Structural Response of Modular Buildings – An Overview

Andrew W Lacey a, Wensu Chen a, Hong Hao a*, and Kaiming Bi a

a
Centre for Infrastructure Monitoring and Protection, School of Civil and Mechanical
Engineering, Curtin University, Kent Street, Bentley, WA 6102, Australia

* [email protected]

Prefabrication by off-site manufacturing leads to a reduced overall construction

schedule, improved quality, and reduced resource wastage. Modular building is
therefore increasingly popular and promoted. With the recent promotion a
number of relevant studies have been completed, however, a review of the
design, construction, and performance of modular buildings under different
loading conditions is lacking. This paper presents a state-of-the-art review of
modular building structures. First, structural forms and construction materials are
presented as a brief introduction to the modular structures. Modular building is
shown to refer not to a single structure type, but a variety of structural systems
and materials. These modular structures might perform differently to similar
traditional structures and the structural performance is highly dependent on inter-
and intra-module connections. The structural response of modules to different
hazards is then considered, followed by the current design practice and
methodology. As a currently developing area there is great potential for
innovation in modular structures and several key research areas are identified for
further work.

Keywords: modular building, prefabrication, off-site fabrication, multi-hazard

1. Introduction

Modular building is a construction technique whereby building modules are prefabricated off-
site. It is a type of off-site fabrication referring specifically to volumetric units which may be a
structural element of a building [1-4]. Modular building refers to the application of a variety of
structural systems and building materials, rather than a single type of structure. Prefabrication
by off-site manufacturing leads to a reduced overall construction schedule, improved quality,
and reduced resource wastage [5-7]. The disadvantages include the limitations of existing

1
design guidance and module size limits due to transport requirements. The advantages of
modular building outweigh the disadvantages particularly for hotel and residential development
applications. Modular building is therefore increasingly popular and promoted. With the recent
promotion a number of relevant studies have been conducted. This paper presents a state-of-the-
art review of modular building structures. First, recently developed structural forms and
construction materials are presented as a brief introduction to the modular structures. The focus
is on steel framed modules with concrete and timber frame modules excluded, not for lack of
importance, but for lack of recent research into the structures. Structural connections are the key
to overall performance and so a detailed review of connection types is presented. Then, the
structural response of modules to different hazards is considered, followed by the potential
applications and future research work.

2. Module classification and developments in structural form

Modules are classified as steel, precast concrete and timber frame modules according to the
primary construction material. Steel modules are further classified as Modular Steel Building
(MSB) modules [8], light steel framed modules and container modules. Their applications,
advantages and disadvantages are given in Table 1. Load bearing steel modules are also
categorised as column supported or continuously supported [9] as shown in Figure 1. Column
supported modules have edge beams which span between corner or intermediate columns.
Continuously supported modules have load bearing walls which provide continuous support [9,
10]. Three examples of steel modules are shown in Figure 2. The examples of precast concrete
and timber framed modules are also shown in Figure 3.
Recent study of modular building was focussed on light steel framing applied to
modular buildings [9-13], followed by consideration of overall building design using modules
[14], and then high-rise building applications [5, 15]. A broad overview of modular construction
using light steel framing was given with the application of relevant British and European
standards. Several types of modular construction have been presented. Many modular buildings
are not exclusively modular but are hybrid structures. Modular construction is combined with a
primary steel or concrete structure, for example, using a podium or skeletal structure, or a
concrete core around which modules are arranged [5, 12, 15]. Column supported MSBs are well
suited to medium and high-rise building applications and popularly used in current practice.
They have been developed through the research of Annan [8], Fathieh [16] and Gunawardena
[17]. Annan [8] presented a summary of traditional steel building systems and appropriate
analysis procedures, documented detailing requirements, reviewed floor connections and
explored seismic behaviour [18-21]. Fathieh [16] contributed to the review of MSBs subject to
earthquake loading [22]. Gunawardena et al. [23] subsequently extended the application of

2
MSBs. Noting that many modular buildings are not exclusively modular, a new system was
presented with strategically placed stiff modules replacing the conventional core structure [23].
Gunawardena et al. [24] refined the module design and demonstrated that modular buildings can
be self-stable for a ten-storey building subject to earthquake ground motion. The dynamic
behaviour of high-rise MSBs remains to be investigated [22].

Table 1. Module classification

Category Applications Advantages Disadvantages Ref.
Steel – Hotel, residential Suited to high rise Corrosion, lack of design [18-
MSB apartments buildings, high strength guidance 24]
module
Steel – Max. 10-storey, 25- Lightweight Suited to low rise [4, 5,
Light steel storey with additional buildings 9-15,
framed core 25]
module
Steel – Post-disaster housing, Recycle shipping Additional reinforcing [26-
Container military operations, and containers, easy transport required to strengthen 29]
module residential container when openings
developments are cut in wall
Precast Hotel, prison, secure Fire resistance, acoustic Heavy, potential cracking [4]
concrete accommodation insulation, thermal at corners
module performance, high mass
helps meet vibration
criteria, high capacity
Timber 1- to 2-storey, Sustainable material, easy Poor fire resistance, [4,
frame education buildings, to fabricate durability 30]
module housing

