EieM

The present invention relates to a connector, a connector system, and a building element connectable to another building element by using the connector or connector system. The present invention also relates to a modular building and parts of a building, such as an outdoor area, for mounting to a building element.

Background

Recently, rapid population expansion and the need to increase population density in cities have led to the development of modular buildings. In general, modular buildings have developed Into so-called "unitised" style buildings In which a frame is erected and a series of like units (e.g. a unit comprising a bathroom laundry has the same dimensions as a unit comprising a bedroom or kitchen) are inserted into the frame. Other such buildings constitute a plurality of like modules stacked on top of, and beside, similar modules (hereinafter "neighbouring modules").

To manufacture modules cost-effectively, they must be substantially similar in shape. In general modules have a regular rectangular shape (see module 100 in Figure 1): the outer dimensions of one module being substantially the same as the outer dimensions of neighbouring modules.

Modules 100 of a modular building 102 also tend to have a structural frame 104 defining the edges of the respective module. The structural frames 104 of the modules 100 are typically connected together (e.g. by welding) to form a single overall structural frame for the building 102.

There are many drawbacks with currently available modules 100. In particular, since a module 100 will typically be assembled in a factory and subsequentl be transported to the site of the building 102, the module must be configured to be carried by a truck and/or ship. If the module 100 is provided with footings 106, those footings may need to be removed in order for the structural frames 104 of neighbouring modules to be connected together.

The connecting of modules 100 also tends to be by welding, or other permanent connection, so that the structure of one module 100 supports the structure of neighbouring modules 00. Since it is desirable to complete the modules 100 (e.g. install internal wall cladding, electrical wiring and other element) as much as possible when in the factory, so as to lessen the work that must be conducted on site in prevailing weather conditions, welding structural frames 1 4 together can cause thermal damage to already installed elements of the module 100. ln addition, once the modules 100 have been welded together it is difficult to relocate any particular module 100 if it is found to be faulty or improperly positioned.

A further difficulty is that the structural frames 104 of modules 100 tend to be fabricated from steel and, in connecting the frames 104 of modules 100, a single steel frame is created that extends across the building in all directions. While the connection of the frames 104 is necessary so as to confer structural rigidity and stability upon the building 102, the resulting structure readily transmits acoustic vibrations across the building. In many countries, acoustic transmission in buildings having more than one residence (e.g. apartment buildings) is tightly controlled. Thus many modular buildings are rendered unsatisfactory for use in those countries.

A unitary frame comprising the connected frames 04 also suffers from the creation of lines of weakness that extend generally linearly from one side of a modular building 102 to the other. For example, if each of the modules 100 has a structurally weak corner post 114 extending from the roof to the floor of the respective module 1,00, when modules 100 are stacked atop one another the weak regions 114 will align thereby creating a line of weakness extending from the top of the building 102 to the bottom.

Yet another problem with modular buildings 102 is the creation of "blind corners" 108. Frames 104 tend to be connected at the corners 108, 110, providing typically the strongest overall frame once the building 102 is completed. However, . after the modules 100 are connected together as shown in Figure 1 , comer 108 can no longer be accessed when module 112 (indicated by the broken lines) is moved into position. Therefore, module 112 is not connected to the other modules 100 at corner 108.

Summary of the Invention

In accordance with the invention there is provided a connector for connecting a first building element to an adjacent building element, comprising:

an elongate member having a first anchor at or near one end, the elongate member being adapted to lie in the first building element so that it is moveable in use to move the first anchor from the first building element into engagement with the adjacent building element; and

a second anchor provided on the elongate member in spaced relation to the first anchor and to engage with the first building element, wherein the connector is actuable in use to reduce a distance between the first and second anchors to connect the first building element with the adjacent building element In some embodiments the second anchor may be actuable i use to reduce a distance between the first and second anchors to thereby connect the first building element with the adjacent building element

In some embodiments the distance between the first and second anchors may be reduced by rotating the second anchor along the elongate member.

In some embodiments the elongate member is a rod.

In some embodiments at least one anchor has a first orientation to allow the first anchor to move into the adjacent building element, and a second orientation to fix the elongate member between the building elements.

In some embodiments the device is actuable using a detachable handle.

In some embodiments the detachable handle connects to an eyelet in the elongate member.

The present invention also provides, a connector system including:

a connector comprising an elongate member having a first anchor at or near one end, and a second anchor provided on the elongate member in spaced relation to the first anchor;

a first connector channel provided in a first building element for receiving the elongate member, and having an engagement element for engaging the second anchor and

a second connector channel provided in an adjacent building element and having an opening through which the first anchor can be extended from the first connector channel/ and including an engagement element for engaging the first anchor,

wherein the connector is actuable to reduce a distance between the first and second anchors, the anchors engaging with their respective engagement elements to connect the first building element with the adjacent building element.

In some embodiments the elongate member extends in use along a substantial portion of one side or edge of the first building element.

In some embodiments the system further comprises a retainer for maintaining a position of the connector system in the first building element prior to movement of the first anchor.

In some embodiments the retainer is a spring.

In some embodiments the first anchor is a keyed anchor shaped to engage the engagement surface in the adjacent building element

In some embodiments the engagement surface in the adjacent building element is a keyed rebate shaped to cooperate with the shape of the first anchor. In some embodiments the first anchor is moveable into abutment with a surface of the adjacent building element and the second anchor is moveable Into abutment with the first building element to connect the first building element to the adjacent building element.

The present invention further provides, a method for connecting a first building element to an adjacent building element via a connector provided in the first building element, comprising:

moving the connector so that an anchor at one end of the connector extends into the adjacent building element;

engaging the anchor with the adjacent building element; and

actuating the connector to engage a second anchor at an opposite end of the connector to the first building element and to reduce a distance between the anchors to connect the first building element to the adjacent building element

Described herein is a connector comprising: .

an elongated member having a keyed first anchor at one end;

a second anchor provided, or attachable, at or near an opposite end of the elongated member, the second anchor being axially displaceable with respect to the first anchor; and

a retainer for maintaining a position of the elongated member to allow the axial displacement of the second anchor with respect to the first anchor.

Described herein is a connector for connecting a first building element to an adjacent building element, comprising:

an elongated member having a keyed first anchor at one end, the first anchor for abutting the adjacent building element;

a second anchor provided, or attachable, at or near an opposite end of the elongated member, the second anchor being axially displaceable with respect to the keyed anchor, and

a retainer for maintaining a position of the elongated member to allow the axial displacement of the second anchor with respect to the keyed anchor, so that the second anchor abuts the first building element thereby to connect the first building element to the adjacent building element.

Described herein is a connector system for connecting a first building element to an adjacent building element, comprising:

a fixing member extending, in use, along a length of the first element through an opening into the adjacent element, the fixing member including a first anchor and a second anchor at respectively opposite ends of the fixing member, the anchors cooperating to hold the first building element to the adjacent building element.

Described herein is a connector system for connecting a first building element to an adjacent building element, comprising:

a fixing member extending, in use, along a length of the first element through to the adjacent element, the fixing member including a first anchor and a second anchor at or near respectively opposite ends of the fixing member,

wherein at least one of the anchors is aligned in a first orientation to allow the fixing member to extend through to the adjacent element, and is movable into a second orientation to fix the member between the elements and thereby connect the elements.

Described herein Is a connector system for connecting a first building element to an adjacent building element, comprising:

a fixing member extending, in use, along a length of the first element through to the adjacent element, the fixing member including a first anchor and a second anchor at respectively opposite ends of the fixing member, the anchors cooperating to hold the first building element to the adjacent building element, wherein

the first anchor is positioned to extend through an opening in the adjacent element, the fixing member, being movable to bring the first anchor into abutment with a surface of the adjacent element and the second anchor into abutment with a surface of the first element to connect the first building element to the adjacent building element.

