HYBRID VOLUMETRIC CORE MODULAR CONSTRUCTION

Description

BACKGROUND OF THE INVENTION

The present application relates to volumetric modular building construction, and more particularly to hybrid volumetric core modular construction, preferably of multifamily buildings. This innovation aims to improve the capacity of the multifamily residential construction industry.

The use of volumetric modular buildings is known in the industry. FIGS. 1 and 2 are schematics showing examples of known modular constructions. The benefits of constructing buildings in this way are: increased production speed, which may result in reduced cost of capital and faster return on investment; reduced construction costs; improved building performance and sustainability; reduced waste; improved working conditions, in climate-controlled indoor environments; improved safety and ergonomics; and improved workforce training and development.

However, after many decades of effort, the promise of prefabricated construction has yet to be realized in the market. Industrialized construction of all types amounts to approximately 3% to 6% of the total annual volume of construction, with volumetric modular construction methods accounting for only a small portion of industrialized construction's total share.

One major issue is that buildings often cannot be constructed with modular construction methods due to specific geometric needs, whether due to preference, program needs, zoning requirements, or architectural differentiation. Examples of buildings that cannot be constructed with known modular construction methods are shown in FIG. 3.

There is thus a need to adapt the current methods of known volumetric modular construction to include methods that result in modular buildings being more readily used.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present disclosure to provide systems and methods for building construction which includes standardized, volumetric, pre-built interior modules in combination with a non or less standardized design exterior. The purpose is to overcome the drawbacks, such as design aesthetics and market needs for building geometries and forms, for a fully modular building and the time and expense of a completely site-built building.

In one embodiment, the four main portions of the systems and methods are as follows. There are prefabricated volumetric modular “core” modules, which make up the interior of a building. These modules are built off-site, transported to the building site and installed. Second, there are pre-designed or prefabricated sub-components located within the “core” modules. This provides a range of configurations for the interior of the core modules and allows for ease in variance of the interior of the building. Third, a perimeter construction of the building includes the outer portions of the residential units and the building envelope, which may be constructed to meet a range of building form or geometry as required. These may be prefabricated, such as volumetric modular, panelized or kit-built construction, site-built, or a combination of these. Lastly, there is a vertical distribution of major building services through the building. These include services such as HVAC, electrical, and plumbing components. Relationships and connections between risers and individual unit services may be standardized which can be achieved with the modular core.

In another embodiment, a method for constructing a building includes the steps of constructing a building core and core subcomponents, constructing a perimeter of the building, and vertical distribution of major building services via connection to the core modules. Constructing the building core includes using a plurality of prefabricated volumetric modules, wherein the width of the modules is in the range of 7 to 17 feet wide and the core modules comprise greater than 50 percent of the structural capacity of the building and of the building services. The core sub-components include interior predefined arrangements for at least one of kitchens, bathrooms, mechanical closets or cabinets, laundry closets or headwalls, and distribution elements, fixtures, fittings, and appliances for building services. The arrangements can be installed prior to constructing the building core or after. The perimeter construction includes outer portions of residential units and building envelopes, including at least one of living rooms, bedrooms, dens, home offices, and other occupiable spaces and preferably includes varying geometries.

In a further embodiment, the building core includes additional attributes. For double-loaded corridors, with residential units on both sides of the corridor, the core modules span both sides of the corridor and include the corridor and a portion of the residential unit on each side. For single-loaded buildings with enclosed corridors and residential units on one side of the corridor, the modules include the closed corridor and a portion of the residential on the one side. For single-loaded buildings with open corridors and residential units on one side of the corridor, the modules include the open corridor and a portion of the residential on the one side,

In yet another embodiment, core modules are arranged such that the functions on one side of the corridor are different from the functions on the other side of the corridor and within the same core module.

In certain embodiments, functions such as bathrooms or kitchens may be located within the volume of perimeter construction. In those cases, those elements may be provided as sub-components.

Construction of the elements of the perimeter volumes, such as floor sections, unit demising wall sections, exterior wall sections, or building services distribution and appliances, may be prefabricated, such as volumetric modular or panelized construction, or site-built, or any combination of the two.

