Modular Tray Building Components for Faster Construction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The construction of multi-story buildings is hindered by lengthy processes due to the need for a concrete core for lift shafts, which delays finishing trades and increases costs, and existing methods lack architectural flexibility and efficient use of non-combustible materials for fire resistance.
Innovation Solution
A modular building system using tray-like components and column assemblies that are assembled into a frame, filled with concrete, and post-tensioned to provide structural strength, allowing for faster construction and integration of services before concrete pouring, while ensuring fire resistance through the use of steel and reinforcing mesh.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a concrete core for lift shafts is constructed prior to floors using traditional methods, then stability and trueness of shape are provided to the building structure, but construction time is increased and finishing trades are delayed
Solution Approach 1:
The building structure is divided into modular components (tray-like elements and column assemblies) that can be independently fabricated and assembled. This segmentation allows parallel construction of multiple building elements simultaneously, eliminating the sequential dependency where the concrete core must be completed before floor construction can begin.
Solution Approach 2:
Tray-like building components and column assemblies are pre-fabricated off-site in factory conditions before being transported to the construction site for assembly. This preliminary action enables finishing trades to commence preparation work while the modular components are being manufactured, significantly reducing overall construction time compared to traditional on-site construction.
2Strength
If finishing trades wait until the building structure is complete and concrete is strong enough, then structural integrity is ensured, but total construction time is significantly increased
Solution Approach 1:
Finishing trades such as plumbing, electrical, rendering, and sanitary work are performed in advance during the off-site fabrication of modular building components. This allows these trades to proceed in parallel with structural construction rather than waiting sequentially, dramatically improving overall construction productivity while maintaining structural integrity requirements.
3Productivity
If pre-assembled rooms are fabricated off-site in factory conditions, then construction time is reduced, but the rooms become cumbersome to transport and deliver
Solution Approach 1:
The building is divided into smaller, manageable modular components (tray-like elements and column assemblies) rather than large pre-assembled rooms. This segmentation reduces the size and weight of individual modules, making them easier to transport and deliver to the construction site while still enabling off-site fabrication to accelerate construction speed.
Solution Approach 2:
The modular tray-like components are designed with universal applicability, where each module can serve multiple functions and be configured for different building requirements. This standardization allows for efficient transportation and assembly without the complexity of custom-designed pre-assembled rooms, maintaining construction speed benefits while reducing transport difficulties.
4Reliability
If buildings are constructed from non-combustible materials for fire resistance, then fire safety and code compliance are achieved, but architectural flexibility is reduced
Solution Approach 1:
The modular building components utilize composite construction with steel or timber frameworks combined with concrete infill. This composite approach maintains fire resistance through the non-combustible concrete and steel elements while the modular design provides architectural flexibility. The tray-like components can be configured in various arrangements to create different building forms and layouts.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly reduces construction time, allows for earlier completion of finishing trades, and provides architectural flexibility by enabling faster assembly of multi-story buildings with reduced material costs and preliminary overheads, while maintaining fire resistance standards.
Implementation Method 1
The trays are preferably tensioned before being constructed into the frame so as to deform the trays, whereafter the filling of the trays with concrete flattens the trays and induces post tensioning strengthening therein.
Implementation Method 2
tensioning the beams by adjusting the tensioners and thereby deforming the beams and the sheet
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A method of constructing a modular building, the method including the following sequential steps: constructing a multi-floor building frame (300) by connecting a plurality of like open topped-trays (80) and column assemblies (100), with the trays (80) forming floors and the column assemblies (100) separating the floors; assembling walls or walls formwork to the frame (300); and pouring wet concrete into the trays (80) to form the building.