This disclosure relates to a method of constructing a modular pod that is suitable for use as permanent formwork to form e.g. a stairwell comprising a stairway.

This disclosure also relates to the modular pod itself. It should be understood that the modular pod is not limited to the forming of a stairway and may, for example, be used to form a lift well or a similar shaft or structure in a building. The modular pod finds particular application in multi-storey constructions.

BACKGROUND ART

Modular pods for use as permanent formwork are known in the art. Examples are shown in AU 2018101022 and US 7,805,908.

US 7,805,908 discloses a load-bearing fill material formation structure that is constructed from a series of discrete increments referred to as‘hydrostatic resistance trusses’. The hydrostatic resistance trusses are collectively assembled to form the permanent formwork.

It is to be understood that, if any prior art is referred to herein, such reference does not constitute an admission that the prior art forms a part of the common general knowledge in the art, in Australia or any other country.

SUMMARY

Disclosed in a first aspect is a method of constructing a modular pod that is suitable for use as permanent formwork used to form a stairwell for a stairway, etc. in a building. During formation of a floor in a building from concrete, the modular pod may integrate with the floor (i.e. the floor concrete may be poured simultaneously and contiguously with the pod concrete).

As set forth above, the modular pod finds particular application in multi-storey constructions but is not limited to the forming of a stairwell for a stairway. For example, the modular pod may provide permanent formwork suitable for the forming of a lift well, a shaft or another similar structure within a building.

The method of constructing the modular pod as disclosed herein comprises arranging a base frame for the pod. For example, the base frame may be arranged with respect to an existing floor of a building.

The method also comprises arranging one or more supports that are each connected to extend up from the base frame in use. Each support may be elongate. Each support may be post-like. As set forth below, the one or more supports can support a top frame spaced above the base frame, and each support can support one or more formwork modules at the base frame. The one or more supports can be connected to the base frame via welding (e.g. spot welding) or may be secured thereto via one or more fasteners.

The method further comprises arranging a base of the one or more formwork modules at the base frame. Each formwork module can be arranged to extend up from the base frame in use. Each formwork module can define a receptacle for the receipt therein of concrete during construction of a building. As set forth above, such concrete can be poured into each module at the same time as the pouring of an overlying floor in a building.

The method additionally comprises arranging the top frame of the pod. In this regard, the top frame can be connected with respect to the one or more supports. The top frame can be arranged such that a top of each formwork module extends to the top frame in use. For example, the top frame may receive and locate therein each formwork module. Thus, each formwork module can be“sandwiched” between the base and top frames.

When the modular pod is either delivered assembled to (or is constructed on site from e.g. a base frame that is arranged at) a given floor of a building, the pod once in place may be used to provide access to a next upper floor of the building. In this regard, in the case where the modular pod is configured to provide a stairwell for a stairway (as set forth below), the stairs of the pod may be used by construction workers to access the next upper floor of the building. Later, after the building has been completed, the stairs can remain in place as e.g. fire and/or emergency evacuation stairs.

Further, the pod may be used to in part support the formwork for the next upper floor of the building. As set forth above, when pouring the concrete for the next upper floor of the building, the concrete can also flow into each formwork module such that the floor becomes integrated with the pod.

In an embodiment, the method may comprise connecting the base of each formwork module to the base frame, and connecting the top of each formwork module to the top frame. For example, each module may releasably connect to each of the base and top frames (e.g. a base of each module may extend into, to be located within, the base frame and a top of each module may extend into, to be located within, the top frame in use). Alternatively or additionally, each module may be connected to each of the base and top frames via separate fasteners.

In an embodiment, the method may comprise connecting at least two supports to extend up from the base frame in use. For example, multiple, discrete supports may be spaced around to extend up from the base frame.

In an embodiment, the method may further comprise connecting at least one landing frame to the at least two supports. The landing frame can function to provide a landing (e.g. for users) within the pod. The landing frame may also function to provide bracing to and within the pod.

In an embodiment, the method may comprise connecting the at least one landing frame at an upper location of the at least two supports. The upper landing frame may be connected such that, when the top frame is connected to the at least two supports, the top frame is able to surround the upper landing frame. The upper landing frame can provide an upper landing within the pod. For example, when an overlying (e.g. like) pod is located above the existing pod, the upper landing frame can provide a base landing within the overlying pod. This can continue for each next upper floor of the building.

In an embodiment, the method may comprise connecting at least two further supports to extend up from the base frame in use. For example, four supports may extend up from the base frame (e.g. each support may be located at, so as to extend upwardly from, a respective corner of the base frame).

In this embodiment, the method may further comprise connecting a further landing frame at an intermediate location of the at least two further supports. The intermediate landing frame can provide an intermediate landing within the pod in use. Such an intermediate landing can e.g. allow for a stairway with a reverse turn to be formed within the pod.

In an embodiment, the method may further comprise connecting a set of stairs to the upper landing frame. The stairs may be connected to extend downwards from the upper landing frame. This set of stairs may also be connected to the intermediate landing frame, such the stairs extend downwards from the upper landing frame to the intermediate landing frame.

In an embodiment, the method may further comprise connecting a further set of stairs to the intermediate landing frame, such the further stairs extend downwards from the intermediate landing frame. This can provide for a stairway with a reverse turn to be formed within the pod. For example, the further set of stairs may extend from the intermediate landing frame downwards to the base frame. The further set of stairs may extend to (and may be connected to) the upper landing frame of an underlying pod.

In an embodiment, the method may further comprise arranging one or more infill panels in the or each landing frame to form a landing thereat. Each infill panel can be affixed (e.g. adhesively) and/or fastened to the landing frame. The infill panels can complete the landing. As set forth below, each infill panel can be formed from an available building material, such as an autoclaved aerated concrete panel, a fibre-cement sheet, etc.

In an embodiment of the method, a first formwork module may be arranged at the base frame adjacent to a first support extending up from the base frame in use.

The first formwork module may be connected (e.g. fastened) to the first support.

In an embodiment of the method, the first formwork module, or one or more further formwork modules that are arranged at the base frame adjacent to the first formwork module, may be arranged to extend to a second support that is spaced from the first support in use. Either the first formwork module or a last of the one or more further formwork modules may be connected (e.g. fastened) to the second support. In this way, a wall of the pod may be defined between the first and second supports.

In an embodiment of the method, each of the base and top frames can be rectangular. The method may comprise arranging a respective support at, so as to extend between, a respective comer of the base and top frames (i.e. four such supports can extend between the base and top frames). Further, formwork modules may be arranged to extend between each of an adjacent two supports along corresponding sides of each of the base and top rectangular frames. This can define four walls of the pod.

