002 may be generally the same as for ground floor modular building unit 2 described above in connection with Fig. 1 , which includes a floor assembly 5 and walls 7, except of course for the absence of a ceiling assembly 6. As such, the details of the construction of the floor 3001 and walls 3002 will not be described again. In other examples the modular building unit 3000 may include a floor assembly and walls according to any other framing system previously described.

[0124] Separately, a partial ceiling assembly 3010 as illustrated in Fig. 37 is constructed, wherein the ceiling assembly includes a load transfer section 3011 configured to transfer load to the walls 3002. Ceiling assembly 3010 may be generally the same as ceiling assembly 6 of Fig. 1 , as also illustrated and described in connection with Figs. 3 to 8. In particular, the load transfer section 3011 comprises a loop member 3012 corresponding to loop member 10 of Fig. 4 extending around the periphery of the ceiling assembly 3010 in the form of a perimeter frame and at least one support member 3013 corresponding to support member 13 of fig. 4 within the loop member 3012.

[0125] The ceiling assembly 3010 further includes mounting members 3014 which are identical to mounting members 11 illustrated for instance at Figs. 1 to 6 and so will not be described again.Furthermore, the ceiling assembly 3010 includes struts or joists 3015 extending between portions of the load transfer section 3011 . These may be generally the same as struts or joists 14 of Fig. 7. They serve to support building services equipment within the ceiling assembly 3010, as described below in connection with Figs. 29 and 30. The joists 3015 may be considered to form a support section connected to the load transfer section 3011 within at least a portion of the partial ceiling assembly 3010, the support section being configured to support at least part of the building services equipment. In some cases, the joists may be supplemented with or replaced by panelling to form the support section. In some cases, the support section may be integrally formed within the load transfer section. Advantageously, according to some embodiments, the support section provides a generally flat surface to install building services. The support section may define a generally planar surface within a portion of the ceiling assembly. In some cases, the support section is recessed relative to an upper surface of the load transfer section, or at least recesses relative to the mounting members 3014.

[0126] It will be appreciated that the floor assembly 3001 and walls 3002 of Fig. 27 and the partial ceiling assembly 3010 of Fig. 37 may be constructed in any order or simultaneously. They may suitably be constructed proximal to one another, for instance side by side. However, they may be separately constructed at remote locations. Suitably, the ceiling assembly 3010 may be built up at floor level next to the floor assembly 3001 and walls 3002 prior to being lifted on top.

[0127] Next, as illustrated in Fig. 29, building services equipment may be provided. In Fig. 38 this is in the form of a separately constructed services module 3020 as previously described in connection with Figs. 9 to 11 for services module 35. The constructed services module 3020 includes housing 3021 and building services equipment 3022 (not all of which is separately identified), such as one or more of an electricity supply cable, a data cable, a cold water pipe, a hot water pipe, a drainage pipe, a gas pipe, an air ventilation duct, or an energy storage system. The building services equipment is configured to form part of a building services system within a building defined in part by the modular building unit.

[0128] The housing 3021 takes the form of at least a bottom sheet 3024 and a top sheet 3023, and optionally one or more side walls 3025. The building services equipment 3022 may be built upon the bottom sheet 3023 and then sandwiched within the remaining portions of the housing 3021 in a location spaced apart from the partial ceiling assembly 2010 of Fig. 37.

[0129] The housing 3021 includes a plurality of cutouts 3026 that are spaced apart in a matched pattern to the arrangement of mounting members 3014 shown in Fig. 28. The cutouts may be the full depth of the housing 3021 , or some cutouts may not include the top sheet 3023 such that when the building services module 3020 is lifted onto the partial ceiling assembly 3010 of Fig. 37 as shown in Fig. 39 the top surface extends over the top of a mounting member 3014. In combination, the building services module 3020 and the partial ceiling assembly 3010 form a complete ceiling assembly 3030. The building services module 3020 rests upon joists 3015 such that it is supported within the ceiling assembly 3030. It may be fixed in position. In other examples of the invention there may be two or more services modules 3020 sized and shaped to fit into different portions of a ceiling assembly 3010, for instance in the situation in which the construction of the ceiling assembly 3010 includes intermediate support structure that prevent the use of a single services module 3020 extending across a large portion of the ceiling assembly 3010.

[0130] In other examples of the invention, it may be that in place of using a building services module 3020, building services equipment 3022 is fitted directly into the partial ceiling assembly 3010 of Fig. 37, supported by the joists 3015. The building services equipment 3022 may subsequently be covered over with a top sheet for protection and to support the weight of workers during subsequent manufacturing processes and at the final location for assembly of a hybrid building.

