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архитектура Prefab city
1.
2. Northeastern University
Graduate Program of Architecture
Masters Research Studio
Littell | Fall 2010
Prepared By:
Ahmed Almulla, Matt Arnold, Hope Blanchette, Travis Blake, Joanna Grab, Melissa Goldfarb,
Sarah Laliberte, Andrea Leveille, Brad Mckinney, Luke Palma, Sara Rosenthal, John Stoddard
3. Introduction Statement
This book was written by twelve graduate students of
architecture (M. Arch.) at Northeastern University in the
fall of 2010 as part of our Master’s Research Studio. This
book will explore issues related to pre-constructed
building strategies in urban environments, thus the title,
Prefab City. As a result of this exploration and analysis,
we hope to uncover potential design opportunities in an
area that seems to be less well documented and
researched in the field. This book is intended to be used
by our studio, and could be useful to peers, professors or
professionals wanting an integrated understanding of an
approach to prefabricated building in a urban context.
4. Table of Contents
Introduction Determinants Deployment Tactics
Purpose ...............................................1 Transportation ..................................10 Density on Demand...........................68
by Ground: Rail ..........................................11 Definition, Factors ...................................69
Definitions .......................................... 2 by Ground: Road ........................................13 Mobility and Adaptability .........................70
by Water .....................................................21 Construction .............................................71
Research Methodology + Scope ......4 by Air ..........................................................23 Connections .............................................73
Process.....................................................77
Site Access + Assembly....................26
Site Access ...............................................27 Parasite + Barnacle............................80
Crane Operation and Extents ...................29 Urban Infill Sites ......................................81
Cranes and Obstacles .............................31 Definitions ................................................83
Off Frame Assembly ................................33 Parasite Precedents ................................85
Barnacle Precedents ...............................89
Modular Strategies ............................38
Logistics ...................................................39 Instant Utopia ..................................98
Site Placement Strategies .......................43 Introduction..............................................96
Aggregation Techniques .........................45 The Plug-In Tower .................................100
Mechanical Systems.................................47 The Expanding Monolith .......................106
The Artificial Hill town ............................110
Component Strategies .....................49
Definitions ..................................................51 Extreme Prefab................................118
On-Site Labor ...........................................53 Launching Gantry Game .......................120
Fabricated Unit .........................................55 Incremental Launching System ............124
Panel System ............................................57 Extra-Large Prefab ...............................128
Precast Concrete ......................................59
Kit-of-Parts ................................................61
5. Non Physical Contexts Precedents
Building Code..................................136 Rating Precedents .........................168
Regular....................................................137 Rating Systems ......................................169
HUD Code ..............................................138 Matrix Chart ............................................170
Prefab Scale ...........................................171
Zoning Code ...................................144 Enchridion................................................173
Boston ..................................................145
Charlottesville, VA ................................147 Precedents .....................................176
Little Rock, AK .....................................148
Economics ......................................150
Overview ...................................................151
HUD Code ................................................153
Single Family Modular .............................155
Stick Built Modular....................................156
Multi Family Modular ................................157
Multi Family Stick Built .............................158
Policy...............................................160
6. Purpose and Definitions
Pre-fabrication in urban settings is an Four main purposes of the book:
underlooked, under-researched subject. This
• Exploring prefab through the city lens: explaining the process of using prefab relative to
might have to do with the fact that there are
dense, urban environments.
limited examples of prefabricated architecture in
the city, even less that have actually been
• Identifying and analyzing delivery methods; tracking the prefab process from the
realized, and even less that have actually been
manufacturer to site placement.
successful. Those reasons (limited built
examples) as well as the stigma associated with
• Identfying advantages vs. disadvantages; why would someone want to use prefab in an
prefabrication (cheap, indistinct) aren’t the only
urban environment.
factors; social and economic factors (such as
unions) also play an important role.
• To uncover potential design opportunities in an area that seems to be less well understood
or studied in the general field. This gathering, dissecting and organizing of specific
There is a disproportionally high number of
information is potentially valuable in the generation or advancement of a design idea.
prefab buildings (especially residential homes) in
rural settings. Our research, therefore, has
purposely limited looking into this well-
documented area of prefab in order to explore
and eventually identify the challenges that are
What this book is not about:
unique to urban environments. • Prefabrication in rural settings.
• How elements are prefabricated in a factory (not part of the construction or delivery
process), unless it is significant in terms of time/labor/quality issues.
7. INTRODUCTION
DETERMINANTS
Urban
Relating to, or belonging to, a city. Examples of prefabricated architecture are disproportionally located
in rural or suburban settings. Therefore, our aim is to focus on researching prefabrication in a more
dense urban fabric. Although the ‘density’ factor is loosely defined, the context should be clearly
understood as urban.
Prefab
DEPLOYMENT
Definitions for this word vary slightly but are all common in the sense that they are too broad and
general (factory-built, factory-made, pre-cut, panelized, manufactured, modular, mobile). For our
purposes, we are defining prefab as a building or structure that is manufactured in standard parts off-
site to be shipped and assembled elsewhere.