However, one or more formwork modules may be omitted from the pod, adjacent to where the further set of stairs terminates at the base frame. This can provide an opening for e.g. a door to be mounted at the pod. For example, in use, such a door may be a fire and/or emergency exit door at a given floor.

In an embodiment of the method, the or each landing frame may be mounted to extend between each of an adjacent two supports. For example, each landing frame may extend from one side of the pod to an opposite side of the pod. This can provide a landing that extends from one side of the pod to an opposite side of the pod. This arrangement can also allow the landing frame to provide bracing to the pod, as set forth above.

In an embodiment, the method may further comprise providing a cap for the or each support. Such a cap may be elongate to a similar extent to its respective support. Such a cap may be configured to be connected to the pod such that, when connected, the cap can define a corner of the pod. Further, each cap may be configured to be connected so as to span between a formwork module located on one side of its respective support and a formwork module located on another side of its respective support.

In an embodiment, the method may further comprise securing a plurality of projections to the top frame. Each projection may be secured to project upwardly in use from the top frame.

In an embodiment, the method may additionally comprise arranging a base frame of a next uppermost modular pod on the top frame of the underlying modular pod. Then, via the plurality of projections, the top frame of the underlying modular pod may be connected to the base frame of the next uppermost modular pod. In this way, each of the pods can be tied together during the pouring of concrete into the next uppermost modular pod. Thereafter, the pods become integrated together so as to form e.g. a stairwell (or similar) for the building.

In an embodiment of the method, the next uppermost modular pod can be constructed on the top frame of the underlying modular pod. The next uppermost modular pod can be constructed using the methodology as set forth above for the first aspect.

Also disclosed herein, in a second aspect, is a modular pod suitable for use as permanent formwork (e.g. to form a stairwell for a stairway or similar in a building). The modular pod may be constructed using the methodology as set forth above for the first aspect. The modular pod comprises a base frame for the pod. The base frame may have a truss-structure. For example, the base frame may comprise inner and outer strips that are arranged to define side walls of the base frame, with a plurality of spaced, inter-connecting members extending between and connecting the side walls in a truss-type arrangement.

The modular pod also comprises one or more supports that are each connected to extend up from the base frame in use. For example, each support may comprise an elongate (e.g. C-profile) channel. When the base frame comprises comers (e.g. when in rectangular form), each channel can be configured to fit within a respective comer of the base frame. An in use lower end of each channel can be connected (e.g. spot-welded) to e.g. inner wall(s) of the base frame.

The modular pod further comprises one or more formwork modules. A base of each module can be arranged at the base frame. Each formwork module can extend up from the base frame in use. An in-use lower portion of each formwork module can be configured to mate with the base frame. For example, the base frame may receive and locate therein the lower portion of each formwork module. Optionally, the lower portion of each formwork module may be secured (e.g. fastened) to the base frame.

The modular pod additionally comprises a top frame for the pod. The top frame can be connected with respect to the one or more supports. The top frame can be arranged such that a top of each formwork module is able to extend to the top frame in use. The top frame may also have a truss-structure similar to the base frame. When the top frame comprises corners (e.g. when in rectangular form), and when each support comprises an elongate channel (e.g. a C-channel), each channel can be configured to fit within a respective corner of the top frame.

Again, an in use upper end of each channel can be connected (e.g. spot-welded) to e.g. inner wall(s) of the top frame. An in-use upper portion of each formwork module can also be configured to mate with the top frame. For example, the top frame may receive and locate therein the upper portion of each formwork module. Optionally, the upper portion of each formwork module may be secured (e.g. fastened) to the top frame. In an embodiment of the modular pod, the pod may comprise at least two supports that each extend up from the base frame in use. At least one landing frame may be connected to the at least two supports. For example, the at least one landing frame may be connected to an upper location of the at least two supports. The landing frame may be configured such that, when the pod has been constructed, the top frame surrounds the upper landing frame.

In an embodiment of the modular pod, the pod may comprise at least two further supports arranged to extend up from the base frame in use. A further landing frame may be connected to the at least two further supports at an intermediate location thereof. Each of the upper and intermediate landing frames may be configured to extend from one side of the pod to an opposite side of the pod.

In an embodiment of the modular pod, the pod may further comprise a first set of stairs that is connected to the upper landing frame. The first set of stairs may extend downwards from the upper landing frame. The first set of stairs may also be connected to the intermediate landing frame. Thus, the first set of stairs may extend downwards from the upper landing frame to the intermediate landing frame.

In a variation of the modular pod, the set of stairs can comprise (e.g. it can be supplied with) a cover plate. The cover plate may be arranged in use to form an underside beneath the set of stairs. Thus, when the modular pod is assembled with the set of stairs, the cover plate can be arranged to form an enclosed underside of the set of stairs. When the cover plate is arranged (and affixed) in this way, a fill material (e.g. a cementitious material such as concrete), can be arranged in (e.g. poured into) a space that is defined between the stairs and the cover plate. Thus, the cover plate can allow the set of stairs to function as a formwork for e.g.

concrete stairs to be formed. For example, the fill material once poured can be formed (e.g. screeded) into respective treads of the stairs. In this way, the fill material can replace the tread members of the stairs. In an embodiment of the modular pod, the pod may further comprise a second set of stairs connected to the intermediate landing frame. The second set of stairs may extend downwards from the intermediate landing frame to the base frame.

In an embodiment of the modular pod, the pod may further comprise one or more infill panels that are arranged in the or each landing frame to form a landing thereat. Each infill panel may comprise a panel of autoclaved aerated concrete. Alternatively, each infill panel may be formed from fibre cement such as compressed fibre cement. For example, the infill panel may be defined by opposing sheets of fibre cement that are each affixed to and separated by a plurality of supporting elongate spacer (e.g. C-) channels. In an embodiment of the modular pod, each landing frame may comprise a tray. Each tray may be arranged in use to extend between the perimeter defined by the landing frame so as to form an enclosed underside of the landing frame. The enclosed landing frame may comprise one or more bracing members arranged above the tray and that extend within the perimeter defined the landing frame and tray. These can strengthen the tray, with each bracing member also able to act as reinforcing when e.g. a fill material, such as concrete, is poured into the tray.

In this regard, each landing frame may be configured to receive therein a fill material, such as concrete. When poured into the tray, the fill material can be arranged (e.g. screeded, trowelled) to form a respective landing of the modular pod.

