Modular Building Panels with Building Services

The present disclosure relates generally to modular building, and more particularly, to an improved system of modular panels for building.

Modular construction has been garnering increasing attention as a pivotal area of growth in the construction industry. The predominant form of modular construction today is volumetric, focusing on the assembly of three-dimensional units in an off-site location before their integration on-site. In contrast, panelized modular construction typically has been limited to the shell, frames, and occasionally the inclusion of exterior insulation and windows.

The integration of building services such as electrical, plumbing, heating, ventilation, and air conditioning (HVAC), and fire protection into panelized modular construction brings significant benefits. However, it simultaneously presents distinct challenges, particularly relating to the multiple disconnection points for these services within a modular panel. Moreover, the requirement for these panels to be inspected and certified at the manufacturing location before they can be approved for installation on-site adds an extra layer of complexity. This can increase both the time and cost associated with the panels, altering the traditional building process which usually involves on-site inspection.

Despite the potential advantages that panelized modular construction offers, such as greater design flexibility, easier and cheaper transportation compared to volumetric modules, and compatibility with a range of materials for framing, current practices in the industry do not fully capitalize on these benefits. Challenges associated with precise cutting and measurement for integration of services, the need for off-site certification and inspection, and the complexity of managing multiple disconnection points continue to impede the broader adoption of modular panel construction.

What is therefore needed is a module panel design that circumvents the need for inspection and certification at the manufacturing plant, while providing a solution that aligns with the standard local building inspection requirements.

A modular construction including a module panel having a length, a width, and a shorter cross-sectional depth, where the module panel is open for visual inspection. The module panel has a customized metal frame member, where the customized metal frame member has a cutout, and where the cutout enables a building services to route through the customized metal frame member.

The modular construction system may include a building service installed in the module panel. The custom metal frame member may be formed from a roll of metal. The sides of the module panel may be open for visual inspection. The custom metal frame member may be made using a steel-roll forming machine with stations that create cutouts. The module panel has a final orientation and the cutout may be longer in one dimension to accommodate ridged building services to move vertically when in the final orientation. The module panel may be a floor section with the customized metal frame member being joists. The module panel may be a wall section with the customized metal frame member being studs. The building services may be rigid building services. The building service may be flexible building service and cut to a length to enable joining of the building services to a corresponding building service of another module panel. The flexible building service may be wound-up and may be located inside the module panel.

A modular construction process includes providing a first module panel with a frame member having cutouts and a building service routed through the cutout. Placing the first module panel in a final location at a build site. Providing a second module panel with a second frame member having a cutout and a second building service routed through the cutouts. Placing the second module panel in a second panel final position. Joining the first building service with the second building service.

The modular construction process may also include providing a module panel and corresponding finishing materials, where the corresponding finishing materials are arranged in an order that facilitates closing the module panel. The process may include installing the corresponding finishing material on the module panel in a predetermined pattern. The modular construction process where the module panel has a bottom, a top and a bottom left; and the predetermined pattern starts in the bottom left going up to the top and then moving right and start at the bottom and going up to the top and repeat pattern.

The system may include a building information modeling system with an electronic model of a building using modules and corresponding framing components with the modules being composed of framing members and the framing member include cutouts for building services, and the corresponding framing components cover the modules. The system also includes a list of customized metal framing member for creating the modules where the list of customized metal framing member is based on the electronic model. The system also includes a list of framing components including cutouts where the framing components will cover the.

presents a flowchartwhich demonstrates a high-level process flow for a modular panel construction system. The system enables adding building services (for example, Mechanical Electrical Plumbing and Fire suppression, MEP-F) into prefabricated modules.

The process starts at oval. Following the ovalis box.

At boxthe building design may be imported into a Building Information Management (BIM) System. Panelized framing is not limited to platform framing, the framing can be standard framing, balloon framing or any other types of framing.

Design of the building services (like plumbing) may take into consideration the overall limitations of the modular paneling method implementation and trying to minimize crossing between panels by design knowing that crossing cannot be entirely avoided.

It is preferable to have the least amount of module panels. Whenever possible it is preferable to have the wall modules continuous from wall to wall. Preferably the floors are cut based on O.C. (on center) multiples so the end caps of the module are a joist needed for structural purposes for the final assembled structure.

