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Vectorbloc presentation online Feb 2015

  1. 1. Precision HSS Connection System For Modular Buildings by Entire contents protected by Copyright. US and International Patents Pending
  2. 2. Greater use of modular construction could help construction productivity catch up with other industries, but every project seems to start from scratch and many hit a glass ceiling at 10 floors, as tolerance accumulation and loads overwhelm unsophisticated structural approaches. Does the modular industry need a standardized structural solution?
  3. 3. Imagine standardized, pre- qualified and pre-engineered “building blocks” that come from multiple suppliers and assemble efficiently to create complete, operational buildings…… Imagine designing and bidding a tower in a few days….. A standardized construction system would make that possible!
  4. 4. A standardized, scalable, modular connection system for HSS
  5. 5. • Vectorbloc was inspired by the ISO corner that is used to lift and lock ocean freight containers • The infrastructure of the ocean freight business is standardized on the ISO corner and multiples of its 8’ x 20’ dimensional grid • The advantages of a single system being used by all shipbuilders, container fabricators and freight handlers are obvious
  6. 6. Due to these advantages containers are widely used as temporary and even permanent housing
  7. 7. However the vertical tension capacity of the ISO corners that joins stacks of containers limits the height of buildings, and the fixed grid limits space planning options
  8. 8. Typical structural steel connections don’t work for modular construction either, as connections occur in inaccessible locations and splices cross matelines
  9. 9. For modular construction to be successful, there are actually 7 challenges to be overcome, and they all become exaggerated as buildings get taller and wider…….
  10. 10. Challenge 1: The accumulating tolerances of low- precision modules can result in interior finish defects, assembly clashes and façade failure The Fix: Jig-built precision modules and a simple system for monitoring and adjusting the dimensions of the assembled structure
  11. 11. Challenge 2: A separate brace frame or brace core adds erection time, adds cost, complicates waterproofing during construction and reduces the GFA The Fix: Interconnected, stackable load bearing modules, which eliminate the need for the fabrication and erection of a separate brace structure and eliminates the gaps around the frame
  12. 12. Challenge 3: Re-rigging for level hoisting of the module variants within each floor is slow and costly The Fix: A quick-connect rigging attachment and halo that can be quickly and reliably levelled and released
  13. 13. Challenge 4: Tasks which require work under a suspended load are inherently unsafe The Fix: Integral walkways and stairs, modules that are easily rigged with safety barriers, and modules that connect from inside
  14. 14. Challenge 5: Projections beyond the mateline result in gasket / facade damage during placement The Fix: A field-extendable gasket that is closed and mated from inside the module after modules are placed
  15. 15. Challenge 6: Precipitation which falls during building assembly penetrates voids, damages module finishes and compromises insulation The Fix: Eliminating the brace frame makes it easy to waterproof the top level during building assembly
  16. 16. Challenge 7: Modular systems are costly to develop because they require high-end software and expert knowledge The Fix: An off-the-shelf design and engineering process
  17. 17. The Vectorbloc strategy: Reduce the cost of design, coordination, fabrication and building assembly by concentrating the load- bearing and connection functions in a standard, scalable, precision component used by all suppliers to a project
  18. 18. To be a standard, the solution has to be economical at all scales. In fact scalability is so important to modular systems that we say: ”By solving tall, you solve it all”
  19. 19. Vector Praxis delivers the industry-leading Vectorbloc modular solution via 7 categories of products and services: Vectorbloc Connection System Factory Setup Vectorjig Precision Fabrication System Vectorloc Extendable Gasket System Vectorig Hoisting System Vectorsight Surveying and Levelling System Modular Building Design
  20. 20. 1 Vectorbloc Standardized Precision Structural Connection System Vectorbloc Connection System Factory Setup Vectorjig Precision Fabrication System Vectorloc Extendable Gasket System Vectorig Hoisting System Vectorsight Surveying and Levelling System Modular Building Design
  21. 21. The heart of the Vectorbloc system is a connector assembly specifically designed to build robust modules with integral building structure Vectorblocs have many advantages over both the ISO corner and competing modular systems: • Builds modules of any size, including wider, longer, taller modules • Provides the scalable vertical tension and gravity capacity needed for real buildings • Assembles safely from inside the module • Provides accessory connection points for connecting balconies, floors and façade cassettes • Does not rely on continuous walls for structure
  22. 22. Vectorbloc Anatomy • Tension bolts • Lower Vectorbloc • Façade assembly • Accessory connection points • Hallway or balcony slab • Gusset plate • Tapered locating pins • Upper Vectorbloc • Hoisting point
  23. 23. The Vectorbloc structural connectors are located at the corners of the modules and at intermediate points, if required by loading. Modules are stacked and held together horizontally with gusset plates, then vertical bolts are then inserted through the Vectorbloc connectors to hold the building together.