In an embodiment of the modular pod, a first formwork module may be arranged at the base frame adjacent to a first support that extends up from the base frame in use. The first formwork module may be connected (e.g. fastened) to the first support. This first formwork module may be configured to extend to a second support that is spaced from the first support in use. Alternatively, or one or more further formwork modules may be arranged at the base frame adjacent to the first formwork module. The one or more further formwork modules may extend to the second support. Further, the first formwork module or a last of the one or more further formwork modules may be connected (e.g. fastened) to the second support.

Typically (though not exclusively), each of the base and top frames can be rectangular. Thus, the pod may comprise a respective support that is arranged at, so as to extend between, a respective corner of the base and top frames (i.e. the pod typically comprises four supports extending between the base and top frames). Typically, formwork modules can be arranged to extend between each of an adjacent two supports along corresponding sides of each of the base and top rectangular frames.

In an embodiment of the modular pod, the pod may further comprise a cap for the or each support. The cap may be configured to be connected to the pod such that, when connected, the cap can define a corner of the pod. When connected, each cap may span between formwork modules at a comer (e.g. to span between a formwork module located on one side of the respective support and a formwork module located on another side of the respective support).

In an embodiment of the modular pod, the pod may further comprise a plurality of projections (e.g. discretely spaced plates) secured to the top frame. Each projection may project upwardly in use from the top frame. Each projection can be configured to be connected to a base frame of an overlying modular pod (e.g. to connect to that base frame during construction of an overlying pod and overlying floor). Thus, the connection can secure the overlying pod to the underlying pod prior to concrete pouring of an overlying floor.

In an embodiment of the modular pod, each formwork module may comprise a pair of parallel facing sheets separated by a plurality of web members. Each web member may comprise one or more apertures for receipt therethrough of reinforcing. The reinforcing (e.g. reinforcing rods/bars) can locate between the facing sheets in use (i.e. prior to concrete pouring into each formwork module.

In one embodiment, each of the parallel facing sheets of the formwork module can be a fibre-cement sheet. Each web member can be defined by a channel section (e.g. a C-section formed from a metal such as galvanized steel or aluminium). The channel section is typically affixed to the sheets along opposite respective sides (e.g. adhesively affixed via the channel flanges). In another embodiment, each formwork module can be extruded from plastic (e.g. PVC). Also disclosed herein, in a third aspect, is a formwork module for use in the modular pod as set forth in the first and second aspects. The formwork module comprises a pair of parallel facing sheets separated by a plurality of web members. The formwork module of the third aspect is characterized in that at least a portion of at least one of the sheets can be moved and/or removed to expose the web members of the formwork module.

For example, movement and/or removal of the sheet or a portion thereof can allow reinforcing that is arranged within the formwork module to be inspected prior to the pouring of concrete therein. Such movement and/or removal can also allow the reinforcing arranged within the formwork module to be connected to external reinforcing (e.g. to be connected to reinforcing provided for an adjacent floor). Additionally, such movement and/or removal can also allow concrete that is poured into the formwork module to join to externally poured concrete (e.g. to join to concrete of an adjacent floor).

In one embodiment, an in-use lower and/or upper portion of said at least one sheet can be removed. For example, the portion(s) may be detached from a remainder of the formwork module. Each of the lower and upper portions may be detached.

In another embodiment, at least one of the sheets may be connected to a remainder of the formwork module such that said sheet is able to be moved (but e.g. not detached) relative to the remainder of the formwork module. For example, said sheet may be moved by sliding up or down along the web members of the formwork module.

Further, said at least one sheet may define an in-use outer sheet of the formwork module when the module is arranged in a modular pod as set forth in the first or second aspects (e.g. once the pod has been constructed and/or installed at a site).

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the modular pod and its method of construction will now be described, by way of example only, with reference to the accompanying drawings in which:

Fig. l is a perspective view of an embodiment of a“completed” modular pod according to the disclosure, the modular pod shown with some of the formwork modules removed therefrom to reveal the pod interior.

Fig. 2 shows a perspective view of a truss-type frame which is suitable for use as both a lower frame and an upper frame in the modular pod, with Fig. 2D showing a detail of Fig. 2.

Figs. 2A to 2C respectively show an initial construction stage of the modular pod, being perspective views of: the lower frame of Fig. 2 with four support posts connected thereto; a detail of one such support post; and a detail of one such support post connected to the inside comer of the lower frame.

Fig. 3 shows a next construction stage of the modular pod, being a perspective view of upper and intermediate landing frames connected to the four support posts, as well as first and second sets of stairs connected to extend respectively from the upper to the intermediate landing frame, and from the intermediate landing frame to the lower frame. Fig. 4 shows a next construction stage of the modular pod, being a perspective view of infill panels arranged in each of the upper and intermediate landing frames.

Figs. 5 & 6 respectively show perspective views of two different types of infill panel suitable for being arranged in each of the upper and intermediate landing frames.

Figs. 7, 7A & 7B respectively show perspective and upper and lower detail views of a prefabricated permanent formwork module for use in the modular pod.

Fig. 8 shows a next construction stage of the modular pod, being a perspective view of first and second formwork modules being arranged at a comer of the lower frame on either side of a support post, with Figs. 8A & 8B respectively showing perspective lower detail views of the first and second formwork modules arranged at the lower frame.

Fig. 9 shows a next construction stage of the modular pod, being a perspective view of formwork modules being arranged along each of the four sides of the lower frame, as well as an upper frame being connected to the four support posts and the formwork modules, with Figs. 9A & 9B respectively showing a perspective upper corner detail view and upper wall view including the upper frame.

Fig. 10 shows a perspective detail view of the“completed” modular pod of Fig. 1 illustrating the mounting of the upper frame to a support post and to respective comer formwork modules, with Fig. 10 also illustrating the mounting to the pod of a corner cap.

Fig. 11 shows a perspective detail view of the“completed” modular pod of Fig. 1 illustrating the mounting of a support post the lower frame, and illustrating the mounting of respective corner formwork modules to the lower frame, with Fig. 1 1 also illustrating the mounting to the pod of the corner cap. Fig. 12 shows a reverse perspective view of a“completed” modular pod that is essentially the same as the pod of Fig. 1, but wherein different formwork module embodiments are mounted to the pod.

Figs. 13 & 13A respectively show a perspective view and reverse perspective detail of the different formwork module embodiment of Fig. 12.

Fig. 14 is a perspective view of a“completed” modular pod that is essentially the same as the pod of Fig. 1, but wherein different landing and stair set embodiments are mounted to the pod.

DETAILED DESCRIPTION

In the following detailed description, reference is made to accompanying drawings which form a part of the detailed description. The illustrative embodiments described in the detailed description, depicted in the drawings and defined in the claims, are not intended to be limiting. Other embodiments may be utilised and other changes may be made without departing from the spirit or scope of the subject matter presented. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings can be arranged, substituted, combined, separated and designed in a wide variety of different configurations, all of which are contemplated in this disclosure.