Major building services may include HVAC, such as refrigerant piping, supply, return, and exhaust air ducts, stair pressurization shafts, etc., or electrical, such as electrical duct banks and power distribution to each unit, or plumbing, such as water supply and sanitary piping, or fire protection, such as sprinkler and fire alarm systems, or telephone or data systems.

Risers for the various building services may be designed to accommodate different configurations of functions on each floor. Relationships and connections between risers and individual unit services may be standardized.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and advantages of the disclosure will become apparent from a study of the following specification when viewed in the light of the accompanying drawing, in which:

FIGS. 1 and 2 are perspective views of known modular constructions;

FIG. 3 is a schematic of known building designs that cannot include modular construction;

FIG. 4 is a perspective view of the core of a building according to the present disclosure;

FIG. 5 is a perspective view of the core of FIG. 4 with a perimeter attached according to the present disclosure;

FIG. 6 is a perspective view of one modular core of a building with perimeter removed according to the present disclosure;

FIG. 7 is a vertical cross-section view of a schematic of a modular core with perimeter according to the present disclosure;

FIG. 8 is a top view of a schematic of a modular core with perimeter according to the present disclosure;

FIG. 9 is a top view of the schematic of FIG. 8 with the modular core modules and perimeters separated;

FIG. 10 is a top view of the schematic of FIG. 9 with sub-components shown; and

FIG. 11 is an embodiment of building constructed according to the present disclosure.

DETAILED DESCRIPTION

As detailed herein, the present disclosure relates to systems and methods for building construction which includes standardized, volumetric, pre-built interior modules in combination with a non or less standardized design exterior. Such systems and methods preferably include a prefabricated volumetric modular “core” of modules, pre-designed or prefabricated sub-components located within the “core” modules, a perimeter construction of the building that includes outer portions constructed to meet a range of building form or geometry, and vertical distribution of major building services. The result is a building that is partially prefabricated and partially built on-site. The on-site, outer perimeter build could be completely designed and constructed for the specific needs of a building, or prefabricated components, such as panelized or stick-built sections could be used, or secondary full modular construction could be used, tailored to meet project requirements. Regardless, the final building includes separate inner and outer constructed portions.

In conventional volumetric modular construction, manufacturers strive to design what they consider the best solution for multifamily housing. However, a single “best” solution often does not work. What is needed is a “best fit” for the unique set of requirements for a project. The result is that modular manufacturing solutions often end up being re-engineered for each specific project application, which minimizes or completely negates the efficiencies of a modular plan. For production efficiencies to be realized, project teams must set aside project-specific priorities; however, this results in lost square footage, thus the building needs are not met.

In the modular core approach disclosed herein, key project parameters are established based on specific project needs, as is normally done, which includes planning bay widths and project-specific features like kitchen and bathroom layouts, living and bedroom sizes, etc. Core module shell widths are then selected and configured using components and subcomponents (rather than redesigning the modules), all based on the specifications of a project. The result is that the design process and solutions do not need to be changed in consideration of the modular construction limitations.

As shown in further detail in FIGS. 4-10, the prefabricated volumetric modular “core” modules include attributes as follows. In the case of double-loaded corridors (see FIGS. 8-10), with residential units on both sides of the corridor, the modules span both sides of the corridor and include the corridor and a portion of the residential unit on each side, which are preferably, approximately 10 to 16 feet deep and have a width of one residential planning bay (typically defined as the width of a living room or bedroom).

In a separate embodiment not shown herein, such as the case of single-loaded buildings with enclosed corridors and residential units on one side of the corridor, the modules include the closed corridor and a portion of the residential on the one side, which are approximately 10 to 16 feet deep and have a width of one residential planning bay.

In a further embodiment not shown herein, such as with single-loaded buildings with open corridors and residential units on one side of the corridor, the modules include the open corridor and a portion of the residential on the one side, which again are approximately 10 to 16 feet deep and have a width of one residential planning bay.

The width of the modules can vary to meet the desired planning bay widths, with the preferred smallest width being approximately 8 feet wide and the preferred widest width being approximately 16 feet wide. It will be understood by those with skill in the art that these widths can vary without deviating from the scope and spirit of the invention.

