EP-4739856-A1 - MODULAR BUILDING UNIT MANUFACTURING

Abstract

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

Inventors

• SHENTON, Edward Ross
• JONES, David Lee

Assignees

• SANO DEVELOPMENT LIMITED

Dates

Publication Date

20260513

Application Date

20240702

Claims (20)

1. 1. A method of manufacturing a modular building unit, the method comprising: constructing a floor assembly and walls extending upwardly from the floor assembly; separately constructing a ceiling assembly, wherein the ceiling assembly includes a load transfer section configured to transfer load to the walls; coupling building services equipment to the ceiling assembly; and lifting the ceiling assembly onto the walls and securing the walls to the load transfer section such that the walls connect the floor and ceiling frame assemblies.
2. 2. A method according to claim 1 , wherein the building services equipment is configured to form part of a building services system within a building defined in part by the modular building unit.
3. 3. A method according to claim 2, wherein the building services equipment comprises one or more of: an electricity supply cable; a data cable; a cold water pipe; a hot water pipe; a drainage pipe; a gas pipe; an air ventilation duct; or an energy storage system.
4. 4. A method according to any one of the preceding claims, wherein constructing the ceiling assembly further comprises: forming a support section connected to the load transfer section within at least a portion of the ceiling assembly, the support section being configured to support at least part of the building services equipment.
5. 5. A method according to claim 4, wherein the support section defines a generally planar surface within a portion of the ceiling assembly.
6. 6. A method according to claim 4 or claim 5, wherein the support section is recessed relative to an upper surface of the load transfer section.
7. 7. A method according to any one of claims 4 to 6, wherein the support section comprises joists or panelling spanning or interconnecting at least part of the load transfer section, or wherein the support section and the load transfer are integrally formed.
8. 8. A method according to any one of the preceding claims, further comprising forming a load bearing structure over at least part of the building services equipment.
9. 9. A method according to claim 8, wherein at least part of the building services equipment is sandwiched between and at least partially protected by the support section and the load bearing structure.
10. 10. A method according to any one of the preceding claims, further comprising: constructing a services module comprising building services equipment and a housing at least partially containing the building services equipment; and coupling the services module to the ceiling assembly.
11. 11. A method according to claim 10 when dependent on claim 4, wherein the services module is located on or coupled to the support section.
12. 12. A method according to any one of the preceding claims, wherein the load transfer section including at least one first portion and at least two second portions extending above a top surface of the first portion; wherein the second portions are configured to support a floor assembly of a further modular building unit stacked on top of the modular building unit; wherein each first portion of the load transfer section is configured to form an aperture between the stacked modular building units; and wherein the building services equipment are configured to connect through the aperture between the stacked modular building units.
13. 13. A method according to any one of claims 1 to 11 , comprising providing the load transfer section as a lattice structure comprising a lower structural member defining a lower surface of the load transfer section, an upper structural member defining an upper surface of the load transfer section, and at least one connecting member extending between and connecting the lower structural member to the upper structural member, and arranging the at least one connecting member so that it transfers loads from the upper structural member to the lower structural member and so to the walls.
14. 14. A method according to claim 13, comprising providing the load transfer section with a plurality of generally elongate portions which together define the load transfer section, a generally elongate portion being provided for each wall, and arranging each generally elongate portion so that it comprises respective lower and upper structural members and at least one connecting member extending between and connecting the lower and upper structural members.
15. 15. A method according to either of claims 13 or 14, comprising providing the ceiling assembly with a ceiling section forming a support section configured to support at least part of the building services equipment, and arranging the ceiling section so that it is disposed inwardly of the load transfer section and connected to it.
16. 16. A method according to claim 15, comprising arranging the ceiling section so that a lower surface of the ceiling section is disposed at a position that is lower than an upper surface of the walls.
17. 17. A method according to either of claims 15 or 16, comprising arranging the ceiling assembly so that it defines a services void comprising an upper boundary defined by a plane containing an upper surface of the load transfer section, and a lower boundary defined by a plane containing the lower surface of the ceiling section, and positioning the building services equipment within the services void.
18. 18. A method of constructing a building defined in part by a modular building unit manufactured according to the method of any one of claims 1 to 17, the method comprising delivering the manufactured modular building unit to a final location for the building in a substantially assembled form.
19. 19. A services module for a modular building assembly, the services module comprising: building services equipment; and a housing at least partially containing the building services equipment; wherein the services module is configured to be received in or connected to a floor or ceiling assembly of a modular building unit forming part of the modular building assembly such that when two modular building units are stacked to form the modular building assembly, the services module is located between the two stacked modular building units.
20. 20. A services module according to claim 19, wherein the building services equipment is configured to form part of a building services system within a building defined in part by the modular building unit.