Described herein with reference to Figures 1 to 14 is a modular pod and a method of constructing the modular pod. The modular pod finds particular application in multi-storey constructions. The modular pod is suitable for use as permanent formwork in the construction of a stairwell for a stairway, lift well, shaft or similar structure within a building. During concrete pouring of an overlying floor in a building the modular pod is able to integrate with the floor (i.e. the overlying floor concrete is poured simultaneously and contiguously with the pod concrete). The modular pod can be arranged on and connected to an existing modular pod at a floor of the multi-storey construction. Thus, a series of stacked, inter-connected modular pods can define the stairwell or similar structure within the building.

Figure 1 illustrates a“completed” modular stairway pod 2 for mounting within the multi-storey building structure (i.e. completed in the sense that some formwork modules are removed therefrom to reveal the pod interior). The modular pod 2 can be constructed offsite (e.g. at a factory) and transported in its erected form to a building site, and then craned into position. Alternatively, the components for each modular pod 2 can e.g. be flat-packed, transported to and the pod then constructed on site (e.g. on top of a pre-existing, already concrete-poured pod).

The modular pod 2 is also able to integrate with other adjacent building (e.g. formwork) structures. The adjacent building structures can be ceilings, floors, walls or similar building structures. In specific embodiments, the pod 2 can be constructed using existing permanent formwork modules, such as those disclosed in AU 2008202281 or WO 2015/066758. In specific embodiments, the pod 2 can also make use of stair modules such as those disclosed in co-pending AU provisional application No. 2019901070. The relevant contents of each of these patent applications are incorporated herein by reference.

The“completed” modular pod 2 of Fig. 1 comprises a base frame in the form of a lower frame 4 that has a rectangular form. As shown and described with reference to Fig. 2, the lower frame 4 has a truss-type structure and is typically fabricated (e.g. welded) from steel components (e.g. steel strips and steel rods).

In this regard, the lower frame 4 (as well as the upper frame 66) of the pod 2 is constructed as a rectangular frame, whereby the rectangular shape of frame 4 defines two elongate side portions 6 which extend at right angles to two relatively shorter end portions 8. The side 6 and end 8 portions can each comprise an individual truss assembly. Typically, each truss assembly is fabricated from a metal (such as steel) and can e.g. be welded-up individually, and then the assemblies 6 and 8 can be welded together to form the lower frame 4. Other frame shapes are within the scope of the disclosure. As best illustrated by the detail shown in Fig. 2D, the truss assembly of each of the side 6 and end 8 portions comprises an outer wall 16 and inner wall 18, with a plurality of web members 14 (e.g. of metal rod of generally circular cross section) extending therebetween to connect the outer 16 and inner 18 walls together in the truss-type arrangement. The outer and inner walls 16, 18 can each be of e.g. metal strip to be welded to opposite sides of e.g. an elongate, zig-zag metal rod 14. The resultant web members 14 extend at angles so as to form a generally‘V’ shaped repeating sequence (i.e. a truss pattern). When the lower frame 4 is welded-up from the side 6 and end 8 portions, the outer walls 16 and the inner walls 18 of the truss assemblies together define outer 16 and inner 18 walls of the lower frame 4.

As best shown in Fig. 2C, the outer walls 16 and the inner walls 18 each define internal 20 and external 22 surfaces. The internal surfaces 20 face each other, whereas the external 22 surfaces face away from each other. The web members 14 are connected to extend between opposing internal surfaces 20 of walls 16 & 18. In-use of the lower frame 4 (and upper frame 66), the internal and external surfaces 20, 22 extend vertically.

The modular pod 2 of Fig. 1 also comprises a number of supports, each in the form of an elongate beam 24. As shown and described below with reference to Figs. 2B & 2C, each beam 24 is defined by a comer angle (i.e. of a general C- profile) that is typically fabricated from cold-rolled steel section. External faces of an in-use lower end of each beam 24 are connected (e.g. spot-welded and/or bolted) to external surfaces 22 of inner walls 18 of the lower frame 4 at a corner thereof. Each beam 24 extends up from the lower frame 4 in use. As shown in Fig. 11, the lower end of each beam 24 can be bolted to external surfaces 22 of the inner walls 18 of the lower frame 4 via preformed bolt holes 25.

The modular pod 2 of Fig. 1 further comprises a number of formwork modules 58 that each also extend up from the lower frame 4 in use. As shown and described below with reference to Figs. 7 & 8, each module 58 is typically prefabricated (e.g. in a factory) from spaced, parallel sidewalls 78 formed of compressed fibre- cement sheets, the sheets being bonded to and separated by a plurality of spaced, parallel webs in the form of studs 70, each stud of a galvanised steel frame.

Examples of such a module are shown in AU 2008202281. However, for certain applications, the modules 58 may be be replaced with a plastic-extruded formwork module such as those shown in WO 2015/066758.

As best shown in Fig. 8, each stud 70 projects down beyond the sidewalls 78 such that each stud 70 is able to locate between the outer wall 16 and inner wall 18, to thereby mate with the lower frame 4. Thus, each module 58 can stand on and be supported by the lower frame 4. Optionally, the base region of each formwork module may be separately secured (e.g. screwed or affixed) to the lower frame 4, as set forth below.

In Fig. 1, a number of modules 58 have been omitted from the pod 2 to illustrate the interior thereof. It should be understood that omission of one or more modules 58 can enable e.g. a door or window to be arranged in the pod (e.g. a fire door and/or emergency escape door, or a window to allow light to enter a stairwell, etc.). The frame of e.g. fire door or emergency escape door can be preinstalled into the pod 2 prior to delivery of the pod 2 to the building site.

The modular pod 2 of Fig. 1 additionally comprises a top frame in the form of upper frame 66. The upper frame 66 also has a rectangular truss-structure and is typically fabricated identically to the lower frame 4 (i.e. upper frame 66 is fabricated at the same time and in the same way as the lower frame 4, but is inverted in use).

As shown and described below with reference to Figs. 9 & 10, the upper frame 66 is connected to in-use upper ends of the beams 24. In this regard, external faces of the upper end of each beam 24 are connected (typically spot-welded) to external surfaces 22 of inner walls 18 of the upper frame 66 at a corner thereof. Thus, each beam 24 extends up from the lower frame 4 to the upper frame 66 and supports the upper frame in a spaced relationship relative to the lower frame. As shown in Fig. 10, the upper end of each beam 24 can be bolted to external surfaces 22 of the inner walls 18 of the upper frame 66 via preformed bolt holes 27.