Core modules can be arranged such that the functions on one side of the corridor vary from functions on the other side of the corridor, within the same core module.

It is preferred, though not required, that building cores that are assembled using core modules will provide a substantial portion of the total structural capacity of the building. FIG. 11 shows an example of this, wherein the core modules include 60% of the structure and 90% of shear load requirements. This simplifies the structural engineering required for the remainder of the building, and as a result allows for a building that has a form and geometry that can easily vary because the perimeter construction can be formed with minimal engineering needs for lateral structural loads.

As shown in FIG. 8-10, building cores that are assembled using core modules can provide a substantial portion of the building services. This results in reduced costs and reduced design and construction errors and conflicts for building services, which commonly amount to 30% or more of total construction costs and, in conventional construction, are the source of a high proportion of construction cost risk. This process takes advantage of the known, predesigned structure of the core modules, allowing for certainty in planning and execution.

The portions of the modules that will include portions of residential units may include the highest-cost or most technically complex elements of the units, such as kitchens or kitchen headwalls, bathrooms, mechanical closets or cabinets, and laundry closets or laundry headwalls. They may also include distribution elements, fixtures, fittings, and appliances for HVAC, plumbing, electrical, sprinkler, tele/data and other building services.

Turning now to the pre-designed or prefabricated sub-components that are located within the “core” modules, these preferably include sub-components such as those portions of core modules noted above and as shown in FIG. 10. These sub-components allow for multiple design options for any given core module, resulting in a range of configurations that may be possible to meet different needs from one project to another. The sub-component options may be designed to follow pre-determined dimensional, structural, and services distribution rules, and organized into a master catalog, within which sub-components may be shared across different module configurations and different projects. This provides variance yet predictability in the modules.

The sub-components provided herein are examples only. Additional sub-components that can be pre-designed and prefabricated could be included to meet a specific project's needs. These sub-components could be manufacturable by third-party suppliers, which may in turn provide opportunities for further variations in residential unit module configurations.

Referring now to FIGS. 5-11, attributes of the perimeter construction of the building preferably include the outer portions of the residential units and the building envelope, which can include living rooms, bedrooms, dens, home offices, and other occupiable spaces. In some cases, functions such as bathrooms or kitchens may be located within the volume of perimeter construction. In those cases, those elements may be provided as sub-components. The perimeter construction of the building may be constructed to meet a specific building form or geometry, which may be based on preference, program needs, zoning requirements, or architectural differentiation.

Construction of the elements of the perimeter volumes, such as floor sections, unit demising wall sections, exterior wall sections, or building services distribution and appliances, may be prefabricated, such as volumetric modular or panelized construction, or site-built, or any combination of those. If prefabricated, elements of the perimeter construction may be manufactured by the same supplier as the core modules, or supplied to that manufacturer by other suppliers, or supplied directly to the site by other suppliers.

Regarding vertical distribution of the major building services, and the connections of those services to the core modules, these preferably include major building services, such as related to HVAC, which might include refrigerant piping, supply, return, and exhaust air ducts, stair pressurization shafts, and others, electrical, which might include electrical duct banks and power distribution to each unit, plumbing, which might include water supply and sanitary piping, fire protection, such as sprinkler and fire alarm systems, telephone, and/or data systems.

Risers for the various building services may also be designed to accommodate different configurations of functions on each floor. Relationships and connections between risers and individual unit services may be standardized.

The following is one embodiment of a building according to the systems and method disclosed here. The standard configurations of core modules include modules that are rectangular in plan. Residential core modules are fully-enclosed on three sides, including the floor, ceiling, and corridor wall, partially- or fully-enclosed on two sides (i.e. the left and right side), and fully open on one side.

The core modules in this instance contain the inner 15 feet of the residential unit. For such units, the total depths typically range from 25 to 35 feet, with approximately 30 feet deep being a common standard

In single-loaded corridors, the configuration would be one unit core plus one corridor width. In double-loaded corridors, the configuration would be two unit cores, one on each side of the corridor.