Figure 1: (L) Column supported modules and (R) Continuously supported modules (after
Gorgolewski et al. [9])

Figure 2: (L) Modular steel building [31], (M) Light steel framed module [12], (R) Shipping
container [26]

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Figure 3: (L) Precast concrete modules [17]; (R) Timber frame modules [4]

3. Component materials

Prefabricated components should be as light as possible as they are transported sometimes long
distances. Traditional materials of steel, concrete and timber are commonly used. The potential
applications of composite sandwich structures have not been well explored [32]. Manalo et al.
[33] gives an overview of fibre reinforced polymer (FRP) sandwich systems in the context of
lightweight civil infrastructure. Many of the developing materials presented by Manalo et al.
[33] may find application in modular buildings. To date such composite systems have been
developed for application as roof, wall or floor components. Some examples of composite
materials are given in Table 2. Use of FRP composite materials for complete modular building
façades is appealing although their performance, especially with respect to wind-borne debris
impact and fire, is a developing area. In addition, the design and manufacture of reliable jointing
systems is noted as a challenge which has received growing research attention [33].

Table 2. Composite materials with application in modular buildings

Use Composite material Advantages Ref.
Wall Rigid polyurethane foam stud Environment, lightweight, low cost [32]
frame with magnesium oxide
cladding
Floor Glass FRP web-flange sandwich, Lightweight, strength, high serviceability [34,
adhesively bonded stiffness, corrosion resistance, low thermal 35]
conductivity
Floor FRP-steel composite beam system Lightweight, high strength, corrosion resistance, [36,
low thermal conductivity 37]
Floor Glass fibre reinforced cement, Lightweight, acceptable strength, 5% damping [38,
polyurethane, steel laminate 39]
Floor Steel-timber composite Lightweight, sustainable [40-
42]
Floor Cold-formed steel – timber sheet Lightweight, efficient material use, simple [43,
Roof composite beam, or truss fabrication, low cost, renewable and reusable 44]
materials

4. Connection systems

Interconnection of frame members and modules is critical to the capability of modular buildings
to withstand applied loads [45]. Despite the need for a thorough understanding, studies on the
connections are limited [45]. Connections are grouped into three types: inter-module, intra-

4
module, and module to foundation as shown in Figure 4. Table 3 provides a summary of
connections for steel modules with further details given in the following sections.

Figure 4. Illustration of connection types

Table 3. Summary of connection types

Type Sub-Type Advantage Disadvantage
Inter-module Bolted Reduced site work; Access, slotted holes, slip, bolt
demountable tensioning
Welded No slip, compact, Site work, corrosion, not
accommodate misalignment demountable
Composite (concrete- Strength, no slip, compact Site work, not demountable
steel)
Intra-module Bolted Tolerance for shop Relatively low moment capacity,
assembly, deconstructable ductility and rotation capacity
Welded Suited to factory based Does not permit rotation, steel
construction using jig to members should be designed for
ensure module uniformity hogging moments and axial
forces
Module to Chain/cable/keeper Low cost Limited to low rise construction;
foundation plate tensioning requirements
Site weld to base Rigid connection Additional trade on site, hot
plate work, damage to steel corrosion
protection system
Base plate – cast in Ductility Positioning of cast in anchor
anchor bolts bolts, tolerance in steel base
plate, corrosion
Base plate embedded Full column strength and Positioning of column during
in concrete good ductility concrete curing, site welding

4.1. Inter-module connection

Inter-module connection includes horizontal connections (HC) between adjacent modules in

two plan directions, and vertical connection (VC) between stacked modules. It is reported that

5
bolted connection is preferred over site welding. A gap is usually provided between the floor
and ceiling beams, as shown in Figure 1(L), allowing for external access to inter-module
connections and for services to pass between the beams. This suits connection between the
columns, rather than between the beams. Bolted connections can be complex to accommodate
connection of modules stacked in three directions while ensuring access to fasteners is provided
during the install sequence. Use of long slotted holes may introduce the potential for tolerance
accumulation over multiple levels, and vulnerability to slip failure in the event of large
horizontal force [17]. The potential for connection slip may be controlled with the use of
friction-grip or pre-tensioned bolts. VCs may incorporate a shear key or spigot [46], which
assists in positioning modules and may provide structural connection where physical access is
not possible or practical. In some cases, concrete or grout is used to lock the joint in place,
creating a composite concrete-steel connection. Table 4 presents a summary of inter-module
connections for steel modules from the literature, and identifies the numerical and experimental
investigation completed. In the latest studies, force-displacement (F-d) and moment-rotation (M-
θ) behaviours of the connection are established by detailed numerical analysis of the connection
(see also Section 7).