Again, the upper frame 66 is arranged to engage (i.e. mate) with a top region of each formwork module 58. In this regard, the upper frame 66 can receive and locate therein the top region of each formwork module 58. As shown in Fig. 10, each stud 70 projects up beyond the sidewalls 78 such that each stud 70 locates between the outer wall 16 and inner wall 18, to thereby mate with the upper frame 66. This mating can secure the modules 58 to the completed pod 2. Optionally, the top region of each formwork module 58 may be separately secured (e.g. screwed or affixed) to the upper frame 66, as set forth below.

The resultant modular pod 2 of Fig. 1 comprises opposing side walls 60 and 61, and opposing end walls 62 and 63. However, other than an upper landing 40 and lower stair set 52”, the pod 2 is open at its upper and lower ends. This enables the space within pod 2 to connect with respective spaces in e.g. underlying and overlying like modular pods (e.g. in a multi-story building).

The modular pod 2 of Fig. 1 also comprises an upper rectangular landing frame 30 (see also Fig. 3), with two adjacent comers of landing frame 30 being connected (e.g. spot-welded, screw/bolted) to inside lips 29 (see Fig. 2B) of each of two beams 24 (i.e. as shown, the two left end beams). The landing frame 30 is connected to an uppermost location of each of the two beams 24. Once the pod 2 has been constructed, the upper frame 66 surrounds the upper landing frame 30.

The modular pod 2 of Fig. 1 further comprises an intermediate rectangular landing frame 31 (see also Fig. 3), with two adjacent corners of intermediate landing frame 31 being connected (e.g. spot-welded, screw/bolted) to inside lips 29 (see Fig. 2B) of each of two beams 24 (i.e. as shown, the two right end beams). The intermediate landing frame 31 is connected to an intermediate location of each of the two beams 24. Each of the upper and intermediate landing frames 30, 31 is configured to extend from one side of the pod 2 to an opposite side of the pod 2, thereby contributing to the bracing of the pod 2, during construction and in-use.

The modular pod 2 of Fig. 1 additionally comprises a first, upper stair set 52’ and a second lower stair set 52”. Together, the upper and lower stair sets 52’, 52” define a set of stairs 52. As set forth above, the modular pod 2 is not limited to providing a modular stair pod and may, for example, define part of a lift well, shaft or similar structure within a building, in which case the set of stairs 52 can be omitted.

When the pod 2 defines part of the lift well, a lift rail and lift track can be installed in pod 2. This installation can occur prior to delivery of pod 2 to a building site. Additionally, a lift carriage may be pre-installed into the pod 2 prior to delivery to a building site.

The upper stair set 52’ is connected (e.g. spot welded, fastened) to the upper landing frame 30. The upper stair set 52’ extends downwards from the upper landing frame 30. The upper stair set 52’ is also connected (e.g. spot welded, fastened) to the intermediate landing frame 31. Thus, the upper stair set 52’ extends downwards from and between the upper landing frame 30 and the intermediate landing frame 31.

The lower stair set 52” is connected (e.g. spot welded, fastened) to the

intermediate landing frame 31 to extend downwards therefrom. A side edge 59 at a lower free end 55’ of the lower stair set 52’ is also connected (e.g. spot welded, fastened) to the lower frame 4 of pod 2. Thus, the lower stair set 52” extends downwards from and between the intermediate landing frame 31 and the lower frame 4. Each of the upper stair set 52’ and lower stair set 52” can be formed of metal, fibre-cement, etc., and each can take the form of a stair module as set forth in co pending AU provisional application No. 2019901070, the relevant contents of which are incorporated herein by reference. The modular pod 2 of Fig. 1 further comprises a number of infill panels 34 that are arranged in each of the upper and intermediate landing frames 30, 31 to form respective landings 40, 41 at the landing frames. The infill panels 34 are explained in further detail below with reference to Figs. 5 & 6.

Referring specifically to Figs. 2A, 2B & 2C, once the lower frame 4 has been formed and arranged, in the next stage of forming pod 2 four substantially parallel, elongate beams 24 are arranged to seat in and to be connected to respective inside corners of the lower frame 4 (e.g. by spot-welding/bolting to the external surfaces 22 of adjacent walls 18). Each beam 24 has a length

corresponding to a single building level and extends vertically in use (i.e. at right- angles to the plane defined by lower frame 4). A base of the beam 24 aligns with a base of the lower frame 4. As set forth above, each beam 24 can be cold-rolled from e.g. steel to provide a structural beam having a type of C-profile.

As best shown in Fig 2B, the corner of each beam 24 is substantially right-angled so as to locate snugly in a correspondingly shaped corner of the lower frame 4.

The right-angled profile of the beam 24 defines webs 26, each web having an outward facing surface 28 that is connected to a respective external surface 22 of wall 18.

Referring now to Fig. 3, the next stage of constructing the modular pod 2 involves the formation of the upper and intermediate landing frames 30, 31. Typically each landing frame is fabricated separately from the beams 24. The landing frames 30,

31 are positioned adjacent to but spaced above respective opposing ends 8’, 8” of the lower frame 4. The upper landing frame 30 is connected (e.g. bolted) to the two beams 24’ located at the illustrated left-hand end 8’ of the lower frame 4. The intermediate landing frame 31 is connected (e.g. bolted) to an intermediate location of the two beams 24” located at the illustrated right-hand end 8” of the lower frame 4.

Each landing frame 30, 31 comprises four members that each comprise an elongate angle, typically of a metal such as steel. Two of the angles 32 are spaced, parallel and arranged width-wise in the pod 2 (i.e. parallel to the ends 8 of lower frame 4). The other two of the angles 33 are spaced, parallel and arranged width- wise in the pod 2 (i.e. parallel to the ends 8 of lower frame 4). Typically, each landing frame 30, 31 is prefabricated (e.g. welded-up) from the four angles 32, 33 prior to connecting (e.g. bolting) each frame 30, 31 to its respective beams 24’ or 24”.

As set forth above, one of the angles 32 is arranged to extend between and be connected (e.g. spot- welded, bolted) via an outer face 35 thereof to a respective one of the inside lips 29 (see Fig. 2B) of each of two beams 24. Each of the other adjacent angles 33 is also arranged to extend from and be connected (e.g. spot- welded, bolted) via an outer face 38 thereof to a respective one of the inside lips 29 of a respective beam 24.

The four angles 32 are also arranged in each frame such that the‘L’ shape profile of each angle faces inwardly to define an inner step against which a respective edge of an infill panel 34 can locate and be supported thereat.