At building end conditions, in cases where the corridor does not extend the full distance to the end of the building, the configuration may be either one single-loaded residential core, or two back-to back residential cores, with no corridor between them.

The depth of the residential core modules, excluding corridors, is standardized, and does not change from project to project. This is based on industry standard planning bay modules for multifamily design. For instance, living room planning bay widths typically range from eleven and a half feet to fifteen feet and bedroom planning bay widths typically range from ten to thirteen feet. Narrower planning bay widths are typically found in more urban locations, and wider planning bay widths are more common in more suburban or rural locations.

For improved design, engineering, and construction efficiency, planning bay width adaptability can be limited to incremental steps, such as three-to-six-inch increments. Thus, a planning bay may be eleven feet, six inches or eleven feet, nine inches, but not eleven feet, five and a half inches, or eleven feet, eight inches. Similarly, corridor width can vary, preferably on incremental steps of three to six inches. To accommodate the installation and attachment of the modules, module widths may be slightly narrower than the planning bays.

Preferably, there is one core module per planning bay in each unit, which might include an efficiency or studio sized residential unit that is one planning bay wide, a one-bedroom unit that is two planning bays wide, a two-bedroom unit that is three planning bays wide, a three-bedroom unit that is four planning bays wide, etc. For example, there could be one living area planning bay plus one planning bay for each additional bedroom.

Units containing special conditions, such as corners of building ells or irregular dimensions or geometries, may be site-built or panel-built without core modules, though units without core modules may still contain sub-modules such as those used in the core modules.

Core modules may also contain core building functions, such as elevator shafts, stair shafts, utility rooms, such as electric rooms, tele/data rooms, trash chute rooms, maintenance rooms, etc., and vertical building services.

Of the core modules discussed herein, the core module or modules for a building are selected with the primary goal of aligning as seamlessly as possible with existing design processes. In other words, design teams select planning modules based on project context and needs. Architecture/Engineering team planning modules may be adjusted to fit manufacturing efficiencies, within design objectives of a project team.

Core modules are then designed similar to module selection with the ability to adapt unit configurations and allow a modular provider to be responsive to design team direction, rather than restricting the team to modular manufacturing standards.

Specific components include bathrooms, mechanical closet, laundry closet, smaller sub-components. Bathrooms may be two-fixture (powder rooms, with toilet and sink), three-fixture (toilet, sink, tub or toilet, sink, tub with shower), four-fixture (toilet, two sinks, tub with shower; toilet, two sinks, shower, or toilet, tub, separate shower), or five-fixture (toilet, two sinks, tub, separate shower). Other variants may include the addition of a bidet, linen cabinet, or linen closet, or use of free-standing tub in lieu of a built-in. Bathroom variations may build upon standard base configurations to maximize standardized components

Mechanical closets may contain HVAC air handling equipment, water heaters, and/or related equipment serving an individual unit. Laundry closets may be fabricated as part of a larger sub-component including mechanical closets, fabricated separately from mechanical closets, or served by plumbing equipment prefabricated into one exterior wall of the mechanical closet. In lieu of mechanical closets, HVAC sub-components may comprise prefabricated ceiling modules

Smaller sub-components include unit entry doors, standardized structural components, such as wall, floor, or ceiling sections, prefabricated piping distribution sub-assemblies, prefabricated electrical wiring harnesses, prefabricated ductwork sub-assemblies.

These components could be arranged in core modules with standardized “anchor” locations that are pre-determined in core modules, providing access to key building services. Anchor locations need not be sub-component specific. Any function, for example kitchen, bath, mechanical closet, or laundry, may tie to any anchor location.

Building from a few standard sub-component designs for each function, a catalog of sub-components may be developed over the course of completing projects to ensure a wide range of solutions.

In one arrangement for a living room bay module, subcomponents include a kitchen, mechanical closet, laundry, and unit entry door. The kitchen component may be fully installed or may be a pre-manufactured “headwall” component (similar to the headwall concept commonly used at hospital beds) with plumbing, power, and data distribution pre-installed. Living room bay modules can be designed to accommodate several common kitchen sizes and configurations, such as a half galley, full galley, ell-shaped, or u-shaped arrangements.

