vectorbloc presentation online feb 2015

Precision HSS Connection System For

Modular Buildingsby

Entire contents protected by Copyright. US and International Patents Pending

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?

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!

A standardized, scalable, modular connection system for HSS

• 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

Due to these advantages containers are widely used as temporary and even permanent housing

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

Typical structural steel connections don’t work for modular construction either, as connections occur in inaccessible locations and splices cross matelines

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…….

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

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

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

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

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

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

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

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

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”

Vector Praxis delivers the industry-leading Vectorblocmodular solution via 7 categories of products and services:

VectorblocConnection System

Factory Setup

VectorjigPrecision Fabrication System

VectorlocExtendable Gasket System

VectorigHoisting System

VectorsightSurveying and Levelling System

Modular Building Design

1 Vectorbloc Standardized Precision Structural Connection System


Factory Setup






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

Vectorbloc

Anatomy

• Tension bolts

• Lower Vectorbloc

• Façade assembly

• Accessory connection

points

• Hallway or balcony slab

• Gusset plate

• Tapered locating pins

• Upper Vectorbloc

• Hoisting point

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.

Accurate, loadbearing, volumetric modulesbuilt 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.

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.

Buildings have many unique conditions, so the Vectorblocsystem is comprehensive

Vectorbloc modules can be created with the tapering shapes required to assemble buildings with curves

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

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.

When HSS are welded to the Vectorblocs a moment connection is created, which resists lateral forces in all directions

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.

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

MEP modules with compatible facades built in identical jigs simply “plug in” to a Vectorbloc building, eliminating countless hours of trade and supplier coordination

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

Premium over-height studio apartments, lobbies and gathering spaces can be created by stacking floorless / roofless modules

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

…..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………

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

Stacked and Bundled

Vectorbloc Systems

Explained!

Entire contents copyright February 2015

Vectorbloc and related systems US, Canada and WIPO Patent pending

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

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: StackedBottom: Bundled

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.

“Stacked”Typical details

Typical transition block4”x 4” to 6”x 6”

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……..

Robust groupings can be created using one size of HSS welded corner to corner and joined in groups with flat-bar ears.

“Bundled”Typical details

Section transitions

A Vectorbloc

building designer

using FEA software

selects the column

configuration that

best suits the

loading on each

module.

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

Vectorbloc Prototypes

3D Printing

Casting and Machining

February 2015


3D-printed investments and application of ceramic coating

Investment casting and machining

Checks of material quality, alignment and dimensions

Complete prototype of typical connection with cutaways

Prototype of typical module with detail of fireproofing and baseboard leave-out at Vectorbloc connection

Vectorbloc

Concept Building

February 2015


By examining a Vectorbloc-based concept building we can better understand the practical application of the Vectorbloc structural system

Vectorbloc concept building: Renders

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”

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

Module size matrix

Minimizing module size variants is not essential, but it is desirable

Vectorbloc sectional frame elevations showing conventionally-constructed parking structure, podium and transfer beams

Vectorbloc Frame

Typical two-module grouping

Typical two module grouping with finishes and furnishings

Typical single module frame construction

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.

Lateral Frame

FrameDetails

Deep spandrel beams can be integrated in to the framing if required to eliminate diagonal bracing which obstructs openings

LongitudinalFrame

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.

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.

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

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

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.


Factory Setup






2 Vectorjig Precision Fabrication System

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 andwelding of steel members to establish the finished dimensions of themodules. However even the highest AISC specifications have provenunworkable. As a result, it is considered standard practice to adjustabutting work on site so it fits.

Site work is expensive, in fact modular construction exists to reduce sitework!

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

Since connections of a Vectorbloc-based building takes place through the Vectorblocs, precision drilling and cutting of the HSS members is not required

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

The root of Vectorjigprecision:

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.

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.

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.

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”

Precision fixtures are a pre-requisite for robotic welding!

Testing on the Vectorjig assembly system has been completed using “Moc Blocs”; Connectors built from plate instead of castings

Vectorjig is available in two versions:

VJM: manual clampingVJA: 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


Factory Setup






3 Vectorig Rigging, Leveling and Hoisting System

A single story in a modular building can have numerous module variants, making constant re-rigging for level hoisting a key schedule driver

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

The Vectorig connector features a positive lock which prevents accidental release of the load.

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

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


Factory Setup






4 Vectorsight Surveying, Levelling and Safety System

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

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

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


Factory Setup






5 Vectorloc Extendable Façade Gasket System

Gasket and façade panel damage during module placement and poor sealing after placement are significant issues in modular construction.

The Vectorloc façade system leverages the precision of the Vectorblocmodules to accurately locate factory-installed windows, sealing and insulating features.

The Vectorloc factory-installed façade system features a mechanically extendable gasket that is closed and mated from inside the module aftermodules are placed and bolted in position.

Cruciform closure takes place at the same time that outer-wall gusset plates are installed.

The next layer of modules completes the flashing grouping.

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.

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


Factory Setup






7 Factory Design and Management

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 bestguarantee of a successfulentry in to this dynamic and growing market.


Factory Setup






About Vectorbloc and Vector Praxis

The Vectorbloc System is covered by Patents Pending in over 100 countries

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

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 www.vectorpraxis.comPhone: 416 766 9018 Mobile: 416 575 1630530 Keele Street, unit 403, Toronto, Ontario, Canada M6N 3C9

http://www.vectorpraxis.com/

VectorblocThe sky’s the limit

http://meshcities.com/index.php/meshcities/comments/can_vectorblocs_patented_building_system_make_cities_more_energy_efficient#.VCXAb_ldU9J

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/prefabricated-broadway-stack-project-makes-headway/

http://meshcities.com/index.php/meshcities/comments/can_vectorblocs_patented_building_system_make_cities_more_energy_efficient#.VCXAb_ldU9J

http://atlanticyardsreport.blogspot.ca/2014/09/in-dispute-over-stalled-modular-tower.html

http://therealdeal.com/blog/2013/03/13/prefabricated-broadway-stack-project-makes-headway/