1.
Precision HSS Connection System
For
Modular Buildings
by
Entire contents protected by Copyright. US and International Patents Pending

2.
Greater use of modular construction could
help construction productivity catch up
with other industries, but every project
seems to start from scratch and many hit a
glass ceiling at 10 floors, as tolerance
accumulation and loads overwhelm
unsophisticated structural approaches.
Does the modular
industry need a
standardized
structural solution?

3.
Imagine standardized, pre-
qualified and pre-engineered
“building blocks” that come
from multiple suppliers and
assemble efficiently to create
complete, operational
buildings……
Imagine designing and bidding
a tower in a few days…..
A standardized
construction system
would make that
possible!

4.
A standardized, scalable, modular
connection system for HSS

5.
• Vectorbloc was inspired by
the ISO corner that is used to
lift and lock ocean freight
containers
• The infrastructure of the
ocean freight business is
standardized on the ISO
corner and multiples of its 8’
x 20’ dimensional grid
• The advantages of a single
system being used by all
shipbuilders, container
fabricators and freight
handlers are obvious

6.
Due to these advantages
containers are widely used as
temporary and even permanent
housing

7.
However the
vertical tension
capacity of the
ISO corners that
joins stacks of
containers limits
the height of
buildings, and
the fixed grid
limits space
planning options

8.
Typical structural
steel connections
don’t work for
modular
construction
either, as
connections
occur in
inaccessible
locations and
splices cross
matelines

9.
For modular
construction to be
successful, there are
actually 7 challenges
to be overcome, and
they all become
exaggerated as buildings
get taller and wider…….

10.
Challenge 1:
The accumulating tolerances of low-
precision modules can result in interior
finish defects, assembly clashes and
façade failure
The Fix:
Jig-built precision modules and a simple
system for monitoring and adjusting the
dimensions of the assembled structure

11.
Challenge 2:
A separate brace frame or brace core
adds erection time, adds cost,
complicates waterproofing during
construction and reduces the GFA
The Fix:
Interconnected, stackable load bearing
modules, which eliminate the need for the
fabrication and erection of a separate
brace structure and eliminates the gaps
around the frame

12.
Challenge 3:
Re-rigging for level hoisting of the
module variants within each floor is slow
and costly
The Fix:
A quick-connect rigging attachment and
halo that can be quickly and reliably
levelled and released

13.
Challenge 4:
Tasks which require work under a
suspended load are inherently unsafe
The Fix:
Integral walkways and stairs, modules that
are easily rigged with safety barriers, and
modules that connect from inside

14.
Challenge 5:
Projections beyond the mateline result in
gasket / facade damage during
placement
The Fix:
A field-extendable gasket that is closed
and mated from inside the module after
modules are placed

15.
Challenge 6:
Precipitation which falls during building
assembly penetrates voids, damages
module finishes and compromises
insulation
The Fix:
Eliminating the brace frame makes it easy
to waterproof the top level during building
assembly

16.
Challenge 7:
Modular systems are costly to develop
because they require high-end software
and expert knowledge
The Fix:
An off-the-shelf design and engineering
process

17.
The Vectorbloc strategy:
Reduce the cost of design,
coordination, fabrication
and building assembly by
concentrating the load-
bearing and connection
functions in a standard,
scalable, precision
component used by all
suppliers to a project

18.
To be a standard, the solution has to be
economical at all scales. In fact scalability is so
important to modular systems that we say:
”By solving tall, you solve it all”

19.
Vector Praxis delivers the industry-leading Vectorbloc
modular solution via 7 categories of products and services:
Vectorbloc
Connection
System
Factory
Setup
Vectorjig
Precision
Fabrication
System
Vectorloc
Extendable
Gasket
System
Vectorig
Hoisting
System
Vectorsight
Surveying and
Levelling
System
Modular
Building
Design