Described herein is a building element for forming one of a plurality of building elements connectable together to form a building, the building element having walls, a roof and a floor thereby defining an internal volume, the building element further including an access chute that, when the plurality of modules are connected together, aligns with one or more access chutes of a respective one or more of the plurality of building elements, the aligned access chutes together forming an access shaft

Described herein is a building element for forming one of a plurality of building elements connectable together to form a building, the building element having walls, a roof and a floor thereby defining an internal volume, the building element further including a supply box for connection to a corresponding box of a neighbouring one of the plurality of building elements so that supplying power to the neighbouring building element results in power also being supplied to the building element, the supply box being mounted to one of the walls, roof or floor.

Described herein is a building element comprising walls, a roof and a floor that are supported by a structural frame, at least one of the walls, roof and floor being substantially acoustically separated from the frame by one or more impactors. Described herein is a building element for forming one of a plurality of building elements connectable together to form a building, the building element Including a structural frame from which walls, a roof and a floor of the building element are supported, the structural frames being connectable together to provide the structure of the building.

Described herein is a building element including a structural frame from which walls, a roof and a floor of the building element are supported, the structural frame being supported on footings, wherein the footings include apertures shaped to facilitate mounting to more than one of a deck of a cargo ship or truck, a roof of a shipping container and a roof of another building element

Described herein is an outdoor area for mounting to a building element, the outdoor are including a drainage tray for draining water away from the outdoor area.

Described herein is a building element being a combination of two or more building elements as described above.

Described herein is a building element including a connector system as described above.

The outdoor area described above may be for mounting to a building element as described above.

Described herein is a building including one or more building elements as described above.

Described herein is a method for connecting a first building element to an adjacent building element, comprising:

inserting a fixing member along the length of a first element and through to an adjacent building element so that an anchor at one end of the fixing member extends into the adjacent building element;

moving the anchor into an engagement position for engaging the adjacent building element;

anchoring an opposite end of the fixing member to the first building element so that the fixing member connects the building elements.

Some embodiments of the invention provide a footing or similar that is configured (i.e. shaped and sized) to be secured to a truck, ship and to similar neighbouring building elements in a modular building.

Some embodiments of the invention provide a connection system that enables the connection of all neighbouring building elements at blind comers.

Some embodiments of the invention provide a connection system that enables the building elements of the building to be disconnected from neighbouring building elements. Some embodiments of the invention provide a building element having a frame that is acoustically disconnected from the frames of neighbouring building elements.

Some embodiments provide a connection system for connecting corner regions of neighbouring building elements so that all building elements meeting at the respective comer region contribute to the structural strength of the modular building at that comer region.

Brief Description of the Drawings

The present invention will now be described by way of non-limiting example only, with reference to the accompanying drawings, in which:

Figure 1 is a front perspective view of an illustrative embodiment of a modular building generally;

Figure 2 is a partial close-up perspective view of an upright edge of a building element in accordance with the present invention;

Figure 3 is a slightly reoriented view of the edge shown in Figure 2;

Figure 4 shows a twist-lock arrangement of the present invention in an open

(transit) or unlocked position;

Figure 5 shows a twist-lock arrangement of the present invention in a closed or locked position;

Figure 5A shows an alternative embodiment of a twist-lock arrangement of the present Invention with twist-locks fastening being possible on both forwaroTlong sides of the module 10 and return/short sides of the module 10; ,

Figure 6 is a partial close-up exploded view of a connector system In accordance with the present invention;

Figures 7 and 6 show steps In the insertion and use of a connector system in accordance with the present invention;

Figure 9 is a simplified plan view of a floor of a building, the floor having four modules the corners of which are obscured by stiffening plates;

Figures 10 to 14 are various partial cross-sectional section views of a module built in accordance with the present invention;

Figure 15 is a partial cross-sectional plan view of a module built in accordance with the present invention;

Figure 16 is a perspective cross-sectional plan view of a module built in accordance with the present invention, demonstrating the location of an access shaft; and

Figure 17 is a schematic plan view of a floor in a modular building constructed using modules of the present invention. Detailed Description

Figure 2 shows a partial close-up perspective view of an upright edge of a building element or module 10. In particular, Figure 2 shows a connector 12 positioned in a connector channel 17. The connector 12 is for connecting a first building element or module 10 to an adjacent building element or module 22.

The connector 12 comprises an elongate member 14 having a first anchor 6 at or near one end. The elongate member 14 is adapted to lie in the first building element 10 so that it Is moveable in use to move the first anchor 16 from the first building element 10 into engagement with the adjacent building element 22.

The connector 12 further comprises a second anchor 18 provided on the elongate member 14 in spaced relation to the first anchor 16. The second anchor 18 engages with the first building element 10. The connector 12 is actuable to reduce a distance between the first and second anchors 16, 8 to connect the first building element 10 with the adjacent building element 22.

In the present case the second anchor 8 is actuable to reduce the distance between the first and second anchors 16, 8 in order to connect the first building element 10 with the adjacent building element 22. The second anchor 8 is actuated by rotation along the elongate member 14. In this regard the second anchor 18 has a screw thread that mates with a screw thread on the elongate member so as to guide movement of the second anchor 18 along the elongate member 14.

As discussed above, the connector 12 comprises comprising an elongated member 14 having a keyed first anchor 16 at one end, and a second anchor 18 provided, or attachable, at or near an opposite end of the elongated member 1 .

The second anchor 8 is axially displaceable with respect to the first anchor 16.. The second can thereby translate along the elongated member 14 towards (and away from) the first anchor 16.

The connector further includes a retainer 20 (see Figures 4 and 5) for maintaining a position of the elongated member 14 to allow the axial displacement of the second anchor 18 with respect to the first anchor 16.

More particularly, Figure 2 shows a connector 12 for connecting a first building element or building module 10 to an adjacent building element or module 22. The first anchor 6 abuts the adjacent building element 22, and the second anchor, which is provided or is otherwise attachable at or near the opposite end of the elongated member 14, abuts the first building element 10 thereby to connect the first building element 10 to the adjacent building element 22.

The connector 12 forms part of a connection system including: the connector 12, which as described above comprises an elongate member 1 having a first anchor 16 at or near one end, and a second anchor 18 provided on the elongate member 14 in spaced relation to the first anchor 16;

a first connector channel 17 provided in a first building element or module 10 for receiving the elongate member 14, and having an engagement element or rebate 19 for engaging the second anchor 18; and

a second connector channel 17 provided in an adjacent building element or module 22 and having an opening 21 through which the first anchor 16 can be extended from the first connector channel 1 , and including an engagement element 23 for engaging the first anchor 16.

The connector 12 is, as described above, actuable to reduce a distance between the first and second anchors 16, 18, the anchors 16, 8 engaging with their respective engagement elements 19, 23 to connect the first building element or module 10 with the adjacent building element or module 22.

To ensure the connector 12 positively locks in position, the first anchor 16 is keyed and shaped to engage the engagement element or surface 23 in the adjacent building element or module 22. The engagement element 23, and similarly engagement element 19, can be shaped to cooperate with the shape of the first and second anchors 16, 18 respectively. In other words, the first anchor 16 is moveable into abutment with the surface of engagement element 19 of the adjacent building element 22 and the second anchor 8 is moveable into abutment with the first building element 10 to connect the first building element 10 to the adjacent building element 22.

It will be appreciated that the elongate member 14 of the connector system extends along a substantial portion of one side or edge of the first building element or module 10. Thus the elongate member 14 enables modules to be connected at a corner that is remote from the comer from which the connector 12 is being actuated.