[0131] Finally, the complete ceiling assembly 3030 may be lifted onto the walls 3002 and secured in position to form the complete modular building unit 3000 as illustrated in Fig. 40. Lifting may be achieved using the mounting members 3014 as already described in connection with Figs. 13 and 14. By “complete”, it is meant that substantially the whole of the structure of the modular buildingunit 3000 is complete to define its outer shape and internal spaces. Furthermore, the building services equipment within the ceiling assembly is at least partially formed and ready to be connected to building systems within the modular building unit 3000 (or adjacent modular building units or site-built building sections during construction of a hybrid or fully modular building. However, it will be understood that further processing of the modular building unit 3000 may be required, including fit out of the internal volume. The substantially complete modular building unit 3000 may then be delivered to a final location for a building and placed in position to form part of the structure of the building (including where it is stacked with further modular building units to form a modular building assembly, as previously described).

[0132] The method of Figs. 36 to 40 results in a modular building unit 3000 which is substantially as previously described, for instance in connection with Fig. 1 and the following figures. The key difference lies in that the building services equipment provided within a modified ceiling assembly may be at least partially assembled prior to lifting onto the module walls. As such, the modified ceiling assembly including services may be referred to as a ceiling cassette or a ceiling services cassette.

[0133] Turning now to Figs. 41 to 43, a method of manufacturing a modular building unit 4000 according to another embodiment of the invention will now be described. Components which are similar to those discussed above in relation to Figs. 36 to 40 share some of the same reference numerals, incremented by 1000. Other components, which are similar to some of those discussed above in relation to Figs. 31 to 33, share the same reference numerals, incremented by 4000.

[0134] The modular building unit 4000 is shown in the exploded isometric view of Fig. 41 , without building services equipment located in a ceiling assembly of the unit (and so Fig. 41 shows a partial ceiling assembly). Fig. 42 is a partially exploded view of the ceiling assembly, whilst Fig. 43 shows a ceiling cassette containing building services equipment. As with the embodiment of Figs. 36 to 40, certain sections of the modular building unit 4000 have been removed for illustration purposes.

[0135] In the illustrated embodiment, the modular building unit 4000 is a ground floor modular building unit upon which a first floor modular building unit is to be stacked. As with the embodiment of Figs. 36 to 40, the ceiling assembly may be separately kitted out with building services prior to being lifted and installed upon the walls of the modular building unit. For instance, a structural frame of a ceiling assembly may be separately constructed and kitted out at ground level. The frame may comprise a load transfer section for instance as previously described in connection with Figs. 31 to 33. Building services equipment may be installed coupled to, within or connected to the load transfer section.

[0136] The method of manufacturing a modular building unit begins with constructing a partial modular building unit comprising a floor assembly 4001 and walls 4002 extending upwardly from the floor assembly, as illustrated in Fig. 41 . The walls 4002 in the example of Fig. 41 include both external walls 4003 and internal walls 4004, and included associated features such as doors 4005. The partial assembly of floor assembly 4001 and walls 4002 (shown disconnected in the exploded view of Fig. 41) may be generally the same as for ground floor modular building unit 2b describedabove in connection with Figs. 31 to 33, which includes a floor assembly 5b and walls 7b, except of course for the absence of a ceiling assembly 6b. As such, the details of the construction of the floor 4001 and walls 4002 will not be described again. In other examples the modular building unit 4000 may include a floor assembly and walls according to any other framing system previously described.

[0137] Separately, a partial ceiling assembly 4010 as illustrated in Fig. 41 is constructed, wherein the ceiling assembly includes a load transfer section 4011 configured to transfer load to the walls 4002. Ceiling assembly 4010 may be generally the same as ceiling assembly 6b of Fig. 31 . In particular, the load transfer section 4011 comprises a lattice type structural frame formed from generally elongate portions 4290-4296 comprising respective lower and upper structural members 4278 and 4280, and connecting members 4282, 4284. The upper structural members 4280 of the elongate portions 4290-4296 together form an upper loop member 4012 corresponding to loop member 12b, whilst the lower structural members 4278 together form a lower loop member 4012' corresponding to loop member 12b'. The loop members 4012 and 4012' both extend around the periphery of the ceiling assembly 4010, and generally form a perimeter frame. Support members 4328-4332 corresponding to support members 328-332 are also provided within the structure forming the loop members 4012, 4012'.

