Scalable Precision Modular Construction System

Transcription

1 Scalable Precision Modular Construction System January 2016 Entire contents protected by Copyright. US and International Patents Pending

2 Contents 1. About VectorBloc and Atlas / JMC 2. Tolerances and scale 3. VectorBloc VectorBloc Building Product development 6. Test Stack 7. Commercialization 8. The Market 9. Patents

3 VectorBloc / Atlas Tube Strategic Partnership Ownership Julian Bowron: Shareholder and founder Atlas Tube: Shareholder and strategic partner. Atlas Tube is owned 100% by JMC Steel Group, NA s largest producer of HSS w sales of > $2.5B / annum Board of Directors Julian Bowron: President and CEO John Reich: Director and CFO Helen Casanova: Director Tom Muth: Director VBC, President Atlas Tube Bradlee Fletcher: Director VBC, Sales Engineer JMC Steel Group

4 Project and Facility Map Production Foundry Muskegon Michigan VectorBloc HQ and Fixture Fabrication Toronto Ontario Coarchitecture Project Lac Megantic Quebec Connexio Windsor Ontario Retirement Home Project Cambridge Ontario JMC Steel Group HQ and Plant Chicago Illinois VectorBloc Fabrication Harrow Ontario

5 Tolerances and Scale in Modular Construction The construction industry has an antiquated approach to tolerances. Current building practice includes these pitfalls: Incomplete drawings Large just in case tolerances Inaccurate buildings MEP systems, FF&E etc. must be cut to size on site so they fit

6 Why are tolerances so important? Modules stack (vertical) or rack (horizontal) in numbers of 20 or more, so even tight tolerances accumulate quickly. Example: A 20-unit stack of modules each 1/16 too high next to a stack of modules each 1/16 too short creates a 2-1/2 (60mm) difference! What this tells us is that standard + - construction tolerances as described in the CISC / AISC handbooks are excessive for a large modular building. All VectorBloc systems are based on plus zero, minus 1/16 / (1.5mm) tolerances controlled by precision fixtures, ensuring that the stacking process proceeds without clashes between adjacent modules.

7 Unlike construction, the automotive and aerospace industries have employed integrated design and dimensional control techniques since the 1950 s. The multi-lateral production environment requires agreement among suppliers on the tolerances of the Body-in-White (bare chassis).

8 If parts from suppliers fit the reference fixtures used in the supplier plants, they will fit together to make a car.

9 Even a fuzzy material like wiring is predictively detailed and fixturefabricated in accordance with a shared computer model

10 The Scale Problem The modular industry consists of many plants each manufacturing a unique product that is incompatible with the modules of other modular producers. Capacity factor in the modular industry is limited by the flow of deals which sync with availability. Despite all the hype about modular, several NA producers closed in 2015.

11 The Scale of the Scale Problem? To house the 2.5b people that will move to cities by 2050, we need to complete 400 buildings housing 500+ people every day. Traditional single-factory details and inaccurate fixtures cannot meet this demand. And no modular plant currently produces high-end building system modules such as HVAC plants, elevators, etc. so these are built on site conventionally

12 A multi-site structural and dimensional platform solves the Scale Problem by allowing multiple, specialized suppliers to produce compatible building blocks for multiple projects, on independent schedules

13 Compatible Production Example: Pre-fabricated elevator shafts and stairwells can be easily stacked at the same time as the building itself, with the additional benefit of improving access for workers and materials

14 Compatible Production Example: Facade cassettes and thermally-broken balconies connect to a precise grid of accessory connection points

15 Compatible Production Example: MEP modules with compatible facades built in common jigs will plug in to a modular building, eliminating countless hours of trade and supplier coordination

16 Even better. A standardized system means that owners are not reliant on one supplier for design and delivery, so a large project can be designed and launched in a few days..instead of months, or years.

17 Summary of the VectorBloc strategy: Reduce the cost of design, coordination, fabrication and building assembly by concentrating the loadbearing and connection functions in a standard, scalable, precision, pre-engineered component assembled in common fixtures by all suppliers to a project.