20.
1 Vectorbloc Standardized Precision Structural Connection
System
Vectorbloc
Connection
System
Factory
Setup
Vectorjig
Precision
Fabrication
System
Vectorloc
Extendable
Gasket
System
Vectorig
Hoisting
System
Vectorsight
Surveying and
Levelling
System
Modular
Building
Design

21.
The heart of the Vectorbloc system
is a connector assembly specifically
designed to build robust modules
with integral building structure
Vectorblocs have many advantages over both the
ISO corner and competing modular systems:
• Builds modules of any size, including wider,
longer, taller modules
• Provides the scalable vertical tension and
gravity capacity needed for real buildings
• Assembles safely from inside the module
• Provides accessory connection points for
connecting balconies, floors and façade
cassettes
• Does not rely on continuous walls for
structure

22.
Vectorbloc
Anatomy
• Tension bolts
• Lower Vectorbloc
• Façade assembly
• Accessory connection
points
• Hallway or balcony slab
• Gusset plate
• Tapered locating pins
• Upper Vectorbloc
• Hoisting point

23.
The Vectorbloc structural connectors are
located at the corners of the modules and at
intermediate points, if required by loading.
Modules are stacked
and held together
horizontally with
gusset plates, then
vertical bolts are
then inserted
through the
Vectorbloc
connectors to hold
the building together.

24.
Accurate, loadbearing,
volumetric modules
built with Vectorbloc
connectors can be
outfitted with
interiors and MEP
systems in plant, then
easily hoisted and
quickly assembled to
create cost-effective,
tight and energy-
efficient buildings,
ranging from low-rise
to high-rise.

25.
So that building tolerances can be maintained and columns effectively grouped, a precision
assembly fixture is used during chassis manufacturing to ensure that no intermediate part
of a module frame crosses the mateline and prevents the Vectorbloc corners from touching.

26.
Buildings have many unique
conditions, so the Vectorbloc
system is comprehensive

27.
Vectorbloc modules can be created with the
tapering shapes required to assemble
buildings with curves

28.
Like the ISO fittings used to build
containers, Vectorblocs are cast and
machined from a weldable steel alloy.
Vectorblocs provides integral points
for structural connection, hoisting
and connection of balconies and
hallways all in an easy-to-weld
precision connection
Module frames supplied by
Vector Praxis are welded in
our CWB-certified facility

29.
Vectorblocs come in 4”, 6” and 10”
series, so that in compression,
tension and bending modes,
Vectorblocs are not the limiting
factor in the strength of the
structure.

30.
When HSS are
welded to the
Vectorblocs a
moment
connection is
created, which
resists lateral
forces in all
directions

31.
The tapered pin on the Vectorbloc
gusset plate accurately locates the
modules during assembly and the
gusset plate connects the modules
horizontally.
When the vertical tension bolts
between modules are tightened, a
horizontal connection between the
floors of the modules is created.
The result is a structural “diaphragm”
which extends the bracing within stair
towers and elevator shafts to the
entire structure.

32.
The vertical tension
bolts are hidden
behind removable
feature panels in the
hallways, or behind
the baseboard at the
outer wall
After the gusset
plates and stanchions
are installed on top
of the modules, the
Vectorsight system
provides a stable
surveying platform
and a fall arrest
system

33.
MEP modules with compatible
facades built in identical jigs
simply “plug in” to a
Vectorbloc building,
eliminating countless hours of
trade and supplier
coordination

34.
Pre-fabricated elevator shafts
and stairwells are likewise easily
and quickly erected at the same
time as the building itself, with the
additional benefit of improving
access for workers and materials

35.
Premium over-
height studio
apartments,
lobbies and
gathering spaces
can be created by
stacking floorless /
roofless modules

36.
Vectorbloc’s accurate,
pre-configured
accessory connection
points are ideal for
the integration of
high-performance
building features such
as “facade cassettes”
and thermally-
broken balconies

37.
…..and Vectorblocs can be used
to build Data Center modules
Vectorblocs are also ideal for the
production of Precision Modular
Armatures (PMA’s) for resource
industry applications………