To be even more rigid in our definition of prefab, we have developed a matrix and identified projects or
methods of construction just outside the matrix to define the borders of our research zone. The
projects within the matrix re-enforce our definition of prefab.
CONTEXT
Delivery Method
‘Delivery method’ has different meanings in different fields and even within the field of architecture, it
can have various implications. Since it is an important factor in Prefab City, a precise definition, for our
purposes, is required. By delivery methods, we mean the mode of transportation and route from
factory where a prefab element was made to the actual construction site, and everything in between.
PRECEDENTS
Introduction • 2
8. Research Methodology and Scope
To make our research and findings more effective Asphalt Road Drop House
and useful, we have devised a strategy to
calculate or ‘rate’ the degree or ‘prefabness’ for
each of the examples presented. Firstly, the
matrix helps us define our boundaries on what
constitutes prefab. In other words, the limits of
degree of ‘prefabness’ are defined by the projects
around the border of the matrix, and everything
within falls in our realm of study.
By developing this matrix, we have given
ourselves two extremes of prefab and therefore
100% on-site 100% off-site
now have a scale from which we can place other
objects relative to the two ends. As our own
commitment to being objective about these
examples, our ratings and matrix placements
primarily use measurable facts and figures.
9. INTRODUCTION
Off-site
Prefabrication
Puma City
DETERMINANTS
Drop House Nomadic
Museum
Precast Concrete
Metastadt Segmented Bridges
Pierson Court
Nakagin Tower
DEPLOYMENT
Use Kim House Elemental Box City Bailey Use
Residential Bridge Infrastructure
Hong Kong
Tower
Habitat 67
CONTEXT
2 x 4 Res. Elemental Permanent
Infill
Zollverein Temporary
PRECEDENTS
Keetwonen Asphalt
Road
Custom
Adobe Hut/ On-site
Igloo Construction Standard
Introduction • 4
11. INTRODUCTION
DETERMINANTS
DEPLOYMENT
CONTEXT
de·ter·mi·nant
[dih-tur-muh-nuhnt]
–noun
1. a determining agent or factor.
A multitude of factors go into the design and
PRECEDENTS
delivery of a prefabricated element. Prefab
delivery must be carefully thought through to
ensure smooth transition from factory to site.
Factors to pay special attention to include method
of transportation, site restrictions, and the
construction strategy.
Determinants • 6
14. Transportation Types
Ground: Rail Ground: Road Ground: Crane
Rail transportation is one of the most efficient With many different types, transportation by Cranes provide the means of moving a container
modes of tranport for moving freight. However, trucks provides some flexibility for moving or module to its place on site. The cost of having
the constraints of connectivity to other modes of materials and modules to site. Trucks are limited a crane is one limitation. The dimensions of the
transport and the rigidity of the rail car are both by the roads that lead them to a site. Local height site and its constraints also are limiting factors.
limitations that need to be considered when using and weight restrictions, as well as the turning
rail. radius of the truck, must be considered.
15. INTRODUCTION
DETERMINANTS
DEPLOYMENT
CONTEXT
Water: Barge Air: Skycrane Air: Freight Airplane
Barges allow for the tranport of ‘mega structures’ Skycranes allow typically inaccessible sites to Freight airplanes can expedite the delivery
that would otherwise be precluded from use receive materials that could not be delievered process of containers and kit of parts projects.
because they are unable to be moved by rail or there otherwise. The distance of the pick up to However, because of the dimensional and weight
road. While size of the component is not a factor site is very limiting, as well as the skill needed to restrictions, the typical container size is excluded
PRECEDENTS
when using a barge, port locations in relation to operate the device and the cost associated with from this mode of transportation.
site are critical factors that limit the use of water delivery.
transport.
Transportation • 10
16. by Ground: Rail
Rail transportation provides an economical
alternative to truck transport for longer shipping Seattle
distances (over 250 miles). In the United States,
there is an existing network of freight railways
that serve the major metropolitan areas.
Boston
Chicago
Cities that are located close to water most often New York
have the greatest convergence of railroads. Philadelphia
Waterways offer the greatest capabilities for Los Angeles Washington D.C.
intermodal transport.
The two most commonly used methods of Atlanta
transportation (shown below) are “trailers on flat
cars” (TOFC) and “container on flat cars” (COFC).
Both types allow undisturbed shipment of freight.
US System of Railways
TOFC COFC Beacon Park Freight Yard, Boston, MA
17. INTRODUCTION
The container has become the unit of
measurement for rail transport. The dimensional
properties of the container dictate the length of
the rail car and the vertical clearance needed for
transport. This can be a limiting factor when
transporting containers into an urban
DETERMINANTS
environment.