18 101 A standardized, scalable, modular connection system

19 Vectorbloc was inspired by the ISO corner 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

20 However..the limited vertical tension capacity of the ISO corners that joins stacks of containers limits the height of buildings, while the fixed grid limits space planning options Simulation of the effect of an earthquake and wind on a stack of containers!

21 VectorBlocs are connected vertically with HSCS and horizontally with a Gusset Plate sandwiched between machined faces. The resulting 12-way connection delivers vertical tension capacity, good fixity and diaphragm action attributable to the module floors.

22 Volumetric module chassis with VectorBloc corners are finished in a factory setting, then stacked on site to produce a complete building

23 A wide range of connection options provides design flexibility. Modules shown bare for clarity

24 Module frames are welded in inexpensive fixtures that coordinate critical dimensions among multiple sites and suppliers, which facilitates an industry with scale.

25 VectorJig installed in Atlas Tube mill, Harrow, Ontario

26 The VectorJig aligns the HSS members with each other and with the cast-in weld prep on the VectorBlocs

27 Digital design, Laser cut HRPO structure and robust construction ensure that VectorJigs deliver longlasting precision

28 The system s consistent dimensional grid delivers many benefits, including predictable hoisting points and a known and controllable COG

29 The re-configurable VectoRig halo system can be used in plant or on site and can lift modules with pre-rigged safety lines.

30 Modules built with VectorBlocs can be picked and released remotely by the crane operator using shacklefinding hooks and remote radio control

31 VectorBloc Building 101

32 Building Height and Scalable Structure To become a standard, a modular solution has to be both structurally viable and economical at all scales. Tall buildings are the most difficult to engineer and require more material per unit area, so as we say: By solving tall, you solve it all

33 To balance economy and loadbearing capacity, tall buildings have larger columns in lower floors and lighter columns in upper floors

34 VectorBloc offers two ways to build modules, which we call Stacked and Bundled. The stacked system scales with load using progressively larger HSS, while the bundled system uses progressively wider groups of HSS. These wide assemblies also function as shear walls. Top: Stacked (rotated 90 degrees) Bottom: Bundled (rotated 90 degrees) Vector Praxis production office

35 By grouping HSS columns on the VectorBlocs (and using plate columns in extreme cases), configurations ranging from a single 12 lbs / foot 4 x 4 HSS, to massive built-up columns weighing over 400 lbs per foot, both fit in a 10-1/2 wall

36 VectorBloc structures are diagonally braced entirely within the module walls. Using transfer structures, modules can be set on conventionallyconstructed podiums and parking garages

37 Lateral brace frames (blue) can be concentrated in the party walls, while the longitudinal system (pink) is loaded in to areas where the diagonal bracing does not obstruct openings Brace locations

38 The vertical tension bolts that hold the modules together are hidden behind access 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

39 Recent product development VectorBloc is North America s leading R&D group focused exclusively on volumetric modular construction

40 FEA results and feedback to design Extensive FEA guided the design of the VectorBloc castings

41 Results of FEA (on smallest VBloc!) Reduction in bolts: 50% from 4 to 2 Reduction in machining cost: 50% Weight / upper: Reduction from 48 to 37 lbs = 23% lighter Weight / lower: Reduction from 102 to 77 lbs = 25% lighter Decision to use cast steel alloy 1020

42 Eagle Alloy Mold flow and solidification analysis

43 High-volume shell mold tooling

44 Shell mold forming and mold assembly

45 Current VectorBloc capacity = 3,800 units / mo. = 200,000 sqft / 20,000 sqm / mo. Expandable in increments of 3,800 / mo. on < 6 weeks notice

46 Testing and documentation of Vbloc assemblies Non-destructive and destructive testing of connection and materials: University of Windsor Dr. Skreekanta Das Seismic analysis of full structure: University of Toronto Dr. Oya Mercan Testing programs funded by NSERC and VBC October 2015 load tests on small VBloc: Tension: 250kn.0003 micro strain / 2.4 mm displacement Compression: 500kn micro strain /.6 mm displacement Bending, shear and combined: Within design limits

47 November 2015 Pin pullout test: Shackle failed at 303kN October 2015 PP weld tests: Failure in HSS MPa

48 Cement board + HSS shear capacity tests.750 setback values: 500lbs / 1 fastener 450 lbs / fastener for multiple fasteners 2 setback values: 1710 lbs / 1 fasteners! Results: Yes, you can use HSS + fiber- cement board as a diaphragm floor system!