Description

MODULAR BUILDING UNIT MANUFACTURING TECHNICAL FIELD [0001] The present invention relates to a method of manufacturing a modular building unit as well as modular building units manufactured according to the method. The present invention also relates to services module that may be used during manufacture of a modular building unit or a modular building assembly comprising two or more modular building units. BACKGROUND [0002] Prefabricated buildings (also known as ‘modular’ buildings) are well known in the construction industry, particularly modular residential buildings such as houses, flats or apartments, and hotels. Modular buildings typically comprise a series of building units which are constructed in a factory, transported to a final location (or site) for the building, and then arranged in a predetermined configuration and coupled together to form the finished building. The modular building units are typically constructed to a substantially assembled form in the factory, in which they can be transported to the final location. Construction of the building can involve stacking one or more upper modular building unit on a lower such unit, so that the lower unit supports the upper unit. [0003] Hybrid buildings have been developed by the applicant which comprise a first building section that is constructed at a final location for the building, and a second building section comprising one or more modular building units constructed in a dedicated facility, away from the final location. A hybrid building of this type can provide advantages including that: construction of the first building section is simplified, with more complex parts of the building provided in the section formed by the modular building unit(s); and the first building section can provide the primary living space in the building, without being constrained by construction and transport limitations imposed on the modular building unit(s). The hybrid buildings and associated construction techniques are disclosed in International patent publication nos. WO2022/243696, WO2022/243695, WO2022/243694, WO2022/243693, and WO2023/222853. [0004] When a hybrid building is constructed there is a need to interconnect building services such as heating, ventilation, power, communications, water, and drainage, between the first (site- built) building section and the second (modular, or off-site constructed) building section (as well as between modular building units if a plurality of units is used in the construction). Such interconnections can require wires, pipes, or ducts to pass from one building section to another. Also, for fully modular buildings, there is a similar requirement for such interconnections between modular building units. Current solutions to interconnecting building services, including for fully modular buildings, often required holes or ducting to be formed through walls or floor or ceiling assemblies of the modular building unit, which can interfere with the structural integrity of those structures or otherwise impact on the building, for instance by compromising insulation or restricting architectural freedom in arranging rooms and doorways. [0005] Furthermore, during manufacture of a modular building unit where building services are incorporated into a ceiling assembly, conventionally the services such as wires, pipes and ducts are incorporated into the ceiling assembly after the structure of the modular building unit is substantially complete. Consequently, this may involve working at height within a factory which poses a risk to personnel as well as being inefficient or making it harder to access certain areas of the ceiling assembly. [0006] It is an aim of certain examples of the present invention to provide for improved interconnection of services within a hybrid or fully modular building. BRIEF SUMMARY OF THE INVENTION [0007] According to a first aspect of the present invention there is provided a method of manufacturing a modular building unit, the method comprising: constructing a floor assembly and walls extending upwardly from the floor assembly; separately constructing a ceiling assembly, wherein the ceiling assembly includes a load transfer section configured to transfer load to the walls; coupling building services equipment to the ceiling assembly; and lifting the ceiling assembly onto the walls and securing the walls to the load transfer section such that the walls connect the floor and ceiling frame assemblies. [0008] The building services equipment may be configured to form part of a building services system within a building defined in part by the modular building unit. The building services equipment may comprise one or more of: an electricity supply cable; a data cable; a cold water pipe; a hot water pipe; a drainage pipe; a gas pipe; an air ventilation duct; or an energy storage system. [0009] Constructing the ceiling assembly may further comprise: forming a support section connected to the load transfer section wi