Modular building assembly
The modular building assembly addresses limitations in hybrid constructions by using a ceiling structure with varying height sections to enhance design freedom and access in upper storeys, overcoming footprint overlap challenges.
Patent Information
- Application Number
- PCT/EP2025/054264
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-02-20
- Filing Date
- 2025-02-18
- Publication Date
- 2025-08-28
AI Technical Summary
Existing modular building constructions face challenges when forming assemblies with modular units having different footprints or partial overlap, limiting design freedom and access in upper storeys, particularly in hybrid buildings.
A modular building assembly design featuring a first unit with a ceiling structure having a first section to support a further unit and a second section at a greater height, allowing the further unit to overlie only a portion of the first unit's footprint, providing greater design freedom and access to upper storeys.
Enhances design flexibility and access in upper storeys by allowing the further unit to overlie only a portion of the first unit's footprint, reducing restrictions from structural frames and enabling more versatile building configurations.
Smart Images

Figure EP2025054264_28082025_PF_FP_ABST
Abstract
Description
[0001] MODULAR BUILDING ASSEMBLY
[0002] The present invention relates to a modular building assembly configured to form at least part of a building, the modular building assembly comprising a first modular building unit, and at least one further modular building unit configured to be positioned on top of the first modular building unit. The present invention also relates to a building system comprising the modular building assembly, a building comprising the modular building assembly, a method of constructing a modular building assembly, and a method of constructing a building using the modular building assembly.
[0003] 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.
[0004] Construction of the building can involve forming a modular building assembly comprising a first (or lower) modular building unit, and a further (or upper) modular building unit stacked on the first unit. Typically, the first modular building unit has a footprint, and the further modular building unit has a footprint which corresponds to that of the first unit. The second modular building unit is positioned on top of the first modular building unit so that it overlies substantially the entire footprint of the first unit. Whist the modular building assembly may form substantially the entire building, it is common to connect one or more further modular building unit to the assembly to form the completed building. Optionally, the modular building assembly forms a first such assembly of the building, and one or more further modular building assembly is provided which, in conjunction with the first modular building assembly, forms the completed building.
[0005] 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 unit constructed in a dedicated facility, away from the final location. 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. The hybnd buildings can comprise two or more storeys, and so can include one or more modular building assembly of the type described above, having stacked first and second modular building units.
[0006] The applicant has recognised that it can be desirable, in certain building constructions, to form a modular building assembly comprising first and second modular building units having different footprints, and / or by arranging the second modular building unit so that it only overlies a part of the footprint of the first modular building unit. This can however present certain challenges when it comes to completing a building comprising the modular building assembly. According to a first aspect, there is provided a modular building assembly configured to form at least part of a building, the modular building assembly comprising: a first modular building unit comprising an internal volume, the first modular building unit having a base and a footprint; and at least one further modular building unit comprising an internal volume, said further modular building unit configured to be positioned on top of the first modular building unit overlying a first portion of its footprint; in which the first modular building unit comprises a ceiling structure, the ceiling structure comprising: a first section defining at least one first surface configured to support said further modular building unit, said first surface disposed at a first height relative to the base; and a second section positioned laterally relative to the first section overlying a further portion of the footprint, the second section defining at least one second surface disposed at a second height relative to the base which is greater than the first height, said second surface configured to support or define at least part of a floor for an upper storey of the building.
[0007] In the modular building assembly of the first aspect, the further modular building unit overlies only the first portion of the first modular building unit footprint, whilst the second section of the ceiling structure overlies the further portion. This may provide greater design freedom for an upper storey of a building comprising the modular building assembly, the upper storey including, and / or being formed at least partly by, the further modular building unit and the second section of the ceiling structure. For example, living space provided in the upper storey of a building comprising the modular building assembly, and / or access into such living space, may be less restricted by the shape and / or size of a support structure (e.g. a structural frame) of the further modular building unit. Previously, the living space / access had to fit around the structural frame, particularly upright support posts of the frame. The greater design freedom may be provided particularly in a hybrid building comprising the modular building assembly, which will be discussed in more detail below.
[0008] The reference to a footprint of the first modular building unit should generally be understood to mean the area (on, in or above the ground) which the unit accommodates, measured from outer surfaces or boundaries of the unit.
[0009] Reference is made to the further modular building unit and the second section of the ceiling structure overlying portions of the first modular building unit footprint. It will be understood that they may overlie the respective portions of the footprint in that they may substantially (or completely) cover said portions of the footprint, when viewed from above or in plan. The footprint portions may each have a respective perimeter, and the further modular building unit and said second section may extend at least up to the respective perimeter, in order to overlie said footprint portions.
[0010] Reference is made to said further modular building unit being positioned on top of / on the first modular building unit. This may effectively require that said further modular building unit be positioned above, and supported by or on, the first modular building unit. Typically it will be in direct contact with the first modular building unit, and so positioned directly on the first unit. However, it may be in indirect contact with the first modular building unit, and so positioned indirectly on the first unit (i.e. not in direct contact, and so for example with an intermediate component between them).
[0011] The further modular building unit and said second section may be configured so that they together overlie at least a substantial part, and / or a majority, of the footprint of the first modular building unit. The further modular building unit and said second section may be configured so that they together overlie substantially the entire footprint of the first modular building unit.
[0012] The first modular building unit may provide or define at least part of an access route or pathway, which may provide for access from the first modular building unit to at least one of: a) the floor; and b) the internal volume of the further modular building unit.
[0013] The first modular building unit may comprise at least a main part of a staircase, which may form said part of the access route. The second section of the ceiling structure may comprise an aperture, which may communicate with the main part of the staircase in the first modular building unit. The floor may comprise an aperture which communicates with: the aperture in the ceiling structure; and / or with the main part of the staircase in the first modular building unit. The further modular building unit may comprise an aperture, which may communicate with the main part of the staircase in the first modular building unit when the further modular building unit is positioned on top of the first modular building unit.
[0014] The second section of the ceiling structure may be configured to support or define at least part of a landing, and the access route may open on to, and / or may communicate with, the landing. Where the second section comprises an aperture that communicates with the main part of the staircase in the first modular building unit, the aperture may open adjacent to the landing.
[0015] The further modular building unit may be configured to support or define at least part of a landing, and the access route may open on to, and / or may communicate with, the landing. Where the further modular building unit comprises an aperture that communicates with the main part of the staircase in the first modular building unit, the aperture may open adjacent to the landing.
[0016] The floor may be configured to provide access into the further modular building unit. The floor may: communicate with the internal volume of the further modular building unit; and / or provide access (optionally direct access) into the internal volume of the further modular building unit.
[0017] The second section of the first modular building unit may be a raised section, and may be raised relative to the first section. The first modular building unit may have a stepped profile, viewed from the side, the stepped profile being defined at least in part by the first and second sections.
[0018] The second section of the first modular building unit may extend laterally from the first section. The floor may be configured to extend laterally from the further modular building unit. It will be understood that this is during normal use of the modular building assembly, and so with the further modular building unit positioned on top of the first modular building unit and supported by said first surface. The second section, and / or the floor, may extend in a generally horizontal direction or plane, and may extend in a direction which is generally away from the first section / further modular building unit.
[0019] The second section of the ceiling structure may be configured to be positioned adjacent to the further modular building unit, in particularly laterally adjacent, considered for example in a generally horizontal plane or direction. The second section of the ceiling structure may be configured to be disposed immediately adjacent to the further modular building unit, and / or in contact with said further unit. A perimeter portion of the second section of the ceiling structure may be configured to be positioned adjacent, optionally abutting and / or in contact with, a perimeter portion of said further modular building unit.
[0020] The floor may be for an internal volume or space defined by a further part of a building comprising the modular building assembly, such as a first building section of a hybrid building. The floor may be configured to facilitate circulation or transition within the building during use, e.g. facilitating communication between different parts of the building.
[0021] Where there are a plurality of further modular building units, the second section of the ceiling structure may be configured to be positioned adjacent to one of said further units, but could be positioned adjacent to more than one of said further unit depending on the layout / configuration of said further units.
[0022] The further modular building unit may be a second modular building unit. The further portion of the footprint of the first modular building unit which is overlaid by the second section of the ceiling structure may be a second portion of the footprint. The modular building assembly may comprise a third modular building unit, which may comprise an internal volume. The third modular building unit may be configured to be positioned on top of the first modular building unit overlying a third portion of its footprint. The second modular building unit, third modular building unit and said second section may be configured so that they together overlie at least a substantial part, and / or a majority, of the footprint of the first modular building unit. The second modular building unit, third modular building unit said second section may be configured so that they together overlie substantially the entire footprint of the first modular building unit. Said first surface of the first section may be configured to support the third modular building unit.
[0023] The internal volume of the first modular building unit may be configured to form at least part of at least one room of the building. The at least one room may provide living space. The first modular building unit, in particular said part of the at least one room, may comprise a wet facility. The at least one room may be selected from the group comprising: a hallway; a washroom or W / C; and a utility or technical room / space.
[0024] The internal volume of the at least one further modular building unit may be configured to form at least part of at least one room of the building. The at least one room may provide living space. The further modular building unit, in particular said part of the at least one room, may comprise a wet facility. The wet facility may be selected from the group comprising: a washroom or W / C; a bathroom; and an ensuite. Where there are a plurality of further modular building units (e.g. second and third), at least one of said modular building units, and optionally both, may contain a wet facility, or respective wet facilities. The further modular building unit may define part of said room, e.g. in conjunction with a further part of a building comprising the modular building assembly, for example a first building section of a hybrid building, which will be described in more detail below. The further modular building unit section may however define substantially the entire room.
[0025] The first modular building unit may comprise a perimeter, which may comprise a plurality of perimeter portions. Each perimeter portion may be disposed transverse to at least one other perimeter portion. The at least one further modular building unit may be configured to overlap at least one perimeter portion of the first modular building unit. The at least one further modular building unit may be configured to extend beyond said perimeter portion in order to overlap it.
[0026] The at least one further modular building unit may comprise a perimeter, which may comprise a plurality of perimeter portions. Each perimeter portion may be disposed transverse to at least one other perimeter portion. The at least one further modular building unit may be configured to be positioned on top of the first modular building unit so that at least one perimeter portion of the further modular building unit is disposed laterally spaced from and / or beyond a perimeter portion of the first modular building unit, which may be a corresponding perimeter portion. Where the further modular building unit overlaps at least one perimeter portion of the first modular building unit, said perimeter portion of the further modular building unit may be disposed outwardly or outboard of, and / or not within, the footprint. The further modular building unit may be adapted to overhang the first modular building unit, and may be adapted to overhang at least one perimeter portion of the first modular building unit, which perimeter portion may be at or may define a side of the first modular building unit. An overhanging portion of the further modular building unit may be configured to form at least part of a porch or awning for a building comprising the modular building assembly. A space may be provided beneath the overhanging portion, which space may define a location for the porch. An overhanging portion of the further modular building unit may be configured to form an interior space or volume within the building. Said space may communicate with a further part of the building, in particular with a part of a room defined by the first modular building unit. Said space and said part of the room may together form a completed room in the building.