DEPLOYMENT
Typical Railcar dimension is set by
container container dimension so that
dimension two containers can fit on
one car
Trailer lengths also
accomodate container
dimensions
CONTEXT
req’d clearance 18’-9” req’d clearance 20’-9”
Worcester Boston
20’ -3”
18’ -3”
PRECEDENTS
< 19’-6”
Other Railway
Two 8’-6” Two 9’-6”
Containers Stacked Containers Stacked Vertical Railway Clearance in Massachusetts
Transportation • 12
18. by Ground: Road
Transportation of pre fab elements in a urban
environment is constrained by a number of
obstacles. One of which is the complex network
of roads that comprise many cities.
In order to deliver pre fab modules to a site many
different sized trucks need to be considered as
part of the delivery process. Each truck has its
own set of limitations for maximum freight weight.
Truck Types
All of these factors must be considered when Pickup Truck
siting a pre fab project in an urban context. Advantages: Can easily navigate small urban
streets
Disadvantages: Lowest freight weight
capacity, very limited by size
Single Unit Truck
Advantages: Comparitively narrow width
(fairly easy for navigating small streets). Mid
size compacity for freight (panels could fit)
Disadvantages: Constrained by height.
Dump Truck
Advantages: Large freight weight compacity
Disadvantages: Width could be problematic
when trying to traverse complex sites.
Semi Tractor Trailer Truck
Advantages: Largest carrying capacity;
multiple trailer options to facilitate different
sized pieces.
Disadvantages: Hardest to maneuver complex
street network.
20. Semi-Trailer Load Capacities
Semi-Tractor trailer trucks have the greatest
carrying capacity. There are a number of options 48’-0”
for the trailer; some maximize the length, some
height of the element that needs to be
transported. Outlined below are the options. 8’-6”
48,000 lbs. 8’-6”
Flatdeck Trailer
11’-0”
37’-0”
8’-6”
a b 10’-0”
48,000 lbs. 8’-6”
a: Height restriction for truck (varies by state from 13’-6” to 14’-6”)
b: Height limit for vertical clearance (typ. 14’-0” for urban areas, 16’-0” rural)
Vertical Clearance for Semi-Trailers Single Drop Trailer
10’-0”
52’-6” 29’-0”
8’-6” 9’-0”
11’-6”
9’-2” 10’-0”
45,000 lbs. 8’-6” 45,000 lbs. 8’-6”
* maximizes height
Box Trailer Double Drop Trailer
21. INTRODUCTION
48’-0”
80’-0”
8’-6”
DETERMINANTS
8’-6” 14’-0”
45,000 lbs. 48,000 lbs.
* Trailer Stretched
maximizes length 8’-6”
Flatdeck Oversized Load
10’-0”
48’-0”
DEPLOYMENT
63’-0”
8’-6”
8’-6”
10’-0”
16’-0”
48,000 lbs.
* Oversized Load
43,000 lbs. 8’-6” permits required
Single Drop Trailer Stretched Way
CONTEXT
10’-0”
50’-0”
8’-6”
11’-6”
9’-0”
PRECEDENTS
10’-0”
40,000 lbs.
* maximizes height 8’-6”
* dimensions contrained
by road restrictions of
local municipalites
Double Drop Trailer Stretched Super Oversized Load
Transportation • 16
22. Roadway Design & Obstacles
Roadway design can either help or hinder the
transport of prefab elements to site by truck.
Outlined below are the guidelines for the
dimensions of driving and parking lanes in a city.
a1 b1 c b2 a2
23. INTRODUCTION
DETERMINANTS
Landscape Street Furniture Signage Pedestrian Utilities
DEPLOYMENT
CONTEXT
Truck Turning Obstacles
PRECEDENTS
‘Making the turn’ is one of the challeneges of
truck transport when building in an urban
environment. The many obstacles the city
presents (parked cars, telephone poles, stop
signs, etc.) make routing a truck to site one of the
City Utilities Lighting Parallel Parking
most important parts of the process.
Transportation • 18
24. Truck Turning Radii
The swept path a truck takes as it makes a right Swept path of truck 60°
turn is a critical moment. To the right is a diagram
that explains the logics of how a truck makes a
turn.
The most common trucks used for transport in
the city are the standard semi-truck and the 60’ radius
single unit truck. The paths for oversized loads from point on sidewalk
need to be considered if larger elements need to
get to site.
Critical points that
determine swept path
Truck Making 60° Turn
60°
60°
90° 90°
a
a
b
b
180° 180°
a: 53’-0” a: 53’-0”
b: 8’-6” b: 8’-6”
critical swept path critical swept path
Standard Semi-Truck Single Unit Truck
25. INTRODUCTION
DETERMINANTS
DEPLOYMENT
60° 60° 60°
CONTEXT
90° 90°
90°
a a
a
b
*cannot make a 180° b
PRECEDENTS
b with a 60’ radius
180°
a: up to 80’-0” a: 48’-0” a: 75’-0” or 1/3 truck bed length
180°
b: 8’-6” b: 16’-0” b: 8’-6”
critical swept path critical swept path critical swept path
Stretch Semi-Truck Oversized Load (Width) Oversized Load (Length)
Transportation • 20
26. by Water
Vessels used for transport range in size based on
the depth of water being traveled. The prefab
component’s size, if only traveling by water, is
restricted by the smallest body of water it travels
through.