38.
By reducing sitework and re-work to its
theoretical minimum, Vectorbloc makes it
feasible to deliver the all-trade, 95%
factory completion that realizes the full
cost-saving potential of modular
construction.
Appropriate building types include:
• Apartments
• Hotels and dormitories
• Hospitals and clinics
• Offices
• Industrial facilities
• Urban infill
• Relocatable / emergency facilities

39.
Stacked and Bundled
Vectorbloc Systems
Explained!
Entire contents copyright February 2015
Vectorbloc and related systems US, Canada and WIPO Patent pending

40.
Because loads in a
building vary,
Vectorblocs are
designed to support a
wide range of column
configurations
This means that the minimum of
steel and labour can be used to
build a member which suits specific
load conditions
Each bolt in the standard connector
series has a clamping strength of
60kips, so a group of 8 delivers over
400 kips, adequate for buildings
well over 30 stories

41.
Vector Praxis production office
Vectorbloc offers two ways to build modules, which we call “Stacked” and
“Bundled”. The stacked system scales with load using modules with progressively
larger HSS, while the bundled system adds horizontal tiers of HSS in ever wider
assemblies. These wide assemblies also function as shear walls.
Top: Stacked
Bottom: Bundled

42.
The two systems are interchangeable, so
designers can select the connection and member
configuration that best suits each project, or
even each part of a project.

43.
“Stacked”
Typical details

44.
Typical
transition block
4”x 4” to 6”x 6”

45.
The “structural bundling” of columns is similar to the story of the boy
who was challenged to break a bundle of sticks……
……and found it impossible because a group of members acting together
are stronger than the sum of the parts……..

46.
Robust groupings can be created using one size of HSS welded
corner to corner and joined in groups with flat-bar ears.

47.
“Bundled”
Typical details

48.
“Bundled”
Typical details

49.
Section
transitions
A Vectorbloc
building designer
using FEA software
selects the column
configuration that
best suits the
loading on each
module.

50.
By joining bundled columns in adjacent modules, configurations ranging
from a 24 lbs / foot grouping of 4” x 4” HSS , to massive built-up
columns weighing over 400 lbs per foot, can all fit in a 10-1/2” wall

51.
Vectorbloc Prototypes
3D Printing
Casting and Machining
February 2015
Vectorbloc and related systems US, Canada and WIPO Patent pending

52.
3D-printed
investments and
application of
ceramic coating

53.
Investment
casting and
machining

54.
Checks of
material
quality,
alignment
and
dimensions

55.
Complete
prototype
of typical
connection
with
cutaways

56.
Prototype of typical
module with detail of
fireproofing and
baseboard leave-out
at Vectorbloc
connection

57.
Vectorbloc
Concept Building
February 2015
Vectorbloc and related systems US, Canada and WIPO Patent pending

58.
By examining a
Vectorbloc-based
concept building
we can better
understand the
practical
application of the
Vectorbloc
structural system

59.
Vectorbloc
concept
building:
Renders

60.
Plan of typical floor
Apartment buildings and condominiums are highly optimized and every square foot is
utilized. Vectorbloc’s bundled column reduces lost GFA by packing load-bearing structures
in to the wall cavities, eliminating inconvenient “bumpouts”

61.
Brace locations
Lateral brace frames (blue) are concentrated in the party walls, while the longitudinal
system (pink) is loaded in to areas where the diagonal bracing does not obstruct openings

62.
Module size matrix
Minimizing module size variants is not essential, but it is desirable

63.
Vectorbloc
sectional frame
elevations
showing
conventionally-
constructed
parking
structure,
podium and
transfer beams

64.
Vectorbloc
Frame

65.
Typical two-
module grouping

66.
Typical two module grouping
with finishes and furnishings

67.
Typical single
module frame
construction

68.
The brace frame is
created when
modules are
interconnected to
unite the integral
diagonal bracing in
the modules.
Bracing can be
integrated in
locations such as
the party walls,
elevator shafts and
stairwells.