The BIM may be used for the process, and the module is unique in relying on uniquely designed cut-out stations for hole cutting and other cut-outs. This unique stations allows the translation of BIM data directly to the rolling machine for cutting and punching. Examples for such stations or molds may be for electrical receptacles, lights, plumbing, fire sprinklers, etc.

For non-structural walls and for case of construction, the top plate of walls may have much longer flanges and may come with elongated holes situated exactly where the top plate meets the studs. The purpose of this shape is account for any variations in height that may occur from the different types of structural flooring used, for example: The bow in precast concrete, or the fire rated ceiling in steel joist etc. This adjustable height top plate wall enables non-structural walls to be installed after the erection of structural elements and the shell. This feature mirrors the staging process of conventional construction, thus offering familiarity for inspectors and workers, and aiding in permit acquisition and financing procedures. It also substantially decreases the high upfront costs generally associated with modular or prefab construction, where multiple trades or services are often required to work concurrently within a factory setting. Importantly, this financial advantage is an optional feature facilitated by the proposed precast method. The system also bypasses the structural limitations that typically dictate the number of stories for which a modular or prefab system can be designed. Furthermore, it facilitates the use of the modular prefab method in retrofitting and renovation scenarios, thereby demonstrating its adaptability to various construction contexts.

From box, the flowchart splits into two distinct pathways.

The first pathway leads to box, where the BIM system provides the necessary details for fabricating custom steel members for modular panels.

This system needs precise cuttings and measurements, while this can be achieved manually, the method is best suited to be designed in Building Information Modeling (BIM) software to accurately measure and calculate. The system will also work best with use of Computer Numerical Controlled (CNC) machines for steel or wood framing cuttings with data provided by the BIM software.

A module panel can be a floor, a wall, bulkhead, fake wall, etc. Modular panels may have integrated building services (Mechanical/Electrical/Plumbing/Fire-protection, MEP-F). The modular panels are designed for prefabricated panelized assembly. Individually, the modular panels do not create volumetric modular structures.

The modular panel can be of any sturdy material that is acceptable for construction, for example steel, wood, etc. An exterior wall modular panel may include insulation, vapor barrier, drywall and cladding added at the factory. Floor modular panels may include the subfloor added at the factory. Roofs modular panels are most recommended for flat roofs as it is easier to divide a flat roof into modular panels.

Modular panels, in contrast to volumetric modules, are able to support more diverse designs and have less limitations as the design is not confined to a box or rectangular shapes as is typical in volumetric modular construction.

Building services (line, pipe, duct, wire, etc.) that crosses between modules can be referred to as a crossing point. Crossing line or crossing point or crossing plane or crossing pipe, wire or duct etc. is defined as the crossing point or planar cross in-between two modules that will be connected at the construction site. Example, crossing pipe is the pipe that crosses between two module panels.

After designing the building the BIM software may be used to identify the modular panels and the connection points between the modules. At connection points any wire crossing between modules is referred to as crossing wire, that is wires that cross between the modular panels.

Next at box, a steel framing machine creates custom frame members as indicated by the BIM system by punching the requisite openings from a big role of flat steel and forming C-channel of the required cross section lengths, with the openings in the desired locations.

Many types of materials can be used for the frame members of the module panels, for example, wood or tubular steel etc., this system allows for use of light gauge steel as the structural element which reduces the cost as compared to volumetric modules.

Next at box, the modular panels are constructed using the custom frames members. The system implements building services, MEP-F, in modular panels in the factory. The module panel can be framed manually or preferably using machines driven by data from BIM software that punches, cut and drills any holes needed in the module panel. The use of BIM software can increase the accuracy of the results.

A wall frame module panel is standard framed wall at factory. The wall module panels may be structural or non-structural, a partition wall. Wall modular panels going the width of the wall may be the most efficient.

The floors are preferably joists with cut holes precisely especially for plumbing and drain slope. Open web could rearrange the opening web The floor joist are to be connected by bridging or linear connectors. Subfloors can be added at the factory or at the construction site. The floor to start with a joist and ends with a joist preferably to avoid caps on the end. The bridges or connectors are to be added at the construction site in order to tie the different floor modules together.

Roof to be done at factory in parts, parts are the ceiling joist and other parts are the roof rafters, this enables the whole roof to be done as in modular panels.

