PPVC modular construction building has become one of the most recent construction technologies in the civil engineering sector and has piqued researchers’ interest. Few published studies consider the overall structural response to extreme wind load. As a result, there is a lack of appropriate design for PPVC modular systems under extreme wind standards. However, the existing literature has not yet studied the wind flow dynamic behaviors of PPVC modular steel construction (MSC) systems subjected to extreme wind loads. This paper, therefore, presents a numerical investigation into the structural performance and wind flow dynamic behavior of innovative PPVC modular steel construction (MSC) systems under extreme wind loads. The numerical technique varied in comparison with previous studies. The results showed that the suggested novel (MSC1) modular system is applicable to prevention of extreme wind action up to cyclone ^2nd degree, the high story drift resistance compared with previous research, high stiffness performance, and overall strain energy. Additionally, the actual wind velocity surrounding (MSC2) was 31.5% higher compared to the Saffir–Simpson wind speed scale, and the 1.5 wind speed safety factor was suggested.

Interlocking Inter-Module Connections (IMCs) in Modular Steel Buildings (MSBs) have garnered significant interest from researchers. Despite this, the optimisation of plate thicknesses in such structures has yet to be extensively explored in the existing literature. Therefore, this paper focuses on optimising the thickness of interlocking IMCs in MSBs by leveraging established experimental and numerical simulation methodologies. The study developed various numerical models for IMCs with plate thicknesses of 4 mm, 6 mm, 10 mm, and 12 mm, all subjected to compression loading conditions. The novelty of this study lies in its comprehensive parametric analysis, which evaluates the slip prediction model. A random forest regression model, trained using the ‘TreeBagger’ function, was also implemented to predict slip values based on applied force. Sensitivity analysis and comparisons with alternative methods underscored the reliability and applicability of the findings. The results indicate that a plate thickness of 11.03 mm is optimal for interlocking IMCs in MSBs, achieving up to 8.08% in material cost reductions while increasing deformation resistance by up to 50.75%. The ‘TreeBagger’ random forest regression significantly enhanced slip prediction accuracy by up to 7% at higher force levels.

Modular steel buildings (MSBs) interlocking inter-module connections (IMCs) have piqued researchers’ interest. However, the existing literature has not yet studied the optimisation of its plate thicknesses. This paper, therefore, focuses on optimising interlocking (IMCs) plate thickness in (MSBs), leveraging previous experimental and numerical simulation methodologies. Various numerical models for four MSBs interlocking (IMCs) with plate thicknesses (4 mm, 6 mm, 10 mm, and 12 mm) were developed under compression loading conditions. The study’s novelty lay in its comprehensive parametric analysis, which evaluated the slip phenomenon in (MSBs) connections and introduced a slip prediction model validated against empirical data. Further innovative machine learning approach was utilised to predict slip values based on applied force through a random forest regression model trained using the 'Treebagger' function. Sensitivity analysis and comparisons with alternative methods were utilised to underscore the reliability and applicability of the findings. The results showed that 11.03 mm was the optimal plate thickness for interlocking (IMCs) in modular steel buildings, with up to 8.08% reduced material costs. Increasing plate thickness boosts its deformation resistance by up to 50.75%. ‘TreeBagger’ random forest for anomaly detection and machine learning improves slip prediction up to 7% at higher force levels.

Extreme wind loading remains a critical design concern for high-rise prefabricated prefinished volumetric construction (PPVC) buildings. The main contribution of this study is the development of a PPVC specific pressure to response workflow. This workflow transfers large eddy simulation based computational fluid dynamics (LES-CFD) pressure fields into nonlinear finite-element (FE) analysis. It enables the wind-induced response to be traced from external aerodynamic flow to roof displacement, inter-storey drift, stress development, and modular connection-level demand. This study analyses the wind-induced behaviour of a 40-storey high-rise PPVC composite modular building under six wind categories. LES-CFD was used to simulate the wind field and surface pressure distribution around the building. The CFD pressure fields were then mapped onto a nonlinear FE model. The FE model was used to assess roof displacement, inter-storey drift, stress distribution, and the response of inter-module, intra-module, and corner connections. The CFD results showed a clear stagnation separation flow pattern. This produced strong windward compression, roof-level suction, and leeward recirculation. The FE results showed a cantilever-dominated lateral response. Roof displacement increased from 5.1 mm under normal wind loading to 309.2 mm under Category 4 loading. The peak global stress increased from 2.8 MPa to 169.0 MPa. At the connection level, the inter-module connection developed the highest shear resistance of 8879.5 kN. The intra-module connection showed stable deformation and rotational response. The corner connection showed the post-peak softening behaviour. The proposed workflow provides a PPVC-specific method for linking wind pressure, global deformation, and modular connection demand in high-rise modular buildings