[0027] The at least one further modular building unit may be configured to be positioned on top of the first modular building unit so that at least one perimeter portion of said further unit is disposed inwardly or inboard of at least one perimeter portion of the first modular building unit. The at least one perimeter portion of said further modular building unit may be disposed inwardly or inboard of, and / or within, the footprint.
[0028] The first modular building unit may be elongate, and / or may comprise a main axis extending along a main or primary length direction. The at least one further modular building unit may be elongate, and / or may comprise a main axis extending along a main or primary length direction. The at least one further modular building unit may be configured to be positioned on top of the first modular building unit so that the main axis of the at least one further modular building unit is disposed substantially parallel to the main axis of the first modular building unit. The at least one further modular building unit may be configured to be positioned on top of the first modular building unit so that the main axis of the at least one further modular building unit is disposed transverse to the main axis of the first modular building unit, optionally substantially perpendicular. This may apply for example where the at least one further modular building unit overlaps at least one perimeter portion of the first modular building unit.
[0029] The footprint of the first modular building unit may be a first footprint. The at least one further modular building unit may comprise a footprint, which may be a second footprint. The second footprint may be different to the first footprint, e.g. the second footprint may have a different shape to the first footprint, and / or at least one dimension of the second footprint (such as a length or width) may differ from a corresponding dimension of the first footprint. The second footprint may be substantially the same as the first footprint (e.g. the same shape and / or dimensions). Said further modular building unit may be configured to be positioned on top of the first modular building unit so that the second footprint partially overlaps the first footprint, and / or so that the first and second footprints are not aligned. At least part of the second footprint may overhang a perimeter portion of the first modular building unit.
[0030] The base of the first modular building unit may be defined by a floor structure of the unit. The base may comprise, or may define, a lowermost surface of the unit, which may be configured to engage or abut e.g. the ground. There may be a plurality of first surfaces, which may be configured to together support said further modular building unit. Where there are a plurality of first surfaces, the surfaces may be at a common height above the base. There may be a plurality of second surfaces, which may be configured to together support or define the floor. Where there are a plurality of second surfaces, the surfaces may be at a common height above the base.
[0031] Where the second section of the ceiling structure is configured to support a floor, said second surface may be a floor support surface, and may be an upper surface. The at least one further modular building unit may comprise a floor support surface, which may be configured to support a floor of the unit. The second section of the ceiling structure and the at least one further modular building unit may be configured so that their floor support surfaces are disposed at a common height above a base of the first modular building unit. The floor(s) may be generally planar. The floor(s) may be configured to define or receive a decorative floor covering.
[0032] Where the second section of the ceiling structure defines the floor, said second surface may be an upper surface of the floor. The at least one further modular building unit may comprise at least one floor support surface, which may be configured to support a floor of the unit. The second section of the ceiling structure and the at least one further modular building unit may be configured so that their respective second surface(s) and floor support surface(s) are disposed at a common height (the second height) above a base of the first modular building unit. The floor(s) may be generally planar. The floor(s) may be configured to define or receive a decorative floor covering. The ceiling structure may comprise a structural frame, which may be of a metallic, timber or timber-based material. Suitable materials can include hot-formed steel, cold-formed steel (e.g. light gauge steel), timber, composite timber materials such as plywood and oriented strand board (OSB), and combinations of these materials.
[0033] The first modular building unit and / or the at least one further modular building unit may be constructed or constructable to a substantially assembled form away from a final location for a building comprising the modular building assembly. The first modular building unit and / or the at least one further modular building unit may be transportable in the substantially assembled form, e.g. to a final site or location for a building comprising the assembly.
[0034] The modular building assembly may be configured to define a circulation space (which may also be referred to as a circulation zone or transition space / zone), which may provide at least one access function for the building, during use. The access function may be selected from the group comprising: access between upper and lower living spaces of the building (e.g. between upper and lower storeys); access between a first living space and at least one further living space, said living spaces optionally being isolated from one another within another part of the building, optionally on a same level / storey (e.g. via a hallway / landing and one or more doorway or walkway); and access into the building from the outside / exterior (e.g. via one or more doorway or walkway, and optionally also a hallway). The first modular building unit may be configured to define at least part of the circulation space. The further modular building unit may be configured to define at least part of the circulation space. The floor structure (forming part of the first modular building unit) may be configured to define at least part of the circulation space. The first modular building unit and / or the further modular building unit may be configured to together form the circulation space.
[0035] The ceiling structure of the first modular building unit (and / or a floor structure of the further modular building unit) may be configured to provide a route for the connection of services, optionally building services equipment, to the further modular building unit, and / or between the further modular building unit and the first modular building unit. For example, the further modular building unit may comprise at least one wet facility, and the services may be connectable to said wet facility. Suitable wet facilities are discussed elsewhere in this document, and can comprise e.g. a bath, shower, washbasin and toilet. The services may comprise water supply conduits and / or waste conduits for connection to said wet facility. Other services may be selected from the group comprising: electrical power (provided by suitable cables or wires); water heating pipes; ventilation which may comprise air supply and / or extraction (provided by ducts or conduits); and communications (which may be provided by telecommunication / data cables or wires). The ceiling structure (and / or the floor structure of the further modular building unit) may comprise a space or void by or through which services may be connected to the further modular building unit.
[0036] The modular building assembly, optionally the further modular building unit, may comprise a service module configured to connect services, e.g. building services equipment, between the first and the further modular building unit. The service module may contain one or more building services connector, for connecting building services equipment in the first modular building unit to building services equipment in the further modular building unit. The one or more building services connector may comprise ducting, conduit, pipe, cable, wire or the like connectable to equivalent ducting etc. and / or other equipment in the first and further modular building units. The service module may be provided separately from the further modular building unit and may be connectable to it. Connection may occur at the site or during manufacture, prior to transportation to the site. The service module may be positionable on or above the second section of the ceiling structure. This may facilitate access to the equipment contained by the service module e.g. for maintenance or replacement. The service module may comprise a frame or outer support structure defining an internal void or space containing said building services connector.
[0037] According to a second aspect, there is provided a building system comprising a first building section and a second building section, the first and second building sections together configured to form at least part of a building, in which the second building section comprises a modular building assembly, the modular building assembly comprising: a first modular building unit comprising an internal volume, the first modular building unit having a base and a footprint; and at least one further modular building unit comprising an internal volume, said further modular building unit configured to be positioned on top of the first modular building unit overlying a first portion of its footprint; in which the first modular building unit comprises a ceiling structure, the ceiling structure comprising: a first section defining at least one first surface configured to support said further modular building unit, said first surface disposed at a first height relative to the base; and a second section positioned laterally relative to the first section overlying a further portion of the footprint, the second section defining at least one second surface disposed at a second height relative to the base which is greater than the first height, said second surface configured to support or define at least part of a floor for an upper storey of the building.
[0038] According to a third aspect, there is provided a building comprising a first building section and a second building section, the first and second building sections together forming at least part of the building, in which the second building section comprises a modular building assembly, the modular building assembly comprising: a first modular building unit comprising an internal volume, the first modular building unit having a base and a footprint; and at least one further modular building unit comprising an internal volume, said further modular building unit positioned on top of the first modular building unit overlying a first portion of its footprint; in which the first modular building unit comprises a ceiling structure, the ceiling structure comprising: a first section defining at least one first surface which supports said further modular building unit, said first surface disposed at a first height relative to the base; and a second section positioned laterally relative to the first section overlying a further portion of the footprint, the second section defining at least one second surface disposed at a second height relative to the base which is greater than the first height, said second surface configured to support or define at least part of a floor for an upper storey of the building. Optional further features of the building system and / or building are as follows.
[0039] The building may be a hybrid building, in particular a hybrid residential building. The first building section may be an on-site construction at a final location for the building. An internal volume of the second building section may be defined at least partly by the modular building assembly, and may be defined substantially entirely by the modular building assembly. The first and at least one further modular building units may be configured to be constructed away from a final location for the building, for example in a factory or facility that is spaced from the final location. The facility may be located away from a site containing the final location, but could be located on the site, e.g. in the case of a large building site containing multiple plots, each plot forming a final location for a building. The first and second building sections may be configured to be connected / fitted together at the final location to form the building.
[0040] The building may be a modular building comprising a plurality of modular building units. At least some of the modular building units may be arranged to form a modular building assembly or assemblies according to the second / third aspect. An internal volume of the building, optionally excepting an upper or outer roof of the building, may be formed entirely by said units / assemblies.
[0041] The hybrid building may have a lower storey and an upper storey. The first building section may comprise an internal volume defining at least one room which may provide a living space within the building. The internal volume of the at least one further modular building unit may define at least one room providing a further living space within the building. The first building section and the second building section may together form at least part of the building. The second section of the ceiling structure may support or define a floor for an internal space in the upper storey of the building. The internal space may be defined by the first building section, and may be enclosed by the walls. The first building section may form at least some external walls of the building, and the internal space may be at least partly enclosed by one or more of said external walls. The first building section may form at least one internal wall of the building, and the internal space may be at least partly enclosed by said internal wall. The internal space may be enclosed in that it may not open (e.g. directly) to an exterior of the building, other than via a walkway, window or the like. The internal space may be at least partly enclosed by one or more wall of the further modular building unit.
[0042] Further features of the building system / building, in particular of the modular building assembly, may be derived from the text set out elsewhere in this document, in particular in or with reference to the first aspect.
[0043] According to a fourth aspect, there is provided a modular building unit configured to form part of a modular building assembly, the modular building unit comprising an internal volume, a base, a footprint and a ceiling structure, in which the ceiling structure is configured to receive a further modular building unit so that said further modular building unit is positioned on top of the modular building unit, and in which the ceiling structure comprises: a first section defining at least one first surface configured to support the further modular building unit so that the further modular building unit overlies a first portion of the footprint, said first surface disposed at a first height relative to the base; and a second section positioned laterally relative to the first section, the second section overlying a further portion of the footprint and defining at least one second surface disposed at a second height relative to the base which is greater than the first height, said second surface configured to support or define at least part of a floor for an upper storey of a building comprising the modular building assembly.
[0044] Further features of the modular building unit may be derived from the text set out elsewhere in this document, particularly in or with reference to any one of the first to third aspects.
[0045] According to a fifth aspect, there is provided a method of constructing a modular building assembly configured to form at least part of a building, the method comprising the steps of: constructing a first modular building unit, comprising providing the unit with an internal volume, a base and a footprint; and constructing at least one further modular building unit, comprising providing said unit with an internal volume; in which the step of constructing the first modular building unit further comprises providing the unit with a ceiling structure comprising: a first section defining at least one first surface disposed at a first height relative to the base; and a second section positioned laterally relative to the first section, the second section defining at least one second surface disposed at a second height relative to the base which is greater than the first height; and in which the method further comprises positioning said further modular building unit on said first support surface overlying a first portion of the footprint; and arranging the second section so that said it overlies a further portion of the footprint, and so that said second surface supports or defines at least part of a floor for an upper storey of the building.