Table 4. Inter-module connection types

Type Illustration Ref. Description Numerical / Experimental
Study
HC [9, Tie plate, connecting -
22] hollow or open steel
section columns
HC [18- In-situ concrete encased -
21] bolted cleat, connecting
open steel section beams
HC [47] Bolted side plate, Numerical – Load-
connecting hollow steel displacement (F-d) and
sections (HSS) moment-rotation (M-θ)
VC [18- Site weld end plate (one -
21] side), connecting HSS

VC [4] Bolted end plate, -

connecting HSS with
access hole, or open angle
section columns
VC [46] Lifting plate shear key, -
connecting HSS

VC [48] Bolted connection, Numerical – F-d in 1-direction

connecting open steel (compression) and M-θ in 2-
section beams directions
VC [47] Bolted end plate (bolts on Numerical – F-d and M-θ
two sides), connecting
HSS
VC/HC [17] Complex bolted end plate, Numerical and experimental –
connecting HSS F-d in 1-direction (shear)

6
 VC/HC [49, Bolted connection plate, Numerical – M-θ in 1-
50] connecting HSS direction, cyclic loading

VC/HC [51] Steel bracket welded to Numerical and experimental –

corner columns Shear and simply supported
VC/HC [52] Steel bracket, bolted or Numerical and experimental –
welded to floor and M-θ in 1-direction, cyclic
ceiling beams loading

VC/HC [53] Pre-tensioned connection Numerical and experimental –

of columns Simply supported, static and
(Composite steel- cyclic loading
concrete)

VC/HC [54] Bolted interior steel Numerical and experimental –

connection Lateral loading of beam-
column assembly, static and
cyclic loading

4.2. Intra-module connection

Intra-module connections, i.e. connections within a module, are generally representative of

traditional connection details. For MSBs both welded and bolted connections are used.
Considering column to beam connections, the bolted connection types include single web (or
fin) plates [4, 55, 56], double angle cleats [47], and bolted end plates [56]. It is suggested that a
moment resisting connection consisting of an end plate or a deep fin plate may provide lateral
stiffness for low rise buildings [4]. This is unusual in that fin plate connections are often
classified as simple shear connections. Fin plate connections have relatively low moment
capacity, ductility and rotation capacity [57], hence their use is suggested only for low rise (3-
storey or less) buildings [4]. However, the use of such connections may make open modules
susceptible to progressive collapse [57]. In this case the fin plate connection may have
inadequate moment capacity, and so require strengthening. In contrast, Annan et al. [19]
investigated steel floor framing with secondary beams welded directly to the main beams. This
is compared with conventional steel construction which may use clip angles permitting greater
rotation. The welded connections do not necessarily permit rotation such that steel members
should be designed for hogging moments and axial forces which may be developed as a result
[19]. Linear elastic analysis is demonstrated to be adequate for this issue and Annan et al. [19]

7
present a process which may be adopted in design.

4.3. Module to foundation connection

Foundations may consist of in situ or precast concrete footings, bored concrete piles, augered
steel piles, or some combinations. Low rise modular buildings located in areas with high lateral
loading may be vulnerable to overturning and sliding failures if not adequately restrained by
connection to an appropriate foundation. Building modules are commonly connected by chains,
cables, keeper plates or welding to concrete or steel piles, or large mass concrete footings. Each
connection type has associated disadvantages including tensioning requirements for chain and
cable. In medium and high-rise construction foundations are more substantial. Base plates may
be incorporated in modules and fixed to cast-in anchors, or welded on site to accessible cast-in
plates. Park et al. [45] developed an embedded column connection (Figure 5), as an alternative
to the traditional cast-in or post-fixed steel bearing plate. This connection was developed to
ensure best use of the full column strength and provide good ductility. The disadvantages
include the requirement for site welding between MSB columns and the end plate.

Figure 5. Embedded column connection [45]

5. Case study

To define the range of existing modular buildings, a list of multi-storey modular building
projects has been compiled based on a review of the literature. Table 5 shows a selected sample.
The tallest identified prefabricated building is J57 Mini Sky City located in Changsha, China,
being 57 storeys or 207.8m tall [30]. In Australia, the tallest prefabricated building identified is
La Trobe Tower, Melbourne, being 44 storeys or 133m tall. It is in an area with relatively low
wind and earthquake loading. In areas with higher lateral load requirements the maximum
building height is less. For example, the tallest building within Australia’s severe cyclone region
is Concorde South, being 6 storeys.

Table 5. Selected modular building projects

Project Location Storeys Use Completed

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 Agricola College Student Kalgoorlie, Australia 4 Student 2017
Accommodation Accommodation
La Trobe Tower Melbourne, Australia 44 Residential 2016
461 Dean Street New York City, United States 32 Residential 2016
Coast Apartments Rockingham, Australia 4 Residential 2016
J57 Mini Sky City Changsha, China 57 Residential / 2015
office
Concorde South South Hedland, Australia 6 Residential 2014
SOHO Apartment Darwin, Australia 29 Residential / 2014
Hotel
Unite Student Apartment / Wembley, England 19 Student 2014
Hostel Accomm.
Port View Apartments Port Hedland, Australia 4 Residential 2013
Little Hero Building Melbourne, Australia 8 Residential 2010
Victoria Hall Wolverhampton, England 25 Student Accom. 2009
Paragon Student Housing West London, England 17 Student Accom. 2006
Royal Northern College of Manchester, England 9 Student Accom. 2001
Music

6. Hazards and structural responses

The hazards for modular buildings include transport activity, cyclone (hurricane, tornado),
earthquake, explosion, progressive collapse, and fire. Hazards can be classified as natural,
anthropogenic, or technological [58, 59] and the interaction can be concurrent, cascading or
independent [60]. Each hazard has associated actions, or loads, for which the building structure
must be designed. Different loads have different characteristics, design criteria and mitigation
strategies (Table 6). No studies have been identified to address the method for selection of an
optimal design to suit the competing requirements of different loads for modular building.

