Prefabricated Stair and Elevator Modules for Faster Multi-Story Assembly
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Solution Overview
Problem
Conventional construction methods are time-consuming, costly, and labor-intensive, with increasing complexity due to changing codes and reduced trade labor availability, while modular construction techniques face challenges in meeting housing demands efficiently.
Innovation Solution
The use of prefabricated stair and elevator modules, comprising orthogonal vertical, transverse, and longitudinal members, which are self-supporting and pre-manufactured, allowing for efficient assembly and integration with elevator system components, reducing reliance on traditional structural frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional construction methods are used, then workers can measure, cut, and install materials on-site, but the construction process becomes time-consuming and labor-intensive
Solution Approach 1:
The building structure is divided into standardized modular components (walls, floors, stairs, elevators) that are pre-manufactured in factories and then assembled on-site. This segmentation enables parallel production of multiple components simultaneously, dramatically increasing productivity while maintaining design flexibility through modular configuration.
Solution Approach 2:
Building components are pre-manufactured in factories before delivery to the construction site. This preliminary action includes pre-installing utilities, finishes, and structural elements during manufacturing, which eliminates time-consuming on-site installation work and accelerates the overall construction process.
2Ease of operation
If traditional construction sequences are followed, then trades can perform their activities, but the linear sequence increases construction time and complexity
Solution Approach 1:
The construction process is segmented into independent modular units that can be manufactured and prepared simultaneously in factories. Different trades work in parallel on different modules during the manufacturing phase, eliminating the need for sequential on-site trade operations and significantly reducing overall construction time.
Solution Approach 2:
Multiple trade activities (electrical, plumbing, finishing, structural work) are performed in advance during the factory manufacturing of modular components. This preliminary execution of trade activities allows simultaneous preparation of multiple building systems before on-site assembly, compressing the construction schedule.
3Productivity
If modular construction techniques are used, then assembly efficiency is improved, but challenges remain in meeting housing demands efficiently
Solution Approach 1:
The modular building components are designed with universal interfaces and standardized dimensions that allow the same basic modules to serve multiple functions and be configured in various arrangements. This universality enables rapid response to different housing demands (single-family, multi-family, affordable housing) while maintaining efficient standardized manufacturing processes.
Solution Approach 2:
The modular system allows easy adjustment of building parameters (number of stories, unit configurations, floor plans) by changing the number and arrangement of standardized modules rather than redesigning entire structures. This parameter-based adaptability meets diverse housing demands while preserving the efficiency gains from modular construction.
Data Source
AI summary
A building includes a prefabricated modular stair or elevator module. The prefabricated stair or elevator module may form either a fully functional stairwell with an internally supported internal landing and handrails, or a fully functional elevator shaft ready to install an elevator system through a plurality of engagement features. Each prefabricated stair/elevator module includes four vertical members extending orthogonally from a reference plane, four transverse members forming transverse edges of the module, and four longitudinal members forming longitudinal edges of the module. The prefabricated modules may be stacked upon one another and fixedly attached to one another through fastening members and fasteners. Furthermore, each module may be covered in wall panels such that each module forms a segment of either an elevator shaft or a stairwell.