Pattern buildings An Industrial Building System for Mass-Customizable Buildings Version: Beta 12.06.2020 Estonian Academy of Arts, Faculty of Architecture June 2020, Tallinn Authors August 2019 - June 2020 Renee Puusepp Lauri Läänelaid Marianna Zvereva Egle Vogt Kristo Kalbe Eero Tuhkanen Estonian Academy of Arts Estonian Academy of Arts Estonian Academy of Arts Harmet OÜ TalTech TalTech License Pattern Buildings by Renee Puusepp, Egle Vogt, Lauri Läänelaid, Marianna Zvereva, Eero Tuhkanen, Kristo Kalbe is licensed under CC BY 4.0. To view a copy of this license, visit https://creativecommons.org/licenses/by/4.0 Pattern Buildings Table of Contents Authors4 License4 Table of Contents 6 Concept8 Core design requirements 9 Design10 The Parts of Pattern Building 12 Room Module 13 Body15 Skeleton19 Skin21 Base22 Circulation23 Utility systems 24 Production and transport 29 Assembly and construction 31 Operation of the Building 33 Pattern Buildings Concept Pattern Building is an industrial construction system based on modular design for creating up to 7-storey buildings of different typology and appearance. Every Pattern Building is • • • • • mass-customizable; environmentally friendly; made primarily of wood; modular; ready to be produced, assembled, and transported in most European countries. Pattern Building is flexible and adjustable to plots of various shapes and in different spatial contexts. The design is suitable for construction in the climatic conditions of Northern and Central Europe. Pattern Buildings alternate in function, size and outline, facade solutions as well as utility systems. Pattern Building is designed to adjust to the varying construction regulations and standards set in different countries and regions. Pattern Building “Quadrant.” Architect Taavi Lõoke Pattern Buildings Core design requirements Informative Universal Environment-friendly Re-configurable Durable Adaptable Using a limited number of components the Pattern Building enables to achieve a large number of varied design outcomes. Pattern Buildings Open Autonomous The Pattern Building architecture must be informative. Its constructive and technical structure must be easily readable by the builder, the user and the maintainer of the building. The Pattern Building must be simple enough for it to be produced at different factories and assembled by different builders. The transport of modules must be legally and technically possible without special permits or escort to all regions of Europe by road, rail and water. The Pattern Building needs a minimal amount of energy for production, transport and operation. The components of Pattern Building are easily accessible for disassembling and upgrading. Given the growth cycle of wood used in construction, the main structures of the building must last for at least 100 years. The modular system should not constrain design freedom and can be adapted to different typologies, providing only the technical means for achieving the design goals. The Pattern Building concept remains available without restrictions (see License) to anyone who wishes to develop it further. Functional units of the building (for example, apartments in the case of an apartment building) should be independent of each other both in terms of access and in terms of utility systems. Design The design process is a significant hindrance in the overall off-site construction process as it seizes up to three quarters of the total production time. Predesigned modules help to significantly reduce the design time. The Pattern Building system provides architects with tools to design various functional layouts and spatial aesthetics, while having the overall structure and technical junctions already standardised and resolved. scenarios and assess their suitability from a functional, financial and aesthetical perspective. By using pre-designed modules, it is also possible to accurately calculate ahead the quantity of materials, costs and other quantitative data necessary for the production and construction of the building. The Pattern Building system provides an opportunity to easily try out different spatial The Pattern Building system has been passed on to architects and planners by this report, its annexes and CAD and BIM files. Documents with an open usage license are available at www.patternbuildings.com In addition to standardised modules, Pattern Building can feature custom designed parts such as basement, entrances, atriums, etc. Pattern Building is a customised solution by its nature, allowing sensitivity to context and flexibility in the creation of buildings with varied character. The Pattern Building is a combination of pre-designed modules and custom designed parts. Pattern Buildings The Parts of Pattern Building Pattern Building can be divided into following components: 1. 2. 3. 4. 5. 6. 7. room module body made up from the modules skeleton skin base circulation utility systems 2 4 1 The following chapters will further introduce the components. 6 3 7 5 Pattern Buildings End frame formed from posts and beams Ceiling element Room Module Metal corner fittings join the LVL elements into a rigid frame The module is composed of four corner columns, a ceiling element and a floor element made of laminated veneer lumber or LVL, and metal corner fittings that provide the structural stability. Floor element Module post Pattern Building Module M6 Pattern Buildings The key part of the building is the factory-produced room module. The module is designed for up to seven floor buildings and withstands the dynamic loads applied on transport and installation. Interior walls, finishing layers and equipment for utility systems are all added to the room module at the factory. If transport restrictions permit, facade elements are also added to the perimeter modules. Module M3, 2967×2969×3444 mm (L×W×H) The modules are produced in three nominal sizes: 3×3 m (M3), 3×6 m (M6) and 3×9 m (M9), and two heights: 3.45 m and 3.13 m. It is important to distinguish the nominal dimensions from the actual dimensions of the modules, which are somewhat smaller. The minimum internal dimensions of the modules