[0046] The method may comprise arranging the further modular building unit and second section of the ceiling structure so that they together overlie at least a substantial part, and / or a majority, of the footprint of the first modular building unit. The method may comprise arranging the further modular building unit and the second section of the ceiling structure so that they together overlie substantially the entire footprint of the first modular building unit.
[0047] The method may comprise arranging the first modular building unit so that it defines at least part of an access route or pathway, which may provide access from the first modular building unit to at least one of: a) the floor; and b) the internal volume of the further modular building unit. The method may comprise providing the first modular building unit with at least a main part of a staircase, which may form said part of the access route. The method may comprise providing an aperture in and / or extending through the second section of the ceiling structure. The method may comprise arranging the aperture so that it communicates with the main part of the staircase. The method may comprise providing the further modular building unit with an aperture, and arranging the aperture so that it communicates with the main part of the staircase in the first modular building unit.
[0048] The method may comprise arranging the second section of the ceiling structure so that it supports or defines at least part of a landing, and arranging the access route so that it opens on to, and / or communicates with, the landing. The method may comprise arranging the aperture so that it opens adjacent to the landing.
[0049] The method may comprise arranging the further modular building unit so that it supports or defines at least part of a landing, and arranging the access route so that it opens on to, and / or communicates with, the landing. The method may comprise arranging the aperture so that it opens adjacent to the landing.
[0050] The method may comprise arranging the floor so that it provides access into the further modular building unit. The method may comprise arranging the floor so that it: communicates with the internal volume of the further modular building unit; and / or provides access (optionally direct access) into the internal volume of the further modular building unit.
[0051] The further modular building unit may be a second modular building unit. The further portion of the footprint of the first modular building unit which is overlaid by the second section of the ceiling structure may be a second portion of the footprint. The step of constructing the second building section may further comprise: at a location away from the final location, constructing a third modular building unit, comprising providing the third modular building unit with an internal volume. The method may further comprise: transporting the third modular building unit to the final location in its substantially assembled form; and positioning the third modular building unit on top of the first modular building unit overlying a third portion of its footprint. The method may comprise arranging the second modular building unit, the third modular building unit and the second section of the ceiling structure so that they together overlie at least a substantial part, and / or a majority, of the footprint of the first modular building unit. The method may comprise arranging the second modular building unit, third modular building unit and the second section of the ceiling structure so that they together overlie substantially the entire footprint of the first modular building unit.
[0052] The method may comprise arranging the internal volume of the first modular building unit so that it forms at least part of at least one room of the building. The at least one room may be selected from the group comprising: a hallway; a washroom or W / C; and a utility or technical room / space.
[0053] The method may comprise arranging the internal volume of the at least one further modular building unit so that it forms at least part of at least one room of the building. The at least one room may provide living space. The further modular building unit, in particular said part of the at least one room, may comprise a wet facility. The wet facility may be selected from the group comprising: a washroom or W / C; a bathroom; and an ensuite.
[0054] Where there are a plurality of further modular building units (e.g. second and third), at least one of said modular building units, and optionally both, may be arranged so that it contains a wet facility, or respective wet facilities.
[0055] The method may comprise providing the first modular building unit with a perimeter, which may comprise a plurality of perimeter portions, each perimeter portion optionally disposed transverse to at least one other perimeter portion. The method may comprise arranging the at least one further modular building unit so that it overlaps at least one perimeter portion of the first modular building unit. The method may comprise arranging the at least one further modular building unit so that it extends beyond said perimeter portion.
[0056] The method may comprise providing the at least one further modular building unit with a perimeter, which may comprise a plurality of perimeter portions, each perimeter portion optionally disposed transverse to at least one other perimeter portion. The method may comprise arranging the at least one further modular building unit so that at least one perimeter portion of the further modular building unit is disposed laterally spaced from and / or beyond a perimeter portion of the first modular building unit, which may be a corresponding perimeter portion. The method may comprise arranging the further modular building unit so that it overhangs the first modular building unit, in particular so that it overhangs at least one perimeter portion of the first modular building unit, which perimeter portion may be at or may define a side of the first modular building unit. The method may comprise arranging the further modular building unit so that an overhanging portion of said unit forms at least part of a porch or awning for the building. The method may comprise arranging the further modular building unit so that an overhanging portion of said unit forms an interior space or volume within the building.
[0057] The method may comprise positioning the at least one further modular building unit so that at least one perimeter portion of said further unit is disposed inwardly or inboard of at least one perimeter portion of the first modular building unit. The at least one perimeter portion of said further modular building unit may be disposed inwardly or inboard of, and / or within, the footprint.
[0058] The first modular building unit may be elongate, and / or may comprise a main axis extending along a main or primary length direction. The at least one further modular building unit may be elongate, and / or may comprise a main axis extending along a main or primary length direction. The method may comprise arranging the at least one further modular building unit so that its main axis is disposed substantially parallel to the main axis of the first modular building unit. The method may comprise arranging the at least one further modular building unit so that its main axis is disposed transverse to the main axis of the first modular building unit, optionally substantially perpendicular.
[0059] The footprint of the first modular building unit may be a first footprint. The method may comprise providing the at least one further modular building unit with a footprint, which may be a second footprint. The method may comprise arranging the second footprint so that it is different to the first footprint, e.g. providing the second footprint with a different shape to the first footprint, and / or so that at least one dimension of the second footprint (such as a length or width) differs from a corresponding dimension of the first footprint. The method may comprise arranging the second footprint so that it is substantially the same as the first footprint (e.g. the same shape and / or dimensions). The method may comprise arranging the further modular building unit so that the second footprint partially overlaps the first footprint, and / or so that the first and second footprints are not aligned. The method may comprise arranging at least part of the second footprint so that it overhangs a perimeter portion of the first modular building unit.
[0060] The method may comprise providing the first section of the ceiling structure with a plurality of support surfaces, and arranging the support surfaces at a common height above the base.
[0061] The method may comprise constructing the first modular building unit and / or the at least one further modular building unit to a substantially assembled form away from the final location. The method may comprise transporting the first modular building unit and / or the at least one further modular building unit to the final location in the substantially assembled form.
[0062] The method may comprise positioning the first modular building unit at the final location, and then positioning said further modular building unit on said first support surface overlying the first portion of the footprint.
[0063] The method may be a method of constructing a hybrid building, in particular a hybrid residential building. The method may comprise constructing a first building section on-site at a final location for the building. The method may comprise forming an internal volume of a second building section at least partly using the modular building assembly, and optionally substantially entirely using the modular building assembly. The first and at least one further modular building units may be constructed away from the final location, for example in a factory or facility that is spaced from the final location. The method may comprise connecting and / or fitting the first and second building sections together at the final location to form the building.
[0064] The second building section may be assembled at the final location prior to construction and connection of the first building section to the second building section. The first modular building unit may be positioned at the final location, and a part of the first building section then constructed (e.g. a lower floor / storey) and optionally connected to the first modular building unit. The at least one further modular building unit may then be positioned on the first modular building unit, and a further part of the first building section (e.g. an upper floor / storey) may be constructed and optionally connected to one or more of the first modular building unit and said further modular building unit.
[0065] The first building section may be constructed at the final location and the second building section then assembled and optionally connected to the first section, for example during assembly. The second building section may be assembled within a perimeter or boundary defined by the first building section.
[0066] The method may be a method of constructing a modular building comprising a plurality of modular building units. The method may comprise arranging at least some of the modular building units to form the modular building assembly or modular building assemblies according to the fifth aspect. An internal volume of the building, optionally excepting an upper or outer roof of the building, may be formed entirely by said units / assemblies.
[0067] Further features of the method may be derived from the text set out elsewhere in this document, particularly in or with reference to any one of the first to fourth aspects.
[0068] Reference is also made to the hybrid building and associated construction methods disclosed 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.
[0069] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0070] Fig. 1 is an isometric view of a building comprising a first building section, and a second building section defined by a modular building assembly, according to an embodiment of the invention;
[0071] Fig. 2 is an enlarged, detailed isometric view of the modular building assembly shown in Fig. 1, with certain features removed for ease of illustration, the assembly drawn to a larger scale and viewed from a rear left corner;
[0072] Fig. 3 is an exploded isometric view of the modular building assembly shown in Fig. 2;
[0073] Fig. 4 is a side view of the modular building assembly shown in Fig. 2, taken in the direction of the arrow A in Fig. 1;
[0074] Figs. 5 and 6 are floorplan views of lower and upper storeys, respectively, of the building shown in Fig. 1 ;
[0075] Fig. 7 is a plan view of a floor frame portion of a structural frame forming part of a lower modular building unit of the assembly shown in Fig. 2;
[0076] Fig. 8 is a plan view of the modular building assembly of Fig. 2, following stacking of an upper modular building unit of the assembly on the lower modular building unit;
[0077] Fig. 9 is a further enlarged view of a part of the lower modular building unit of Fig. 2, viewed from a different angle;
[0078] Fig. 10 is a further enlarged isometric view of the modular building assembly of Fig. 2, showing a front left corner region of a ceiling frame portion of the lower modular building unit; Fig. 11 is an enlarged side view of the modular building assembly shown in Fig. 4, showing a rear part of the ceiling frame portion of the lower modular building unit;
[0079] Fig. 12 is an enlarged vertical cross-sectional view of part of a foundation of the building shown in Fig. 1, showing the lower modular building unit located on the foundation;
[0080] Fig. 13 is a detailed isometric view of a modular building assembly according to another embodiment of the invention, similar to Fig. 2;
[0081] Fig. 14 is an exploded isometric view of the modular building assembly shown in Fig. 2;
[0082] Fig. 15 is an enlarged side view of the modular building assembly shown in Fig. 13, taken in the direction of the arrow B in Fig. 13;
[0083] Fig. 16 is a detailed isometric view of a modular building assembly according to a further embodiment of the invention, similar to Fig. 2;
[0084] Fig. 17 is an exploded isometric view of the modular building assembly shown in Fig. 16;
[0085] Fig. 18 is an enlarged, detailed isometric view of a modular building assembly according to a still further embodiment of the invention, similar to Fig. 2;
[0086] Fig. 19 is an exploded isometric view of the modular building assembly shown in Fig. 16;
[0087] Fig. 20 is a side view of the modular building assembly shown in Fig. 18, taken in the direction of the arrow C in Fig. 18;
[0088] Fig. 21 is a detailed isometric view of a modular building assembly according to a further embodiment of the invention, similar to Fig. 2;
[0089] Fig. 22 is an exploded isometric view of the modular building assembly shown in Fig. 21;
[0090] Fig. 23 is a highly schematic front view of a building comprising the modular building assembly of Fig. 21;
[0091] Fig. 24 is a floorplan view of an upper storey of the building shown in Fig. 21, viewing in the direction of the arrow D-D (taken just above a lower storey); and
[0092] Fig. 25 is an exploded isometric view of the modular building assembly shown in Figs. 2 to 11, illustrating an option for routing building services between the lower and upper modular building units. Turning firstly to Fig. 1, there is shown an isometric view of a building according to an embodiment of the invention, the building indicated generally by reference numeral 10. In the illustrated embodiment, the building 10 is a residential building, in particular a hybrid residential building in the form of a detached house. The principles of the invention can however apply to other types of house, including semi-detached, terraced and townhouses. 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, e.g. industrial or commercial buildings. In general, the principles of the invention can apply to any building having a plurality of storeys.