A laundry component may be a complete closet, or it may be a pre-manufactured “headwall” subcomponent with plumbing, power, and data distribution pre-installed. Further, a laundry headwall subcomponent may be standalone or may be pre-installed to replace one conventional wall subcomponent in a mechanical closet component.

In a second arrangement for a bedroom bay module, subcomponents may include a full bathroom, closet, powder room (serving the living room bay module). Bathrooms have configuration options as noted above and closet components may be panelized or fully pre-assembled, depending on the level of complexity involved.

To further improve capacity to scale production and inventory products, MEP service riser and connection locations (“anchors”) may be standardized such that the base modules could accommodate subcomponents for either living bay or sleeping bay functions.

Core modules may also include base building functions, such as electrical rooms, tele/data closets, trash rooms/chutes, and building-scale services, for example ductwork for outside air or exhaust shafts, roof drains, mechanical piping, etc.

The size and shape of the perimeter are determined by the project team, based on project needs and constraints. Simpler geometries may be constructed of volumetric modular or panelized prefabricated components, while more complex geometries may be constructed of panelized prefabricated components or be completely site-built.

Portions or all of the offsite-fabricated components can be provided by the core modules manufacturer or by other manufactures. For example, a manufacturer that specializes in a façade design may be preferable.

Having a standardized modular core improves the viability of applying the “mass customization” approach to offsite fabrication for the perimeter of the building because mass customization can be applied to the portions of the building that most benefit from project-specific variability (i.e. the perimeter). The modular core approach would thus be applied to portions of the building that most benefit from standardization and economies of scale.

The perimeter can be connected with the core through a range of engineering connections, which may vary depending on how they are constructed. Core modules may be pre-designed to accommodate a limited range of different structural connection conditions.

Vertical distribution includes HVAC building-scale services, such as outside air intake ductwork, stair pressurization shafts, exhaust shafts for amenity spaces, retail, restaurants, HVAC lineset banks, if split systems. HVAC residential unit-scale services can also be provided, such as exhaust shafts (if required) for bathroom exhaust, kitchen exhaust, and laundry exhaust.

Furter vertical distribution includes plumbing and power and data. Plumbing building-scale services may include roof leaders, supply and waste riser piping serving common areas, amenities, commercial/retail spaces, and sprinkler system risers. Plumbing residential unit-scale services may include waste drains and vents and potable water supply, which includes cold water only if there is an in-unit water heater, and would include cold and hot water if there is central water heating.

The power and data building-scale services include electrical duct banks to electrical rooms/closets, data trunk wiring to tele/data rooms/closets. Electrical and tele/data rooms might be on alternating floors.

Vertical distribution of building-scale services may be located within common building components. For instance, HVAC lineset risers and stair pressurization shafts may be located within stair component bays, electrical duct banks and tele/data trunks may be located in electrical room and tele/data room component bays, respectively, and amenity, retail, or restaurant exhaust shafts and trash chutes may be located in trash room component bays.

Vertical distribution of residential unit-scale services may be located within unit core bays. For instance, sanitary risers serving kitchens, bathrooms, and laundry rooms may be located in standardized positions in each module. Potable water risers may be located in standardized positions in the living module bays. In some examples, sleeping module bays are designed to accommodate optional potable water risers that pass through the bays. Where unit type mixes vary from floor to floor, such that if a higher or lower floor in the same tier has a living bay, potable water services are available.

Further vertical distribution of residential unit-scale services includes residential exhaust shafts, such as kitchen exhausts, bathroom exhausts, and laundry exhausts. In certain instances, some or all residential exhaust ducts may run laterally to the building façade and not vertically through the building; however, core modules are designed with the capacity to accommodate vertical residential exhaust shafts.

Power, data/tele, outside fresh air, and sprinkler services are commonly delivered to each unit horizontally through the corridors, not vertically through each unit as described herein. Vertical distribution of building-scale services, as described above, might not be located within residential module bays.