The size of the locks in at the Panama Canal
determine the size of the ships allowed through.
Each lock is 1,050 ft long, 110 feet wide. The
Bridge of the Americas at the Pacific Entrance to
the canal is the height determinate; 201 ft at high
tide. These dimensions set the maximum size of
ship elligible to travel through the canal known as
the Panamax. A typical Panamax Container ship
holds about 4,400 TEUs.
Container ship unit of measure: World’s Largest Ports
(ranked by container traffic, 2006)
TEU, twenty-foot equivalent units:
containers measuring 20ft L x 8ft W x 8.5ft H
1. Singapore
2. Hong Kong
3. Shanghai
4. Shenzhen 140 million
5. Busan
6. Kaohsiung
containers shipped
worldwide each year
7. Rotterdam
8. Dubai
9. Hamburg
10. Los Angeles
22. New York/ New Jersey
28. Port Said
Ro-RO Ship passing through a lock at - Dampier
the Panama Canal - Newcastle
27. INTRODUCTION
Size Comparison
Boeing 757-200PF Cargo Freight:
155 feet long, 125 feet wing span
DETERMINANTS
World’s largest container ship, Emma Maersk:
1,302 feet long, 184 feet wide
11,000 full TEU 14-ton containers
Football field:
DEPLOYMENT
300 feet long
Transport Ships Types
Name Water Type Qualities
CONTEXT
RO-RO Roll-on/Roll-Off varies by size subdivided into multiple types, many carry vehicles and containers
Sto-Ro off wheel cargo, brought on board by a ramp at stern or side entry
Container/Ro-Ro flexibile storage- containers on + under deck forward, ramps at stern for aft
underdeck. Ro-Ro cargo is often construction equipment
Ferry Shallow transport distance less than 300miles, often personal vehicles and rail cars
Heavy Lift Deep capable of unloading/loading heavy/bulky components - typical single lift of 100 tons
Crane Ship off-load containers from non self-sustaining ships offshore or underdeveloped ports
PRECEDENTS
FLO-FLO Float-On/Float-Off submerges open deck entirely under water surface, smaller cargo ship is
floated over, water is pumped out of ballast tanks
Barge Carrier Ships Shallow very long length compared to width, hard to handle and off-load to
Container Ships Deep containers stack 5 or 6 high, twelve across and interlocked with fittings- typically rely
on shore cargo handling gear for unloading/loading
Transportation • 22
28. by Air
It may be cost effective to transport by air using a
freight aircraft if the elements are small enough
and light enough to fit inside a cargo hold.
Utilizing an air crane, despite its hourly cost, may
container /
palette
be necessary if the urban site is particularly
difficult to access by truck and standard cranes.
The boom height necessary to place a prefab
large main-deck
component may require too large of a crane for
cargo door
the adjacent street size. In this instance lifting a
prefab unit as large as many typical single family
homes may be the efficient option for transport.
Cargo Freight Specs:
Boeing 757-200PF Cargo Freight:
Length: 155 feet
Tail Height: 44 feet
Wing span: 125 feet
Max takeoff weight: 250,000 lb - 255,000 lb
Main deck capacity: 15 max containers/palette
Palette size: 7’-4” x 10’-5”
Main deck volume: 6,600 cubic ft (palette loads)
Size Comparison Upper deck volume: 1,830 cubic ft (bulk loads)
Football field: Cruise Speed: 530 mph
300 feet long Range: 2,900 miles
Rate of climb: 1,3330 ft/min
Ceiling: 12,800 ft
Cargo Freight
Air Crane / Skycrane Must land to transport
29. INTRODUCTION
difficult access
urban site
DETERMINANTS
23
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im
DEPLOYMENT
ax
im
um
dis
t
an
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Air Crane / Skycrane Specs:
CONTEXT
Length: 70 feet
Height: 18ft 7 inches
Empty Weight: 19,234 lb
Max takeoff weight: 42,000 lb
prefab component Max Speed: 126 mph
extracted from fabricator,
Range: 230 mi
PRECEDENTS
truck/rail/water transport
Rate of climb: 1,3330 ft/min
vessel
Ceiling: 9,000 ft
Cost: $5,000 per hour
able to hover over site for delivery
Transportation • 24
31. Site Access + Assembly
Site Access + Assembly • 26
PRECEDENTS CONTEXT DEPLOYMENT DETERMINANTS INTRODUCTION
32. Site Access
There are several logical reasons for using
cranes in prefab construction. Sites completely
surrounded are rendered inaccessible to bulky
construction equiptment.Other existing site
conditions like single access to site, corner site,
or narrow site greatly limit the access points to
bring in construction equiptment and modules.
Buildings can be constructed on these accessible
(but difficult) sites and open sites using stick
frame methods, but in some cases the speed of
prefabricated construction methods can expedite
the process.
courtyard
crane necessary for construction
surrounded site single access to site
33. INTRODUCTION
DETERMINANTS
DEPLOYMENT
alley
crane necessary for speed
CONTEXT
PRECEDENTS
corner site narrow site full access to site
Site Access + Assembly • 28
34. Crane Operation + Extents
Special crane components
There are some extra equiptment items that make
craning a module more efficient and precise.