[0093] The building 10 comprises a modular building assembly, which is shown in solid outline in Fig. 1, and indicated by reference numeral 12. The modular building assembly 12 is shown separately in Fig. 2, which is a detailed isometric view of the assembly, with certain features (particularly internal and / or external wall panels) removed, for ease of illustration. The assembly 12 is drawn to a larger scale in Fig. 2, and viewed from a rear left comer of the building 10. Fig. 3 is also referred to, which is an exploded isometric view of the modular building assembly 12, and Fig. 4, which is a side view taken in the direction of the arrow A in Fig. 1.
[0094] The assembly 12 comprises a first modular building unit 14 comprising an internal volume 16, the first modular building unit having a footprint (shown cross-hatched in Fig. 1 and indicated by numeral 18) and a base 154. The first modular building unit 14 also comprises a ceiling structure 342 having a first section 344 (Fig. 3), and a second section 346 positioned laterally relative to the first section. The first section 344 defines at least one first surface 348 disposed at a first height Hi (Fig. 4) relative to the base 154. The second section 346 defines at least one second surface 350 disposed at a second height H2 relative to the base 154, which is greater than the first height Hi.
[0095] The assembly 12 also comprises at least one further modular building unit 20, which comprises an internal volume 22. The further modular building unit 20 is configured to be positioned on the first support surface 348 (defined by the first ceiling section 344) so that it overlies a first portion 24 of the footprint 18 (Fig. 1). The second ceiling section 346 is configured to overlie a further portion 27 of the footprint 18, and is configured so that the second surface 350 supports or defines at least part of a floor 76 (Fig. 4) for an upper storey of the building. In the illustrated embodiment, the floor 76 is provided as a separate structure that is seated on the second support surface 350, and typically takes the form of a planar panel or panels such as of a timber -based material (e.g. OSB).
[0096] The modular building unit 14 forms a lower unit of the assembly 12, and the further modular building unit 20 forms an upper unit of the assembly. The upper modular building unit 20 is stacked on the lower modular building unit 14. In the illustrated embodiment, only a single further modular building unit is provided (the unit 20), although in further embodiments which will be described below, a modular building assembly can be provided comprising a plurality of such further (upper) modular building units.
[0097] In the hybrid building 10 of this embodiment, the building comprises a first building section 28, shown in broken outline in Fig. 1, and a second building section 30. The first building section 28 is an on-site construction at a final location 32 for the building, and is approximately L-shaped in plan-view (although not restricted to that shape). The second building section 30 is formed or defined by the modular building assembly 12 and, in the illustrated embodiment, has a generally rectangular shape in plan-view, defined by the first modular building unit footprint 18. As can be seen particularly in Fig. 4, viewed from the side, the modular building assembly 12 is generally L-shaped. The lower modular building unit 14 and the upper modular building unit 20 are constructed to a substantially assembled form away from the final location 32, for example in a dedicated factory or facility. The units 14 and 20 are each transported to the final location 32 in their substantially assembled form, and arranged to form the modular building assembly 12 (and so the second building section 30). The lower modular building unit 14 and the upper modular building unit 20 are of the same general construction, which will be discussed in more detail below.
[0098] As explained in detail in International patent publication nos. WO2022 / 243696, WO2022 / 243695, WO2022 / 243694, WO2022 / 243693 and WO2023 / 222853, the hybrid building 10 is formed by connecting the first and second building sections 28 and 30 together at the final location 32. Numerous construction options exist, as will be explained briefly below. However, in the illustrated embodiment, the second building section 30 (defined by the modular building assembly 12) is effectively built-in to the first building section 28, the first section being constructed around the second building section so as to enclose or encapsulate it within the structure of the first section.
[0099] Reference is also made to Figs. 5 and 6, which are floorplan views of lower 34 and upper 36 storeys respectively of the building 10 shown in Fig. 1. The lower and upper modular building units 14 and 20 are shown in bold outline in the drawings. The modular building unit 14 comprises a structural frame, indicated generally by numeral 38. The structural frame 38 comprises a floor frame portion 40 configured to support a planar floor structure, a ceiling frame portion (forming the ceiling structure) 342, and a support structure 44 extending between and connecting the floor frame portion to the ceiling frame portion. Numerous options for forming the structural frame 38 exist. Preferred options include a metallic frame, which can be of a cold-formed metal or metal alloy (e.g. light gauge steel), a hot formed metal or metal alloy (e.g. 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 frame 38 is formed from a combination of hot-formed steel and cold-formed steel, comprising elongate members which may be of a generally hollow box shape in cross-section, or channels having a C, L or U-shape. The floor frame portion 40 and the ceiling frame portion 342 comprise respective perimeter frames (or ring beams) 46, 48 formed from structural elements of hot-rolled steel. The support structure 44 forms external side walls of the modular building unit 14, and typically comprise cold-formed structural elements. For example, and referring to internal end wall 49 of the unit 14 shown in Fig. 2, the end wall comprises: comer support posts or columns 50 and 52: intermediate support posts or columns 54 and 56; cross brace 58; and ‘K-braces’ 60 and 62. Connection methods for structural components of the frame can include welding (metallic frames, particularly hot-formed components), bonding and mechanical fixations such as nut and bolt assemblies, rivets and self-drilling screws (‘tek screws’). As can be seen from Figs. 1 , 5 and 6, the second building section 30 fits with the generally L -shaped first building section 28 in order to form a building having a generally rectangular shape in plan-view. Other shapes are of course possible. The lower modular building unit 14 can have any suitable dimensions, with the proviso that it will generally be required to be transported e.g. by road or rail from the factory to the final location 32. The illustrated unit 14 is around 5300mm to 5400mm in length, and around 2500mm to 2600mm in width, which is particularly suited to such transportation. The lower unit 14 is smaller than many conventional modular building units, which can facilitate transportation and handling, as well as material, weight and cost savings. Although the illustrated lower unit 14 extends only part way between the front and back of the building 10, other units according to the invention may extend the full length of the building, and so may e.g. have a greater length dimension. The upper modular building unit 20 is of course arranged to fit on top of the lower modular building unit 14, and so of generally the same width, but smaller length. The upper unit 20 is of similar construction to the lower unit 14, and will not be described in detail here.
[0100] As can be seen particularly from Figs. 1 and 2, the upper modular building unit 20 overlies only the first footprint portion 24, whilst the second ceiling section 346 overlies the further footprint portion 27. This may provide greater design freedom for the upper storey 36 of the building 10, the upper storey including, and / or being formed at least partly by, the upper modular building unit 20 and the floor 76 on the second ceiling section 346. For example, living space provided in the upper storey of the building 10, and access into such living space, may be less restricted by the shape and / or size of a structural frame 64 of the upper unit 20 (in particular a support structure 66 of the upper unit). This is because the living space / access is less restricted by a requirement to fit around the structural frame 64, particularly upright support posts of the frame.
[0101] Reference will now be made to Fig. 7, which is a plan view of the floor frame portion 40 of the lower modular building unit structural frame 38, and Fig. 8, which is a plan view of the assembly 12 following stacking of the upper unit 20 on the lower unit 14. The footprint 18 of the lower modular building unit 14 is the area on, in or above the ground which the unit accommodates, measured from outer surfaces or boundaries of the unit. In this embodiment, the lower unit 14 comprises front 67, rear 68, left side 70 and right side 72 boundaries which together define the footprint 18 (the footprint being the area bound or bordered by the boundaries). These boundaries are effectively defined by the floor frame portion 40, and the sides of the unit 14.
[0102] The first and second portions 24, 27 of the footprint which are overlaid respectively by the upper modular building unit 20, and the second ceiling section 346, are shown in Fig. 7 cross-hatched. The upper unit 20 and second ceiling section 346 overlie the respective portions 24 and 27 of the footprint in that they substantially cover the portions of the footprint, when viewed from above or in plan. The footprint portions 24 and 27 each have a respective perimeter, and the upper unit 20 and second ceiling section 346 extend at least up to the respective perimeter, in order to overlie the footprint portions. This is best shown in Figs. 1 and 2. The upper unit 20 and the second ceiling section 346 are configured so that they together overlie a majority of the footprint 18, excepting a stairwell aperture 74 shown in Fig. 8, which will be described in more detail below. The lower modular building unit 14 defines at least part of an access route or pathway, which provides for access from the lower unit to at least one of: a) the floor 76; and b) the internal volume 22 of the upper modular building unit 20. In this embodiment, the lower unit 14 provides access to the floor 76, which in turn provides access into the internal volume 22 of the upper modular building unit 20, via a walkway aperture in the form of a doorway 78. The access route is provided by means of a staircase 80 in the modular building assembly 12, shown in Fig. 9, which is a further enlarged view of a part of the lower unit 14 of Fig. 2, viewed from a different angle. The lower modular building unit 14 comprises a main part 82 of the staircase 80, which is positioned in the internal volume 16 of the lower unit. The main staircase part 82 is typically installed during construction of the lower unit 14, and so in the factory / facility. The staircase 80 can be completed at the final location, following positioning of the upper unit 20 on the lower unit 14, for example by connecting an uppermost riser / step portion (not shown) to an uppermost step 84 of the main staircase part 82, following positioning of the floor 76 on the support surface 350.
[0103] The second ceiling section 346 of the ceiling structure 342 comprises a floor support structure 26, which in this embodiment takes the form of a structural frame. The floor structural frame 26 extends above the perimeter frame 48, and defines the support surface 350 (at the height H2 above the base 154). As best shown in Figs. 3 and 4, the second ceiling section 346 is raised relative to the first ceiling section 344, providing the lower modular building unit 14 with a stepped profile, when viewed from the side. The ceiling frame portion 342, specifically the part of the perimeter frame 48 of its second section 346, comprises a stairwell aperture 74, which extends through the ceiling frame portion to provide access to the floor 76. The floor support structure 26 includes a corresponding aperture 86, which aligns with the aperture 74 in the perimeter frame 48. This facilitates the required communication with the main staircase part 82 in the lower unit 14. The lower unit 14 is typically constructed to include the floor support structure 26, for example in the off-site factory or facility. The lower unit 14 is this transported to the final location 32 with the floor support structure connected to the perimeter frame 48, as shown in Fig. 3.