69.
Lateral
Frame

70.
Frame
Details
Deep spandrel
beams can be
integrated in
to the framing
if required to
eliminate
diagonal
bracing which
obstructs
openings

71.
Longitudinal
Frame
The longitudinal
brace frame is
created on the upper
floors by
interconnecting
modules to combine
the moment action of
the module frames.
On lower floors,
bracing is added to
the shaft, stairwell
and hallway
modules.

72.
Vectorbloc modules incorporate the ideal vertical load bearing capacity at each level in the
building, they provide a moment connection and they are interconnected connected
horizontally.
As a result, a separate brace frame or brace tower can be eliminated, saving
valuable space and reducing construction complexity.

73.
Eliminating the separate
brace frame confers
numerous benefits:
• The additional work of fabricating and
erecting the brace frame is eliminated,
and the number of required crane cycles
and super-elevation differentials are
both reduced
• Party wall voids are eliminated, so
wasted GFA is reduced and
waterproofing during erection is
simplified
• Movement of workers across the top
surface of the structure is safer and
clashes with the Halo are eliminated

74.
The accessory connection points on a
Vectorbloc module are precisely located in
3D space, making it easy and cost-effective to
deliver desirable and progressive building
features:
• Panelized facades with thermally-broken
hanging, cantilevered or suspended
balconies
• Hallways with factory-integrated MEP
trains
• Over-height studio spaces, lofts, roof
decks and parapets
• Pre-fabricated elevators, stairs and waste
disposal chutes
• Factory-integrated MEP systems

75.
Using the hall
slabs as MEP
carriers, the
Vectorbloc system
supports factory-
integrated wiring,
piping and ducts in
trains up to 50’ in
length.
During building
assembly, the
hallways also
double as access
platforms.

76.
Vectorbloc
Connection
System
Factory
Setup
Vectorjig
Precision
Fabrication
System
Vectorloc
Extendable
Gasket
System
Vectorig
Hoisting
System
Vectorsight
Surveying and
Levelling
System
Modular
Building
Design
2 Vectorjig Precision Fabrication System

77.
Model VJS (Vectorjig Standard Model VJA) utilizes screw clamps. Model VJA (Vectorjig Auto) features hydraulic locking and release to further reduce cycle time
Replace with images from SW tooling model
It’s expensive to make something accurate!
Accurate = cheap!
Traditional modular frame construction relies on cutting, fitting and
welding of steel members to establish the finished dimensions of the
modules. However even the highest AISC specifications have proven
unworkable. As a result, it is considered standard practice to adjust
abutting work on site so it fits.
Site work is expensive, in fact modular construction exists to reduce site
work!

78.
To build a Vectorbloc
module frame, HSS
columns, floor beams and
ceiling joists are joined to
Vectorblocs by welding in
precision fixtures.
All spatial relationships in a
Vectorbloc-based structure
are established by the
relative position of the
Vectorblocs, which is
established in the factory
by the logical grid of the
fabrication fixtures

79.
Since connections of a
Vectorbloc-based building
takes place through the
Vectorblocs, precision
drilling and cutting of the
HSS members is not required

80.
Using the same techniques as the automotive and aerospace industries,
Vectorjig allows modular fabricators to build precision structural modules
using inexpensive materials processed with just three pieces of
equipment.
BandsawVectorjig Welding machine

81.
The root of Vectorjig
precision:
Rock-solid building geometry
created in a precision fixture
aligned by Vector Praxis
technicians using LASER
Metrology, the same technique
used to calibrate precision
tooling.

82.
The Vectorjig system ensures a Go / No
Go tolerance regimen which locates
the Vectorblocs and structural
members to a + 0” – 1/16” accuracy
This assembly methodology ensures
that no intermediate part exceeds
the mateline, resulting in tight
structural connections.
The Vectorjig also elevates the
members ideally for manual or
robotic welding.