The sizes of the upper and intermediate landing frames 30 and 31, and thus of their respective upper and intermediate landings 40, 41 is typically determined by industry standards, building codes and/or regulations.

Fig. 3 also shows the upper stair set 52’ having been connected (e.g. bolted, spot- welded) to each of the upper landing frame 30 and the intermediate landing frame 31. Likewise, Fig. 3 shows the lower stair set 52” having been connected (e.g. bolted) to each of the intermediate landing frame 31 and the lower frame 4 (i.e. the side edge 59 at a lower free end 55’ of the lower stair set 52’ is also e.g. spot welded or bolted to the inside surface 20 of an inner wall 18 of the lower frame 4). Typically, each stair set 52’, 52” is prefabricated (e.g. welded-up) prior to connecting (e.g. bolting) to the landing frames, etc. Each stair set can be prefabricated according to the method disclosed in AU2019901070. The upper and intermediate landing frames 30 and 31 also function to brace and to tie the side walls 60 and 61 together in pod 2. Further, the upper landing frame 30 braces and ties the end wall 62 to the side walls 60 and 61, whereas the intermediate landing frame 31 braces and ties the end wall 63 to the side walls 60 and 61. In addition, the upper stair set 52’ braces and ties the upper landing frame 30 to the intermediate landing frame 31, and the lower stair set 52” braces and ties the intermediate landing frame 31 to the lower frame 4. Thus, the stairs and landings can provide a structural reinforcing function in the modular pod 2, both during construction and in-use.

As shown in Fig. 4, the upper stair set 52’ is offset towards and parallel to but spaced above a first side 6’ of the lower frame 4. An upper end 54 of the stair set 52’ is connected (e.g. bolted, spot-welded) to the upper landing frame 30, and a lower end 54’ is connected (e.g. bolted, spot-welded) to the intermediate landing frame 31. A first stringer 56 of the upper stair set 52’ aligns parallel and adjacent to an imaginary vertical plane defined by the first side 6 of the lower frame 4 (i.e. to sit close to side wall 60 in pod 2). A second stringer 56’ of the stair set 52’ aligns parallel to a centre plane of the pod 2, and is also parallel to the first side 6’ of the lower frame 4.

Likewise, as shown in Fig. 4, the lower stair set 52” is offset towards and parallel to but spaced above a second side 6” of the lower frame 4. The lower stair set 52” has an upper end 55 that is connected (e.g. bolted, spot-welded) to the

intermediate landing frame 31. A lower free end 55’ of lower stair set 52” terminates at an imaginary horizontal plane defined by an underside of the lower frame 4. A first stringer 57 of the lower stair set 52” aligns parallel to a centre plane of the pod 2, and is also parallel to the second side 6” of the lower frame 4. A second stringer 57’ of the second stair set 52” aligns parallel to an imaginary vertical plane defined by the second side 6” of the lower frame 4 (i.e. to sit close to side wall 61 in pod 2). Referring now to each of Figs. 4 to 6, in the next stage of construction of pod 2, one or more infill panels 34 are disposed in and secured (e.g. typically screwed, adhered, etc.) to each of the upper and intermediate landing frames 30 and 31. Each infill panel 34 can be fabricated from various construction materials.

For example, as shown in Fig 5, each infill panel 34 can comprise one panel or multiple sub-panels of autoclaved aerated concrete (e.g. such as CSR Hebei ^®

AAC panels).

Alternatively, as shown in Fig 6, each infill panel 34 can comprise opposing sheets 46, 48 of compressed fibre cement. The sheets 46, 48 can each be affixed to and separated by a number of spaced, elongate and parallel C-channel studs 53, each of which can be of metal.

The panel 34 of Fig. 5 comprises top 46 and bottom 48 horizontal surfaces and vertical side surfaces 50 that are sized and spaced such that each panel 34 is able to nest snugly within a respective landing frame 30, 31 (i.e. to sit on a respective step of the L-profile of each angle 32, 33, as shown in Fig. 4). The panel 34 of Fig. 5 is also shown with cut-off corners 51, which enables the panel to sit flush against the beams 24 (see Fig. 4).

The panel 34 can conceal services e.g. electrical wiring, within the open cavities defined by surfaces 46 and 48, and channel studs 53. The services can be pre installed within the panel 34 cavities prior to delivery of pod 2 to the building site.

Referring now to Figs. 7, 7A & 7B, a prefabricated permanent formwork module 58 is shown that is suitable for use in the pod 2. A number of such prefabricated permanent formwork modules 58 (e.g. such as those disclosed in AU

2008202281) are typically each pre-assembled in a factory to match the height of the pod 2. The beam 24 is formed to have a height corresponding to the height of modules 58, i.e. the typical height of a single building level. The prefabricated modules 58 can be delivered (e.g. in packs) to a pod assembly line or to a building site (i.e. to construct the pod on site). Each formwork module 58 comprises two parallel spaced sidewalls 78. Each sidewall 78 can comprise a sheet of compressed fibre-cement. Each formwork module 58 also comprises a number of webs in the form of spaced, parallel studs 70 that each extend between and connect to (typically adhesively) the sidewalls 78. Each stud 70 is typically a shallow El-channel of metal (e.g. steel) and comprises multiple spaced discrete apertures 72 therethrough. The apertures 72 of each stud 70 are aligned such that, in use, one or more reinforcing bars or rods can be passed horizontally through a module to locate in the aligned apertures (i.e. to ultimately become embedded in concrete poured into each module 58 in use).

In Figs. 7, 7A & 7B, it will be seen that all of the studs 70 protrude above 73 as well as below 64 the sidewall sheets 78. Further, in Figs. 7 & 7A, it will be seen that the outer sidewall sheet 78’ is shorter than the inner sidewall sheet 78”. In the modular pod 2 (see Figs. 1 & 9 & 9A), this results in an externally facing upper opening O being defined around the top of the pod 2, thereby exposing the interior of each formwork module 58 to enable a wall-to-floor slab connection. In this regard, horizontal reinforcing within the upper apertures 72 of each module 58 as well as vertical reinforcing within each module 58 can be tied to reinforcing for the floor slab, with the concrete for the floor and pod 2 able to be poured simultaneously so as to extend continuously between the floor and pod.

The protrusion 64 of the studs 70 below the sidewall sheets 78 enables each formwork module 58 to be aligned with and supported in an upright orientation by the lower frame 4. The lower frame 4 is fabricated with a predetermined width between inner 18 and outer 16 walls to correspond to the width of the formwork panel 58. This enables each formwork panel 58 to be self-supported once positioned on the lower frame 4. Likewise, with the width of the upper frame 66.