[0104] The ceiling structure 342 supports or defines a floor for an internal space within the upper storey 36 of the building 10, the internal space indicated generally by numeral 87 in the drawings. The internal space 87 is effectively defined by the first building section 28, and is enclosed by walls of the building 10. The first building section 28 forms at least some external walls of the building 10, and in the illustrated embodiment forms front wall 231, back wall 233, left-side wall 236 and right-side wall 238. The internal space 87 is at least partly enclosed by one or more of the external walls 231 , 233, 236 and 238, and in the illustrated embodiment is effectively completely enclosed within these external walls. The first building section 28 additionally forms various internal walls of the building, two such walls in the upper storey 36 indicated by numerals 243 and 245. These internal walls 243 and 245 border the internal space 88, and may be considered to partly enclose the internal space 87. The internal walls 243 and 245, together with a perimeter portion 92 of the upper modular building unit 20 (which defines a wall of the unit) and the left side external wall 236, may be considered to completely enclose the internal space 87. It will be understood that the internal space 87 may be enclosed in that it may not open (e.g. directly) to an exterior of the building 10, other than via a closable walkway, window or the like. The floor 76 is configured to define at least part of a landing, and in the illustrated embodiment, defines a complete landing 88 (Figs. 2, 3 and 9). The access route provided by the staircase 80 opens on to the landing 88. This is achieved by arranging the aperture 86 of the floor support structure 26 so that it opens adjacent to the landing 88. An occupant of the building 10 may therefore pass from the lower storey 34 of the building 10 by entering the lower modular building unit 14, passing up the staircase 80 through the aligned apertures 74 and 86, and stepping on to the landing 88 defined by the floor 76. This provides access not only to the internal volume 22 of the upper modular building unit 20, but also to areas of the building 10 defined by the first building section 28, including living space such as bedrooms, which will be discussed in more detail below.
[0105] As can be seen particularly in Figs. 2 to 4, the floor support structure 26 extends laterally from the upper modular building unit 20, following positioning of the upper unit on top of the lower modular building unit 14. The floor support structure 26 extends in a generally horizontal direction or plane, generally away from the upper modular building unit 20. The floor support structure 26 is laterally adjacent to the upper modular building unit 20, and abuts the upper unit 20. This provides for the required access from the floor 76 into the upper unit internal volume 22. A perimeter portion 90 of the floor support structure 26 is positioned adjacent to, and in abutment with, a perimeter portion 92 of the upper modular building unit 20 (see Fig. 2), the perimeter portion communicating with or including the doorway 78.
[0106] The floor support structure 26 effectively defines a floor for an internal volume or space defined by a further part of the building 10, in particular by the first building section 28. This can be seen by comparing Fig. 1 with Figs. 5 and 6. The first building section 28 comprises an internal volume 94, which includes a generally L- shaped portion 95 having a footprint 96, shown cross-hatched in Fig. 1. The internal volume 94 also includes a further generally cubic or cuboid portion 98 which is effectively disposed above the floor support structure 26. The floor 76 supported by the floor support structure 26 therefore defines a floor for the cuboid internal volume portion 98. A height H3 (Fig. 4) of the floor support structure 26 is therefore considerably less than a height H4 of the upper modular building unit 20.
[0107] The internal volume 16 of the lower modular building unit 14 is configured to form at least part of at least one room of the building, in particular a room comprising a wet facility. Referring to Fig. 5, it can be seen that the internal volume 16 of the lower unit 14 comprises a washroom or W / C 100, containing wet facilities in the form of a toilet 102 and a sink or washbasin 104. The lower unit 14 additionally defines a hallway 106, and a utility or technical room 107. The technical room 107 contains equipment providing service functions within the building 10, including but not limited to a ventilation system, water heating and storage equipment, space heating equipment and laundry facilities (e.g. washer / drier). The internal volume 22 of the upper modular building unit 20 is similarly configured to form at least part of at least one room of the building, again particularly a room comprising a wet facility. Referring to Fig. 5, it can be seen that the internal volume 22 of the upper unit 20 defines a bathroom, containing wet facilities in the form of a bath 108, toilet 110 and a sink or washbasin 112. Referring to Fig. 7, the lower modular building unit 14 comprises a perimeter, which is defined by a plurality of perimeter portions. The front 67, rear 68, left side 70 and right side 72 boundaries of the floor frame portion 40 define respective perimeter portions, each of which is disposed transverse to the adjacent perimeter portions. Referring to Figs. 4 and 6, the upper modular building unit 20 also comprises a perimeter, which is defined by a plurality of perimeter portions. The perimeter portion 92 discussed above forms a rear perimeter portion, and the upper unit 20 further comprises front 114, left side 116 and right side 118 perimeter portions, each perimeter portion again disposed transverse to the adjacent perimeter portions. The upper modular building unit 20 is configured to be positioned on top of the lower modular building unit 14 so that its front 114, left side 116 and right side 118 perimeter portions align with the respective perimeter portions 67, 70 and 72 of the lower unit 14. The rear perimeter portion 92 of the upper unit 20 is however disposed laterally spaced from the rear perimeter portion 68 of the lower unit 14, and so inwardly or inboard of the rear perimeter portion 68, and within the footprint 18.
[0108] Referring back to Fig. 2, it can be seen that the lower modular building unit 14 is generally elongate, comprising a main axis 120 extending along a main length direction of the unit. The upper modular building unit 20 in this embodiment is generally cubic or cuboid in shape, comprising a main axis 122 extending in a front-to-back direction. The upper unit 20 is positioned on the lower unit 14 so that their main axes 122, 120 are disposed substantially parallel. This provides the aligned arrangement of the units 14 and 20 shown in Fig. 2, forming the generally L-shaped structure, viewed from the side. The upper modular building unit 20 comprises its own footprint 126 (Fig. 1), which forms a second footprint of the assembly 12. The second footprint 126 is of course different to the first footprint 18 of the lower unit 14, the second footprint having a different shape, and a different length.
[0109] As discussed above, the first ceiling section 344 is configured to support the upper modular building unit 20, comprising the first support surface 348. Referring back to Figs. 2 to 4, it can be seen that, in the illustrated embodiment, the first ceiling section 344 comprises a plurality of such first support surfaces 348. In more detail, the first ceiling section 344 comprises a plurality of mounting members for the upper unit 20, each mounting member taking the form of a block, post, stub, pin or peg. A plurality of module mounting posts are provided, posts 134 to 137 visible in Fig 3, although it will be understood that additional mounting posts are provided spaced around the first ceiling section 344. Corresponding mounting posts are provided for the floor support structure 26, posts 130, 132, 142 and 144 shown in Fig. 2. Again, additional mounting posts are provided spaced around the second ceiling section 346.
[0110] The mounting posts (e.g. 130-136 shown in Fig. 4) all extend upwardly from the ceiling perimeter frame 48. A series of apertures are defined between adjacent pairs of mounting posts, spaced around the perimeter of the frame 48. Service conduits can be routed through the apertures, including for the supply of services from the modular building assembly 12 (forming the second building section 30) to the first building section 28. One such aperture shown in Fig. 4 is labelled with the numeral 140. The service conduits, and / or other service equipment, can be contained within and / or routed through an internal space or void 138 (shown in broken outline in Fig. 4) bordered by the perimeter frame 48, and routed out through the apertures (e.g. 140) to the first building section 28. The service conduits can include, amongst other things, electrical power wires or cables, communication cables, fluid conduits such as for water supply, ventilation conduits, and wastewater / sewerage conduits. Three such service conduits are shown in Fig. 4, which are an electrical power conduit 139, a water supply conduit 141 and a ventilation conduit 143. Generally speaking, a mounting post will be provided for main structural members of both the upper modular building unit 20 and the floor support structure 26, particularly at intersections between the main structural members. For example, and referring to Fig. 2, it will be noted that in addition to the mounting posts 130-134, further mounting posts e.g. 142 and 144 are provided for the floor support structure 26.
[0111] Referring to Fig. 10, there is shown an enlarged view of the modular building assembly of Fig. 2, showing a front left comer region of the ceiling frame portion 42 of the lower modular building unit 14, and the connection between the lower unit and the upper unit 20. A floor frame portion 146 of the upper unit 20 is shown in the drawing, and comprises a floor perimeter frame (or ring beam) 148. The mounting post 136 shown in the drawing comprises an upper mounting surface 150. A base or bottom surface 152 of the upper unit 20 is defined by the perimeter frame 148, and is seated on the mounting surface 150. The mounting member 136 typically comprises a mounting component, such as a tapered pin 153 (Fig. 3), which can be located in a socket (not shown) provided in the perimeter frame 148, to locate the units 14 and 20 relative to each another.
[0112] The lower modular building unit 14 comprises the base 154 (Fig. 2), which is defined by the floor frame portion 40 (which forms a floor structure of the unit), in particular by the floor perimeter frame 46. The support surfaces defined by the various mounting posts (e.g. the surface 150 of the mounting post 136), for both the upper modular building unit 20 and the floor support structure 26, are at a common height Hi (Fig. 4) above the base 154. The upper modular building unit 20 and floor support structure 26 have respective bases 155 and 157, and are configured so that their bases are disposed at a common height above the base 154 of the lower modular building unit 14. This is the same height Hi, since the upper unit base 155 and the floor support structure base 157 rest on the support surfaces (e.g. 150) defined by the lower unit 14 mounting posts. A benefit to this is that the floor support structure 26, and the floor frame portion 146 of the upper unit 20, can be of substantially the same height (the height H3), which can facilitate standardisation of components.
[0113] The first (floor) support surface 350 of the floor support structure 26 is best shown in the enlarged side view of Fig. 11 . The floor support surface 350 supports the floor 76, and is defined partly by frame members forming a perimeter frame (or ring beam) 158 of the floor support 26. The part of the support surface 350 shown in Fig.
[0114] 10 is that defined by an end frame member 160 of the perimeter frame 158. The upper modular building unit 20 similarly comprises a floor support surface 162 (Fig. 4), which supports a floor 164 of the unit (shown in Fig. 2). The floor support structure 26 and the upper modular building unit 20 are configured so that their floor support surfaces 350 and 162 are disposed at a common height (the height H3, Figs. 3 and 10) above the base 154 of the first modular building unit. A benefit to this is that it avoids a requirement to accommodate a significant change in height at the intersection between the floor support structure 26 and the upper modular building unit 20. Referring back to Fig. 2, the floor support structure 26 takes the form of a structural frame 166. The structural frame 166 comprises the perimeter frame 158 which, like the floor and ceiling frame portions 40 and 42 of the lower unit 14, is formed from structural elements of hot-rolled steel. The structural frame 166 also comprises an intermediate beam 168 extending in the length direction of the floor unit 26 between end beams of the perimeter frame 158. The intermediate beam 168 is also formed from hot-rolled steel and, together with the perimeter frame 158, defines or describes the aperture 86 which communicates with the stairwell aperture 74 in the lower unit 14. The structural frame 166 further comprises a plurality of joists extending in the width direction, between a side of the perimeter frame 158 and the intermediate beam 168. One such joist is labelled 172 in the drawing. The various joists are typically of cold-formed (e.g. cold rolled) steel. The perimeter frame 158, intermediate beam 168, and the various joists 172 together define the support surface 350.
[0115] The lower modular building unit structural frame 38, upper modular building unit structural frame 64, and floor structural frame 166 are typically of a metallic materials as discussed above, but can be of other materials such as a timber or timber-based material. Suitable materials can include hot-formed steel, cold-formed steel (e.g. light gauge steel), timber, composite timber materials such as plywood and oriented strand board (OSB), and combinations of these materials. In a variation, the floor support structure 166 may be or may comprise a substantially uniform or one-piece structure, such as a sheet e.g. of a cementitious or timber-based material (not shown). An upper surface of the floor support structure 166 may then form the floor 76. Also, the floors 76 and 164 of the floor support structure 26 and upper modular building unit 20 are generally planar and, although not shown in the drawings, configured to receive a decorative floor covering of any suitable type, including but not limited to tiles, carpet, laminate / composite materials and the like.