Table 6. Summary of load characteristics and design criteria

Load Characteristics Design Criteria
Transport & Lifting: dynamic amplification Stability, strength and serviceability;
Handling depending on module and lift Deflection criteria to protect components, e.g.
arrangement; h/500, L/500
Transport: acceleration coefficients in
three orthogonal directions
Wind Load Low frequencies, ~0.01 to 2.5Hz; Stability, strength, serviceability (inter-storey &
Mean component and fluctuating overall deflection, and vibration);
component (gust-factor approach) Deflection limits for serviceability limit state,
e.g. H/600 for total drift and h/500 for inter-
storey drift [61]
Debris Local impact Local penetration, opening area for internal
Impact pressure calculation [62, 63]
Earthquake Ground motion with frequency Damage criteria – displacement based i.e.
contents in the range of 0.5 to 25Hz; ductility ratio & inter-storey drift e.g. 1.5% inter-
Excites fundamental, low vibration storey drift [64]
modes resulting in a global structural Design criteria – life safety, collapse prevention
response
Blast Short duration; local response for Descriptive building damage level and
close-in blast, might lead to component response
progressive collapse;

9
 For far field blast, uniformly
distributed loading
Fire High temperature Fire resistance level (time)

6.1. Transport and handling

Modules are designed to be lifted, with designated lift points provided on the module. They are
usually lifted by a crane, although forklifts may be used in the manufacturer’s yard. The number
and positioning of lift points is often determined by deflection criteria chosen to protect fragile
components. Lift points are typically positioned in from each end, reducing member design
actions and deformation of the chassis. General guidance on the design of lifters is available in
existing documents, for example, American Standard [65-67] and DNV Offshore Standard [68].
The stiffness of a whole module is likely to be influenced by internal and external linings and
manufacturers may test complete modules to establish composite stiffness. For transportation,
including road, rail and sea, the loading is defined by acceleration coefficients, for example 0.8g
forward, 0.5g rearward, and 0.5g transverse during road transportation. General guidance is
available in the existing documents, for example, the CTU Code [69] for cargo transport units
(CTU). Transit bracing is often provided, particularly in open modules, to strengthen the
structural frame and increase stiffness to help control damage to fragile components.
Few studies on the response of modular buildings to transport and handling have been
reported. Smith et al. [70] investigated transport and handling for single storey timber framed
modules. Field testing and numerical modelling using SAP2000 were conducted and the
relevant data is provided in the referenced report. It was reported that the main form of damage
was cracking of internal plasterboard linings. This was caused by the lifting practices with road
transport propagating cracks. It was recommended that areas for further work included the
development of laboratory techniques to simulate transport under controlled conditions and the
development of dampers to reduce dynamic forces.

6.2. Wind

Natural hazards such as cyclones and tornadoes encompass multiple actions including both
primary wind loading, and secondary debris impact and water ingress. Wind loads are
characterised by low frequencies, approximately 0.01 to 2.5Hz, and mean and fluctuating
components [71-73]. Design criteria are typically based on stability, strength and serviceability
by considering inter-storey deflection, overall deflection, and vibration [74]. For example, the
limits of H/600 for total building drift and h/500 for inter-storey drift [61] are specified, where
H is the total building height and h is the storey height. Generally, structures are regarded as
wind sensitive if the fundamental frequency is less than 1Hz, and slenderness ratio is greater
than five [62, 74, 75]. Static analysis is therefore appropriate for buildings with height less than

10
50m [74], based on an empirical formula for the fundamental frequency [76, 77]. However,
results presented in the literature for modular buildings suggest a value of 30m could be more
appropriate, with a frequency of approximately 1Hz obtained numerically for a 10-storey
modular building [17] (refer Section 6.3.3). Therefore, dynamic analysis is required for modular
buildings over 30m high. No studies are identified to address cyclonic wind loads for modular
buildings.
Few studies on the response of modular structures to wind loading have been
conducted. Gunawardena et al. [78] presented base shear and storey drift results for static
analysis of a 10-storey modular building with wind loading applied following AS 1170.2:2011
[62] for Region A, Terrain Category 4. Three different cases of inter-connection were
considered for this building – rigid connection by a rigid floor diaphragm, flexible connection
by a semi-rigid diaphragm, and no connection. The results indicated the actual structural
behaviour fell between that for the semi-rigid diaphragm and no diaphragm. Styles et al. [47]
investigated the effect of joint rotational stiffness on the response to wind loading for an 11-
storey modular building. It was reported that increasing horizontal inter-module and intra-
module connection stiffness effectively reduced inter-storey drift due to wind load. Intra-
module connection stiffness was shown to have a greater effect than horizontal inter-module
connection stiffness. It is indicated that further studies are needed to address the factors
including vertical inter-module connection stiffness and building height.