It will be appreciated that the building element 10 forms one of a plurality of building elements connectable together to form a building, the building element 10 having walls 24, a roof 26 and a floor 28 thereby defining an Internal volume (more clearly shown in Figure 15). The modules 10, 22 are substantially rectangular and comprise a frame 30.

The frame 30 of the module 0 comprises beams 32 that extend along the length of the module 10, beams 34 that extend along the width of the module 10 and columns 36 extending generally from the top and the bottom of the module 0. It will be appreciated that a similar arrangement will be present in each of the four corners or comer regions 38 of each module 10, 22. The beams 32, 34 and columns 36 together form the frame 30 of the module 10 and provide a substantial proportion of the structural strength thereof. In some instances, wall panelling 40 (discussed in greater detail hereafter) can be selected so as to supplement the structural strength of the frame 30.

To facilitate positioning of one module 10 atop another module 22, mounting blocks 42 are positioned at either end of the column 36. The mounting blocks 42 facilitate vertical alignment of building elements 10, 22 between levels (e.g. I, II) in the modular building (similar to the building shown in Figure 1).

Each mounting block 42 includes an aperture or slot 44, the aperture or slot 44 in the mounting block 42 at the upper end of the column 36 including a bevelled edge or perimeter 46. Before, during or after positioning of the module 10, a locking pin 48 is positioned in the bevelled port 44 of the upper end of the column 36. The locking pin 48 includes an outwardly projecting rib 50 having a sloped surface that abuts the bevelled edge 46 of the port 44 thereby positioning the locking pin 48 in the port 44.

Once one module 22 has been secured in position in the manner discussed hereafter, locking pins 48 are positioned in the apertures 44 at in each mounting box 42 at the upper end of the column 36 in each comer region 38 of the module 22, and another module 10 is then positioned on top of the module 22. In so doing, the alignment member 42 of the module 10 now being positioned, receives the locking member 48 lodged in the mounting block 42 of the already positioned module 22, to align the comer region 38 of the top module 10 with the comer region 38 of the bottom module 22.

Each cast mounting end 42 of the column 36 includes one or more inspection ports 52 (presently two such ports 52 as shown in Figure 3) to enable a visual determination of the correct positioning, or otherwise, of the locking member 48 between the column ends 42 to be made. Such inspection ports 52 may also be provided for visually inspecting a position of the first anchor 16 or second anchor 18.

While the apertures 44 in the cast mounting ends 42 of the column 36 may be shaped to closely correspond with the shape of the locking pin 48, it is desirable that the aperture 44 be longer in one dimension than the pin 48. This allows some tolerance in the positioning of the top module 10 atop the bottom module 22 to ensure alignment with locking pins 46 in all four comer regions 38 of the bottom module 22 is achieved with ease. If no such tolerance were provided then alignment of the modules 10, 22 would become a far more time-consuming process.

After positioning of the top module 10 on the bottom module 22, the top module

10 can be pushed in towards the neighbouring modules until exact alignment is achieved. For the purpose of illustration, with reference to Figure 1, the 'neighbouring modules' would include those modules in the upper level I, and the module 10 being aligned would be the module 1 2 shown in broken lines.

In some embodiments, the upper end of the column 36 of the lower module 22 can have a permanently fixed mounting protrusion or pin for aligning with the upper module 10. This will avoid the labour required to position the pins in the slots of the lower module 22, but may increase the height of the module 22 and thereby increase shipping costs or correspondingly decrease the maximum height of the module 22.

After the upper module 10 has been positioned and aligned on the lower module 22, the two modules 10, 22 are fixed together. The modules 10, 22 are provided with a fixing box 54 on neighbouring sides of the mounting block 42. Each fixing box 54 of one module 10, 22 includes a slot or aperture 56 that aligns with a corresponding slot or aperture 56 in a neighbouring module 10, 22. A fastening means 12, 58 can then extend through the aligned apertures 56 and be fastened to couple the modules 10, 22 together.

In the present embodiment, two fastening mechanisms 66, 58 are shown. The first fastening mechanism 58 is a typical bolt fastener. Two aperture plates 60 are threaded over the shank of the bolt 62 and a nut 64 is thereafter attached to the end of the shank opposite the head of the bolt 62, thereby forming a bolt assembly 58. The two plates 60 are separated and the bolt assembly 58 is sljd into position with the head of the bolt 62 and internal wall of a mounting box 54 in the upper module 10 sandwiching one aperture plate 60, and the nut 64 and internal surface of another mounting box 54 in the lower module 22 sandwiching the other aperture plate 60. Tightening of the nut 64 thereby secures the two modules 10, 22 together, with the aperture plates 60 effectively acting as washers for the nut 62 and bolt 64.

In some embodiments, the washers are not provided and are not necessary.

This will generally depend on required bolt tensions for fastening the modules 10, 22 together and the grade of the material of the mounting boxes 54. Moreover, the slot 56 can be replaced with an aperture through which the bolt 62 is threaded between the upper and lower modules 10, 22 respectively.

For securing modules 10, 22 together where both sides of each module 10, 22 at a particular comer region 38 are accessible, the first fastening means 58 will usually be suitable. For blind corners (as illustrated by comer 108 in Figure 1) on the other hand, a more sophisticated fastening mechanism 66 is required.

The second fastening means 66, as best shown in Figures 4 and 5, is arranged to connect modules 10, 22 together at blind comers. The second fastening means 66 forms a connector system 68 for connecting the first building element 10 to the second building element 22 (or a module 10, 22 to the foundations 70) and comprises a fixing member 14 by which the modules 10, 22 are fixed together. The fixing member 14 extends, in use, along a length of the first element 10 through to the adjacent element 22, in the present case through an opening 44 into the adjacent element 22.

The fixing member 14 has a first anchor 16 and a second anchor 8 at respectively opposite ends of the fixing member 14 as mentioned above. The anchors 16, 18 cooperate to hold the first building element 10 to the adjacent building element 22. Similarly, a connector system 68 is provided to secure the lower building element 22 to the foundations 70 of the building.

One of the anchors, presently the first anchor 6, is able to be positioned to extend through an opening 44 in the adjacent element 22, the fixing member 14 being movable to bring the first anchor 16 into abutment with a surface of the adjacent element 22 and the second anchor 8 into abutment with a surface of the first element 10 to connect the first building element 0 to the adjacent building element 22. To facilitate positioning of the first anchor 16, one of the anchors (presently first anchor 16) can align in a first orientation to allow the fixing member 14 or first anchor 16 to extend through to the adjacent element 22. The anchor (presently first anchor 16) is then movable into a second orientation (e.g. by rotation) to fix the member 14 between the elements 10, 22 and thereby connect the elements 10, 22.

A particular advantage of the manner in which modules 10, 22 can be locked together in accordance with the present invention is that the locking mechanisms 66 can be unlocked in future, thereby allowing the modules 10, 22 to be decoupled. In the event of a fire or when demolishing the building, for example, the modules 10, 22 can be unfastened and individually removed for relocation and/or refitting.

While the mounting boxes 54 for the first fastening system are accessible through the side, to enable insertion of the bolt assembly 58 into the respective mounting box 54, the mounting heads or boxes 72 for the second fastening system 66 do not need to have open sides as the second fastening mechanism 66 is inserted through a top aperture 74 in the mounting head 72 of the upper module 10, down an connector channel 76 in a structural or mounting column 36, and through

corresponding apertures 44 in the lower mounting head 78 of the upper module 10 and upper mounting head 80 of the lower module 22.