Rigging keeps the forces of tension perpindicular
to the module, reducing the bending forces on the
unit. An antirotation device helps control a crane’s
motion and the way the module shifts from pickup
Winch up to placement.
Winch Wood frame modules are best moved with
Winch right
strapping and rigging. Steel frame modules use
left
Crane school hooks and holes intentionally in the design of
Winch down Heavy equiptment training school is essential for modular structures to pick up the unit (as in
crane training and operation. It involves written shipping containers).
tests based on state laws and practical
Emergency examinations employing students’ skilled Outriggers extending from the crane vehicle are
stop
manipulation of the crane operations. necessary to temporarily ground the module to
Start Stop the site.
Jog Reset
The jib is very useful to hold the modular unit in
an almost upright position. It has the potential to
resolve design issues thanks to its ability to
Crane cab controls
suspend the module in a way different from the
way a crane typically does.
Rigging for wood frame module
35. INTRODUCTION
Small And Large Crane Extents
Telescopic Boom Crane All Terrain Crane
National Crane 1395 Tadano ATF 110G-5
20 Ton capacity 130 Ton capacity jib 20°
20°
143' 80°
DETERMINANTS
jib
122' 44°
95' 20°
80°
DEPLOYMENT
42' 72' 101' 130' 170'
56'
CONTEXT
24'-7"
340'-0"
outrigger
190'-0"
20'-0"
outrigger
PRECEDENTS
360°
360° work area
work area
Site Access + Assembly • 30
36. Crane + Obstacles
Hand signals Permitting obstacles
Hand signals are necessary for communication Permits in Boston one must obtain through the
between the crane operator and the individual on Inspectational Services Department include: long
site guiding the placement of the crane. These form permit, amendment, use of premise permit
simple gestures are necessary for several (for using open space), electrical & fire alarm
reasons. Construction sites are often loud. There permits, plumbing, gas, and sprinkler installation
is a lot of space between the crane operator and permits.
the individual conducting the crane’s motions.
The dual perspectives of crane operator and Call Boston Public Works Department 24 hours
conductor are critical in ensuring safety and prior to work to get a permit. Coordinate with
precision. recycling, santiation, and street sweeping. Signs
must be posted near the sitewith the construction
schedule. In addition to this, it may be required to
hire an officer to direct traffic.
Hoist Lower Raise Boom Lower Boom
Swing Raise Boom + Lower Boom + Stop
Lower Load Raise Load
Hand signals
37. INTRODUCTION
Obstacles on a construction site
There are a variety of existing physical barriers
that must be worked around. These can lead to
interesting, even fruitful design moves. They
includew but are not limited to:
Utility poles
DETERMINANTS
Power lines
Lamp posts
Trees
Fire hyrdants
Subterranian utilities
DEPLOYMENT
CONTEXT
PRECEDENTS
Site Access + Assembly • 32
38. Off Frame Assembly
Site Dimensions Determined by
Truck Turn
Truck turn dimensions can influence the decision
to use a site or not. Sometimes scale and cost
20'
can dictate the use of an off frame assembly
system. Often obstacles, like powerlines, can 6'
make modular construction on a site unfeasible
52'
without the use of an off frame solution. Still other
obstacles, like sidewalks and buildings
6'
surrounding the site (both immediately and across
the street), can impact the delivery of an off frame
modular unit.
Knowing the limits and minimum site dimensions
can transform a once unusable site into a
valuable piece of real estate. Standard Semi Truck
minimum site dimensions
Efficiency 20’ wide x 53’ deep
Efficiency percentage is calculated by dividing the
module dimensions
8’-6” wide x 53’ deep
area of the module by the area of the smallest
possible rectangular site. It is clear that the most
dense and efficient module-site relationship
happens when the module is shorter and wider,
as in the case of the oversized load (width)
example.
Module Site 43 %
39. INTRODUCTION
41' 25' 17'
DETERMINANTS
6' 6' 6'
53' 53' 53'
6' 6' 6'
DEPLOYMENT
Stretch Semi Truck Oversized Load (Width) Oversized Load (Length)
minimum site dimensions minimum site dimensions minimum site dimensions
41’ wide x 80’ deep 25’ wide x 48’ deep 17’ wide x 63’ deep
module dimensions module dimensions module dimensions
8’-6” wide x 80’ deep 16’ wide x 48’ deep 16’ wide x 48’ deep
CONTEXT
21 % 64 % 50 %
PRECEDENTS
Site Access + Assembly • 34
40. Off Frame Assembly
From Truck to Site Off-Frame Modular Delivery
Module delivery is possible without a crane. The
truck begins its delivery by backing into the site.
Next jacks are placed underneath the module,
taking the load off of the transportation chassis.
The chassis is then removed by pulling it out into
the street. In some cases, like the illustrated
scenario, a chassis must be cut into pieces
because the distance between the in place
module and existing structure across from the site
does not allow its removal.
