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Vectorbloc presentation online Feb 2015
- 1. Precision HSS ConnectionSystem For Modular Buildings by Entire contents protected by Copyright. US and International Patents Pending
- 2. Greater use ofmodular 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. Imagine standardized, pre- qualifiedand 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. A standardized, scalable,modular connection system for HSS
- 5. • Vectorbloc wasinspired 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. Due to theseadvantages containers are widely used as temporary and even permanent housing
- 7. However the vertical tension capacityof the ISO corners that joins stacks of containers limits the height of buildings, and the fixed grid limits space planning options
- 8. Typical structural steel connections don’twork for modular construction either, as connections occur in inaccessible locations and splices cross matelines
- 9. For modular construction tobe successful, there are actually 7 challenges to be overcome, and they all become exaggerated as buildings get taller and wider…….
- 10. Challenge 1: The accumulatingtolerances 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. Challenge 2: A separatebrace 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. Challenge 3: Re-rigging forlevel 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. Challenge 4: Tasks whichrequire 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. Challenge 5: Projections beyondthe 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. Challenge 6: Precipitation whichfalls 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. Challenge 7: Modular systemsare costly to develop because they require high-end software and expert knowledge The Fix: An off-the-shelf design and engineering process
- 17. The Vectorbloc strategy: Reducethe 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. To be astandard, 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. Vector Praxis deliversthe 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. 1 Vectorbloc StandardizedPrecision 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. The heart ofthe 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. 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. The Vectorbloc structuralconnectors 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. Accurate, loadbearing, volumetric modules builtwith 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. So that buildingtolerances 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. Buildings have manyunique conditions, so the Vectorbloc system is comprehensive
- 27. Vectorbloc modules canbe created with the tapering shapes required to assemble buildings with curves
- 28. Like the ISOfittings 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. Vectorblocs come in4”, 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. When HSS are weldedto the Vectorblocs a moment connection is created, which resists lateral forces in all directions
- 31. The tapered pinon 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. The vertical tension boltsare 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. MEP modules withcompatible facades built in identical jigs simply “plug in” to a Vectorbloc building, eliminating countless hours of trade and supplier coordination
- 34. Pre-fabricated elevator shafts andstairwells 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. Premium over- height studio apartments, lobbiesand gathering spaces can be created by stacking floorless / roofless modules
- 36. Vectorbloc’s accurate, pre-configured accessory connection pointsare ideal for the integration of high-performance building features such as “facade cassettes” and thermally- broken balconies
- 37. …..and Vectorblocs canbe used to build Data Center modules Vectorblocs are also ideal for the production of Precision Modular Armatures (PMA’s) for resource industry applications………
- 38. By reducing siteworkand 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. Stacked and Bundled VectorblocSystems Explained! Entire contents copyright February 2015 Vectorbloc and related systems US, Canada and WIPO Patent pending
- 40. Because loads ina 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. Vector Praxis productionoffice 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. The two systemsare interchangeable, so designers can select the connection and member configuration that best suits each project, or even each part of a project.
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- 44. Typical transition block 4”x 4”to 6”x 6”
- 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. Robust groupings canbe created using one size of HSS welded corner to corner and joined in groups with flat-bar ears.
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- 49. Section transitions A Vectorbloc building designer usingFEA software selects the column configuration that best suits the loading on each module.
- 50. By joining bundledcolumns 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. Vectorbloc Prototypes 3D Printing Castingand Machining February 2015 Vectorbloc and related systems US, Canada and WIPO Patent pending
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- 56. Prototype of typical modulewith detail of fireproofing and baseboard leave-out at Vectorbloc connection
- 57. Vectorbloc Concept Building February 2015 Vectorblocand related systems US, Canada and WIPO Patent pending
- 58. By examining a Vectorbloc-based conceptbuilding we can better understand the practical application of the Vectorbloc structural system
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- 60. Plan of typicalfloor 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. Brace locations Lateral braceframes (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. Module size matrix Minimizingmodule size variants is not essential, but it is desirable
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- 66. Typical two modulegrouping with finishes and furnishings
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- 68. The brace frameis 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.
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- 70. Frame Details Deep spandrel beams canbe integrated in to the framing if required to eliminate diagonal bracing which obstructs openings
- 71. Longitudinal Frame The longitudinal brace frameis 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. Vectorbloc modules incorporatethe 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. Eliminating the separate braceframe 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. The accessory connectionpoints 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. Using the hall slabsas 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.
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- 77. Model VJS (VectorjigStandard 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. To build aVectorbloc 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. Since connections ofa Vectorbloc-based building takes place through the Vectorblocs, precision drilling and cutting of the HSS members is not required
- 80. Using the sametechniques 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. The root ofVectorjig 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. The Vectorjig systemensures 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. Each cycle beginswith 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. The application offloor 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. Precision fixtures area pre-requisite for robotic welding!
- 86. Testing on the Vectorjig assemblysystem has been completed using “Moc Blocs”; Connectors built from plate instead of castings
- 87. Vectorjig is availablein 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
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- 89. A single storyin a modular building can have numerous module variants, making constant re-rigging for level hoisting a key schedule driver
- 90. Vectorblocs feature prepared connectionpoints 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. The Vectorig connectorfeatures a positive lock which prevents accidental release of the load.
- 92. Modules are shippedwith 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. Precision locating pinsmounted 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
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- 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. During building assembly, elevationand 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. A modular projectbased 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
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- 99. Gasket and façade panel damageduring module placement and poor sealing after placement are significant issues in modular construction.
- 100. The Vectorloc façadesystem leverages the precision of the Vectorbloc modules to accurately locate factory- installed windows, sealing and insulating features.
- 101. The Vectorloc factory-installed façadesystem features a mechanically extendable gasket that is closed and mated from inside the module after modules are placed and bolted in position.
- 102. Cruciform closure takesplace at the same time that outer-wall gusset plates are installed. The next layer of modules completes the flashing grouping.
- 103. The Vectorbloc systemdoes 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. Gasket sealing ispositive 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
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- 106. Fast = Cheap Tobuild 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.
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- 108. The Vectorbloc Systemis covered by Patents Pending in over 100 countries
- 109. The Vectorbloc Systemwas 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. R&D To support ongoingimprovement 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 www.vectorpraxis.com Phone: 416 766 9018 Mobile: 416 575 1630 530 Keele Street, unit 403, Toronto, Ontario, Canada M6N 3C9
- 111. Vectorbloc The sky’s thelimit http://meshcities.com/index.php/meshcities/com ments/can_vectorblocs_patented_building_system _make_cities_more_energy_efficient#.VCXAb_ldU 9J http://atlanticyardsreport.blogspot.ca/2014/09/in- dispute-over-stalled-modular-tower.html Links to chatter about Vectorbloc and related subjects: http://therealdeal.com/blog/2013/03/13/prefabr icated-broadway-stack-project-makes-headway/