In the present embodiment, the fixing member includes an elongate rod 14 that, when inserted to extend between the modules 0, 22, extends from the top mounting box 72 of the upper module 10 down into the top mounting box 80 of the lower module 22. A lower fixing plate or first anchor 16 Is welded or otherwise mounted to the lower end of the rod 14 for fixing the lower end in the mounting box 80 of the lower module 22. The lower fixing plate 16 has an irregular shape (e.g. not circular or square) so that it can pass through aligned apertures 44 In the upper and lower modules 10, 22 yet, upon rotation by a predetermined angle (typically 90°), will not be able to be retracted back through at least the aperture 44 in mounting box 80 of the lower module 44.

A further fixing plate or second anchor 18 is mounted to the opposite end of the rod 14 to anchor the opposite end to the mounting box 72 of the upper module 10. Whereas the first fixing plate 16 will typically be rigidly attached to the rod 14, since it is not accessible after the rod 14 is in position, the second fixing plate 18 has an aperture through which the rod 14 can slide and thereby permit axial translation of the second fixing plate 18 along the rod 14.

To control the position of the second fixing plate 18, the connector system 66 comprises a stop, presently a nut 82 (see Figures 5 and 6), for limiting the axial displacement of the second anchor 18 away from the first anchor 16. The nut 82 is screwed onto the rod 1 above the second fixing plate 8, an internal thread of the nut 82 engaging a threaded portion of the rod 14 such that rotation of the nut 82 along the threaded end of the rod 14 limits the axial displacement of the second anchor 18 away from the first anchor 16 (i.e. the second anchor 18 cannot move further away from the first anchor 16 than is permitted by the nut 82).

The connector system 66 further includes a place-keeper, presently a rubber or plastic ring 84, for limiting the axial displacement of the second anchor 18 towards the first anchor 16. The ring 84 fits around one end of the rod 14 and is held in place by a friction fit The second anchor 18 is then placed into the rod 14, followed by the nut 82. Thus the second anchor 18 is sandwiched between the stop 82 and place-keeper 84. When sandwiched between the nut 82 and ring 84, rotation of the nut 82 in one direction causes movement of the second anchor 18 towards the first anchor 16, thereby displacing the ring 84 towards the first anchor 16.

At the uppermost end of the fixing rod 14 is an actuation means or actuating surface, presently an orifice or ring 86, for engaging with an actuating tool or detachable handle 88 (see Figure 8) to move the connector 12 to a kicking condition in which the first building element 10 is connected to the second building element 22. The fixing member 12 Is accessible, e.g. using the tool or handle 88, from a position on the roof of the module 10. The tool 88 can also be used to subsequently unlock the connector 12 and thereby disconnect the first and second building elements 10, 22.

When part of the locking tool or handle 88 is inserted into and engages the ring

86, rotation of the tool or handle 88 causes the lower fixing plate 1 to move from a first condition in which it can be inserted through the apertures 44 in the first and second modules 10, 22. and a second condition as shown in which it can lock against an internal wall of the mounting box or block 80 of the lower module 22.

The hole 86 can be formed by, for example, welding a ring to the upper end of the rod 14 or by drilling a hole through the upper end of the rod 1 and machining the sides of the end of the rod 14 to create a generally planar flange shape with the hole therein.

To ensure the ring 86 is accessible after the rod 14 has been inserted, a compressible member, presently spring 20, is provided as shown in Figures 4 and 5. The spring 20 extends between a base plate 90 fixed or resting inside the column 75, and an abutment surface, presently flange 92, fixed to the rod 14. The abutment surface limits movement of the spring 20 in one direction along the elongate member 14, and the base plate limits movement of the spring along the elongate member 14 in the other direction when the connector system 66 is in position.

The spring 20 is compressible to urge the lower fixing plate 16 into the lower module 22 but is sufficiently stiff to be able to support the weight of the rod 14 and thereby maintain accessibility to the locking ring 86. Thus the spring 20 has a first condition for maintaining at least a substantial part of the connector 12 within the upper building element 0 and is compressible to move to a second condition in which the first anchor 16 projects from the first building element 10 into the adjacent building element 22.

The spring 20 can be positioned by adding the flange 92 to the rod 14, then threading the rod 14 through the spring 20 before attaching the lower fixing plate 16. The spring 20 then passes through the apertures 44 in the top mounting box 72 of the upper module 10, which may be larger than the apertures 44 in the lower mounting box 78 so that the spring 20 cannot pass into the lower mounting box 78, and comes to rest against the base plate 90.

The tool or handle 88 is then attached to the ring 84 and the rod 14 is urged downwardly against the force of the spring 20. Once the first anchor 16 abuts the internal surface of the lower mounting box 78 as shown In Figure 4, the tool or handle 88 is twisted thereby rotating the rod 14 until the first anchor 16 is aligned with and can pass through the aligned apertures 44 In the upper and lower modules 0, 22. Further compression of the spring 20 cause the first anchor 16 to pass into the lower module 22, and the tool or handle 88 is twisted again to move the lower fixing plate 16 towards or into its second, locking condition wherein it cannot be removed from the lower module 22. When the lower fixing plate 16 Is in a locking condition an edge thereof will come Into abutment with a locking surface 94 (see Figure 5) on an inside surface of the upper mounting box BO of the lower module 22.

The toolor handle 88 can then be removed and the lower fixing plate 16 will be held in position by the spring 20. The nut 82 is then rotated towards the lower fixing plate 16 until the second fixing plate 18 comes into abutment with an inside surface of the upper mounting box 72 of the upper module 10, thereby fixing the modules 10, 22 together. The nut 82 is then tightened in accordance with engineering specifications.

As best seen in Figure 5, the height of the upper mounting box 96 of each module 10, 22, and/or the length of the rod 14 when compared with the height of the respective module 10, 22. should be selected so that once the lower module 22 has been locked by one such connection system 98, there is adequate room in the upper mounting block 96 for receipt of a lower end of a further such connection system 116 when connecting the upper module 0 to the lower module 22.

Since the spring 20 can carry the weight of the rod 14 and fixing plates 16, 18, the second connection system 66 can be inserted prior to transporting the respective module 10, 22 to site, the spring 20 maintaining the connection system 66 within the column 75 whilst in transit to prevent damage to the connection system 66.

Alternatively, the connection system 66 can be inserted on site.

In general, a method for connecting a first building element or module 10 to an adjacent building element or module 22 will be performed via a connector 12 provided in the first building element or module 10. The method will comprise:

moving the connector 12 so that an anchor 16 at one end of the connector 12 extends into the adjacent building element 22,

engaging the anchor 16 with the adjacent building element 22; and actuating the connector 12 (or in this case the second anchor 18) to engage the second anchor 18 at an opposite end of the connector 2 to the first bulding element 10 and to reduce a distance between the anchors 16, 18 to connect the first building element 10 to the adjacent building element 22.

A slightly different method for connecting a first building element 10 to an adjacent building element 22, would include:

(i) inserting a fixing member 12 along the length of a first element 10 and through to an adjacent building element 22 so that an anchor 16 at one end of the fixing member 12 extends into the adjacent building element 22;

(ii) moving the anchor 16 into an engagement position for engaging the adjacent building element 22; (iii) anchoring an opposite end of the fixing member 14 to the first building element 10 so that the fixing member 12 connects the building elements 10, 22.

The method may include such optional steps as: providing a retainer 20 for maintaining a position of the fixing member 12 relative to the first element 10;

compressing the retainer 20 to move the anchor 16; and/or releasing the anchor 16 from engagement with the adjacent building element 22, thereby to disconnect the first building element 10 from the adjacent building element 22.

A typical method for assembling and installing the connector system 66 would include:

(i) Forming the eyelet 86 at the upper, threaded end of the rod 14.