  24. 24. Accurate, loadbearing, volumetric modules built with Vectorbloc connectors can be outfitted with interiors and MEP systems in plant, then easily hoisted and quickly assembled to create cost-effective, tight and energy- efficient buildings, ranging from low-rise to high-rise.
  25. 25. So that building tolerances can be maintained and columns effectively grouped, a precision assembly fixture is used during chassis manufacturing to ensure that no intermediate part of a module frame crosses the mateline and prevents the Vectorbloc corners from touching.
  26. 26. Buildings have many unique conditions, so the Vectorbloc system is comprehensive
  27. 27. Vectorbloc modules can be created with the tapering shapes required to assemble buildings with curves
  28. 28. Like the ISO fittings used to build containers, Vectorblocs are cast and machined from a weldable steel alloy. Vectorblocs provides integral points for structural connection, hoisting and connection of balconies and hallways all in an easy-to-weld precision connection Module frames supplied by Vector Praxis are welded in our CWB-certified facility
  29. 29. Vectorblocs come in 4”, 6” and 10” series, so that in compression, tension and bending modes, Vectorblocs are not the limiting factor in the strength of the structure.
  30. 30. When HSS are welded to the Vectorblocs a moment connection is created, which resists lateral forces in all directions
  31. 31. The tapered pin on the Vectorbloc gusset plate accurately locates the modules during assembly and the gusset plate connects the modules horizontally. When the vertical tension bolts between modules are tightened, a horizontal connection between the floors of the modules is created. The result is a structural “diaphragm” which extends the bracing within stair towers and elevator shafts to the entire structure.
  32. 32. The vertical tension bolts are hidden behind removable feature panels in the hallways, or behind the baseboard at the outer wall After the gusset plates and stanchions are installed on top of the modules, the Vectorsight system provides a stable surveying platform and a fall arrest system
  33. 33. MEP modules with compatible facades built in identical jigs simply “plug in” to a Vectorbloc building, eliminating countless hours of trade and supplier coordination
  34. 34. Pre-fabricated elevator shafts and stairwells are likewise easily and quickly erected at the same time as the building itself, with the additional benefit of improving access for workers and materials
  35. 35. Premium over- height studio apartments, lobbies and gathering spaces can be created by stacking floorless / roofless modules
  36. 36. Vectorbloc’s accurate, pre-configured accessory connection points are ideal for the integration of high-performance building features such as “facade cassettes” and thermally- broken balconies
  37. 37. …..and Vectorblocs can be used to build Data Center modules Vectorblocs are also ideal for the production of Precision Modular Armatures (PMA’s) for resource industry applications………
  38. 38. By reducing sitework and re-work to its theoretical minimum, Vectorbloc makes it feasible to deliver the all-trade, 95% factory completion that realizes the full cost-saving potential of modular construction. Appropriate building types include: • Apartments • Hotels and dormitories • Hospitals and clinics • Offices • Industrial facilities • Urban infill • Relocatable / emergency facilities
  39. 39. Stacked and Bundled Vectorbloc Systems Explained! Entire contents copyright February 2015 Vectorbloc and related systems US, Canada and WIPO Patent pending
  40. 40. Because loads in a building vary, Vectorblocs are designed to support a wide range of column configurations This means that the minimum of steel and labour can be used to build a member which suits specific load conditions Each bolt in the standard connector series has a clamping strength of 60kips, so a group of 8 delivers over 400 kips, adequate for buildings well over 30 stories
  41. 41. Vector Praxis production office Vectorbloc offers two ways to build modules, which we call “Stacked” and “Bundled”. The stacked system scales with load using modules with progressively larger HSS, while the bundled system adds horizontal tiers of HSS in ever wider assemblies. These wide assemblies also function as shear walls. Top: Stacked Bottom: Bundled
  42. 42. The two systems are interchangeable, so designers can select the connection and member configuration that best suits each project, or even each part of a project.