Backing up Entering site
41. INTRODUCTION
DETERMINANTS
DEPLOYMENT
CONTEXT
Placing jacks under module Removing chassis from site Breaking up chassis
PRECEDENTS
Site Access + Assembly • 36
42. Site Access + Assembly
Sources
Rent A Crane, Inc. http://www.rentacraneinc.com/equipment.html
Capitol Building Supply. 2008. http://cbsigms.com/pricing/cranecharges.pdf
Pacific Northwest National Laboratory. September 2010. http://www.pnl.gov/contracts/hoist_rigging/
mobile_cranes.asp#cranetypes
Wikipedia. 2010 2, November. http://en.wikipedia.org/wiki/Crane_(machine)
National Modular Housing Council. http://www.manufacturedhousing.org/mc/admin/template/
brochures/70temp.pdf
City of Boston.2010. http://www.cityofboston.gov/isd/building/boa/permittypes.asp
City of Boston. 2010. http://www.cityofboston.gov/transportation/
Star-Flite Systems. http://www.flickr.com/photos/starflite-systems/4930960368/sizes/m/in/
photostream/
California Crane School. 2004-2010. http://www.californiacraneschool.com/
Pennsylvania Crane School. 2009. http://www.pennsylvaniacraneschool.com/crane_practical_test.
asp
Gokturk, Nurhan. Personal Interview. 13 October 2010.
Curbed Los Angeles. http://la.curbed.com/archives/2008/01/watching_a_pref.php
University of Arkansas. http://architecture.uark.edu/719.htm
44. Logistics
Module Allowable Widths
Modular strategies provide several benefits to the
Module Allowable Widths
12’-0” standard
construction process. The use of modules greatly
reduces time for the construction schedule (see
12’-0” standard
below) by allowing builders to work
simultaneously on and off site. In working
primarily off-site, negative impacts on the
environment 8’-6” post-construction sitepermitting required (standard)
and no revival
12’-0” permit required (wide)
are greatly reduced.
14’-0” escort required (wide)
special route required (oversize) 8’-6” no permitting required (standard)
16’-0”
Module dimensions are determined by the 12’-0” permit required (wide)
14’-0” escort required (wide)
Massachusetts Department of Transportation. special route required (oversize)
16’-0”
MassDOT codes restrict travel of certain trucks
and load sizes during high volume traffic hours.
Module Allowable Lengths
Module Allowable Lengths
standard
12’-0”
standard oversize maximum
40’-0”
53’-0” standard oversize
76’-0”
40’-0”
53’-0”
Site Built Construction Schedule 76’-0”
DESIGN PERMITING ON-SITE ON-SITE ON-SITE
schematics + documents submission + approvals preparation + foundation building construction site restoration
Modular Construction Schedule
DESIGN PERMITING ON-SITE ON-SITE TIME SAVED
schematics + documents submission + approvals preparation + foundation site restoration schedule reduced by 30% to 50%
OFF-SITE
building construction
45. INTRODUCTION
Steel Frame Modular
steel form deck
6” ceiling joists
DETERMINANTS
HSS frame
steel form deck
3” concrete
HSS frame
steel studs
gwb
cladding
DEPLOYMENT
Steel framed modules are constructed with a
hollow structural steel frame that is infilled with
light gague steel studs. The modules arrive on
site with interior and exterior finish materials
installed, are fastened to one another and
finishing touches are made. The steel module
shown to the right allows for the construction of a
maximum twelve story building.
CONTEXT
exploded axonometric
mate-line
concrete floor
mate-line
PRECEDENTS
gwb ceiling
2 layers type x gwb
mineral wool fire stop
firesafing
marriage wall section
Modular Strategies • 40
46. Logistics
Wood Frame Modular
gwb ceiling
2 x 6 ceiling joists
gwb finish wall
(2) 2 x 12 beam
floor sheathing
2x4 studs (2) 2 x 10 beam
2x10 floor joists
2x6 studs
sheathing
cladding
Wood framed modules are built using typical
wood construction methods. Wood beams and
studs act as the main structure, with exterior
sheathing to prevent racking. Interior and exterior
finishes come installed in the module. Wood
modules are often limited in height by local codes
for wood construction.
gwb finish wall
osb sheathing
exploded axonometric
2 x 10 joists
(2) 2x12 beam
air space
2 x 6 ceiling joists
gwb finish ceiling
2 x 4 stud wall
marriage wall section
47. INTRODUCTION
Shipping Container Modular
steel corrugated roof
corrugated side wall
steel square tube
steel block
DETERMINANTS
steel post
steel channel
1” plywood floor
steel joists
rubber gasket
securing bars
Shipping container modules can come from
steel doors
actual recycled shipping containers, or can be
custom constructed for specific projects.