(ii) Attaching the base plate 16 to the lower end of the rod 14. the base plate being in a predetermined alignment with the eyelet 86 so that the use of the connector system 66 will be able to determine the orientation of the base plate 16 by inspecting the orientation of the eyelet 86.

(iii) Sliding a rubber holding ring 84 onto the threaded end of the rod 14, the ring 84 applying sufficient frictional force to the threaded end so that once the upper anchor plate 18 rests on the holding ring 84, the holding ring 84 remains substantially in position on the rod 14.

(iv) Fitting the upper anchor plate 18 onto the threaded end of the rod 14. (v) Screwing the nut 82 onto the rod 14 so that the rubber ring 84 and nut

82 sandwich the plate 18 to hold it in position.

(vi) Loosely screwing the nut 82 onto the threaded end to complete a rod assembly 12.

(vii) Sliding the rod assembly 12 into the mounting boxes 72, 78 and intervening column 75.

(viii) Positioning the module 10 on top of an installed module 22.

(ix) Actuating the connector system 66 by engaging the eyelet 84 using a tool or handle 88, and rotating the tool or detachable handle 88, thereby locking modules 10, 22 together.

Steps (i) to (vi) are applicable for connector systems 66 that do not use a spring

20. The mounting boxes 72, 78 in this circumstance can already be mounted to the end of the column 75. While this is also possible for connector systems 66 that use a spring 20, it can instead be desirable to mount the mounting boxes 72, 78 to the column 75 after insertion of the connector system 66 (see Figures 7 and 8). For example, for connector systems 66 that use a spring 20, the following steps may also be performed: (ii)(a) (between steps (ii) and (iii)) Sliding spring base plate 90, spring 20 and flange 92 onto rod 1 (the flange 92 may alternatively already be permanently fixed to the rod 14 and the spring 20 and spring base plate 90 fitted before attaching the base plate 6 to the lower end of the rod 1 ) and welding the flange 92 into position. Thus the rod 14 passes through the coils of, and is substantially coaxial with, the spring 20.

The steps below are performed as an alternative to steps (vi) and (vii) above.

(vi) Sliding the rod assembly 12 into the column 75.

(vii) Sliding the mounting boxes 72, 76 over the ends of the rod 14. As shown in Figures 7 and 8, the mounting boxes 72, 78 include an inspection port 118 for visibly aligning the mounting boxes 72, 78 with the respective ends of the rod 14 of the connector 12.

(viii) Testing the correct operation of the rod assembly 12 in the mounting boxes 72, 78 and, if operation is as desired, attaching (e.g. welding) the mounting boxes 72, 78 to the ends of the column 75.

(ix) Securing inspection covers 120 (e.g. by welding) over the inspection windows 1 8.

While the embodiment shown in Figure 3 includes two fastening means 58, 60, other embodiments include two second fastening means 60 in place of a first and ^■ second fastening means 58, 60 (e.g. as shown in Figure 5A). In this embodiment, two second fasteners 60 are received In the top boxes 54 of each respective module 10. The fasteners 60 can either be retained in position by a spring 20, and thus be in position prior to transport of the respective module 10 to site, or may alternatively be without a spring 20 and instead be inserted through the respective top box 54 on site. In the latter case, the apertures 56 and anchors 16, 18 must be sized so that the bottom anchor 6 can extend through into the lower module 22.

It will be appreciated that despite each module 0 being provided with two positions (i.e. one on the long side (length of module 10) and one on the return side (width of module 10)) for receiving fastening means 60, a single fastening means 60 may be sufficient to secured modules 10, 22 together. Thus a second fastening means 60 having a spring 20 may be inserted e.g. in a factory before transport of the respective module 0 to site. If the second fastening means 60 having a spring 20 becomes damaged in transit, then a further second fastening means 60 that does not have a spring 20 can be inserted through the apertures 56 on site thereby to connect the modules 10, 22 together.

Particularly as shown in Figure 7, the port 122 in the upper mounting box 72 can be shaped to assist with alignment of the anchor plate 18. In particular, one or more of the apertures, presently aperture 22, in the mounting boxes 72, 78 includes an engagement element to connect to or abut against the second anchor 18, the engagement element including a rebate or offset depression 124. The present rebate or offset depression 124 is offset at 90° to the angle at which the respective anchor plates 16, 18 will fit through the aperture 122 and into the column 75. The anchor plates 16, 18 positively lock into position, once the correct orientation of the anchor plates 16, 18 with the mounting boxes 72, 78 has been achieved, to connect the modules 10, 22 together.

The modules 10, 22 may also be provided with an alignment plate 34 (see Figure 3) that is shaped to guide the first anchor 16 towards the centre of the column 36 and also to align the anchor 16 with the aperture 44 in the mounting box 42.

In the embodiments shown, the building elements 10, 22 comprise a corner post 36 having cast mounting heads 42 for aligning building elements 0 in an upper level I over building elements 22 in a lower level II, and each corner includes a fastening system 58, 66 provided on each of the two sides 126, 128 (see Figure 3) that meet at the respective corner post 36. As such, unless both sides 126, 128 are ultimately external walls of the building, at some stage at least one of the two connections 130, 132 (presently a bolt system 58 and connector system 66 respectively, though either may be a bolt system 58 or connector system 66 as appropriate) will be a blind connection (i.e. not accessible once neighbouring modules are in position) for any given comer of a module 0. That blind connection will therefore require a lockable connection assembly as discussed above.

Rather than providing a single aligning post 36 and two fastening means 130, 132 at each corner, some other system may be used to align modules (e.g. one or more permanently mounted protrusions on the lower module 22 to be received in cooperating recesses in the upper module 10) and the corner post 36 may then be replaced by a single hollow post with a connection system passing therethrough. This would reduce the complexity of the corner regions 38 of modules 10, 22 but may result in a structural weakening of the corners.

Though not essential, a stiffening plate 136 (see Figures 2 to 5) can be positioned between modules 10 in an upper level I and modules in a lower level II, thereby to separate the comers of modules 10 in the upper level I from the corners of modules 22 in a lower level II.

As shown in Figures 2 and 3, the stiffening plate 136 includes apertures 138 for receiving the locking pins 48 and fastening means 58, 12. The apertures 138 are oversized so that there is some tolerance in the position of the stiffening member 136. If the apertures 138 were not oversized then the modules 10 in the upper level I would need to be painstakingly positioned to ensure correct alignment with modules 22 in the lower level II and, if the stiffening member 136 were bumped after being positioned it may result in the need to remove the modules 10 in the upper level i to allow access to . the stiffening plate 136 for repositioning.

The stiffening plate 136 also serves to bind all of the building elements 10, 22 that meet at a particular comer together. At internal comers (see Figure 9) there may be as many as 8 such building elements 0, 22, being 4 elements 10 in the upper level I and 4 elements 22 in the lower level II. For edges and comers of the building there are.fewer modules bound together by the stiffening plate 136 and thus the shape of the plate 136 is adapted to suit.

The stiffening plate 136 receives through its apertures 138 the fastening means 58, 66 for all modules 10, 22 at a particular comer. In so doing, the fastening means 58, 66 between any two modules are, to a degree, supported by the fastening meane between other pairs of modules (a 'pair ¹ constituting a lower module 22 in the lower level II and the module 10 in the upper level I above that lower module 22). The stiffening plate 136 thereby stiffens the connections between modules 10, 22 at joins therebetween, to improve the rigidity of the building formed by the modules 10, 22. The stiffening plate 136 also helps to distribute the weight of upper modules 10 through the entire group of lower modules 22, which is advantageous particularly where some upper modules are considerably heavier (e.g. contain white goods or beds) than others. Thus the weight of the modules 10, 22 can be distributed more uniformly over the foundations of the building.