In this regard, as shown for a first module 58’ in Fig. 8A and for a second module 58” in Fig. 8B, the protruding parts 64 of the studs 70 are able to be inserted (i.e. wedged) inside the lower frame 4 of the pod (i.e. to locate and be retained between the outer wall 16 and inner wall 18). Further, a bottom edge 75 of each of the outer 78’ and inner 78” fibre cement sheets 78 is typically glued to a respective top edge of each of the outer wall 16 and inner wall 18 of the lower frame 4 by applying a large bead line of glue during assembly of the pod 2.

The protrusion 73 of the studs 70 above the sidewall sheets 78 also enables each formwork module 58 to be aligned with, secured to, and supported in its upright orientation by the upper frame 66. This is described below.

Figs. 9, 9A & 9B illustrate a next stage of construction of pod 2, in which a number of formwork modules 58 are arranged side-by-side along the lower frame 4 to define each of the pod side walls 60, 61, 62, 63. Then, the upper frame 66 is arranged on top of the pod side walls 60 to 63 to“cap off’ the pod and to “sandwich” the formwork modules 58 between the lower frame 4 and upper frame 66

Typically, the formwork panels are positioned around the perimeter of the pod 2, save for the omission of one module to define an opening for a door. In the embodiment as shown in the Figures, the end walls 62, 63 of the pod 2 typically comprise two adjacent upright formwork modules 58 and the side walls 60, 61 typically comprise four adjacent upright formwork modules. The pod 2 can be reconfigured such that each side wall and end wall comprises more or less formwork panels.

Further, as shown in Figs. 9A & 9B as well as in Fig. 10, when the upper frame 66 is located on each module 58, the upper protruding parts 73 of the studs 70 are caused to be inserted (i.e. wedged) inside the upper frame 66 of the pod (i.e. between the outer wall 16 and inner wall 18). Further, a top edge 77 of the inner fibre cement sheet 78” can be glued to a respective underside edge of the inner wall 18 of the upper frame 66 by applying a large bead line of glue during assembly of the pod 2. The upper frame 66 and lower frame 4 thereby lock all of the subcomponents of the modular pod 2 together, whereby all subcomponents are secured to provide structural integrity to the pod.

Turning now to Fig. 10, it will be seen that the external faces 28 of an in-use upper end of each beam 24 are connected (e.g. spot-welded and/or bolted) to external surfaces 22 of the inner walls 18 of the upper frame 66 at a comer of the frame. Each beam 24 extends up from the lower frame 4 to the upper frame 66 between respective comers thereof. The upper end of each beam 24 can be bolted to the external surfaces 22 of the inner walls 18 via the preformed bolt holes 27.

Figs. 10 & 11 also illustrate a final stage of construction of the modular pod 2. In this stage, corner caps in the form of corner profiles 74 are provided to

interconnect adjacent formwork modules 58 that form the comers of pod 2. In use, four corner profiles 74 are provided, each provided to cap a respective corner formed by adjacent side 60, 61 and end 62, 63 walls of pod 2. Each corner profile 74 comprises a plate that is bent to define perpendicular sidewalls 76, with each sidewall 76 comprising a stiffening lip 76A formed along its free elongate edge (i.e. each comer is an L-shaped profile 74 with internally formed lips 76A).

As illustrated in each of Figs. 10 and 11, the L-shaped corner profile 75 is configured to be secured to the internal surfaces 20 of each of the outer walls 16 of the lower 4 and upper 66 frames. In this regard, each of the sidewalls 76 of comer profile 74 has a series of spaced bolt holes 81 provided therein, the bolt holes extending along and adjacent to lower and upper edges of each of the sidewalls 76. The bolt holes enable each comer profile 74 to be screwed/bolted to each of the outer walls 16 of the lower 4 and upper 66 frames. Thus, the corner profiles 74 can also tie together the lower 4 and upper 66 frames.

The L-shaped corner profile 75, in use, defines a cavity enclosed by the sidewalls 76 of profile 75 and the sidewalls 78 of formwork module 58. Services, e.g.

electrical wiring, can be installed within said cavity either before pod 2 is installed on a building site or following delivery of pod 2 to the building site. As also shown in Figs. 10 & 11, each comer profile 74 is also configured to lap under proximate ends 65 of the two adjacent formwork components 58 located at each comer. That is, the outer sidewall sheet 78’ of each of the comer formwork components 58 can locate outside of and externally overlay a given corner profile 74, whereby each sheet 78’ can be secured (e.g. adhered and/or screwed) to a respective adjacent sidewall 76 of the corner profile 74. This can serve to secure the ends 65 of the corner formwork modules 58 to provide a complete outer “skin” of the pod 2, i.e. prior to concrete pouring therein.

Likewise, as also shown in Figs. 10 & 11, the inner sidewall sheet 78” of each of the corner formwork components 58 can locate inside of a given beam 24. Thus, again, each inner sidewall sheet 78” at each corner can be secured (e.g. adhered and/or screwed) to a respective adjacent web 26 of beam 24. This also secures the ends 65 of the corner formwork modules 58 to provide a complete inner“skin” of the pod 2, i.e. prior to concrete pouring.

Prior to capping with the corner profiles 74, a number of reinforcing rods/bars can be arranged inside each of the pod walls 60-63. This reinforcing can be tied to adjacent formwork reinforcing (e.g. floor reinforcing). Once capped and inspected, the completed modular pod 2 is now ready to have concrete poured therein.

Referring back to Figs. 9 & 9B, it will be seen the upper frame 66 of each pod 2 has a plurality of projections in the form of discrete projecting plates 68 that are evenly spaced along the sides 60, 61 and ends 62, 63 of the upper frame 66. Each plate 68 typically comprises a bent metal plate that is connected by welding or bolting to the internal surface 20 of the inner wall 18 of upper frame 66. The projecting plates 68 are bent such that an overlying lower frame 4 of an overlying pod can readily be located (e.g. dropped, craned) into place on the upper frame 66 of pod 2. Once the overlying lower frame is in place, the plates 68 can be straightened (e.g. by being hammered) and then secured (e.g. welded or bolted) to the lower frame of the overlying pod. This ties the pods together, prior to reinforcing being put in place and/or tied, and prior to concrete being poured into the overlying pod.

