Chassis Based Modular
Robert J. Simmons
CEO, CTO, Chairman of the Board, Co-Founder, ConXtech, Inc.
Chassis Based Modular
Leveraging Manufacturing Technologies in Construction
AIACC Now Next Future Conference 2012
Copyright©2012 ConXtech, Inc. All rights reserved.
Construction: Decades of Decline in Productivity
“The productivity of the construction industry, as measured by constant contract
dollars of new construction work per hourly work hour, has gradually declined…
over the past 40 years.”
Source: Paul Teicholz, Ph.D. Professor (Research) Emeritus, Dept. of Civil & Environmental Engineering, Stanford
Copyright©2012 ConXtech, Inc. All rights reserved.
Barriers to Systemic Innovation: The “Swarm”
The “Swarm”: A technically and socially complex assembly of diverse, non-aligned
enterprises that self organize around each individual project and never repeat
Stratification and Fragmentation




No single enterprise
No Master Builder
No alignment of interests
Micro specialization
Commoditization of Specialties
 Discourages cross discipline
innovation
 Micro vs. macro optimization
No BETA Forum





Automotive – Racetrack
Aerospace – Military
Marine – Sea Trials
Software – BETA Release
Construction - ?
Data rich anatomically correct Digital Chassis helps organize the “Swarm”
Copyright©2012 ConXtech, Inc. All rights reserved.
Organize the “Swarm” around a Digital Chassis
What can a data rich Digital Chassis do for various stakeholders?
Copyright©2012 ConXtech, Inc. All rights reserved.
5
Henry Ford’s Chassis Based Model T Revolution



Craft based horseless carriage
to automotive industry
9,410
10,000
$20,091
Affordable, high quality autos
for the masses
8,000
1909 –1927 15M automobiles
all based on the same
“Chassis”
$20,000
4,720
6,000

3,080
19 yrs. & 9+ different models
Predictable Chassis enabled
development of 80+ other
modular sub-systems.
1913 “Moving Assembly Line”
reduces Chassis build time
from 14 hrs./car to 1.5 hrs.
$9,237
2,000
$10,000
$3,191
$5,000
110
0
$0
1909

$15,000
$11,819
4,000

$25,000
1913
1915
1920
Number of Cars Produced
Sales Price in Today's Dollars
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6
Why Chassis Based Modular?
“If automobiles were built today using the same principals
and systems the construction industry uses
every car would cost no less than a million dollars”
- Magnus Aspegren, BMW Group, DesignWorks USA
 Nearly every structure built
today can be compared to
building a custom car – from
scratch – in a parking lot
 Must move beyond treating
every structure as a one-off
prototype?
 Need to modularize connectivity
of multiple system & assemblies
that make up a building
 That needs to start with a
predictable modular chassis
Copyright©2012 ConXtech, Inc. All rights reserved.
Organization of the Swarm around a Digital Chassis
Rapid and early creation of data-rich Digital Chassis
Provides a 3D forum for all
stakeholders to organize and
apply their individual discipline
specific expertise and harnesses
the value of mass collaboration.
Copyright©2012 ConXtech, Inc. All rights reserved.
From Wireframe to Parametric Digital Chassis
MODULAR AT
A POINT
Copyright©2012 ConXtech, Inc. All rights reserved.
Chassis System Made up of Modular Assemblies
A Finite number of precise,
factory manufactured
connectors can produce wide
range of mass customizable
assemblies
Building assemblies can be
configured to produce a
modular chassis that
supports other systems in a
predicable way
Copyright©2012 ConXtech, Inc. All rights reserved.
Lower & Locking Connector Technology
ConXR™ for Short-Span Applications
(Spans 12’ to 20’+)
ConXL™ for Long-Span Applications
(Spans 18’ to 65’+)
ConXR
ConXL
ConX Special Moment Frame “Collars”:
Engage the required floor/roof framing element w/ the required vertical support members, creating a lateral system
without additional steel weight. Fully Rigid Nodal connectors free the structure from brace bays or shear walls - creating
ultimate architectural freedom and program flexibility.
Copyright©2012 ConXtech, Inc. All rights reserved.
Two Connections - Multiple Applications
Industrial / Energy
Pipe Rack (2-3 level, ConXR)
Portable Tower (SqFt: 10K, ConXL)
Military / Government
Navy Lodge (SqFt: 152K, ConXR)
Moffett Field (SqFt: 178K, ConXL)
High-Density Residential
The Arpeggio (SqFt: 188K, ConXR)
The Crossing (SqFt: 525K, ConXR)
Educational
Stanford Law School (SqFt: 87K, ConXL)
Data Center
CoreSite DC (SqFt: 101K, ConXL)
Healthcare
Kaiser Permanente (SqFt: 65K, ConXL)
12
Predictable Chassis Enables Further Modularization
Plug & Play Systems & Assemblies
Pre-Cut Decking
Exterior Cladding
Pre-assembled stairs
Modular pre-assembled balconies
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Pods
Inter System Connectivity
Predictable system interfaces create opportunity for added value
Modular Formwork
Predictable Schedule
Pre-assembled Bolt Cassettes
Predictable Quality
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Repeatable Work / Knowledge Carry Forward
 Error proof the process
 Go/no-go fixturing produces
accurate assemblies
 No custom layout or fit-up
eliminates “super specialists”
 All welding conducted in
optimal position ensuring
highest quality
 Quality derived from process
vs. craftsmanship
 Enables “in-process”
inspection
 Eliminates rework (zeropunch list)
Copyright©2012 ConXtech, Inc. All rights reserved.
Leverage Existing Manufacturing Technologies
Automation: CAD/CAM, CNC Machining, Robotics
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Digital Chassis / Intuitive Assembly
 Specifies location and orientation (which
end goes where).
 Simplifies operations in the field
 Accelerates field assembly
 De-couples critical paths
 Eliminates opportunities for error
 Physical chassis precisely matches
digital chassis
 Predictable delivery
 Visual quality control
 Eliminates re-work (zero punch-list)
Copyright©2012 ConXtech, Inc. All rights reserved.
Structural System: Full Scale Erector Set
Mass customizable and configurable assemblies
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Precision Components from Multiple Sources
Standard fixturing enables column & beam assemblies to be manufactured
at separate facilities and meet precise system fit-up tolerances
Copyright©2012 ConXtech, Inc. All rights reserved.
Modular Chassis: A Framework for Building Intelligently
 Building knowledge has expanded exponentially and is
decentralized
 Knowledge held across many minds & many enterprises
 Need to apply specialized knowledge in organized fashion
 Combine Ideas that are currently thought to be unrelated
 Create collective Intelligence through mass-collaboration
 Empower stakeholders with accurate real-time knowledge
 Develop & maintain intersystem connectivity starting at
concept design
 Enable knowledge carry forward and reuse as much earlier
work as possible
 Leverage technology
Copyright©2012 ConXtech, Inc. All rights reserved.
Today, Tomorrow & the Future
Copyright©2012 ConXtech, Inc. All rights reserved.