In addition, the stiffening members 136 physically separate modules 10, 22 in respective pairs. In so doing, any lines of weakness in common to the modules 10, 22 in a particular pair are broken by the stiffening plate 136. There is thus a far lower likelihood that lines of weakness will be created between modules 10, 22 and across the building. If the stiffening plate 36 is made from a porous or vibration absorbent material, acoustic transmission between modules 10, 22 and through the building may also be reduced.

The modular building formed by the modules 10, 22 is supported on a foundation. A typical foundation 232 is shown in Figure 4 and it will be appreciated that that foundation 232 has substantially all of the same features (e.g. alignment blocks 42, mounting blocks 54 and locking pin 48) as are provided by a module 22 in a lower level II for connection with the module 10 in the next upper level I. The features of the foundations 232 have therefore been numbered in accordance with the similar features provided on respective modules 10, 22 and need not be described again. A partial section view of a typical building element 10 formed in accordance with the present invention is shown In Figures 10 and 1 1. With reference to Figure 10, the building element 10 includes a main structural frame 140 comprising rectangular hollow section (RHS) beams 142 extending substantially horizontally between the comers of the module 0. The beams 142 include four end beams extending across the ends of the module 10 (i.e. the short sides of the module) and four side beams extending substantially the length of the module 10 (i.e. the long sides of the module). The frame 140 further includes upright columns 144 (discussed below) extending substantially vertically between comers of the module 10, the beams 142 and columns 144 together defining a generally box-like shaped structural frame 140.

The dimensions of the RHS beams 142 are nominally 160x120x10.0mm, though any suitable dimensions may be used with any appropriate type of beam 42 (e.g. a C-section beam).

C-section joists 146 extend parallel to the end beams 142 of the module 10, and are connected at their ends to the side beams. The joists 146 closest to, but not connected to, the end beams 142 align with the columns 144 (see dotted line) as discussed below.

C-section wall studs 148 extend parallel to the columns 144 of the module 10, and are connected at either end to the end beams 142.

The joists 146 will typically be 100mm high C-section, whereas the studs 148 will typically be a 51 mm C-section as they will usually be called up to support considerably less weight than the joists 146.

Where the beams 142 support the structure of the module 10, the joists 146 support the ceiling 50 and floor 152 of the module 10 and the studs 148 support the internal wall cladding 54, insulation 156 and wall fixtures/fittings.

It will be noted that the comer regions 38, comprising the mounting boxes 54 and column ends 42 discussed above, project slightly above and below the end beams

142. Therefore, the weight of the module 10 is transferred to other modules and to the foundations of the building through the corner regions 38 rather than directly through the beams 142.

While the floor 152 of the module 10 can be any desired flooring, the floor 152 of the present embodiment includes a floor liner 58 positioned over and secured (e.g. by adhesive or screws) to the joists 146, and a pour on gypsum underlayment 160 poured over the liner 158.

It will be appreciated that any appropriate underlayment may be used, or any combination of underlayments, such as a compressed fibre cement (CFC) sheet or sheets. In addition, the sheets of underlayment may have fire or noise attenuating retardant properties resulting from: chemical composition of the sheets; impregnation of the sheets with an additive; or may have a cover or lining on one or both sides of the sheets or between the sheets. Each of the liner 158 and gypsum underlayment 160 are 18mm thick though any suitable flooring and dimensions thereof may be used.

The walls 162 comprise an outer skin, presently a metal wall lining 164 with corrugations of 36mm in depth (see also Figure 14). A thicker wall lining ma be used if the lining is desired to provide additional structural support to the side beams 142 intermediate the columns 144.

Internally of the skin 164 is an air gap 166 (presently 8mm wide though the width may vary as desired) that improves the insulation afforded by the walls 162.

Inwardly of the air gap 166 are the 51mm C-section wall studs 148. A sheet of insulation 156 (presently a 50mm Rockwool ^® insulation) is received in the channel of each stud 148, thereby forming an insulating layer. The top and bottom of the insulation 156 are retained by end caps 68 which may form part of off-the-shelf insulation, or may alternatively be formed from e.g. 51mm C-channel members similar to the wall studs 148.

At the top of the insulating layer 156.is a spacer 170. The spacer 170 provides a cavity between the end beam 142 and stud framing 148 for the passage of electrical wiring (not shown). Presently the spacer 170 is 25mm high, with a 5mm impactor 172 positioned between the spacer 170 and end beam 142, thereby providing a 30mm cavity between the studwork 148 of the wall 162 and the end beam 142. A module 10 is thus provided, that comprises walls 162, a floor 152 and roof 174, and at least one of the walls 162, floor 152 and roof 74 is substantially acoustically separated from the frame 140 by one of more impactors 172.

The spacer 70 may be a continuous body extending the entire width of the module 0 along the end beam 1 2 thereof, or may be between one or more wall studs 148 and the frame 140. In the present embodiment the spacer 170 comprises a plurality of spacers 170, one positioned atop every second wall stud 148. The electrical wiring can then pass between the spacers 170 from above the ceiling 150 to inside the wall cavity 166.

As noted above, a 5.0mm Impactor 172 is positioned between the spacer 70 and ^' end beam 142. The impactor 170 is adhered to the structural frame 140, particularly the end beam 142, and provides some shock absorption by separating the spacers 170 from the end beam 142 but, more importantly, acts as an acoustic barrier to prevent vibrations from transferring from the walls 162 into the structure 140. This is important, particularly for apartment blocks and high rise buildings, in ensuring acoustic transmission characteristics meet construction standards. Whlle a 5.0mm impactor 172 Is shown, any appropriately sized impactor.172 may be used (e.g. a 3.0mm impactor) as desired.

Internally of the insulating layer 156 is a dual liner 154 comprising two adjacent layers of 12.5mm thick plasterboard. Two layers of plasterboard are provided as the noise attenuation and thermal insulation of the two layers is significantly better than the similar properties of a single such layer. Again, the plasterboard (and any other sheeting disclosed herein) may have fire retardant and or noise attenuating properties resulting from a coating or lining, or appropriate additive. In particular, modules 10, 22 built in accordance with the present disclosure can have a sufficient fire rating to avoid statutory requirements for the installation of sprinkler systems.1

While two layers of 12.5mm thick plasterboard have been used in the present embodiment, any number, type and thickness of layers may be used as internal wall cladding 154 as appropriate.

The roof 74 of the module 10 also comprises a skin 176. Presently, the skin 176 is formed from a 2mm thick mild steel sheet though any suitable material may be used.

Internally of the skin 176 and positioned in the channels provided in the C- channel ceiling joists 178 is a thick layer insulating layer 180. Since heat rises, the ceiling insulation 180 will typically be at least as thick (presently twice as thick) as the insulation 156 in the walls 162 to ensure that heat is retained within the building element 10.

While the ceiling material 150 may be any appropriate material, an exemplary ceiling 150 is shown comprising two sheets of plasterboard mounted to resilient mounting brackets 182, the brackets 182 being mounted to the ceiling joists 178 to suspend the ceiling 150 in the module 10.

Figure 11 shows similar features to those depicted in Figure 10, except that the partial section view of the building element 10 in Figure 11 includes an opening 184. The opening 184 is framed by a head beam 186 supported on the lower end beam 142 of the structural frame 140 by two columns 188 (shown in broken lines). The head beam 186 and columns 188 of the present embodiment are of the same thickness and cross-sectional dimensions as the beams 142 and columns 144 of the main frame 140.