[0138] The ceiling assembly 4010 also includes a ceiling section 4302 connected to the load transfer section 4011 , in a similar fashion to the ceiling section 302 and the load transfer section 9b described above. The ceiling section 4302 comprises a perimeter structure 4324, and struts or joists 4014b extending between portions of the perimeter structure 4324 (and so between portions of the load transfer section 4011). The struts or joists 4014b may be generally the same as struts or joists 14b of Fig. 31 , and serve to support building services equipment within the ceiling assembly 4010, as will be described below. The ceiling section 4302 and / or the joists 4014b may be considered to form a support section connected to the load transfer section 4011 within at least a portion of the partial ceiling assembly 4010, the support section being configured to support at least part of the building services equipment. In some cases, the joists may be supplemented with or replaced by panelling, e.g. as shown at 4030b in Fig. 42, to form the support section. In some cases, the support section may be integrally formed within the load transfer section.

[0139] The floor assembly 4001 and walls 4002, and the partial ceiling assembly 4010 of Fig. 41 , may be constructed in any order or simultaneously, as described above in relation to Figs. 36 to 40. Next, as illustrated in the partially cutaway view of Fig. 42, building services equipment may be provided. In Fig. 43 this is in the form of a separately constructed services module 4035b as previously described in connection with Figs. 31 to 33 for services module 35b. The constructed services module 4035b includes a housing 4021 and building services equipment 4021 b of the type described above. Parts of ventilation conduits can be seen in the drawing and are labelled 4216b, 4218b and 4222b, as well as parts of cold and hot water conduits 4252b and 4254b.

[0140] The housing 4021 takes the form of at least a bottom panel or sheet 4030b and a top panel or sheet 4034b, and optionally one or more side walls 4037b. The top sheet 4034b has beenpartly cutaway to show the building services equipment 4021 b, which may be built upon the bottom sheet 4030b and then sandwiched within the remaining portions of the housing 4021 in a location spaced apart from the partial ceiling assembly 4010 of Fig. 41 .

[0141] Fig. 42 shows the services module 4035b located in the ceiling assembly 4010, with the top sheet 4034b removed for illustration. The services module 4035b is positioned within the ceiling section 4302, in a zone 4060 defined by the load transfer section 4011 , similar to the zones described above in relation to Fig. 31 . Other zones 4062-4066 receive further services modules which will not be described here, but which are similar to the services module 4035b. Respective top sheets 4034b of each such services module are shown removed in the drawing, for illustration purposes.

[0142] In combination, the building services module 4035b and the partial ceiling assembly 4010 form a complete ceiling assembly 4030, which is effectively shown in the exploded view of Fig. 42. The building services module 4035b rests upon joists 4014b within the ceiling section 4302, such that it is supported within the ceiling assembly 4030, and may be fixed in position. Finally, the complete ceiling assembly 4030 may be lifted onto the walls 4002 and secured in position to form the (substantially) complete modular building unit 4000 (incorporating the building services equipment 4021 b).

[0143] The method of Figs. 41 to 43 results in a modular building unit 4000 which is substantially as previously described, for instance in connection with Figs. 31 to 33. The key difference lies in that the building services equipment provided within a modified ceiling assembly may be at least partially assembled prior to lifting onto the module walls. As such, the modified ceiling assembly including services may be referred to as a ceiling cassette or a ceiling services cassette.

[0144] Unless explicitly implied by context or stated in the document, the features of any 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 in an order other than that specifically set out in the relevant text / drawings if circumstances permit.

[0145] Features disclosed in this document (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the 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.

[0146] Throughout this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to,” and they are not intended to (and do not) exclude other components, integers, or steps. Throughout this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise. Throughout this specification, the term “about” is used to provide flexibility to a range endpoint by providing that a given value may be “a little above” or “a little below” theendpoint. The degree of flexibility of this term can be dictated by the particular variable and can be determined based on experience and the associated description herein.

[0147] Features, integers, or characteristics described in conjunction with a particular aspect or example of the invention are to be understood to be applicable to any other aspect or example described herein unless incompatible therewith. All of the features disclosed in this specification, and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. The invention is not restricted to the details of any foregoing examples. The invention extends to any novel feature or combination of features disclosed in this specification. It will also be appreciated that, throughout this specification, language in the general form of “X for Y” (where Y is some action, activity or step and X is some means for carrying out that action, activity or step) encompasses means X adapted or arranged specifically, but not exclusively, to do Y.