49 The Test Stack With the recent addition of a full VectorJig, Atlas Tube s Harrow mill is the only place in the world where steel coil is converted in to volumetric modular building chassis under one roof.

50 VectorBloc Test Stack Location Atlas Tube Harrow Mill VectorBloc Fabricating

51 Test stack Completed November

52 Loading coil

53 Rolling and welding

54 Cut to length HSS in VectorBloc bay

55 VectorBloc machined castings

56 Welding HSS floor members

57 Welding VectorBlocs

58 Complete frame leaving VectorJig

59 FYI: VectorBloc chassis can be shipped assembled or flatpacked at up to ~5,000 sq ft / load

60 Fastening fiber-cement board floor panels

61 Connecting to lifting pins

62 Lifting 1 st module

63 Placing 1 st module

64 Docking 1 st module

65 Torquing HSCS fasteners

66 Placing 2 nd module

67 Placing 6 th module

68 Easy alignment

69 Laser cut gusset plates, precisionmachined locating pins and precision fixtures combine to deliver toolroom tolerances to the construction industry.030 tolerance between locating pins and locating holes

70 Placing 8 th / last module

71 VectorCrew!

72 Outer corner

73 Outer corner closeup

74 Centreline of stack and front face

75 Cruciform closeup

76 Typical double connection

77 Underside of dbl connection

78 Underside of intermediate load path

79 Flush condition between adjacent modules

80 View of top level with safety railings

81 Baseplate of VectorSight railing stanchions

82 Ready for visitors!

83 Commercialization

84 140-Unit Retirement Home Construction start: February 2016 Our first licensee! Completed chassis (module frames) fabricated in Harrow will be fit out in the plant of Connexio (VectorBloc s 1st licensee) located 25 minutes north in Windsor, Ontario

85 January 2016: Frame fabrication in Harrow and fitout at Connexio

86 Shop floor problem-solving is fed straight back to the design department

87 Design department upgrade To enhance our ability to support VectorBloc licensees, in December 2015 VectorBloc renovated our offices, hired additional designers and commissioned a brand new, state-ofthe-art network running Dassault SolidWorks 3D design software

88 Chassis production upgrade 2D VectorJigs are being added to create a high-volume work cell in the Harrow mill

89 VectorBloc s skills in cut-file-level mechanical design are evident in the 3D models of the VectorJig fixtures

90 Reference fixture project To ensure consistency of all VectorJigs and building components (stairs, balconies) across the supply chain, the VectorBloc fab shop has fabricated a system of re-configurable precision reference tables

91 15 Fraser Module Map

92 Structural model Centre-loaded L stacks with pre-cast hall slabs Supported on a transfer structure

93 Fully-detailed, parametric manufacturing model

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96 Development of fire separation details

97 Trade input renderings from the parasolid model

98 Development of MEP details: Custom slot drain

99 Approval and marketing renderings from the fabrication model

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104 Development of factory equipment: Chassis towing rig

105 VectorBloc application development: Piperacks and towers

106 The Market: Relevant Segments Multi-family, especially mid to high rise Extended care, secure care, healthcare Education Hotels Resource extraction, relocatable Industrial armatures (mills and plants) Shoring towers Non-combustible portions of multi-storey wood???

107 The Market: Countries Where Patent Applications are Registered Canada USA Mexico Brazil Indonesia Japan India UAE China Singapore Malaysia Australia South Korea EU (~19 Countries)

108 The right frame for high-completion volumetric modular applications