83.
Each cycle begins with the jig in closed position to
receive the Vectorblocs and adjoining members
Once the unit is welded, the jig opens to release the
completed frame.

84.
The application of floor material, wall board and the façade can be completed
before opening the Vectorjig and removing the modules, or the bare “chassis”
can be removed for offline completion in a “Vectorjig Lite”

85.
Precision fixtures are a pre-requisite
for robotic welding!

86.
Testing on the
Vectorjig
assembly system
has been
completed using
“Moc Blocs”;
Connectors built
from plate
instead of
castings

87.
Vectorjig is available in
two versions:
VJM: manual clamping
VJA: Automatic
clamping
The pin rotating mechanism of
the automatic version
(prototype shown at left in the
Vector Praxis toolroom) is
actuated by a heavy-duty rack
powered by a hydraulic
cylinder which is entirely
enclosed to protect it from
weld spatter

88.
Vectorbloc
Connection
System
Factory
Setup
Vectorjig
Precision
Fabrication
System
Vectorloc
Extendable
Gasket
System
Vectorig
Hoisting
System
Vectorsight
Surveying and
Levelling
System
Modular
Building
Design
3 Vectorig Rigging, Leveling and Hoisting System

89.
A single story in a modular
building can have numerous
module variants, making
constant re-rigging for level
hoisting a key schedule driver

90.
Vectorblocs feature prepared
connection points for the
Vectorig quick-connect rigging
and CG compensating system.
Time-consuming and labour-
intensive “iterative rigging” is
required to level modules when the
CG of the load is unknown or
cannot be predicted

91.
The Vectorig connector features a positive lock
which prevents accidental release of the load.

92.
Modules are shipped with
rigging notes generated by CG
simulation, based on the
behavior of the combined
parasolid models of the module
and the Vectorig halo.
The rigging notes tell the rigger
exactly how to set up the
rigging blocks on the halo
frame.
The sliding rigging points are
quickly adjusted at ground level,
then the module is connected
and hoisted level.
Spreaders Beam A End 1 Beam A End 2 Beam B End A Beam B End 2
Position 17 Position 4 Position 4 Position 6 Position 6

93.
Precision locating pins mounted on LASER-
cut gusset plates engage with holes
machined in the Vectorblocs, ensuring
accurate module location.
Using parasolid modeling
and predictive CG
determination together
with the Vectorig fitting
and halo, rigging and
release time is reduced
by 75% and crew size is
also reduced

94.
Vectorbloc
Connection
System
Factory
Setup
Vectorjig
Precision
Fabrication
System
Vectorloc
Extendable
Gasket
System
Vectorig
Hoisting
System
Vectorsight
Surveying and
Levelling
System
Modular
Building
Design
4 Vectorsight Surveying, Levelling and Safety System

95.
Because modules often “stack” or “rack” in numbers of 20 or
more, in both horizontal and vertical dimensions, even tight
tolerances accumulate quickly.
Example: A 20-unit stack built of units 1/16” too high next to a
stack of units 1/16” too short creates a 2-1/2” difference!
So it is easy to see how standard +- tolerances are simply
unworkable for a large modular building

96.
During building assembly,
elevation and distance
measurements are taken
relative to receivers placed
on Vectorsight posts rigged
to the tops of the gusset
plates
Vectorsight posts are
precisely machined to
length ensuring consistent
receiver height and
accurate measurement
Vectorsight posts also
function as safety barriers
and are rigged at the same
time that gusset plates are
installed

97.
A modular project based on the Vectorbloc system is conceived with
all components conforming to a + 0”, - 1/16” tolerance envelope. This
ensures that no part exceeds the tolerance envelope and causes
positive tolerance accumulation.
Excessive negative variations (undersized stacks or racks) are
minimized using sophisticated manufacturing techniques. During
building assembly, module groupings are monitored and variations
are compensated with a systematic and efficient shimming system.
Measure ShimAnalyze
Vectorsight combination
survey post and guardrail

98.
Vectorbloc
Connection
System
Factory
Setup
Vectorjig
Precision
Fabrication
System
Vectorloc
Extendable
Gasket
System
Vectorig
Hoisting
System
Vectorsight
Surveying and
Levelling
System
Modular
Building
Design
5 Vectorloc Extendable Façade Gasket System

99.
Gasket and
façade panel
damage during
module
placement and
poor sealing
after placement
are significant
issues in
modular
construction.

