The prefabricated construction industry, also known as off-site construction, has been operating in North America for several years now and differs from traditional construction in its much shorter project timelines, lower costs, and increased build quality. However, the lack of a suitable and efficient assembly solution has been identified by many as a barrier to the use of off-site construction for larger buildings. To maximise the benefits of off-site manufacturing for multistorey buildings, an automated connection solution is presented in this paper. A new plug-in self-locking device was developed according to the following product design phases: on-site observations, definition of the problem and product specifications, solution generation, prototyping, fabrication, and testing. The plug-in self-locking device allows the assembly process to be accelerated by eliminating the fastening steps and a higher completion of modules off-site to be achieved. The design bears the compressive, tensile, and shear loads and contributes to the load path of the building.

Modular construction is characterized by assembling volumetric units on site. Once assembled on site, the structural integrity of modular buildings highly relies on connections that provide essential performance against critical loading conditions. Connections significantly impact field assembly activities, and previous research has highlighted the importance of their functional performance. In this study, the researchers focus on implementing automated connecting devices in a full-scale experimental project. It presents the implementation of a self-locking inter-modular connector and an investigation of the benefits and limitations of its application in modular building systems. This study also investigates the use of connectors as attachment points for modular handling and lifting. It evaluates the pros and cons of combining a single device’s connecting and lifting functions. The implementation of an automated connecting device in the building design process is covered as well as the evaluation of its impacts on architectural, structural, and functional considerations. Finally, the potential of automated connecting devices to improve modular building systems’ overall performance and efficiency is assessed, and guidelines are identified to facilitate their adoption.