6.2.1. Wind-borne debris

Wind-borne debris impact has been observed in many strong wind events and is well
documented in the existing literature [79-81]. Debris impact causes localised damage and if the
envelope is penetrated may cause additional damage due to water ingress and internal
pressurisation. Debris impact loading is typically specified for standard debris items, with
velocity related to regional wind speed (VR). For example, AS/NZS 1170.2 [62] specifies a 4kg
timber with 100x50mm cross-section impacting at 0.4VR and 0.1VR, and an 8mm (2g) steel ball
impacting at 0.4VR and 0.3VR for the vertical and horizontal trajectory component respectively
[62]. Modular buildings are generally lightweight to facilitate transport and so may incorporate
lightweight cladding materials which are vulnerable to debris impact. Recently, a systematic
study of the performances of structural panels against wind-borne debris impact has been
conducted experimentally by using a pneumatic cannon and numerically by using LS-DYNA
[82-86] and some cost-effective engineering adaptation methods have been developed. The
development of lightweight and resilient structural panel as building envelope can be
incorporated into the design of modular buildings.

11
6.3. Earthquake

Earthquakes are characterised by ground motions with predominant frequencies in the range of
0.5 to 25Hz, which normally excite the fundamental and low vibration modes of engineering
structures and result in global structural responses [71, 72]. Extensive research works have been
carried out to investigate the seismic behaviours of traditional building structures, and
displacement-based damage criteria such as the ductility ratio and inter-storey drift ratio are
widely used by the design guides to measure their seismic performances [72]. For example,
Australian Seismic Design Code AS 1170.4 [64] specifies an inter-storey drift limit of 1.5% for
the ultimate limit state. Modular buildings, due to their obvious advantages, are increasingly
used in areas with high seismic hazard. Their seismic performances are, however, not
adequately understood because they are a relatively new structural form. The rocking and
sliding response of modules after connection damage could be the governing response modes.
In such cases the conventional displacement-based criteria such as drift ratio may no longer be
applicable to quantify modular building damage. Therefore, it is essential to investigate the
performance of modular buildings under earthquake loadings and further propose the
corresponding criteria to evaluate their seismic performances.

6.3.1. Seismic responses

Very limited studies on the seismic responses of modular structures have been
conducted and these studies mainly focused on the MSB-braced frames. Annan et al. [20]
conducted experimental studies on the hysteretic behaviours of an MSB-braced frame and a
regular concentrically-braced frame with similar physical characteristics. It is reported that both
specimens showed stable and ductile behaviour up to very high drift ratio (3.5%). The MSB
frame was more vulnerable to column bending deformation, whereas the traditional frame was
vulnerable to the out of plane buckling of bracing. Annan et al. [21] further conducted
incremental dynamic analysis (IDA) for 2-, 4- and 6-storey two-dimensional (2D) MSB-braced
frames. It is reported that the selected MSB-braced frames exhibit a predominantly first-mode
response (e.g. the mass participation factors for the 2-storey frame are 94% for the 1st mode and
5% for 2nd mode, similarly, for the 4-storey frame, the percentages are 81% and 15%
respectively, and for the 6-storey frame, the values are 77% and 17%) and limited redistribution
of internal forces can result in concentration of inelasticity at the first level. Fathieh and Mercan
[22] conducted non-linear static pushover and IDA analyses for 2D and 3D MSB-braced 4-
storey frames. It verified the concentration of inelasticity at the first level due to limited internal
force redistribution and brace inelasticity, and found the 2D model overestimated the structural
capacity against incipient collapse because torsional response was not accounted for in the 2D
model. Gunawardena et al. [24] conducted non-linear time history analysis for a freestanding

12
10-storey modular building subject to six selected ground motions. Column hinge formation
was found unavoidable in severe ground motions and column ductility was important to
redistribute post yield loads. It was indicated that further studies are needed to investigate
dynamic behaviours for mid- to high-rise modular buildings.