  43. 43. “Stacked” Typical details
  44. 44. Typical transition block 4”x 4” to 6”x 6”
  45. 45. The “structural bundling” of columns is similar to the story of the boy who was challenged to break a bundle of sticks…… ……and found it impossible because a group of members acting together are stronger than the sum of the parts……..
  46. 46. Robust groupings can be created using one size of HSS welded corner to corner and joined in groups with flat-bar ears.
  47. 47. “Bundled” Typical details
  48. 48. “Bundled” Typical details
  49. 49. Section transitions A Vectorbloc building designer using FEA software selects the column configuration that best suits the loading on each module.
  50. 50. By joining bundled columns in adjacent modules, configurations ranging from a 24 lbs / foot grouping of 4” x 4” HSS , to massive built-up columns weighing over 400 lbs per foot, can all fit in a 10-1/2” wall
  51. 51. Vectorbloc Prototypes 3D Printing Casting and Machining February 2015 Vectorbloc and related systems US, Canada and WIPO Patent pending
  52. 52. 3D-printed investments and application of ceramic coating
  53. 53. Investment casting and machining
  54. 54. Checks of material quality, alignment and dimensions
  55. 55. Complete prototype of typical connection with cutaways
  56. 56. Prototype of typical module with detail of fireproofing and baseboard leave-out at Vectorbloc connection
  57. 57. Vectorbloc Concept Building February 2015 Vectorbloc and related systems US, Canada and WIPO Patent pending
  58. 58. By examining a Vectorbloc-based concept building we can better understand the practical application of the Vectorbloc structural system
  59. 59. Vectorbloc concept building: Renders
  60. 60. Plan of typical floor Apartment buildings and condominiums are highly optimized and every square foot is utilized. Vectorbloc’s bundled column reduces lost GFA by packing load-bearing structures in to the wall cavities, eliminating inconvenient “bumpouts”
  61. 61. Brace locations Lateral brace frames (blue) are concentrated in the party walls, while the longitudinal system (pink) is loaded in to areas where the diagonal bracing does not obstruct openings
  62. 62. Module size matrix Minimizing module size variants is not essential, but it is desirable
  63. 63. Vectorbloc sectional frame elevations showing conventionally- constructed parking structure, podium and transfer beams
  64. 64. Vectorbloc Frame
  65. 65. Typical two- module grouping
  66. 66. Typical two module grouping with finishes and furnishings
  67. 67. Typical single module frame construction
  68. 68. The brace frame is created when modules are interconnected to unite the integral diagonal bracing in the modules. Bracing can be integrated in locations such as the party walls, elevator shafts and stairwells.
  69. 69. Lateral Frame
  70. 70. Frame Details Deep spandrel beams can be integrated in to the framing if required to eliminate diagonal bracing which obstructs openings
  71. 71. Longitudinal Frame The longitudinal brace frame is created on the upper floors by interconnecting modules to combine the moment action of the module frames. On lower floors, bracing is added to the shaft, stairwell and hallway modules.
  72. 72. Vectorbloc modules incorporate the ideal vertical load bearing capacity at each level in the building, they provide a moment connection and they are interconnected connected horizontally. As a result, a separate brace frame or brace tower can be eliminated, saving valuable space and reducing construction complexity.
  73. 73. Eliminating the separate brace frame confers numerous benefits: • The additional work of fabricating and erecting the brace frame is eliminated, and the number of required crane cycles and super-elevation differentials are both reduced • Party wall voids are eliminated, so wasted GFA is reduced and waterproofing during erection is simplified • Movement of workers across the top surface of the structure is safer and clashes with the Halo are eliminated
  74. 74. The accessory connection points on a Vectorbloc module are precisely located in 3D space, making it easy and cost-effective to deliver desirable and progressive building features: • Panelized facades with thermally-broken hanging, cantilevered or suspended balconies • Hallways with factory-integrated MEP trains • Over-height studio spaces, lofts, roof decks and parapets • Pre-fabricated elevators, stairs and waste disposal chutes • Factory-integrated MEP systems
  75. 75. Using the hall slabs as MEP carriers, the Vectorbloc system supports factory- integrated wiring, piping and ducts in trains up to 50’ in length. During building assembly, the hallways also double as access platforms.