are shown on the drawing. The thickness of the finishing layers is further added to these dimensions. Module M6, 5967×2969×3444 mm 2717 Module M9, 8967×2969×3444 mm 2947 2645 5645* Module M6 minimum internal dimensions Pattern Buildings Body The body of Pattern Building is the architectural volume of the building, made up of room modules complete with internal finishes. The body is designed for a 3×3m grid and consists of modules of different sizes denoted as M3, M6 and M9. The body of the building is covered with facade and roof elements, here referred to as the skin. Module’s corner posts made of LVL can be an indoors decorative element. Pattern Buildings 31 mm 31 mm between modules in each direction Setting out Since the actual size of the modules is unyieldingly accurate in terms of designing volumes, a planar grid with dimensions of 3m by 3m should be used. All modules have 31 mm space in every direction to fit fastenings and insulation materials. 3m 3m Module design is based on 3m by 3m grid Pattern Buildings Console positioning of modules should be avoided. Balconies are, as a rule, constructed as separate elements which are fastened to the skeleton. Offsetting modules on different floors should be avoided. It is most preferable to place the modules in line with each other on different floors. Modules may be placed perpendicular to each other on different floors, but in this case, posts at lower floors must support the corners. Placement of modules When placing modules in the building’s skeleton, the general rule is that all modules follow the layout grid. Pattern Buildings Skeleton The structural components of room modules once connected together, form the skeleton. The skeleton supports the body and the skin of Pattern Building. The skeleton also includes shear walls and other constructive elements external to the standard room modules, e.g. vertical stair cores and elevator shafts. Skeletti tugevdavad jäikusseinad, mis on valmistatud näiteks ristkihtliimpuidust Pattern Buildings Room modules are connected to one another on-site. The ceiling elements are connected with a steel plate forming a diaphragm, through which the horizontal loads are applied to the share walls. The share walls are enclosed in spaces between the modules and should be placed in accordance with the following requirements: • There must be at least four share walls, two in each grid axis of the building; • Rigid walls running on parallel axles do not need to be side-by-side; • The distance between parallel rigid walls must not exceed 9 m • The minimum thickness of the share wall is 100 mm and the length in plan is 3 m The modules are connected horizontally with metal plates attached to ISO corner fittings. The modules are connected vertically with twist-lock details meant for ISO fitting corners. The corner posts of the modules are connected to each other with the LVL boards. The floor- and ceiling panels of the modules are tied together with additional LVL boards. Pattern Buildings A finished wall part of the external structure Facade element Skin The skin is the layer protecting the body of the Pattern Building from outside, consisting of facade and roof elements. The skin is the most obvious tool for mass customisation of the Pattern Building as it allows the same body to have very different appearances. The facade and the roof of the building can be installed on site and therefore it is important to consider their transport already in the early design phase. The skin of the building is attached to the body of the building in the form of panelised elements; in the case of external structures, the facade elements and the factory-produced wall with interior finishing are joined together. Pattern Buildings ISO PROFIIL VS01 KL01 160 Base IW01 SS01 VS01 EW01 60 3 17 Floor PL01 200 30 EW01 VS01 8 10 The base can be a foundation, a landing, a basement or a ground floor, for example. The base of the building is designed according to the shape of the building, the plot and the purpose of the building. The base must wear the weight of the building’s body and support the corners of the first floor’s room modules. PLEKK Sheet metal PLEKK Sheet metal Base JALAM 15 The base of the building is the lowest part of the building in contact with the ground. It supports the body of wooden modules built on top. 405 The exact shape and type of the base depends on the specific project. Pattern Buildings Circulation Circulation is a functional part of the Pattern Building, which includes the building’s stairways, lifts, corridors and other access points. Circulation is a system that makes all parts of the Pattern Building accessible for the user. Stairwells and corridors can, as a rule, be placed in 3 by 3 grid and solved as standard modules. Lift shafts are parts of circulation but are not modular as a rule and can be used as rigid elements to support the skeleton. Stairs positioned inside M9 and M6. In the case of M6, the width of the stairs tread is not more than 1250 mm; in the case of M9, it may be wider. Pattern Buildings Generally, all parts of the circulation have been designed separately from other parts of the body to improve sound insulation and ensure that the solution complies with the core design requirement of Autonomy (see page 9) Utility systems The Pattern Building’s utility systems ensure the day-to-day operation of the building. The utility systems are divided as follows: ventilation, heating and cooling, water and sewerage, electricity, automation. The indoor climate quality of the building is achieved with an energy efficient ventilation system combined with heat recovery. The rate of heat recovery depends on the specific type of building and its location. The heat recovery rate should generally not be less than 80% and the specific fan power (SFP) should ideally be around 1.5 kW m ³/s. In order to reduce the pressure loss in the pipes and the resulting additional energy consumption, the layout of the rooms should favour the use of relatively short and straight pipes. In the case of apartments, the minimum diameter of the pipes under the ceiling of the room module would be 