DEPLOYMENT
Shipping containers are intended to be stacked
for the transportation of goods, and therefore
stack easily as well to form buildings. The
corrugated side walls provide a lot of the
containers strucural capacity, and need to be
reinforced with columns if sections are removed
as shown above exploded axonometric
CONTEXT
steel angle below
steel channel at plywood seam
corrugated side wall
steel joists below
corrugated end wall
steel permieter beam
1” plywood floor
PRECEDENTS
steel bottom block
steel vertical support
structure detail plan
Modular Strategies • 42
48. Site Placement Strategies
On-Frame Modular
chassis set module on piers detach chassis
There are two main strategies for placing modular Off-frame construction (see below) is commonly
buildings on to a site. On-frame construction (see used for multi-story buildings. The module is
above), also known as mobile homes, is limited to placed onto the back of a flat-bed truck for
single story structures. Modules are placed on a shipment, and is craned into its site upon arrival.
chassis, hitched to a truck, and brought to site. The modules can be stacked according to local
The chassis is lowered onto a set of piers and zoning and codes, as well as the structural
detached from the truck. The chassis and wheels integrity of the system. Off-frame systems are
are left beneath the module, making the structure typically viewed as permanant.
temporary in nature
Off-Frame Modular
flat-bed truck strap module to crane place module on foundation
49. INTRODUCTION
DETERMINANTS
anchor module to ground add skirting
DEPLOYMENT
craning sequence
CONTEXT
PRECEDENTS
anchor module to foundation
Modular Strategies • 44
50. Aggregation Techniques
There are several ways modules can be Non-attached Semi-attached
aggregated to form a building. Modules can be
not attached, semi attached, or attached as seen
in the diagrams to the right. Here are several
examples of how modules can be aggregated
within the different levels of attachment. The
examples listed are existing aggregation
techniques in their simplest form.
The ability of modules to be stacked and shifted
is reliant on their structural integrity. Different
construction methods will allow for smaller or Solo Framework
larger cantilever dimensions and variable building
heights. The height of modular buildings is also
reliant on local zoning codes for specific materials
Field Field joint
Puma City, to the right, is a great example of
aggregated modules where one can actually see
the aggregation technique clearly. Modules
oberseve stack : shift relationships as well as
mate and bridge.
52. Mechanical Systems
Modular Building Parts
As the number of modules in a modular building
increases, the complexity by which they are
attached also grows. A solo module arrives
ready for use, and must only be tied into the
foundation. As more modules are introduced
there is a system by which their mechanical
components are connected. Stacked modules
require shafts, similar to that of standard
buildings, to carry mechanical lines. Large in-site foundation typical module interstitial module
buildings with high volume HVAC and plumbing
systems can introduce interstitial modules to
allow lateral movement of systems in between
stacked modules.
Mechanical + Modular Connections
solo module adjacent modules stacked modules
56. Definitions
Prefab construction is often associated with
whole modules or shipping container architecture.
However, there are other component strategies
that qualify as prefabicated construction.
Fabricated Unit Panel System Precast Concrete
Fabricated units as defined by this section are Panel systems contain integrated systems within Precast concrete is fabricated in a multitude of
typically made of extruded or poured metal one component. Often included are structural, sizes. Precast components are comprised of an
(aluminum or steel) The units range in scale from thermal/waterproofing, electrical, mechanical internal steel rebar framework and high tolerance
a small fasteners to steel bridge trusses. For the systems. Made up of a sandwich of concrete. Concrete is meant to withstand
consideration of construction and design logics, complementary materials. How the panels are transport to and movement on site. Units are
metal fabricated components from the single stud handled on site is dependent on the weight and limited in weight and dimensions based on the
to the 300’-0” bridge truss are in this category. size of each piece. smallest unit of transportation. Refer to the
Transportation chapter for size limitations.
57. INTRODUCTION
DETERMINANTS
DEPLOYMENT
CONTEXT
Kit-of-Parts
The Kit-of-Parts is a packaged set of components
that results in a cohesive end product, not
categorized by materiality; often the shipping
PRECEDENTS
package is used as a portion of the finished
product. It can include any number and
combination of the fabricated unit, the panel
system, or precast components. Coordination of
products is done off-site then delivered.
Component Strategies • 52
58. On-Site Labor
The benefit of prefabricated systems is mostly
realized in the reduction of construction on-site
labor. Prefabricating components, panels, or
modules can significantly reduce the amount of
time workers are present at the site. The
reduction of on-site time obviously reduces
construction labor cost but also has the potential
to reduce the amount of errors experienced at the
construction site.
However, a consequence of prefabrication is that
the building components grow in size. Increased
sizes result in the need to utilize more man-power
and exra equipment. Transport equipment
maximum loads need to be considered in the
design of the components. Logistics in transfer
are key limitations to designing structurally sound
pieces that can handle transport and the loads
inherent in the building design.
