Volumetric Modular Unit Sloped Roof Design
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Solution Overview
Problem
Modular building construction faces challenges such as modular unit height and shipping distance restrictions, alignment and elevation issues between stacked and adjacent units, moisture ingress problems, and difficulties in spanning large open spaces, which complicate the construction process and increase costs.
Innovation Solution
The development of a volumetric modular unit with a floor structure, ceiling structure, and side and end wall structures, incorporating varying ceiling support members for slope and additional support elements like laminated lumbers to address height, alignment, and structural integrity issues, along with features like chases for plumbing and a sloped roof design for water drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If modular unit height is increased to accommodate multi-floor projects, then the building capacity is improved, but shipping distance restrictions and transport feasibility deteriorate
Solution Approach 1:
The modular unit is divided into multiple separate volumetric modules that can be manufactured to standard shipping height limitations and then stacked vertically at the construction site to achieve the desired total building height, resolving the conflict between transport feasibility and building capacity
2Volume of moving object
If modular units are stacked to increase building height, then the building capacity is improved, but alignment and elevation issues between stacked units worsen
Solution Approach 1:
A grading member is introduced as an intermediary component between stacked modular units to accommodate and correct alignment and elevation variations, allowing precise alignment of utility connections while maintaining the benefits of vertical stacking for increased building height
3Productivity
If modular units are designed for rapid assembly, then construction speed is improved, but structural integrity for spanning large open spaces deteriorates
Solution Approach 1:
Reinforcing structures are pre-installed within the modular units during factory manufacturing before shipping, allowing the units to maintain structural integrity for spanning large open spaces while enabling rapid assembly at the construction site since the structural reinforcement is already in place
4Device complexity
If traditional flat roof design is used, then construction simplicity is maintained, but water drainage and moisture ingress control worsen
Solution Approach 1:
The roof structure uses asymmetric ceiling support members with varying vertical heights to create a sloped roof surface that naturally drains water away from the building, preventing moisture ingress while maintaining relatively simple construction through the use of pre-engineered support members
Data Source
AI summary
A volumetric modular unit constructed at a modular unit factory and shipped assembled to a modular building project site is disclosed. A modular building constructed from shipped volumetric modular units is also disclosed. Features of a volumetric modular unit and modular building are designed to account for and leverage traditional building practices. Shipping constraints often dictate volumetric modular unit design constraints. The volumetric modular unit and modular constructed building addresses both design needs and shipping constraints to leverage more economical resources available at a volumetric modular unit manufacturing plant.