125 mm (with a silencer 160 mm), in public buildings up to 600 mm. All utility systems can be connected vertically in the cavity between the modules. Pattern Buildings In the Element system, ventilation is installed as integrated panels of the dropped ceiling. Ventilation The Pattern Building concept does not directly require the use of specific ventilation units, but there are three possible design solutions: Pattern Buildings Autonomous system The ventilation system is serviced by the exhaust air heat pump, which also solves heating and domestic water. The diameter of the pipes is 125 mm. The inlet and outlet pipes are isolated. Element system Ventilation is placed in pre-manufactured modular elements with water and electricity channels (e.g. Silotek) and is located above a dropped ceiling. The diameter of the pipes is 200, 160 and 125 mm. Open system In the case of an open system, the pipes are visible beneath the ceiling. Pipe dimensions are 315, 200, 160 and 125 mm. The channels are painted. Heating and cooling There are two basic options for heating the house: water heating and electric heating. Water heating uses convectors on the walls or below the ceiling. The water heating is either part of the central heating or works on an autonomous boiler. Heating panels are integrated into the dropped ceiling Floor heating works with electricity. Cooling should be passive and achieved by design, orientation, placement and shielding of the building’s openings. In case of water heating, it is also possible to use the ceiling panels as cooling elements. Electric floor heating Convectors beside the module wall Pattern Buildings Water and sewerage All horizontal pipes run into the wall and are connected to vertical pipes It is possible to move the wall with the horizontal pipes anywhere within the module, except for in between the shorter end posts of the module. Pattern Buildings All toilet seats have wallmounted frames Since the beams on the longer side of the module are moved towards the centre of the module, there is a dedicated space for drain stacks between the two modules with a width of 350 mm. In the case of sewerage and water systems, pipes should be as short as possible. In the case of sewerage, it is very important not to design the toilet in such a way that a large diameter pipe should move through the corners of the modules in order to reach the soil stack. In other words, large sewage pipes must remain within the limits of one module. Electricity The electricity cabling runs along the bottom edge of the walls in the in-wall cable channel, allowing to change the position of the plugs and switches according to the layout of the rooms. The horizontal lines are hidden in the cable trays installed behind the floor plates and between the floor beams. The vertical lines are behind the finishing board or, if necessary, vertically installed in the adjustable cable box. The lighting switches are wireless. Vertical connection between floors. Installed behind the finishing board Plugs can be placed anywhere along the wall Pattern Buildings Production and transport The Pattern Building modules are made up of standard details, making their production and handling feasible for most factories. This in turn makes it possible to take assembly of the modules to the logistically most suitable location (e.g. transport hubs and near ports). The factories producing the module elements must be high-tech to today’s standards, have corresponding quality certificates and test capability. The metal corner fittings are produced according to ISO standard, allowing the module to be easily lifted with all common lifting systems. Pattern Buildings The end wall frame of the module is constructed on a horizontal worktop, with the use of a harness for achieving the required accuracy. The walls are installed at the assembly of the module’s frame. Floor, ceiling and wall elements are produced on automatic and semi-automatic production lines and on butterfly turning tables. The module assembly deploys three-dimensional jigs and tension straps. The module is assembled from the finished parts and after the assembly, only the final finishing repairs and sealing of the joints will take place. The modules are transported on 0.9 m high trailer platforms and always with heavy-duty vehicles. The total load height is 4.5 m. The modules are lifted from the ISO corner fittings at the top corners of the module with a lifting frame. These fittings provide an opportunity for automatic digitalised lifting and proper fixing during transport. During transport, support posts and diagonal cargo straps are used to strengthen the structure of the module. It is important to ensure that the ISO corner covers are always installed according to the instructions. Modules are transported by trucks, ships and trains. Pattern Buildings Assembly and construction Before starting the installation of the modules, it is mandatory to check the existence and validity of documentation, approvals and quality and safety certificates. tion site, one must consider the lifting height of the modules, the surface of the access, cable lines and vegetation. Access roads must have sufficient turning and lifting radiuses. The design and construction of the foundation requires the provision and installation of module anchorage elements according to the project. A tolerance of +/-7 mm is allowed for the difference in the height of anchoring points. When the foundation is set up, all junctions will be installed for utility water, sewerage and electricity according to the project. When installing modules, it is necessary to check that all junctions are accessible and that the utility systems of each module are connected to the following one before the new module is installed. Modules must be lifted according to the lifting schemes and safety instructions. Lifting schemes are module-based. Before starting lifting operations, the persons carrying out these works must be instructed and equipped with type-specific lifting schemes. The speed and safety of the installation depends strictly on the location of the crane as well as on the planning