The heaviness of the header beam 186 renders the opening suitable for accessing an outdoor area, such as a balcony, or a walkway 190 (see Figure 13) since the weight of the balcony or walkway 190 can be at least partially taken up by the header beam 186. In addition, to accommodate the opening 184:

(i) the wall studs 148, insulation 56, corrugated fining 164 and plasterboard 154 have been shortened about the opening 84;

(II) the floor lining 158 and gypsum pour 160 have been extended to the external wall of the module 10;

(iii) an insulation layer 192 has been added underneath the header beam 186 and is spaced therefrom by a spacer 194 and impactor 196;

(iv) a further im pactor 198 has been added between the wall studs 148 and header beam 186 to reduce noise transmission therebetween. In the embodiment shown in Figure 10, no additional impactor 196 is necessary since the wall studs 148 abut the flooring 158 which itself serves to inhibit the transmission of vibrations; and

(v) aluminium flat trim 200 has been added to neaten the appearance of the completed module 10.

Similar to Figure 11 , Figure 12 depicts a further structural arrangement for providing an opening 202 in an external wall of a building module 10. However, rather than providing a header beam 186, the construction shown in Figure 11 includes a T- section trimmer beam 204 formed from two angle-section aluminium extrusions. This is a lighter-weight construction than that shown in Figure 10 and is designed to support windows and doors, but is not designed for suspending other structures such as balconies or walkways 190.

The structure around the opening 184 shown in Figure 11 is designed to support the weight of additional building components. To this end, Figure 13 shows a bay window, or walkway. 90 and balcony section 206 attached to the opening 184. Various parts of the module 10 are not shown in Figure 13..

The bay window 190 is supported by C-section beams 208 bolted onto the end beam 142 and header beam 186 of the building module 10, and C-section flooring beams 210 of the balcony section 206 are bolted onto the C-section flooring beams 208 of the bay window 190. Moreover, bottom beams 212 and joists 214 extend outwardly from the module 10 and bay window 190 so as to provide a cantilever support to the bay window 190 and balcony 206.

T e flooring 216 of the bay window 190 and flooring 218 of the balcony 206 can be individually selected so as to provide the desired characteristics (e.g. waterproofing and suitability for external use), and the flooring 216 of the bay window 190 and internal flooring 152 of the building element 10 may form a continuous floor. Moreover, the flooring 2 8 of the balcony 206 Is raised using blocks 220 to bring the balcony decking timbers 218 up to the same height as the flooring 216 behind the bay window 190. The balcony section 206 includes a drainage tray 222 and pipe 224 for draining water off the balcony 206. This ensures the balcony 206 does not become waterlogged and heavy during rainy weather, which may otherwise serve to destabiiise the balcony 206.

As shown in both Figures 13 and 14, other arrangements such as balcony rails

224 and aluminium framed windows 226 can be attached to the structure 140 of the module 10. In addition, one or more mounting brackets 228 are attached to the building element 10 which brackets 228 serve to support a decorative facade 230. Mounting the facade 230 in this manner avoids the need to prepare the surfaces of the module 10 for painting or decorating, enables the facade 230 to be prepared off-site and rapidly installed on site, and also enables' the facade 230 to, be exchanged or taken down for repair.

Since the modules 0 interlink with one another in the presently described manner, in particular by connecting frames 140 together, the modules 10, 22 themselves provide all of the structure of the building above the foundations 232 (see Figure 4). Therefore, facades 230, balcony rails 224, window-frames 226, walkways 190, balconies 206, handrails 224, bay window areas 190, and so forth, are connected to and supported by the modules 0, 22. Therefore, after the foundations have been laid the modules 10, 22 can be directly secured thereto in sequence to form the building without first having to erect structural support for the modules 10, 22.

Importantly, each building element 10, 22 includes a structural frame 140 from which walls 162. a roof 174 and a floor 152 Of the building element 10. 22 are supported. The structural frame 140 itself is supported on footings 42 that include apertures 52 shaped to facilitate mounting to more than one of a deck of a cargo ship or truck, a roof of a shipping container and a roof of another building element 10, 22. In the present embodiment, the apertures 52 serve the second function of being viewing ports for visibly confirming correct positioning of a locking pin 48 and, corresponding, correct alignment of modules 10, 22 on top of each other.

The apertures 52 of the footings 42 of the present embodiment are shaped to facilitate mounting to each of the deck of a cargo ship, the deck of a truck, the roof of a shipping container and the roof of another building element 10, 22. Therefore, the modules 10 can be constructed in a factory, loaded onto a truck, transferred from a truck onto a cargo ship at a loading port, transferred from the cargo ship to another truck at the destination port, and lifted from the truck onto another module 22 on site without having to change the manner in which the module 10 is secured.

The position and configuration of apertures 52 may be adapted to suit, for example, truck mountings at different ports (e.g. if truck mountings in China differ from those in Australia then the footings 52 are adapted to accommodate both types of mounting).

An exemplary plan view of a comer section 38 of a module 22 is shown in Figure 15. The corner region 38 comprises an HS column 234 with a C-section welded 236 to the side to form an irregularly shaped column 144. The present column 44 bounds a substantially L-shaped hollow centre that is divided into the volume of the RHS column 234 and the volume enclosed by the C-section 236 and external surface of the RHS column 234.

While forming a singular L-shaped column (e.g. extruding the column in the "L- shape") without welding a C-section beam to an RHS section beam is possible, it would be typically be far more expensive than taking a single RHS beam, cutting two C-section beams out of a further RHS beam and welding one of the C-section beams to the single RHS beam to form the comer column 144 as presently described.

It has also been found that, in the absence of the C-section, the weight distribution of the column 144 onto the next lower module 22 or foundation 232 Is nonuniform. This can cause the next lower module 22 or foundation 232 to deflect. The issue of a non-uniform weight distribution is exacerbated as modules are stacked atop one another and the non-uniform distribution resulting from the RHS corner column 144 of one module 22 Is compounded by the non-uniform weight distribution through the corner column 144 of the next higher module 10. Thus the modular building can have a "lean".

The substantially L-shaped column 144 assists with load balancing over the height of the modular building.

As discussed above, the irregularly shaped column 144 has a lower end alignment box 42 for receiving an alignment pin 48, and an upper end alignment box

42 into which a further alignment pin 48 is located for aligning the comer region 38 of an upper module 10 with the corner region 38 shown.

The irregular shape of the column 144 also facilitates correct positioning of plasterboard layers 154 as they can simply be pushed into abutment with the corner post 4 at the intersection between the RHS 234 and C-section 236 to be located correctly. Also, the irregular shape of the column 144 facilitates attachment of one of the floor joists 146 thereto, thus strengthening the floor 152 around the edges thereof.

The corner region 38 further comprises two fixing columns 75 the ends of which are provided with the mounting boxes 54 discussed above, to couple modules 10, 22 together. These columns 75 will typically not be used for mounting fittings or cladding as damage to the rod 14 within the column 75 could be detrimental to the strength of the coupling between the modules 10, 22 afforded by that rod 4. Therefore, where openings 184, 202 are required for mounting other structures (e.g. aluminium windows 226, bay windows 190, balconies 206 and walkways 90), it is preferred that such openings 84, 202 be bordered by a further column 238 to which the other structures (e.g. aluminium window 226) can be mounted.

Figure 16 shows a cross-sectional view of a building element 10 for forming one of a plurality of building elements 10 connectable together to form a building. The building element 10 includes walls 162, a roof 174 (not shown) and a floor 152 thereby defining an internal volume.