Mechanical, electrical, plumbing, and fire protection services are a relatively high-risk component of construction, commonly amounting to up to 30% of total construction costs, and often responsible for a high proportion of construction conflicts, installation issues, and post-construction call-backs

By pre-planning and building most of the MEP/S in the controlled environment of a factory, construction costs are reduced, conflicts between different systems are avoided, and construction quality is improved, reducing construction and post-construction risk.

In one example embodiment, there are plans for a building with a non-rectilinear shape with wings at an odd angle to one another due to existing site geometry or design goals. A multifamily volumetric modular manufacturer would likely evaluate and decline such a project. Most residential projects have such irregular building forms, and thus the number of opportunities that an offsite manufacturer can pursue are severely limited, amounting to only around 2% to 4% of the total number of offsite projects in most markets.

Alternatively, for such an embodiment, using the systems and methods described herein, such a building can be successfully delivered by the core components of the building being manufactured by the volumetric modular manufacturer with the irregular elements to be built on-site or through other methods such as panelized or kit construction. The opportunities for an offsite manufacturer expand dramatically from 2%-4% to 60%-80% or more of the total market, excluding only highly unusual projects or very tall projects.

In another example embodiment, a project is planned with a conventional design without modular building as a consideration during design and permitting. In such an instance, though a modular manufacturer might be competitive, but re-engineering and re-permitting would be cost prohibitive, so modular manufacturing is not used.

Alternatively, for such an embodiment, using the systems and methods described herein, such a building can be minimally re-engineered to handle the core zones of the building. The permitters would not be affected, which is where engineering is most specialized. The required changes would be significantly less impactful than a purely modular build.

In a third example embodiment, a project is planned with a modular design; however, during the entitlement, the municipality requests changes to the building, such as setbacks, that cannot easily be accommodated through a modular build. The project team abandons the modular design late in the design process, incurring redesign time and expenses to go back to fully site-built construction. Because of the potential for these issues, modular designs are often not used.

Alternatively, for such an embodiment, using the systems and methods described herein, changes requested during entitlement can be accommodated by the offsite manufacturer.

Other common issues that can derail modular builds late in the process include difficulty defining scope between the manufacturer and the architecture or engineering team, and inability of general contractors to maximize efficiency through trade-specific bidding if some elements that general contractors can improve on are locked in as part of an offsite manufacturing package. The systems and methods herein mitigate both of those issues.

In a fourth example, a modular build project proceeds through design and permitting successfully. However, in order to meet the specific design requirements of the project, there is a need to deviate from the engineered standards, resulting in inefficiencies for design and engineering, and reduced supply chain benefits.

Alternatively, for such an embodiment, using the systems and methods described herein, the irregular portions of the building (massing and facades), the building can be completed without re-engineering and the efficiencies that are associated with that, such as cost, time and negative supply chain impacts.

The methods and systems herein improve the processes for design and construction teams and help improve revenue and costs, which incentivizes builders to use alternative methods.

Importantly, the systems and methods allow manufacturers to build beyond box-shaped buildings, allowing for a significantly broader scope of potential in manufacturing.

Some of the improvements from the systems and methods described herein include, 1) allowing architects to include a significant proportion of offsite construction in plans without restricting the ability to meet complex project requirements; 2) streamline architects production process by reducing redundant work; 3) reducing errors and omissions for architects risk; 4) improves throughput for architects and increases the capacity to produce higher volumes of work relative to staffing levels; 5) improves contractors ability to incorporate offsite construction methods with non-binary solutions; 6) allows for contractors to vary projects more easily to incorporate modular portions as needs arise and as applicable, whether within a specific project or from project to project.

The current binary conditions in the market, where fully modular or fully on-site built is used, is a barrier to entry for volumetric modular construction. The methods and systems described herein isolate the core of multifamily buildings, which is highly repetitive and therefor well-suited to manufacturing, from the perimeter portions of the building, which is highly variable and not well suited to volumetric construction, to create a variable hybrid approach. Thus, unlike conventional modular construction, with the present systems and methods a wide range of building geometries can be implemented easily, without the need for entirely site-built construction. This results in reduced cost and time, as well as reduction in potential design or construction errors and conflicts.

Although the above and accompanying descriptions reference particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised and employed without departing from the spirit and scope of the present disclosure.