6.3.2. Over-strength and ductility

In the seismic analyses of traditional engineering structures, forces derived from an elastic
response spectrum analysis are adjusted to allow for the ductility and other reserved strength.
AS 1170.4 adopts a structural ductility factor (µ) and structural performance factor (Sp) as a
measure of the ability to withstand inelastic displacement and other reserved strength
respectively. For the modular structures, Annan et al. [18] investigated the inelasticity of
modular buildings by conducting non-linear static pushover analyses for 2-, 4- and 6-storey 2D
MSB-braced frames. The over-strength factor (R0=1/Sp) and structural ductility (µ) are reported
as per the National Building Code of Canada (NBCC) [87, 88]. Two methods were used to
calculate the column actions due to bracing – the SRSS (Square Root of the Sum of the Squares)
method [89, 90], and the DS (Direct Summation) method. The SRSS method was found to be
unconservative and so the DS approach was recommended. The ductility, which is calculated as
the ratio of the ultimate drift (Δu) to the yield displacement (Δy) i.e. Δu/Δy, is shown to reduce
with increasing MSB frame height. The values range from 4.6 to 1.8 for 2- to 6-storey MSB-
braced frames. The variation with height is reported to occur for two reasons. First, the yield
displacement of braces increases with increasing frame height due to a decrease in brace
slenderness (i.e. the brace section size is not constant) [18]. Second, the ultimate drift is
determined by the redistribution of load after the compression brace yields [18]. The vertical
inter-module connections affect this ability to redistribute load, and the affect increases with
increasing frame height [18]. Similarly, the over-strength factor, which is calculated as the ratio
of the ultimate load to the design load, is shown to reduce with increasing height [18]. The
values range from 2.5 to 1.9 for 2- to 6-storey MSB-braced frames. The variation with height is
again related to the ability to redistribute internal force [18]. Similar results are reported for
steel moment resisting frame (SMRF) modules. Choi et al. [49] conducted non-linear static
pushover analyses for 3- and 5-storey SMRF modules with varying inter-module connection
type and stiffness, and reported over-strength factors between 2.15 and 3.76 for the 3-storey
frames, and between 1.19 and 1.94 for the 5-storey frames. For each frame height, the SMRF
frames with greater inter-connection stiffness had greater over-strength factor.

6.3.3. Fundamental period of modular building

The fundamental period of a modular building is an important parameter for the prediction of its

13
seismic behaviour [91]. Many standards provide empirical formula for the fundamental period
.
(T1[s]) of traditional building structures. For example, AS 1170.4 [64] gives 1.25 ,
where hn is the height from the base to the uppermost seismic mass in metres, and kt is a
constant depending on the structure type with a value ranging between 0.05 (for all other
structures) and 0.11 (for moment-resisting steel frames). Recently, some studies have been
carried out on modular buildings. Figure 6 shows the fundamental periods for rectangular
modular buildings together with the upper and lower bounds defined in AS 1170.4. These
fundamental periods are the result of numerical analysis of 2D MSB-braced frames [21], 3D
MSB-braced frames [17, 22] and steel moment resisting frame (SMRF) modules [49, 92], and
experimental analysis of stacked timber frame modules [93]. It can be seen that the period
values follow the trend of increasing with building height. From the limited data presented,
kt=0.05 gives a reasonable estimate for both the 2D MSB-braced frames and the timber frame
modules. kt=0.075 appears more appropriate for the 3D MSB-braced frames. For the SMRF
modules greater variation in the fundamental period is shown. This is the result of varying inter-
module connection type and stiffness [49], and varying imposed gravity load [92]. For these
SMRF modules use of kt=0.11 to estimate the fundamental period is most accurate for the case
of rigid inter-module connection. It should be mentioned that the data presented for the MSBs
considers only the main structural elements and excludes the cladding elements. Cladding
incorporated into modules may have a significant effect on the fundamental period due to the
additional mass.

Figure 6. Variation of fundamental period with height for modular buildings

6.4. Blast

Blast loads can induce local and global response. Local response, typically the result of close-in

14
explosion, causes localised failure which might lead to progressive collapse [94]. Global
response occurs for transverse load with longer exposure time [95], such as gas explosion and
far field explosion. Design is typically based on descriptive building damage level (i.e. low,
medium, high) and component response. Modular buildings may be subjected to blast load from
several sources including chemical / industrial / terrorist explosion. They are therefore used in
industry to protect personnel [96-98] where they are referred to as blast resistant modules
(BRM) or blast resistant portable buildings (BRPB) (Figure 7). Steel modules have a primary
steel frame with walls formed by infill between roof and floor. For example, walls may consist
of steel plate, cold-formed steel stud frame or sandwich panels. Typically, BRMs use 3.2 to
7.9mm thick crimped steel plate walls fully welded to the steel frame [96]. For this type of
module construction, finite element analysis is recommended to capture failure modes, although
a single degree of freedom (SDOF) approach may be adopted [96]. For general design,
reference is often made to the standards including UFC 3-340-02 [99] and ASCE 41088 [94].
Hao et al. [100] provide a summary of the current practice. For steel components, response
limits are given based on ductility (µ=1 to 20), support rotation (θ=1 to 12°) and side sway
(height/50 to h/25) for moment-resisting frames. Overall, published qualitative studies for blast
loading are limited and further studies are needed to investigate the behaviour of mid- to high-
rise modular buildings.

Figure 7. (L) One storey BRM building [96], (M) Two storey BRM building [96], (R) Stacked
BRPB complex [97]

6.5. Progressive collapse

Progressive collapse occurs when local damage from an extreme event results in overload and
then failure of successive alternate load paths [101, 102]. It is a relatively rare catastrophic
failure which may occur due to lack of continuity, ductility and/or redundancy [101]. The
methods of design are typically categorised as indirect or direct approaches. The tie force
method is an indirect approach wherein robustness is enhanced by provision of specified
minimum ductility, continuity and strength [101, 102]. Direct design approaches include the
alternative path method and key element design (or enhanced local resistance) [101, 102]. For
modular steel buildings the tie force method may not be appropriate. This method does not
consider beam rotations due to catenary action and failure may occur in low ductility