[0116] The modular building assembly 12 defines a circulation space configured to provide one or more access function for the hybrid building 10. This is shown in Figs. 5 and 6, the circulation space indicated by numeral 176, and shown in broken outline and cross-hatched in the drawings. In the illustrated embodiment, the circulation space 176 provides three access functions. One such function is access between lower 178 and upper 180 living spaces of the building 10, provided respectively by the lower and upper storeys 34 and 36 in the first building section 28. This is achieved by means of the staircase 80, the main part 82 of which is located in the lower modular building unit 14 (but could be achieved e.g. via a lift shaft and lift). The living space 178 forms an open-plan kitchen / dining room, whilst the living space 180 forms a bedroom, and the circulation space 176 therefore provides access between these different living spaces. The first building section 28 also comprises further living space in the form of a lounge or sitting room 182 which is accessed via the kitchen / dining room 178, and so the circulation space effectively also provides access between the bedroom 180 and the lounge.
[0117] Another such function is access between a first living space and at least one further living space of the building 10, the living spaces being isolated from one another within another part of the building. As can be seen in Fig. 6, the first building section 28 comprises the living space 180 (bedroom), and further living spaces 184 and 186, which form second and third bedrooms. The circulation space 176 provides access between these living spaces 180, 184 and 186, by means of walkway openings in the form of doorways 188, 190 and 192, and the landing 88 (which effectively form part of the circulation space). The circulation space 176 additionally provides access between the lower living space 178 (and also the space 182) and the upper living spaces 180, 184 and 186, which are effectively isolated from one another within the first building section 28.
[0118] Another such function is access into the building 10 from an exterior 194 of the building, via a walkway opening in the form of a doorway 196 of the lower unit 14, which in this case forms a front or main doorway for the building. The doorway 196 opens on to the hallway 106 to provide access to the staircase 80 (for access to the upper living spaces 180, 184 and 186), and an internal walkway in the form of a doorway 198 (for access to the lower living spaces 178 and 182).
[0119] Whilst the illustrated modular building assembly 12 comprises a circulation space 176 which provides all three access functions described above, it will be understood that variations may provide only one or only some of the stated functions.
[0120] It will also be understood that the lower modular building unit 14 and the floor support structure 26 are each configured to define a part of the circulation space 176. In particular, the lower unit 14 comprises the main part 82 of the staircase, the stairwell aperture 74, the main or front doorway 196, the hallway 106, and the internal doorway 198, which may be considered to form part of the circulation space 176. Similarly, the floor support structure 26 can comprise part of the staircase 80, and comprises the aperture 86 and the landing 88. The upper modular building unit 20 may also or alternatively be configured to define at least part of the circulation space, as will be described below in relation to further embodiments.
[0121] As explained in the International patent publications mentioned above, numerous construction options exist for the hybrid building 10. The second building section 30 (defined by the modular building assembly 12) may be assembled at the final location 32 prior to construction and connection of the first building section 28 to the second building section. The first (lower) modular building unit 14 may be positioned at the final location 32, and a part of the first building section 30 then constructed (e.g. a lower floor / storey portion) and optionally connected to the first modular building unit. The further (upper) modular building unit 20 may then be positioned on the lower modular building unit 14, and a further part of the first building section 28 (e.g. an upper floor / storey portion) may be constructed and optionally connected to one or more of the lower modular building unit and the upper modular building unit.
[0122] In a variation, the first building section 28 may be constructed at the final location and the second building section 30 then assembled and optionally connected to the first section, for example during assembly. The second building section 30 may be assembled within a perimeter or boundary defined by the first building section 28. This may be achieved by locating the lower modular building unit 14 within the perimeter of the first building section, and then locating the upper modular building unit 20 on the lower unit 14. A first storey portion of the first building section 28 may be constructed first, and then the lower modular building unit 14 located within its perimeter. A second storey portion of the first building section 28 may then be constructed and the upper modular building unit 20 positioned within the perimeter, on the lower unit 14. Whichever construction option is followed, the use of structural insulated panels (SIPs) may be a particularly preferred construction option for the first building section 28.
[0123] A roof structure 204 (Fig. 1) is typically assembled on site, extending over the first and second building sections 28, 30 and connected to them. Numerous options exist including forming the roof structure 204 from roof trusses (not shown), or as a modular (transportable) structure. Joists (not shown) forming ceilings of the lower and upper storeys 21 and 23 in the first building section 28 are connected to and supported by the lower modular building unit 14, and the upper modular building unit 20, respectively. The lower storey ceiling joists in the first building section 28 will typically be connected to the lower unit 14 prior to building up e.g. the SIP panels forming the upper storey portion and connecting them to the upper unit 20.
[0124] The first and second building sections 28 and 30 may rest on a common foundation 206. This is shown in Fig. 12, which is an enlarged vertical cross-sectional view of part of the foundation, showing the lower modular building unit 14 located on it. The foundation 206 supports both the second building section 30 (defined by the modular building assembly 12), and the first building section 28, which has been omitted from the drawing. The foundation 206 is an insulated foundation, comprising a load bearing structure 208 and thermal insulation 210. The modular building unit 14 is located on the foundation 206 so that the load bearing structure 208 provides structural support for the unit, and so that the thermal insulation 210 thermally insulates the modular unit relative to the ground 212. The load bearing structure 208 can take the form of a layer of reinforced concrete, which can be formed at the final location 32 for the building in a conventional fashion. Numerous options for forming the thermal insulation 210 exist, including constructing it from a series of shaped blocks (not shown) of a suitable insulating material which can bear the load of the completed building 10.
[0125] Turning now to Fig. 13, there is shown a detailed isometric view of a modular building assembly 12a according to another embodiment of the invention, similar to the view of the assembly 12 in Fig. 2. Like components of the modular building assembly 12a with the assembly 12 share the same reference numerals, with the addition of the suffix ‘a’. The modular building assembly 12a is also shown in Fig. 14, which is an exploded isometric view of the assembly 12a, and Fig. 15, which is an enlarged side view of the assembly 12a taken in the direction of the arrow B in Fig. 13. The modular building assembly 12a can form part of the building 10 and so be provided in place of the assembly 12 shown in Fig. 1 . Only substantive differences between the assembly 12a and the assembly 12 will be described in detail here.
[0126] The modular building assembly 12a in this embodiment comprises a first (lower) modular building unit 14a, a second modular building unit 20a and a third modular building unit 214. The second and third modular building units 20a and 214 are each upper units, positioned on top of the lower unit 14a in the same way as the upper unit 20 is positioned on top of the lower unit 14 in the assembly 12. The third modular building unit 214 defines an internal volume 216, and comprises a structural frame 218, similar to the modular building unit 20 in the assembly 12. A footprint 18a of the lower modular building unit 14a is shown schematically in the side view of Fig. 15. The second (upper) modular building unit 20a overlies a first portion 24a of the footprint 18a. The lower unit 14a comprises a ceiling structure 342a comprising a first section 344a and a second section 346a. The second ceiling section 346a comprises a floor support structure 26a, which overlies a second portion 27a of the footprint 18a. The third (upper) modular building unit 214 is configured to be positioned on top of the first modular building unit 14a overlying a third portion 220 of its footprint 18a. The second modular building unit 20a, third modular building unit 214 and the floor support structure 26a are configured so that they together overlie a majority of the footprint 18a, excepting a stairwell aperture 74a. The floor support structure 26a again comprises an aperture 86a which communicates with a stairwell aperture 74a, and a main staircase portion (not shown) in the lower unit 14a.
[0127] The second modular building unit 20a comprises a wet facility, in this case a bathroom again containing a bath 108a, toilet 110a and washbasin 112a. The third modular building unit 214 also comprises a wet facility, the unit in this case forming an ensuite bathroom or washroom for a bedroom in the building 10, particularly for the bedroom 180 (which may form a main or master bedroom). In a variation, one or more of the second and third modular building units 20a and 214 may be arranged to define a room in the building 10 in conjunction with the first building section 28. For example, one or more of the units 20a, 214 may be arranged with an open side, so that their interior volume 22a, 216 forms part of a room in the building 10, and the first building section 28 may define a further part of the room.
[0128] It will be noted that the lower modular building unit 14a in the assembly 12a is somewhat longer than the corresponding unit 14 in the assembly 12. This may be for numerous reasons, including but not limited to: providing a larger internal volume 16a within the lower unit 14a, for accommodating additional equipment, larger dimension internal rooms / spaces, or additional rooms / spaces: providing a ‘front-to-back’ module layout, in which the lower unit 14 extends from a front wall to a back wall of the building 10; and providing a proportionally similar internal volume in the modular building assembly (as the assembly 12 does in the building 10) within a larger volume and / or footprint building.
[0129] Turning now to Fig. 16, there is shown a detailed isometric view of a modular building assembly 12b according to another embodiment of the invention, similar to the view of the assembly 12 in Fig. 2. Like components of the modular building assembly 12b with the assembly 12 share the same reference numerals, with the addition of the suffix ‘b’. The modular building assembly 12b is also shown in Fig. 17, which is an exploded isometric view of the assembly 12b. The modular building assembly 12b can form part of the building 10 and so be provided in place of the assembly 12 shown in Fig. 1 . Only substantive differences between the assembly 12b and the assembly 12 will be described in detail here.
[0130] The modular building assembly 12b comprises a lower modular building unit 14b and an upper modular building unit 20b. The lower unit 14b comprises a ceiling structure 342b comprising a first section 344b and a second section 346b. The second ceiling section 346b comprises a floor support structure 26b. The upper modular building unit 20b, together with the second ceiling section 346b, overlie an entire footprint 18b of the lower modular building unit 14b, which is shown schematically in Fig. 16. The second modular building unit 20b is positioned on top of the lower unit 14b in the same way as the upper unit 20 is positioned on top of the lower unit 14 in the assembly 12.
[0131] The upper modular building unit 20b comprises an internal volume 22b, and a structural frame 64b, similar to the modular building unit 20 in the assembly 12. In this embodiment however, the internal volume 22b of the upper unit 20b is arranged to define a plurality of rooms or areas, in this case a bathroom 222 and a room 224 comprising or defining at least part of a circulation space. The room 224 comprises an aperture 86b which communicates with a stairwell aperture 74b defined by the lower modular building unit 14b, and a landing 88b adjacent the aperture 86b. A side wall structure of the upper modular building unit 20b in the vicinity of the aperture 86b has been removed, so that the internal structure can be better seen. The landing 88b is provided by a floor of the second unit 20b, which has been omitted from the drawing. The aperture 86b and landing 88b are thus formed in the upper modular building unit 20b, rather than by a floor (not shown) on floor support structure 26b.