In the present embodiment, the building element 10 further including an access chute 240. When the plurality of modules 10 are connected together the access chute 240 aligns with one or more access chutes 240 of a respective one or more of the plurality of building elements 0 and the aligned access chutes 240 together forming an access shaft. In particular, the maintenance bays or service rooms 240 are positioned to align when modules 10, 22 are stacked on top of each other, thereby creating a continuous shaft from the top of a modular building to the bottom. As the modules 10, 22 can be interconnected in various different orientations (i.e. one module 1 may be positioned on top of another module 22 such that the modules 10, 22 are offset 90° from each other) the service or access chutes 240 are positioned at the same part of each modulelO, 22, which part aligns when the modules 10, 22 are connected. In the present embodiment, the service chute 240 is positioned on a side wall 242 of the module 0, with one side of the service chute 240 being hal way along the respective module 10 (see broken line 244).

The aligned service chutes 240 provide a continuous vertical

access/maintenance shaft running generally from an upper level I of the building down through the lower levels II.

The access shaft can be used to partially or fully house the hydraulics (e.g. waste, hot and cold water) and other utilities (e.g. gas and electricity) for the building. The access shafts may also form a conduit leading to an air vent on an external face of the building. Advantageously, the alignment of such shafts 240 enables a trades person to have single point access to particular utilities for all modules 10, 22 stacked vertically on top of each other.

The access shaft 240 is preferably accessed through an "invisible" door 246, such as a door behind the shelving in a wardrobe or behind white goods (i.e. in a position that is difficult to see and/or reach). The invisible door 246 may also be fitted with a lock requiring a specialised tool for unlocking. These measures ensure that the maintenance shaft 240 cannot be inadvertently or accidentally accessed. Figure 7 shows a typical generalised floor plan of a floor of a building 248 built using modules 10 as described herein. The modules 10 are connected to form a series of separate dwellings, having varying numbers of rooms. For example, sets of modules 250, 252 and 254 may form 2-bedroom 2-bathroom apartments each comprising three modules, modules 256, 258 may form 2-bedroom -bathroom apartments each comprising three modules, and modules 260 may form -bedroom 1- bathroom apartments each comprising either one or two of the modules numbered 260. The intermediate areas 262 form walkways, waste rooms and elevator shafts, the structural support for which comes from the structure of the respective modules 10.

The modules 10 are nominally 3.50m wide and 7.02m long, which is important to fit within shipping and road transport requirements.. In addition, the length is 20mm longer than the width. Therefore, if two modules 10 are arranged side by side with a 20mm air gap therebetween, a further module 10 can be arranged perpendicularly to the first two modules 10 with the sides of the first two modules 10 aligning with the ends of the third module 10 whilst retaining the 20mm air gap. Moreover, the 20mm air gap assists in acoustically and thermally isolating one module'10 from its neighbouring modules 10.

A module of 3.5m width and 7.02m length has been found to fit within an integer number of shipping container spaced on a cargo ship, thereby assisting with keeping costs low.

Alternative dimensions may also be used as appropriate. For example, the length of the module 10 may be twice its width (e.g. a module 10 may be of

3.52mx7.04m dimensions). Particularly for modules 10 used in the same country as that in which they were manufactured, shipping requirements may not pose an imposition as transport by ship is not required. In effect, the dimensions of the modules 10 can be selected to fit within permissible dimensions for each stage of the transportation from fabrication to installation.

Since each of the modules 10 will be substantially (e.g. 95%) complete prior to being installed, all electrical wiring and piping will have been installed in the factory or otherwise off-site prior to transport of the modules 10 to site. The modules 10 shown in Figure 17 may be the same or generally similar to the modules of Figure 16 but, in addition, each module 10 includes an electricity supply box 264 arranged on or in the roof 174, though floor or wall mounting may also be appropriate in particular circumstances. The supply boxes 264 provide a single point of electricity supply to a particular module 10 and enable the electrical interconnection of adjacent modules 10 While the boxes 264 may also include the fuses and/or meter for the respective module 10, the boxes 264 of the present embodiment are only a source of electricity and the fuse boxes are positioned elsewhere. This is due to the boxes 264 being sandwiched between the module 0 to which electricity is supplied through the respective box, and the module of the next upper level of modules, thus making access to the boxes 264 difficult once the next upper level of modules has been installed.

The supply box 264 of any one module 10 is configured to in effect plug into the supply box of an adjacent or neighbouring module 10, Thus Figure 17 shows pairs of supply units 264 abutting each other except where an external or internal wall is reached, in which case the relevant supply boxes (e.g. box 266) are either capped (e.g. terminals insulated) or connected to power supply. In so doing, each of the modules can electrically interconnect

A particular advantage of such electrical interconnection is that electricity need only be supplied to a single module 10 in e.g. each row of modules (such as the row including sets of modules 250, 260 and 254) or floor 248 of the building, to supply electricity to that entire row or floor 246. Smart meters can then be used to detect how much electricity is used by individual modules or dwellings 10.

If electrical supply boxes 264 are appropriately arranged, they may also allow the electrical interconnection of modules 10 between levels in the building.

Electrically interconnecting modules 10 using single supply plugs or supply boxes 264 saves a significant amount of labour and installation time as only one external connection to a particular row or floor of modules 10 needs to be made. In addition, after a module 10 has been connected to its neighbouring modules 10 the supply box 264 of the module 10 provides a single test point to verify correct supply of electricity to the module 10. In this regard, the power box 264 may contain test circuits for the various electrical circuits of the module 10 (e.g. the lighting circuit, wall outlet circuit and wet room circuit). The electrician can then test each of the circuits of the module 10 at one point.

While similar configurations of supply boxes 264 can be used for water and gas supply, with waste water being collected from below the floor of the respective module 10, the modules 10 can be provided with service chutes 240 that already provide a ingle point of interconnection of modules 10 that are vertically atop one another.

With particular regard to hot water supply, though similar comments may apply to a bottle gas supply, large hot water supply units can be positioned atop or in the upper levels of the modular building. The water is then fed Into the service chutes 240 through common supply pipes to which the supply pipes for each individual dwelling 250, 252, 254, 256, 268, 260 are attached. The individual dwellings 250, 252, 254, 256, 268, 260 can be provided with smart meters to determine how much water has been supplied to a particular dwelling 250, 252. 254, 256, 268, 260. In this manner, a small number of very large hot water systems can be used to supply electricity to a large number of dwellings 250, 252, 254, 256, 268, 260, thereby reducing power usage in heat water, heat losses from hot water systems, installation time and the amount of plumbing that would otherwise be required to connect more (smaller) hot water systems to the same number of dwellings 250, 252, 254, 256, 268, 260.

It will be appreciated that any hot water supply may be used, including electrical hot water systems, instantaneous gas hot water systems, solar hot water systems, solar or gas hot water systems or any combination thereof.

Meters for measuring the amount of a particular utility (e.g. water, power, gas) used by a particular module 10 or dwelling 250, 252, 254, 256, 268, 260 can be positioned anywhere that can be conveniently accessed after completion of the building.

Though buildings formed using modules 10 described herein may have upper levels of substantially the same footprint as lower levels (e.g. producing a substantially 'square' or 'rectangular ^* building when viewed from all sides), it will typically be desirable that the upper levels recede or include a 'set-back' from the lower levels. As such, upper levels will have a smaller footprint than lower levels.

Using the coupling arrangement 2, 66 of embodiments of the present invention, the weight of the modules 10 in each upper level is transferred generally uniformly to each of the modules 22 in respectively next lowest level, thereby dispersing the weight of all of the modules 10, 22 over the entire footprint of the building. Such an arrangement can facilitate use of uniform foundations 232 rather than heavier duty foundations toward the centre of the base of the building when compared with the foundations around the periphery of the base of the building.

It will be understood to persons skilled in the art of the invention that many modifications may be made without departing from the spirit and scope of the invention. ' \

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.