15
connections such as standard fin plates [103]. Instead, the alternative load path approach is
adopted [10, 13]. Lawson et al. [13] completed a static analysis for the loss of one corner or
internal support to a light steel module, with load being transferred by shear walls back to a
tying action in inter-module connections. To demonstrate the capability of the modules, tests
were completed to establish the shear wall racking capacity and deflection of the module with
removed supports. The required inter-module tie forces were found to be relatively low [13]. In
another study, container express (CONEX) modules used for barracks were tested in Florida
[104]. The modules were stacked three levels high and connected using twist locks. The work
completed included simulating column removal using SAP2000, experimental column removal
tests using hydraulic jacks, and finally detonation of an artillery shell at a critical location
(Figure 8). The results confirmed progressive collapse was not an issue as per the Unified
Facilities Criteria [101]. Progressive collapse studies have therefore considered only light steel
framed modules and container buildings stacked three storeys high. Modular steel buildings
may be vulnerable due to the use of connections with limited ductility, which is worth studying.
In addition, only threat-independent methods [105] have been used to assess progressive
collapse and it remains to the investigate the limitations of these methods for modular building
structures.

Figure 8. Expeditionary CONEX testing for progressive collapse [104]

6.6. Fire

Fire resistance is a major challenge for modular buildings. Concerns have been reported
considering the use of flammable materials and the presence of a void between modules which
may permit a fire to spread [106, 107]. However, studies into the fire performance of modular
structures are limited. One study considered fire simulation for a container building [27] and
several studies investigated the performance of developing composite materials such as fibre
reinforced polymer (FRP). Composite materials have advantages which make them well suited
to application in modular building. They are lightweight with high strength and stiffness and
offer flexibility in shape [108-111]. However, they generally have low fire resistance and their
performance as a building envelope is not well known [108, 109]. Ngo et al. [108] investigated

16
the performance of an office building constructed from modules with glass FRP composite
components forming the façade. This study provides insight into the fire performance based on
numeric analysis. Nguyen et al. [109] investigated the addition of fire retardant to improve fire
performance. Models were developed to predict “fire growth index and total heat release” for
“organoclay/glass fibre reinforced polymer (GFRP) laminates” [109]. The performance was
then considered for an office building with façade consisting of GFRP laminate on foam core.
The addition of organoclay is found to prevent flash-over and horizontal flame spread. Fire
performance studies are therefore mostly related to the development of FRP materials with no
studies identified for modular steel buildings. In current practice, fire resistance time
requirements are satisfied by providing layers of protective cladding and fire stops to control
fire spread [4].

7. Current design practice and methodology

7.1. Design guidelines and theoretical analysis

General design guidance is available for light steel framed modules in the existing literature
(Table 7). In current practice, guidance is drawn from the traditional literature. A limit state
approach is adopted for design criteria considering stability, strength, and serviceability.
Building serviceability is satisfied by adherence to overall drift limits and acceleration limits for
human comfort. For example, for wind loading, Mendis et al. [74] and Griffis [61] report on
acceleration and drift limits. Modules should also satisfy serviceability criteria during transport
and lifting. Limited guidance is available and current practice is based largely on practical
experience. Serviceability during transport and lifting is mainly concerned with the potential for
damage to finishes and equipment. Therefore, guidance can be found in existing literature such
as Griffis [61]. For example, to control cracking of partition walls during transport and
handling, limits of module height/500 and span/500 can be adopted for lateral acceleration and
gravity loads. Design of MSB connections is similarly based on the traditional literature due to
the lack of modular specific guidelines. For bolted connections, Gunawardena [17] and Styles et
al. [47] showed structural behaviour can be established using finite element analysis based on
comparison with laboratory testing. The resulting force-deformation or moment-rotation
behaviours can then be incorporated into a simplified global model of the building structure. For
example, Gunawardena [17] has demonstrated the use of link elements to model horizontal
connections using ETABS and SAP2000.
As for traditional structures, simplified SDOF models are available following the
standard texts such as Biggs [112], Clough and Penzien [113], and Chopra [88]. Hao et al. [100]
provided a review of current practice and its limitations for blast-resistant analysis. The

17
limitations of SDOF models include assumptions regarding loading conditions, response mode
and deflection shape [72, 100]. No theoretical analysis models developed specifically for
modular buildings are identified in the literature. From low-rise construction, modular buildings
are known to behave as rigid bodies, for example overturning and sliding due to wind loading
[114, 115]. This understanding of modular behaviour could be extended to multi-storey stacked
assemblies, adopting a rigid module, flexible inter-connection approach. Extensive research has
been reported on the rocking response of rigid structures. Hao and Zhou [116] provide a
summary of the development up to 2011. The rocking and sliding response is known to be
highly non-linear. For example, stability depends on structure slenderness, and ground motion
amplitude, frequency and duration [117]. The existing knowledge of rigid bodies could be
applied to modular buildings and could form the basis of theoretical analysis for multiple
hazards.