Next at box, the building services are installed into the panels.

Next at box, the constructed modular panels with building services are transported to and assembled at the building site.

The transportation of modular panels can be much easier, cheaper and faster than volumetric modules. Modular panels dimensions may be limited by transportation and construction site logistic. Panels of up to 50 ft in one dimension is possible to transport using standard means. The width and height of the panel is less restricted, generally, the restriction is in transportation laws per local codes.

At the construction site, the modular panels undergo final processing and installation. The panels are assembled and the building services between panels are connected to form a complete building. Both the assembly and installation of the modular panels must adhere to the locally applicable standards, building practices, and building codes specific to the jurisdiction of the construction site.

Next at boxthe local building inspector comes to the build site and verifies that the assembled structure adheres to all relevant local building codes and safety standards.

The module panel, either floor or wall, has at least one-side open, meaning the module panel is able for inspection at the construction site after incorporated into an assembled structure.

Subject to the local authority in each jurisdiction, by having the MEP-F exposed by at least one side of walls or ceiling, for example at the internal sides of walls and ceilings, the prefabricated modular panels may meet the definition of local standard. In Canada, they might align with the definition of “prefabricated open panel” as defined by the Canadian Standards Association CSA in its standard for modular paneling A277-16 (2021) in A.3 Definitions. Similarly, in the United States, such panels could adhere to standards or guidelines as stipulated by the International Code Council (ICC) or the National Fire Protection Association (NFPA) related to modular construction.

By meeting the definition of “prefabricate open panel” can results in bypassing the requirements in some jurisdictions for the certifications for modular construction which reduces the cost, time and complexity of projects. Having the modular panels open at least on one side makes it easy for local inspectors at construction sites to inspect which provides the option to bypass the requirement for additional licensing for factory modular construction as all services are still exposed after transportation to the construction site and can be inspected other standard onsite construction.

The addition of the MEP-F into modular panels with one side open for inspection enables the modular construction of a buildings from modular panels using local inspector, as opposed to volumetric modules, and can bring the benefits of modular panels to a wider audience.

In parallel to the sequence from boxto box, a second pathway is running from boxto.

At box, the BIM system provides the dimensions and cutouts for the finishing materials.

Next at box, a Computer Numerical Control (CNC) machine, guided by the BIM information, cuts the finishing materials to the desired dimensions and shapes.

The finishing materials (for example, precut drywall or panel board) maybe precut and pre-routed to be sent to construction site, due to the knowledge of the openings and their locations on the interior panels, the cuts to the finishing material can be made precisely in factory and sheeting panels can be sent to the construction site. pre-cut and pre-routed ready to be installed without the need to cut holes or panel sizing on-site, this will reduce cost and debris at the construction-site.

The precise cuts can be done manually but using a CNC machinery is preferable and possible since the information for holes and cuts can be imported from the design software.

Cutouts may be for building services access, for example fire sprinkler pipe holes.

Both pathways from boxes-and-converge at box. At this point, the finishing materials are installed on the assembled structure.

Finally, the process concludes with the end oval.

shows a steel rolling machinethat takes a continuous sheet of metaloff a coil of steelThe sheet of steelprogresses through a series of flattening rollers. Subsequently, a series of stampscreate cut-out openings in the sheet of steel. This sheet of steelthen moves to a series of rollers, which shape it into specific structural components, such as a metalxstud member or axjoist member. The cut-out openings in these components accommodate building services. Following the rolling process, a cuttertrims the shaped frame member to the desired length. The finished frame member may then be accumulated on the finished product stand. A numerical control systemoversees and manages the entire process described, ensuring precision and consistency in the end product.

The steel rolling machine may employ various mechanisms or configurations for bending, stamping, and shaping the sheet of metal. For example, alternative mechanisms or methods could be used to achieve the necessary flattening or smoothing of the steel sheet. The sequence of operations may vary, with stamping or cutting of openings occurring either before, concurrently, or after the rolling or cutting process. The steel rolling machine may produce a diverse range of metal structural components, with varying dimensions, profiles, and features. Variations in the type of metal, its thickness, and other physical characteristics, may necessitate adjustments or modifications to the roll forming process. The machine may incorporate different control systems or algorithms to enhance precision, reduce waste, or optimize production speed.