  76. 76. Vectorbloc Connection System Factory Setup Vectorjig Precision Fabrication System Vectorloc Extendable Gasket System Vectorig Hoisting System Vectorsight Surveying and Levelling System Modular Building Design 2 Vectorjig Precision Fabrication System
  77. 77. Model VJS (Vectorjig Standard Model VJA) utilizes screw clamps. Model VJA (Vectorjig Auto) features hydraulic locking and release to further reduce cycle time Replace with images from SW tooling model It’s expensive to make something accurate! Accurate = cheap! Traditional modular frame construction relies on cutting, fitting and welding of steel members to establish the finished dimensions of the modules. However even the highest AISC specifications have proven unworkable. As a result, it is considered standard practice to adjust abutting work on site so it fits. Site work is expensive, in fact modular construction exists to reduce site work!
  78. 78. To build a Vectorbloc module frame, HSS columns, floor beams and ceiling joists are joined to Vectorblocs by welding in precision fixtures. All spatial relationships in a Vectorbloc-based structure are established by the relative position of the Vectorblocs, which is established in the factory by the logical grid of the fabrication fixtures
  79. 79. Since connections of a Vectorbloc-based building takes place through the Vectorblocs, precision drilling and cutting of the HSS members is not required
  80. 80. Using the same techniques as the automotive and aerospace industries, Vectorjig allows modular fabricators to build precision structural modules using inexpensive materials processed with just three pieces of equipment. BandsawVectorjig Welding machine
  81. 81. The root of Vectorjig precision: Rock-solid building geometry created in a precision fixture aligned by Vector Praxis technicians using LASER Metrology, the same technique used to calibrate precision tooling.
  82. 82. The Vectorjig system ensures a Go / No Go tolerance regimen which locates the Vectorblocs and structural members to a + 0” – 1/16” accuracy This assembly methodology ensures that no intermediate part exceeds the mateline, resulting in tight structural connections. The Vectorjig also elevates the members ideally for manual or robotic welding.
  83. 83. Each cycle begins with the jig in closed position to receive the Vectorblocs and adjoining members Once the unit is welded, the jig opens to release the completed frame.
  84. 84. The application of floor material, wall board and the façade can be completed before opening the Vectorjig and removing the modules, or the bare “chassis” can be removed for offline completion in a “Vectorjig Lite”
  85. 85. Precision fixtures are a pre-requisite for robotic welding!
  86. 86. Testing on the Vectorjig assembly system has been completed using “Moc Blocs”; Connectors built from plate instead of castings
  87. 87. Vectorjig is available in two versions: VJM: manual clamping VJA: Automatic clamping The pin rotating mechanism of the automatic version (prototype shown at left in the Vector Praxis toolroom) is actuated by a heavy-duty rack powered by a hydraulic cylinder which is entirely enclosed to protect it from weld spatter
  88. 88. Vectorbloc Connection System Factory Setup Vectorjig Precision Fabrication System Vectorloc Extendable Gasket System Vectorig Hoisting System Vectorsight Surveying and Levelling System Modular Building Design 3 Vectorig Rigging, Leveling and Hoisting System
  89. 89. A single story in a modular building can have numerous module variants, making constant re-rigging for level hoisting a key schedule driver
  90. 90. Vectorblocs feature prepared connection points for the Vectorig quick-connect rigging and CG compensating system. Time-consuming and labour- intensive “iterative rigging” is required to level modules when the CG of the load is unknown or cannot be predicted
  91. 91. The Vectorig connector features a positive lock which prevents accidental release of the load.