100.
The Vectorloc façade system leverages
the precision of the Vectorbloc
modules to accurately locate factory-
installed windows, sealing and
insulating features.

101.
The Vectorloc factory-installed
façade system features a
mechanically extendable gasket
that is closed and mated from
inside the module after
modules are placed and bolted
in position.

102.
Cruciform closure takes place at the
same time that outer-wall gusset
plates are installed.
The next layer of modules completes
the flashing grouping.

103.
The Vectorbloc system does its part
by ensuring precise location between
modules, resulting in factory-
installed façade panels that fit
accurately on site and develop their
full specification.

104.
Gasket sealing is positive and
multi-chambered, improving
envelope performance
An additional benefit is a
field-releasable and
repairable façade, reducing
both the risk and the cost of
troubleshooting,
maintenance and renewal

105.
Vectorbloc
Connection
System
Factory
Setup
Vectorjig
Precision
Fabrication
System
Vectorloc
Extendable
Gasket
System
Vectorig
Hoisting
System
Vectorsight
Surveying and
Levelling
System
Modular
Building
Design
7 Factory Design and Management

106.
Fast = Cheap
To build a modular
building, you need
to make a lot of
perfect
modules….and you
need to make them
quickly.
Our experience in
factory design and
management is
your best
guarantee of a
successful
entry in to this
dynamic and
growing market.

107.
Vectorbloc
Connection
System
Factory
Setup
Vectorjig
Precision
Fabrication
System
Vectorloc
Extendable
Gasket
System
Vectorig
Hoisting
System
Vectorsight
Surveying and
Levelling
System
Modular
Building
Design
About Vectorbloc and Vector Praxis

108.
The Vectorbloc System is covered by
Patents Pending in over 100 countries

109.
The Vectorbloc System was inspired by
the experience of the Vector Praxis team:
• 30+ years of precision offsite architectural fabrication
• 15+ years of 3D / model-driven architectural fabrication
• 40+ tours of off-site fabrication plants
• Setting up, staffing and running a successful plant
creating AAA modules for a Norman Foster-designed
tower
• Detailed study of numerous modular and structural
projects in the USA, Canada, Asia
• Development of modular buildings and systems in
collaboration with prominent architectural firms and
panelized builders
• Detailed study of residential tower envelope renewal
strategies

110.
R&D
To support ongoing improvement
of the Vectorbloc system and
development of additional
features in response to market
demands, Vector Praxis maintains
a 10,000 square foot research
and development facility in
Toronto, Canada. Our fully-
equipped design and production
facility includes a machine shop,
metal fabricating and wood
working equipment.
The Greater Toronto Area (GTA)
supports a globally significant
cluster of leading custom
architectural fabricators,
providing our product
development team with quick,
world-class access to a wide
range of materials and CNC
processing services.
For more information please contact:
Vector Praxis
www.vectorpraxis.com
Phone: 416 766 9018 Mobile: 416 575 1630
530 Keele Street, unit 403,
Toronto, Ontario, Canada
M6N 3C9

111.
Vectorbloc
The sky’s the limit
http://meshcities.com/index.php/meshcities/com
ments/can_vectorblocs_patented_building_system
_make_cities_more_energy_efficient#.VCXAb_ldU
9J
http://atlanticyardsreport.blogspot.ca/2014/09/in-
dispute-over-stalled-modular-tower.html
Links to chatter about Vectorbloc and
related subjects:
http://therealdeal.com/blog/2013/03/13/prefabr
icated-broadway-stack-project-makes-headway/