[0132] In this embodiment, the upper modular building unit 20b, together with the second ceiling section 346b, effectively overlie the entire footprint 18b of the lower unit 14b. This is because, although the upper unit 20b comprises the aperture 86b, the structural frame 64b of the upper unit 20b comprises a ceiling frame portion 226 which extends over the length of the unit, and so effectively over the aperture 86b. This is in contrast to the floor support structure 26 of the assembly 12, where the floor support structure may not be considered to overlie the footprint portion 27 since the internal volume above the aperture 86 is defined by (and so covered by) structure forming the first building section 28.
[0133] In a variation (not shown) on the modular building assembly 12b, the assembly may comprise a plurality of upper modular building units, for example a second modular building unit forming the bathroom 222, and a third modular building unit forming the room 224. The variation may effectively be a combination of the embodiments 12a and 12b of Figs. 13-15, and Figs. 16-17.
[0134] Turning now to Fig. 18, there is shown a detailed isometric view of a modular building assembly 12c according to another embodiment of the invention, similar to the view of the assembly 12 in Fig. 2. Like components of the modular building assembly 12c with the assembly 12 share the same reference numerals, with the addition of the suffix ‘c’. The modular building assembly 12c is also shown in Fig. 19, which is an exploded isometric view, and Fig. 20, which is an enlarged side view taken in the direction of the arrow C in Fig. 18. The modular building assembly 12c can form part of the building 10 and so be provided in place of the assembly 12 shown in Fig. 1. Only substantive differences between the assembly 12c and the assembly 12 will be described in detail here.
[0135] The modular building assembly 12c of this embodiment comprises a lower modular building unit 14c which is similar in structure and design to the unit 14 of the assembly 12, excepting a ceiling structure 342c, in the form of a ceiling frame portion, which will be discussed below. The assembly 12c also comprises a further modular building unit in the form of an upper unit 20c positioned on top of the lower unit 14c.
[0136] The lower modular building unit 14c ceiling structure 342c comprises a first section 344c and a second section 346c. A footprint 18c of the lower modular building unit 14a is shown schematically in the side view of Fig. 20. The ceiling structure 342c also comprises a further section 228, which extends beyond a front perimeter portion 67c of the lower unit 14c, defining a front boundary of the footprint 18c. The second ceiling section 346b comprises a floor support structure 26c. It will be noted that the footprint 18c excludes the further section 228 of the lower unit ceiling structure 342c.
[0137] The upper modular building unit 20c again comprises a wet facility, defining a bathroom, and overlies a first portion 24c of the footprint 18c. The floor support structure 26c overlies a second portion 27c of the footprint 18c. The second modular building unit 20c and the floor support structure 26c are configured so that they together overlie a majority of the footprint 18c, excepting a stairwell aperture 74c. The floor support structure 26c again comprises an aperture 86c which communicates with the stairwell aperture 74c, and a main staircase portion (not shown) in the lower unit 14c.
[0138] In this embodiment, a portion 230 of the upper unit 20c overhangs the lower modular building unit 14c, extending beyond and overhanging the front perimeter portion 67 c of the lower unit. This overhanging portion 230 of the upper unit 20c forms at least part of a porch or awning for a building comprising the modular building assembly 12. A space 232 is provided beneath the overhanging portion 230, and defines a location for the porch, the space shown in broken outline in Fig. 18 and cross-hatched at the side. In this way, a front perimeter portion 234 of the upper modular building unit 20c is disposed outwardly or outboard of lower unit footprint 18c.
[0139] The ceiling frame portion forming the ceiling structure 342c of the lower unit 14c comprises a perimeter frame 48c, again typically of a hot-formed metallic material. The ceiling frame portion 342c is longer than a floor frame portion 40c of the lower unit 14c, so that its further section 228 extends beyond the front perimeter portion 67c of the lower unit 14c. This overhanging section 228 of the ceiling frame portion 42c is effectively cantilevered beyond the front perimeter portion 67c, and supports the overhanging part 230 of the upper unit 20c. In addition, the overhanging section 228 can provide a route for services to and from the bathroom provided in the upper unit 20c, such as water conduits and sewerage conduits servicing a bath 108c, toilet 110c and washbasin 112c. The services are shown schematically in Fig. 20, in broken outline and indicated by numeral 235. These conduits may extend laterally to a position above a technical room 107c in the lower unit 14c, where they are connected to feed / discharge conduits extending upwardly from the technical room.
[0140] In a variation, the overhanging portion 230 may be configured to form an interior space or volume within the building 10, and may communicate with a further part of the building, in particular with part of a room defined by the first modular building unit 14c. By way of example, the lower unit 14c may be configured to define a part of a washroom or W / C adjacent the space 232, and open on a side facing the space. The space 232, together with the part of the washroom in the lower unit 14c, may form a completed washroom in the building 10.
[0141] Turning now to Fig. 21, there is shown a detailed isometric view of a modular building assembly 12d according to another embodiment of the invention, similar to the view of the assembly 12 in Fig. 2. Like components of the modular building assembly 12d with the assembly 12 share the same reference numerals, with the addition of the suffix ‘d’. The modular building assembly 12d is also shown in Fig. 22, which is an exploded isometric view. The modular building assembly 12d can form part of a building lOd, which is shown in the highly schematic front view of Fig. 23. Only substantive differences between the assembly 12d and the assembly 12 will be described in detail here.
[0142] The modular building assembly 12d of this embodiment comprises a lower modular building unit 14d which is similar in structure and design to the unit 14 of the assembly 12. The assembly 12d also comprises a further modular building unit in the form of an upper unit 20d positioned on top of the lower unit 14d. The lower unit 14d comprises a ceiling structure 342d, comprising a first section 344d (Fig. 22) and a second section 346d. The second ceiling section 346d comprises a floor support structure 26d. A main part 248 of the floor support structure 26d is shown cross-hatched in Fig. 22, and supports a floor (not shown in the drawing). A further part 250 of the floor support structure 26d is defined by part of a side beam 252, and an end beam 254 which, together with an end beam 256 of the main part 248, define an aperture 86d. The aperture 86d is bordered along part of one side by a perimeter portion 92d of the upper modular building unit 20d.
[0143] The lower unit 14d defines a footprint 18d. The upper unit 20d has its own footprint 126d and, in the illustrated embodiment, this is different to the lower unit footprint 18d, being of a greater length along a main axis 124d (compared to a length of the lower unit 14d along a main axis 120d). The upper modular building unit 20d is configured to be positioned on top of the lower modular building unit 14d so that the second footprint 126d partially overlaps the first footprint 18d, and so that the first and second footprints are not aligned.
[0144] Specifically, the upper modular building unit 20d is positioned on the first ceiling section 344d so that its main axis 124d is disposed transverse to the main axis 120d of the lower unit 14d. In the illustrated embodiment, the upper unit 20d is arranged so that its axis 124d is substantially perpendicular to the lower unit axis 120d. The upper unit 20d therefore overlaps a right side perimeter portion 72d of the lower unit 14d, a part 230d of the upper unit overhanging the lower unit 14d.
[0145] As shown in Fig. 23, the lower unit 14d extends part way along a width dimension of the building lOd, whilst the upper unit 20d may extend across a greater extent of the width dimension. External walls of the building lOd (left and right such walls 236 and 238 shown) are provided by the first building section 28d, and enclose or encapsulate the modular building assembly 12d, which forms a second section 30d of the building.
[0146] The upper modular building unit 20d has an internal volume 22d which is arranged to define a plurality of rooms or areas, in this case a bathroom 222d and a room 224d comprising or defining at least part of a circulation space, zone or area 176d. The room 224d is open on a side facing the aperture 86d of the floor support structure 26d, which communicates with a stairwell aperture 74d defined by the lower modular building unit 14d (and a main staircase portion 82d in the lower unit 14d.). The room 224d also comprises a landing 88d, which is disposed adjacent the aperture 86d, and which defines or is provided in said part of the circulation space 176d. The landing 88d is provided by a floor 164d of the upper unit 20d. An internal volume 94d of the building formed by the first building section 28d includes a generally cubic or cuboid portion 98d, which is effectively disposed above the floor support structure 26d, in the vicinity of the aperture 86d.
[0147] In this embodiment, the upper unit 20d is supported partly by the lower unit 14d, and partly by the first building section 28d. Specifically, a portion of the upper unit 20d including a first end 239 (and a part of the circulation room 224d) is supported by the lower unit 14d, whilst a second opposite end 241 (and a part of the overhanging portion 230d) is supported by the external wall 238 of the first building section 28d. The external walls of the first building section 28d (and so including the walls 236, 238) can be of various constructions, but may in particular be formed from SIPs as discussed above. The end 241 of the upper unit 14d may for example be connected to SIPs forming the external wall 236, such as via mounting brackets, one shown in Fig. 23 and given the numeral 242.
[0148] The upper modular building unit 20d (specifically part of the circulation room 224d) overlies a first portion 24d of the footprint 18d, and the main part 248 of the floor support structure 26d overlies a second portion 27d of the footprint. The second modular building unit 20d and the floor support structure 26d are configured so that they together overlie a majority of the footprint 18d, excepting the stairwell aperture 74d.
[0149] The modular building assembly 12d may provide additional flexibility in the overall design of the building lOd, in that the wet facilities provided by the upper unit 20d (bathroom 222d) are not constrained to being arranged in-line with the lower unit 14d, specifically with its main axis 120d. Positioning of the bathroom 222d in the overhanging portion 230d may provide greater flexibility on the positioning of bedrooms in the first building section lOd, which are served by the bathroom, since a doorway 240 providing access into the ensuite from the bedroom can be disposed outside of the footprint 18d, and facing e.g. generally sideways in the building, as shown in Fig. 21.
[0150] For example, and turning to Fig. 24, there is shown a floorplan view of an upper storey 36d of the building lOd, viewing in the direction of the arrow D-D in Fig. 23 (taken just above a lower storey 34d). The modular building assembly 12d is drawn with double lines for easy identification. The drawing shows one possible configuration of bedrooms in the building lOd, which in this embodiment is a four-bedroom house comprising bedrooms 180d, 184d, 186d and 244. Access into the various bedrooms is provided via the circulation space 176d, specifically landing 88d and respective doorways 188d, 190d, 192d and 246. A main or front doorway 196d is provided by the lower modular building unit 14d, and is also shown in the drawing.
[0151] Turning finally to Fig. 25, there is shown an exploded isometric view of the modular building assembly 12 shown in Figs. 2 to 11, illustrating an option for routing building services between the lower modular building unit 14 and the upper modular building unit 20. The modular building assembly 12 further comprises a service module 258 which is configured to connect services, in particular building services equipment, between the lower and upper modular building units 14, 20. The service module 258 is shown both separately, and in a final position, in the drawing. The service module 258 contains one or more building services connector 260, for connecting building services equipment 250 in the lower modular building unit 14 to building services equipment 262 in the further modular building unit 20. The one or more building services connector 260 may comprise ducting, conduit, pipe, cable, wire or the like, connectable to equivalent ducting etc. in the first and further modular building units.