  92. 92. Modules are shipped with rigging notes generated by CG simulation, based on the behavior of the combined parasolid models of the module and the Vectorig halo. The rigging notes tell the rigger exactly how to set up the rigging blocks on the halo frame. The sliding rigging points are quickly adjusted at ground level, then the module is connected and hoisted level. Spreaders Beam A End 1 Beam A End 2 Beam B End A Beam B End 2 Position 17 Position 4 Position 4 Position 6 Position 6
  93. 93. Precision locating pins mounted on LASER- cut gusset plates engage with holes machined in the Vectorblocs, ensuring accurate module location. Using parasolid modeling and predictive CG determination together with the Vectorig fitting and halo, rigging and release time is reduced by 75% and crew size is also reduced
  94. 94. Vectorbloc Connection System Factory Setup Vectorjig Precision Fabrication System Vectorloc Extendable Gasket System Vectorig Hoisting System Vectorsight Surveying and Levelling System Modular Building Design 4 Vectorsight Surveying, Levelling and Safety System
  95. 95. Because modules often “stack” or “rack” in numbers of 20 or more, in both horizontal and vertical dimensions, even tight tolerances accumulate quickly. Example: A 20-unit stack built of units 1/16” too high next to a stack of units 1/16” too short creates a 2-1/2” difference! So it is easy to see how standard +- tolerances are simply unworkable for a large modular building
  96. 96. During building assembly, elevation and distance measurements are taken relative to receivers placed on Vectorsight posts rigged to the tops of the gusset plates Vectorsight posts are precisely machined to length ensuring consistent receiver height and accurate measurement Vectorsight posts also function as safety barriers and are rigged at the same time that gusset plates are installed
  97. 97. A modular project based on the Vectorbloc system is conceived with all components conforming to a + 0”, - 1/16” tolerance envelope. This ensures that no part exceeds the tolerance envelope and causes positive tolerance accumulation. Excessive negative variations (undersized stacks or racks) are minimized using sophisticated manufacturing techniques. During building assembly, module groupings are monitored and variations are compensated with a systematic and efficient shimming system. Measure ShimAnalyze Vectorsight combination survey post and guardrail
  98. 98. Vectorbloc Connection System Factory Setup Vectorjig Precision Fabrication System Vectorloc Extendable Gasket System Vectorig Hoisting System Vectorsight Surveying and Levelling System Modular Building Design 5 Vectorloc Extendable Façade Gasket System
  99. 99. Gasket and façade panel damage during module placement and poor sealing after placement are significant issues in modular construction.
  100. 100. The Vectorloc façade system leverages the precision of the Vectorbloc modules to accurately locate factory- installed windows, sealing and insulating features.
  101. 101. The Vectorloc factory-installed façade system features a mechanically extendable gasket that is closed and mated from inside the module after modules are placed and bolted in position.
  102. 102. Cruciform closure takes place at the same time that outer-wall gusset plates are installed. The next layer of modules completes the flashing grouping.
  103. 103. The Vectorbloc system does its part by ensuring precise location between modules, resulting in factory- installed façade panels that fit accurately on site and develop their full specification.
  104. 104. Gasket sealing is positive and multi-chambered, improving envelope performance An additional benefit is a field-releasable and repairable façade, reducing both the risk and the cost of troubleshooting, maintenance and renewal
  105. 105. Vectorbloc Connection System Factory Setup Vectorjig Precision Fabrication System Vectorloc Extendable Gasket System Vectorig Hoisting System Vectorsight Surveying and Levelling System Modular Building Design 7 Factory Design and Management
  106. 106. Fast = Cheap To build a modular building, you need to make a lot of perfect modules….and you need to make them quickly. Our experience in factory design and management is your best guarantee of a successful entry in to this dynamic and growing market.
  107. 107. Vectorbloc Connection System Factory Setup Vectorjig Precision Fabrication System Vectorloc Extendable Gasket System Vectorig Hoisting System Vectorsight Surveying and Levelling System Modular Building Design About Vectorbloc and Vector Praxis
  108. 108. The Vectorbloc System is covered by Patents Pending in over 100 countries
  109. 109. The Vectorbloc System was inspired by the experience of the Vector Praxis team: • 30+ years of precision offsite architectural fabrication • 15+ years of 3D / model-driven architectural fabrication • 40+ tours of off-site fabrication plants • Setting up, staffing and running a successful plant creating AAA modules for a Norman Foster-designed tower • Detailed study of numerous modular and structural projects in the USA, Canada, Asia • Development of modular buildings and systems in collaboration with prominent architectural firms and panelized builders • Detailed study of residential tower envelope renewal strategies
  110. 110. R&D To support ongoing improvement of the Vectorbloc system and development of additional features in response to market demands, Vector Praxis maintains a 10,000 square foot research and development facility in Toronto, Canada. Our fully- equipped design and production facility includes a machine shop, metal fabricating and wood working equipment. The Greater Toronto Area (GTA) supports a globally significant cluster of leading custom architectural fabricators, providing our product development team with quick, world-class access to a wide range of materials and CNC processing services. For more information please contact: Vector Praxis Phone: 416 766 9018 Mobile: 416 575 1630 530 Keele Street, unit 403, Toronto, Ontario, Canada M6N 3C9
  111. 111. Vectorbloc The sky’s the limit ments/can_vectorblocs_patented_building_system _make_cities_more_energy_efficient#.VCXAb_ldU 9J dispute-over-stalled-modular-tower.html Links to chatter about Vectorbloc and related subjects: icated-broadway-stack-project-makes-headway/