Extra time is needed than on-site construction
calculating and coordinating the connecting
components because on-site flexibility is severly
decreased. Increased coordination is then
necessary for any building components not built
as part of the prefabricated system, ie: the
foundation. Since prefabrication alters the time
and means for on-site labor it is important to
understand the relationship of on-site personnel
to the size and type of prefabricated component.
launching and construction of
Bailey Bridge with manual labor
59. INTRODUCTION
Relationship of On-site Labor and Component Transfer
Labor Personnel Component Max. Weight Dimensions
51 lbs 2” H × 4” W x 8’-0” L
DETERMINANTS
150 lbs 10’-0” H x 4’-0” W x 6” L
577 lbs 5’-0” H x 1’-0” W x 10’-0” L
DEPLOYMENT
< 2,000 lbs 4’ H x 4’ W x 3’-4” L
< 2,000 lbs 5’-0” H × 4’-0” W × 8’-0” L
CONTEXT
20,000 lbs 11’-6” H x 8’-0” W x 48’-0” L
PRECEDENTS
25,000 lbs 15’-0” H x 60’-0” W x 9’-0” L
Component Strategies • 54
60. Fabricated Units
Fabricated units have the advantage of being
constructed in a controlled environment.
Compared to stick-built methodology, fabrication
groups the individual studs, beams and joists
within a factory setting. Instead of installing and
connecting each stud to the foundation through
the footer of a wall, the framing is made into a
component that includes the header, footer and
all the studs for a predetermined length of wall.
Degrees of Prefabrication
Stud Stud Panel Bridge Truss
elevation
plan
61. INTRODUCTION
Roof Structure
Interior Finish
PRODUCED BY AN AUTODESK STUDENT PRODUCT
PRODUCED BY AN AUTODESK STUDENT PRODUCT
Floor Slab
DETERMINANTS
Framing
Column-Beam Connection
DEPLOYMENT
Cladding
Apetures
CONTEXT
Foundation
Fabricated Unit Logic
PRECEDENTS
Steel Frame Construction
Fabricated Units compose the structural framing.
Other systems, energy, aesthetics, and openings
are additive to the unit.
Component Strategies • 56
PRODUCED BY AN AUTODESK STUDENT PRODUCT
62. Panel System
3
4
2
Panellized construction minimizes on-site
construction. Construction materials typically 1
fastened on-site are compiled into a component
constructed in the controlled factory environment.
Most common type of panel system is SIPs,
structural insulated panels.
SIPs are comprised of a thick layer of insulation
between two layers of OSB, oriented strand
board. A basic SIPs panel is composed of both
structure and insulation layer.
Panel systems may increase material cost by up
to 50% but on-site labor cost can potentially Panel Connections
decrease by 50%. The benefit exists in the Connections Fastener Spacing
precision of factory controlled construction with
isolation from problems that exist at the site. 1. Track to Level Platform countersunk screw 2 screws per 24”
1 screw in between
Installation of the panels is based on 2. Track to Panel screw 2 screws per stud
methodology developed for the specific system. 3. Panel to Panel screw (ex: wafer head) 12” OC
Different systems will have different advantages: 4. Track to Panel* screw 2 screws per stud
whether the panel is lightweight or resistent to *upper track connected after 12’-0” of panels installed
weather, earthquakes, winds, insects, debris.
63. ODUCED BY AN AUTODESK STUDENT PRODUCT
Last Panel
Initial Panel
Panel Installation Sequence
Component Strategies • 58
PRECEDENTS CONTEXT DEPLOYMENT DETERMINANTS INTRODUCTION
64. Precast Concrete
Structural Components 1 2 3 4
Slabs
length factor by function of service
width by transportation restriction
5 6 7
Beams
depth is dependent on length 10
length is function of capacity load
Columns
1. Solid
height is dependent on the width
2. Hollow Core
8 9 3. Single Tee
Precast concrete construction is most readily 4. Double Tee
seen within the city as infrastructure. It is a 5. Rectangular
versitile construction type. Any shape and size is 6. Inverted Tee
possible as long as the overall component 7. L-shaped
conforms to the smallest restrictions on size 8. Round|Rectangle
based on transportation used to get from 9. Square
precaster to the job site. Refer to the 10. Double Height
Transportation Sub-Chapter for restraints, per
transport type.
The efficiency of precast concrete units becomes
apparent in the repeatability of the shape. Composition of Precast
Formwork is expensive to fabricate. The more
materials and accessories
rebar
sophisticated the form the higher the cost. Similar
concrete: portland cement, water,
shapes with minimal pour adjustments will result
air, aggregate
in the most cost efficient use of the form.
formwork
positive/negative connection keys
Utilizing precast as a technology will add
epoxy cementitious grout:
additional time to the initial phase of the project
between precast segments/
for design/calculations and decrease on-site time.
components
65. INTRODUCTION
Precast Fabrication to Construction Site
Fabrication of a precast unit mirrors the method
in which the unit will be installed at the site.
Short Line Casting System
Inside Formwork
DETERMINANTS
Bulkhead
New Segment
Older Segment
Older Segment
Soffit adjustable formwork for precast segments
DEPLOYMENT
Carriage
New Old
Outside Formwork
CONTEXT
Long Line Casting System
Outside Formwork Elevation
PRECEDENTS
Inside Formwork
Plan
Component Strategies • 60