[0148] Each feature disclosed in this specification may be replaced by alternative features serving the same, equivalent, or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0149] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

Claims

CLAIMS:

1. A method of manufacturing a modular building unit, the method comprising: constructing a floor assembly and walls extending upwardly from the floor assembly; separately constructing a ceiling assembly, wherein the ceiling assembly includes a load transfer section configured to transfer load to the walls; coupling building services equipment to the ceiling assembly; and lifting the ceiling assembly onto the walls and securing the walls to the load transfer section such that the walls connect the floor and ceiling frame assemblies.

2. A method according to claim 1 , wherein the building services equipment is configured to form part of a building services system within a building defined in part by the modular building unit.

3. A method according to claim 2, wherein the building services equipment comprises one or more of: an electricity supply cable; a data cable; a cold water pipe; a hot water pipe; a drainage pipe; a gas pipe; an air ventilation duct; or an energy storage system.

4. A method according to any one of the preceding claims, wherein constructing the ceiling assembly further comprises: forming a support section connected to the load transfer section within at least a portion of the ceiling assembly, the support section being configured to support at least part of the building services equipment.

5. A method according to claim 4, wherein the support section defines a generally planar surface within a portion of the ceiling assembly.

6. A method according to claim 4 or claim 5, wherein the support section is recessed relative to an upper surface of the load transfer section.

7. A method according to any one of claims 4 to 6, wherein the support section comprises joists or panelling spanning or interconnecting at least part of the load transfer section, or wherein the support section and the load transfer are integrally formed.

8. A method according to any one of the preceding claims, further comprising forming a load bearing structure over at least part of the building services equipment.

9. A method according to claim 8, wherein at least part of the building services equipment is sandwiched between and at least partially protected by the support section and the load bearing structure.

10. A method according to any one of the preceding claims, further comprising: constructing a services module comprising building services equipment and a housing at least partially containing the building services equipment; and coupling the services module to the ceiling assembly.

11. A method according to claim 10 when dependent on claim 4, wherein the services module is located on or coupled to the support section.

12. A method according to any one of the preceding claims, wherein the load transfer section including at least one first portion and at least two second portions extending above a top surface of the first portion; wherein the second portions are configured to support a floor assembly of a further modular building unit stacked on top of the modular building unit; wherein each first portion of the load transfer section is configured to form an aperture between the stacked modular building units; and wherein the building services equipment are configured to connect through the aperture between the stacked modular building units.

13. A method according to any one of claims 1 to 11 , comprising providing the load transfer section as a lattice structure comprising a lower structural member defining a lower surface of the load transfer section, an upper structural member defining an upper surface of the load transfer section, and at least one connecting member extending between and connecting the lower structural member to the upper structural member, and arranging the at least one connecting member so that it transfers loads from the upper structural member to the lower structural member and so to the walls.

14. A method according to claim 13, comprising providing the load transfer section with a plurality of generally elongate portions which together define the load transfer section, a generally elongate portion being provided for each wall, and arranging each generally elongate portion so that it comprises respective lower and upper structural members and at least one connecting member extending between and connecting the lower and upper structural members.

15. A method according to either of claims 13 or 14, comprising providing the ceiling assembly with a ceiling section forming a support section configured to support at least part of the building services equipment, and arranging the ceiling section so that it is disposed inwardly of the load transfer section and connected to it.

16. A method according to claim 15, comprising arranging the ceiling section so that a lower surface of the ceiling section is disposed at a position that is lower than an upper surface of the walls.

17. A method according to either of claims 15 or 16, comprising arranging the ceiling assembly so that it defines a services void comprising an upper boundary defined by a plane containing an upper surface of the load transfer section, and a lower boundary defined by a plane containing the lower surface of the ceiling section, and positioning the building services equipment within the services void.

18. A method of constructing a building defined in part by a modular building unit manufactured according to the method of any one of claims 1 to 17, the method comprising delivering the manufactured modular building unit to a final location for the building in a substantially assembled form.

19. A services module for a modular building assembly, the services module comprising: building services equipment; and a housing at least partially containing the building services equipment; wherein the services module is configured to be received in or connected to a floor or ceiling assembly of a modular building unit forming part of the modular building assembly such that when two modular building units are stacked to form the modular building assembly, the services module is located between the two stacked modular building units.

20. A services module according to claim 19, wherein the building services equipment is configured to form part of a building services system within a building defined in part by the modular building unit.21 . A services module according to claim 20, wherein the building services equipment comprises one or more of: an electricity supply cable; a data cable;a cold water pipe; a hot water pipe; a drainage pipe; a gas pipe; an air ventilation duct; or an energy storage system.

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