Referring again to Figs. 1 and 9, it will be seen that the outer sidewall sheet 78’ of each formwork module 58 comprises a lower removable panel 80 (i.e. located at a lower portion of the formwork module). Each panel 80 can be separately secured to its module such that it can be readily detached on site (e.g. it can be secured with a light adhesive). Each removable panel 80 comprises an elongate sheet strip that is typically formed of the same material as the remainder of outer sidewall sheet 78’ (e.g. compressed fibre cement). When the panel 80 is removed from the formwork module 58, access to lowermost reinforcing is enabled (e.g. such as when tying e.g. the vertical and/or horizontal reinforcing of a given pod to reinforcing that projects up from and beyond the concrete of an underlying pod - e.g. to tie to slab starter-reinforcing). The removable panels 80 also allow onsite engineers to inspect such reinforcing prior to concrete pouring into the given pod 2.

Referring now to Figs. 12, 13 & 13A, in which like reference numerals denote like parts, an embodiment of a pod T is shown in which the formwork modules 58 are each replaced with a formwork module 100. Again, each formwork module 100 extends up from the lower frame 4 in use. Again, each module 100 is typically prefabricated (e.g. in a factory) from spaced, parallel sidewalls 102 formed of compressed fibre-cement sheets. However, in the module embodiment of Figs. 12 & 13, only the rear sheet 102” is bonded (e.g. adhesively) to the plurality of spaced, parallel module webs that, in this embodiment, take the form of central studs 104 and end studs 106. Again, each stud 104, 106 can be fabricated of a galvanised steel frame, or may be moulded from e.g. plastic, and each can comprise a series of spaced, discrete apertures 107 therein to receive reinforcing therethrough. However, whilst the end studs 106 can be fabricated with a similar profile to studs 70, the central studs 104 are each fabricated to have a T-profile 108 along an elongate edge thereof. The T- profile edge 108 of each central stud 104 is able to mate in a sliding manner with a respective track 110. The series of spaced, in-use vertical tracks 110 are in turn secured (e.g. bonded adhesively) to a rear surface of each front sheet 102’ (see Fig. 13B). It will also be seen that a half-track 110’ is provided along each elongate side edge for engaging with and enabling sliding therein of a lip 112 of each end stud 106.

This tracking 110 enables each front sheet 102’ to be slid up and down with respect to a reminder of the module 100. In this regard, when the module forms part of the assembled pod 2’, each front sheet 102’ can be slid up and down as indicated by arrows A in Fig. 12.

Further, in Fig. 13B, it will be seen that an inside upper edge each front sheet 102’ has an upper strip 114 secured (e.g. bonded adhesively to the rear surface of each front sheet 102’). The strip 114 sits above an upper end of each track 110, 100’. The upper strip 114 has an L-profile such that a projecting lip thereof is able to engage with and locate on top of the T-profile edge 108 of each central stud 104 and the lip 112 of each end stud 106. Thus, the strip 114 delimits the downwards sliding movement of each front sheet 102’.

Additionally, lower locator strips 116 can be secured (e.g. bonded adhesively) along a lower outside face of each T-profile edge 108 of each central stud 104 and each lip 112 of each end stud 106. These strips 116 can facilitate each stud 104, 106 locating and mating (e.g. wedging) between the outer wall 16 and inner wall 18 of the lower frame 4. Likewise, upper ends of the studs 104, 106 can locate and mate (e.g. wedge) between the outer wall 16 and inner wall 18 of the upper frame 66

Again, in a similar manner to the removable panel 80, access to lowermost reinforcing is enabled by sliding up each front sheet 102’ (e.g. such as when tying e.g. the vertical and/or horizontal reinforcing of a given pod to reinforcing that projects up from and beyond the concrete of an underlying pod - e.g. to tie to slab starter-reinforcing). The sliding front sheets 102’ also allow onsite engineers to inspect such reinforcing prior to concrete pouring into the given pod 2’. Each front sheet 102’ can be dropped back into position after tying/inspecting the reinforcing.

Variations and modifications may be made to the parts previously described without departing from the spirit or ambit of the disclosure.

For example, the module pod may be constructed to be circular and may support e.g. a set of spiral stairs therein. Other pod shapes/configurations are also possible.

Referring now to Figure 14, an embodiment of a modular pod 203 is shown. This embodiment can comprise any one of the components shown in Figs. 1 to 13 and includes an in-use upper 230 and intermediate 231 landing frames in place of panel 34 of Fig. 5 or Fig. 6. In Fig. 14, like parts to those shown in Figs. 1 to 13, are shown with like reference numbers, but with 200 added thereto.

In Fig. 14, each set of stairs is labelled 222’ and 222”. The‘upper’ set of stairs 222’ is shown extending downwardly from an upper landing frame 230, down to a intermediate landing frame 231. The Tower’ set of stairs 222” is shown extending downwardly from the intermediate landing frame 231.

The upper landing frame 230 comprises a base tray 224 and side walls 212 that extend up from and surround the base tray. The upper landing frame 230 also comprises a number of bracing members in the form of transverse cross-members 220

The intermediate landing frame 231 comprises a base tray 225 and side walls 214 that extend up from and surround the base tray. The intermediate landing frame 231 also comprises a number of bracing members in the form of transverse cross members 221. The upper landing frame 230 and intermediate landing frame 231 each thereby define a tray into which an infill material such as concrete may be poured. When so poured, the transverse cross-members 220 and 221 become embedded in the concrete and thereby also act as reinforcing bars.

The upper landing frame 230 is connected to the structural components of the modular pod 203 and can itself act as bracing within the pod. Likewise, the intermediate landing frame 231 is connected to the structural components of the modular pod 203 and can also act as bracing within the pod.

The upper set of stairs 222’ is connected (e.g. spot welded, fastened) to each of the upper landing frame 230 and intermediate landing frame 231. The lower set of stairs 222” is connected (e.g. spot welded, fastened) to the intermediate landing frame 231 and extends downwardly therefrom. A lower end of the lower set of stairs 222” can be connected (e.g. spot welded, fastened) to a lower frame of the modular pod 203 as shown.

The entire resulting structure shown in Fig. 14 can act as formwork, such that a settable or curable fill material, e.g. concrete, can be poured therein. In this regard, the fill material can be poured (e.g. pumped) into each of the spaces that are defined at the upper 230 and intermediate 231 landing frames, the upper 222’ and lower 222” set of stairs, and within the wall infill panels 262. Once poured into these respective spaces, the fill material can be formed (e.g. screeded, trowelled, etc.) at the upper 230 and intermediate 231 landing frames, and at the upper 222’ and lower 222” set of stairs.

The continuous flow of concrete can be poured during concrete pouring of an overlying floor in a building, such that the concrete can be used to form the floor, the walls of the modular pod, the upper and intermediate landing frames, and upper and lower stairs, i.e. the overlying floor concrete is poured simultaneously and contiguously with the modular pod concrete and all sub-structures contained therein. In the claims which follow and in the preceding description, 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 modular pod.