of the vehicle access sequence, so it is recommended to make simulations with different scenarios before the final plan is carried out. When planning access to the construcPattern Buildings The site work plan must take into account the different weights of the different modules between 6 and 25 t. The module weight must be reflected in its name and on its packaging (for example, M6-3_4, 8T_S). The protective packaging of the modules is environmentally friendly and reusable. When removing the protective packaging, it is made sure that the module is in good condition; that the seals and insulation material on the side of the module are intact and properly installed. The packaging is sent back to the factory with the pallets. The accuracy of the installation of the modules shall be ensured by conical twist-lock connectors. No lifting work shall be carried out during the fixing works and other interconnection works between the floors. During the assembly of the modules, all lifting and connecting metal components shall be insulated with temperature, water and fire resistant materials according to the instructions. During the installation, control measurements shall be carried out after each floor installation and, if necessary, specific levelling plates for height adjustment shall be used. The installation of facade elements shall be carried out according to the unique design of each object. In order to save time on the site, the facade elements may be partially installed in the factory. In this case, the modules have indications about the facade element and extra caution is needed when lifting as not to damage the facade cover materials or openings. When installing roof elements, the rainwater drainage project must be followed and it must be ensured that the internal drainage pipes are installed in the right order according to the plan. The humidity control manual must be followed during the installation of the modules and the modules must be protected against precipitation during working breaks. All external structures of the modular system are added after installation of the modules and delivery of the installation works. Pattern Buildings Operation of the Building Energy efficiency One of the main principles of the Pattern Building is environment-friendly approach, which means, among other things, that the active energy consumption of the building is (very) low (at a minimum level of nearly zero-energy building) and that the building’s structures are long-lasting. This can be achieved by ensuring good insulation appropriate to the local climate and long-term air-insulating building envelope. The envelope of the building is made up of the skin and the skeleton. The vapour and air-insulating layer must be continuous along the whole building envelope. While the skin of the building is airtight, the skeleton Pattern Buildings of the Pattern Building seals the gap between modules. This solution makes the Pattern Building mass-adjustable because the air-tight layer is uninterrupted regardless of the shape or appearance of the building. The Pattern Building is adaptable to different climate zones. Depending on the climate zone, the thickness of the insulation layer required to ensure good thermal insulation varies. The thickness of the insulation layer of the building can be adjusted with the thickness of the skin. This means that the Pattern Building with the same body can theoretically be built in all regions in Europe, with changes only in facade elements. Fire safety Acoustics Life Cycle In accordance with the manual “Standard solutions for building up to eight-storey wooden buildings” by A. Just et al, the Pattern Building’s Portable Structure classifies as the post-beam system. Load bearing posts and beams made of laminated timber or LVL are protected from fire. Exposed LVL elements are designed with a cross-section that allows them to stay in the fire for a considerable period of time without requiring additional fire protection. The fire safety of the facade is ensured by a building-specific project. Automatic fire fighting system must be designed in five-storey and higher buildings. Automatic fire extinguishing system must be installed in the stairway that has reaction to fire of D-s2,d2, in case there are more than two floors in the building. To reduce the spread of noise from one functional unit of the Pattern Building (e.g. an apartment) to another, it is recommended not to design different units in the same module. In other words, each unit should consist only of separate room modules. The eco-friendliness of the house is ensured by modern methods of construction and factory-based production that make the Pattern Building energy efficient. The spread of airborne sound noise between functional units is prevented by double partitions and dropped ceilings. To prevent impact sound noise, the floor board is separated from the end frame by an elastic noise barrier profile, preventing the sound from being transferred to the module’s frame posts. As an additional measure, a noise-cancelling interlayer is installed on the ceiling of the module, preventing the transmission of sound from the floor of the upper module. The load bearing structures and main structures of the house are largely made of wood. As trees grow, the carbon contained in the atmosphere is captured and sequestered in the wooden building for a long period of time. If the construction of wood is to be sustainable, the life expectancy of the main structures of wood buildings in northern Europe should be expected to be at least 80 years, in other words at least as long as the wood used in the construction would be growing in nature. Buildings shall be at least 100 years. The essential conditions for achieving this are the insulation of wooden elements from the ground, proper melting snow water and rainwater treatment; flexibility in changing the spatial layout and straightforward approach to repairing or changing building components. Each Pattern Building should come with a manual which sets out the principles for the maintenance. Thus, the designed life span of Pattern Pattern Buildings