[0152] In the illustrated embodiment, the service module 258 comprises two service connectors in the form of ducts 260 and 260’. Duct 260 serves for connecting a stale air extraction duct 264 in the lower unit 14 to an extraction duct 266 in the upper unit 20, which serves to extract stale air from its internal volume 22 (which in this embodiment defines a bathroom). Duct 260’ serves for connecting a fresh air supply duct 264’ in the lower unit 14 to a supply duct 266’ in the upper unit 20, which serves to supply fresh external air into the upper storey 36 of the building, in the vicinity of the internal space 87 discussed above. These extract and supply ducts 264 and 264’ are connected to a ventilation unit 268 in the technical room 107 of the lower unit 14. It will be understood that ventilation ducts represent just one example of building services equipment which can be connected between the lower and upper units 14 and 20, and that appropriate additional or alternative connectors may be provided, for example selected from the list discussed above.
[0153] The service module 258 can be provided separately from the upper modular building unit 20, and may be connectable to it. Connection may occur at the site during assembly of the module building assembly 12 (when the upper unit 20 is positioned on the lower unit 14), or during manufacture and prior to transportation to the site. The service module 258 is positionable on or above the second ceiling structure section 346, and is provided externally of the upper unit internal volume 22. This may facilitate access to the equipment (ducts 260, 260’) contained by the service module, e.g. for maintenance or replacement. The service module 258 comprises a frame or outer support structure 270, which defines an internal void or space 272 containing the building services connectors (ducts 260, 260’). It will be understood of course that the space 272 may contain other building services equipment beyond connectors, e.g. the ventilation unit 268, water heating equipment, and / or a hot water storage tank.
[0154] It will be understood that further embodiments can comprise the features of any one or more of the embodiments shown in Figs. 1 to 25 and described above. For example, a variation of the modular building assembly 12a shown in Fig. 13 may comprise a single upper modular building unit defining a plurality of rooms or areas, like the upper unit 20b shown in Fig. 16. A variation of the modular building assembly 12c shown in Fig. 18 may comprise two or more further (upper) modular building units, like the upper units 20a and 214 shown in Fig. 13. In this variation, one of the upper modular building units may be located entirely on the overhanging part 228 of the ceiling frame (i.e. in the position accommodated by the overhanging portion 230 of the upper unit 20c). A variation of the modular building assembly 12d shown in Fig. 21 may comprise two or more further (upper) modular building units, like the upper units 20a and 214 shown in Fig. 13. Various modifications may be made to the foregoing without departing from the spirit or scope of the present invention. Further aspects and / or embodiments of the invention may combine the features of one or more aspect and / or embodiment disclosed in this document. Accordingly, such further aspects and / or embodiments may comprise one or more feature selected from one or more aspect or embodiment of the invention disclosed in this document. Unless explicitly implied by context or stated in the document, the features of 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. 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.
Claims
CLAIMS1. A hybrid building having a lower storey and an upper storey, the hybrid building comprising: a first building section which is an on-site construction at a final location for the building, the first building section comprising an internal volume defining at least one room providing a living space within the building; and a modular building assembly forming a second building section, the modular building assembly comprising: a first modular building unit comprising an internal volume, the first modular building unit having a base and a footprint; and at least one further modular building unit comprising an internal volume defining at least one room providing a further living space within the building, said further modular building unit positioned on top of the first modular building unit overlying a first portion of its footprint; in which the first modular building unit comprises a ceiling structure, the ceiling structure comprising: a first section defining at least one first surface which supports said further modular building unit, said first surface disposed at a first height relative to the base; and a second section positioned laterally relative to the first section overlying a further portion of the footprint, the second section defining at least one second surface disposed at a second height relative to the base which is greater than the first height, said second surface configured to support or define at least part of a floor for an internal space in the upper storey of the building, the internal space defined by the first building section and enclosed by walls of the building.
2. A hybrid building as claimed in claim 1, in which the first building section forms at least some external walls of the building, and in which the internal space is at least partly enclosed by one or more of said external walls.
3. A hybrid building as claimed in either of claims 1 or 2, in which the first building section forms at least one internal wall of the building, and in which the internal space is at least partly enclosed by said internal wall.
4. A hybrid building as claimed in any preceding claim, in which the further modular building unit and the second section of the ceiling structure together overlie a majority of the footprint of the first modular building unit.
5. A hybrid building as claimed in any preceding claim, in which the first modular building unit is configured to define at least part of an access route, the access route providing access from the first modular building unit to at least one of: a) the floor; and b) the internal volume of the further modular building unit.
6. A hybrid building as claimed in any preceding claim, in which the first modular building unit comprises at least a main part of a staircase, and in which the second section of the ceiling structure comprises an aperture which communicates with the main part of the staircase in the first modular building unit.
7. A hybrid building as claimed in claim 6, in which the floor comprises an aperture which communicates with the aperture in the ceiling structure, and with the main part of the staircase in the first modular building unit.
8. A hybrid building as claimed in claim 7, in which the floor is configured to define at least part of a landing, and the aperture opens adjacent to the landing.
9. A hybrid building as claimed in any one of claims 1 to 5, in which the first modular building unit comprises at least a main part of a staircase, and the further modular building unit comprises an aperture which communicates with the main part of the staircase in the first modular building unit when the further modular building unit is positioned on top of the first modular building unit.
10. A hybrid building as claimed in claim 9, in which the further modular building unit is configured to define at least part of a landing, and the aperture opens adjacent to the landing.
11. A hybrid building as claimed in any preceding claim, in which the floor is configured to provide direct access into the internal volume of the further modular building unit.
12. A hybrid building as claimed in any preceding claim, in which the second section of the first modular building unit is a raised section, the first modular building unit having a stepped profile, when viewed from the side.
13. A hybrid building as claimed in any preceding claim, in which the second section of the ceiling structure extends in a generally horizontal plane and in a direction which is generally away from the first section of the ceiling structure.
14. A hybrid building as claimed in any preceding claim, in which: the further modular building unit is a second modular building unit; the further portion of the footprint of the first modular building unit which is overlaid by the second section of the ceiling structure is a second portion of the footprint; and the modular building assembly comprises a third modular building unit comprising an internal volume; in which the at least one first surface of the first section of the ceiling structure supports the third modular building unit; and in which the third modular building unit is positioned on top of the first modular building unit overlying a third portion of its footprint.
15. A hybrid building as claimed in claim 14, in which the second modular building unit, the third modular building unit and said second ceiling section together overlie a majority of the footprint of the first modular building unit.
16. A hybrid building as claimed in any preceding claim, in which: the internal volume of the first modular building unit forms at least part of at least one room of the building, the at least one room selected from the group comprising a hallway, a room comprising a wet facility, and a technical room; and the room formed by the internal volume of the at least one further modular building unit comprises a wet facility.
17. A hybrid building as claimed in claim 16, when dependent on claim 14, in which the second and third modular building units each comprise respective wet facilities.
18. A hybrid building as claimed in any preceding claim, in which the first modular building unit comprises a perimeter, the perimeter comprising a plurality of perimeter portions, each perimeter portion disposed transverse to at least one other perimeter portion; and the at least one further modular building unit overlaps at least one perimeter portion of the first modular building unit.
19. A hybrid building as claimed in claim 18, in which: the at least one further modular building unit comprises a perimeter, the perimeter comprising a plurality of perimeter portions, each perimeter portion disposed transverse to at least one other perimeter portion; and the at least one further modular building unit is positioned on top of the first modular building unit so that at least one perimeter portion of the further modular building unit is disposed laterally spaced from a corresponding perimeter portion of the first modular building unit.
20. A hybrid building as claimed in claim 19, in which said perimeter portion of the further modular building unit is disposed outboard of the footprint of the first modular building unit.
21. A hybrid building as claimed in any preceding claim, in which the further modular building unit overhangs at least one perimeter portion of the first modular building unit, which perimeter portion defines a side of the first modular building unit.
22. A hybrid building as claimed in claim 21 , in which an overhanging portion of the further modular building unit forms at least part of a porch for the building.
23. A hybrid building as claimed in any preceding claim, in which the at least one further modular building unit is positioned on top of the first modular building unit so that at least one perimeter portion of said further unit is disposed inboard of at least one perimeter portion of the first modular building unit.
24. A hybrid building as claimed in any preceding claim, in which:the first modular building unit and the at least one further modular building unit each comprise a main axis extending along a main length direction; and the at least one further modular building is positioned on top of the first modular building unit so that the main axis of the at least one further modular building unit is disposed transverse to the main axis of the first modular building unit.
25. A hybrid building as claimed in any preceding claim, in which: the footprint of the first modular building unit is a first footprint; the at least one further modular building unit comprises a footprint, which is a second footprint of the modular building assembly; and the second footprint is different to the first footprint.
26. A hybrid building as claimed in claim 25, in which: the second footprint has a different shape to the first footprint; and / or at least one dimension of the second footprint differs from a corresponding dimension of the first footprint.
27. A hybrid building as claimed in any preceding claim, in which: the first section of the ceiling structure comprises a plurality of first surfaces disposed at the first height; and the second section of the ceiling structure comprises a plurality of second surfaces disposed at the second height.
28. A hybrid building as claimed in any preceding claim, in which: said second surface of the second section of the ceiling structure is a floor support surface; the at least one further modular building unit comprises a floor support surface configured to support a floor of said unit; and the second section of the ceiling structure and the at least one further modular building unit are configured so that their floor support surfaces are disposed at the second height.
29. A hybrid building as claimed in any one of claims 1 to 27, in which: said second surface of the second section of the ceiling structure defines the floor, and said second surface is an upper surface of the floor; the at least one further modular building unit comprises at least one floor support surface configured to support a floor of the unit; and the second section of the ceiling structure and the at least one further modular building unit are configured so that their respective at least one second surface and at least one floor support surface are disposed at the second height.
31. A method of constructing a hybrid building having a lower storey and an upper storey comprising the steps of: constructing a first building section at a final location for the building, comprising arranging the first building section so that it comprises an internal volume defining at least one room providing a living space within the building; constructing a second building section at least partly comprising a modular building assembly ; and connecting the first and second building sections at the final location; in which the step of constructing the second building section comprises: at a location away from the final location, constructing a first modular building unit to a substantially assembled form, comprising providing the first modular building unit with an internal volume, a base, a footprint, and a ceiling structure comprising: a first section defining at least one first surface disposed at a first height relative to the base; and a second section positioned laterally relative to the first section, the second section defining at least one second surface disposed at a second height relative to the base which is greater than the first height; at a location away from the final location, constructing at least one further modular building unit to a substantially assembled form, comprising providing said further modular building unit with an internal volume forming at least part of at least one room of the building; transporting the first modular building unit and the at least one further modular building unit to the final location in their substantially assembled forms; positioning the first modular building unit at the final location; forming the modular building assembly by positioning the at least one further modular building unit on the first section of the ceiling structure so that the further modular building unit overlies a first portion of the footprint; and arranging the second section of the ceiling structure so that it overlies a further portion of the footprint, and so that it supports or defines a floor for an internal space in the upper storey of the building which is enclosed by walls of the building.
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