Table 7. Design guidelines for modular buildings

Guideline Application scope and notes
The Steel Construction Institute (SCI) P272 Architectural and general guidance on typical details for
[11], SCI P302 [9], SCI P348 [14] light steel framed modules
Prefab Architecture: A Guide to Modular General background, applications, and case studies for
Design and Construction [3] modular buildings
Design in Modular Construction [4] General guidance on modular buildings with an
emphasis on light steel framed modules and case studies
Code of Practice for Packing of Cargo General guidance on transport actions for container
Transport Units [69] units
Handbook for the Design of Modular General guidance on design and construction aspects
Structures [118] with an emphasis on Australian codes and standards

7.2. Experimental testing

Testing is typically conducted either to demonstrate compliance with performance requirements

(i.e. proof testing) or to determine the capacity for design purposes (i.e. prototype testing). As a
new developing application, structural design of modular buildings has a greater emphasis on
prototype testing, rather than reliance on standardised or pre-qualified detailing. Prototype
modules may be constructed to establish overall composite stiffness including cladding, test
lining response to transport and lifting actions, and to test the fit and tolerance of connection
systems. Table 8 gives a summary of test methods for modular buildings and prefabricated
components. The documentation of test methods for modular buildings is limited and standard
methods are not available in some cases. For blast loading no modular specific methods are
available and a summary of current practice is provided by Hao et al. [100].

Table 8. Test methods for modular buildings and prefabricated components

Component Test Description Standard Method Example
Module Transport and handling – field testing, measurement - [70]
of wind speed/pressure, deformation & accelerations

18
 Module Overturning – wind tunnel, rigid body scale model - [119]
Module In-plane shear (racking test), e.g. Figure 9 - [55]
Module Progressive collapse – general methods include - [10, 13,
laboratory simulated column removal and field 104]
testing
Module Dynamic properties – field testing, to determine - [93]
fundamental frequency, damping ratio, mode shape
Module Cyclic seismic test – symmetric reversed-cyclic ATC-24 [120] [20]
frame loading history
Panel – In-plane shear, compressive / tensile / concentrated ASTM E 564-06 [32, 123]
wall, floor, load, transverse flexural load (two-point or bag [121], ASTM E
roof method) 72-15 [122]
Connections Evaluation of inter-module connections, e.g. Figure - [17]
9
Module Simulated wind-borne debris impact ASTM E1996-14a [86]
envelope [124], ASTM
E1886-13a [125]

Figure 9. (L) Shear force load testing of connection with contactless strain measurement system
[17], (R) Racking test of complete frame [55]

7.3. Numerical simulation

Structures are typically broken down into components for piecewise analysis. Connections are
modelled using finite element analysis (FEA) and the resulting behaviour is incorporated in a
separate model of the frame for structural analysis. MSBs often incorporate semi-rigid
connections for which the behaviour and stiffness can be established for inclusion in the global
analysis [126]. FEA of connections is commonly conducted using ABAQUS [127] or ANSYS
[17, 47]. For global analysis, various commercial software packages have been adopted for
modular buildings, including ABAQUS [29], ANSYS [47], SAP2000 Nonlinear [19, 70], and
ETABS [23]. In the specific field of earthquake engineering, RUAUMOKO 3D [24], OpenSees
[22] and SeismoStruct [20] have been adopted for incremental dynamic analysis, and pushover
analysis.

19
8. Conclusions

Modular building refers to the application of a variety of structural systems and building
materials. Modular buildings perform differently to similar traditional structures owing to the
requirements of site interconnection for modular building. Analysis, design and construction
technologies of modular building are currently under further development and several key areas
are identified for further study.

(1) Overall module size is limited by transport capabilities and internal layouts are limited
by the requirement for structural elements. Greater flexibility in internal layout could be
provided by a reduction in structural member sizes, and reduction in the number of
braces, shear walls and columns.
(2) There remains a need for efficient lightweight systems which also address issues of
robustness. At the same time, there is also a need to develop new lightweight materials
for specific application in prefabrication and modular building. The performance with
respect to wind-borne debris impact and fire are developing areas.
(3) Accumulated damage must be considered for portable buildings subject to repeated and
fatigue loading. In other cases where a module might be transported only once or twice
in its life, damage during transport and in situ degradation are worth studying. This
affects the performance for all hazard types, yet published quantitative studies are
limited.
(4) Connections are key to the performance of modular buildings. The design and
fabrication of reliable connection systems is a major challenge. Further research is
required to better define the performance of existing connection systems and limit the
potential for overdesign due to limited understanding.
(5) The current studies on modular building under earthquake are limited to 10 storeys.
Further studies are needed to investigate the dynamic behaviour due to earthquake
ground motion for mid- to high-rise modular buildings.
(6) No studies have been identified to address dynamic wind loading, or cyclonic wind
loading for modular buildings. Further studies are needed to investigate the dynamic
response of modular buildings under wind loading.
(7) Further studies are needed to investigate the behaviour of mid- to high-rise modular
buildings subject to blast loading. In addition, progressive collapse studies considered
only light steel framed modules and container buildings. Modular steel buildings may
be vulnerable due to the use of connections with limited ductility, which is worth
studying.

20
9. Acknowledgements

The authors acknowledge the financial support from the Australian Government through the
Australian Research Council (ARC). The first author acknowledges the support received
through the Australian Government Research Training Program Scholarship.

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