Prefabricated Construction Systems adopted in Hong Kong

Presented by

Raymond W M Wong Division of Building Science & Technology City University of Hong Kong

Development and Application of Prefabricated Technology in Building Construction in HK

1. Had been used once in early 1970s in a pilot project to construct a series of 17-storey public houses 2. Used in a broader scale in the mid/late 1980s in the construction of public houses where all the faades of the flats were constructed in precast in a after-fixed manner 3. Improvement to public houses by introducing in-situ joined faade and broader use of other precast elements in early/mid 1990s. 4. A few private developments pioneered in the use of prefabricated system in the construction of buildings of various nature since early 1990s

Development and Application (continue)

5. Packaged projects introduced from late 1990 onward by the Hong Kong government for the construction of a series of schools using semi-prefabricated method 6. A series of government quarter buildings using similar construction techniques were introduced in 2000 7. A few special buildings such as bus depot or train station podium employed large amount of prefabricated elements of which some were primary structural members (1997 onward) 8. Popular use of prefabricated external wall from 2002 onward in residential buildings due to the introduction of a new guideline encouraging the use of precast faades as a form of green elements in construction (exemption of Gross Floor Area)

Prefabricated Construction
Prefabricated construction refers to construction making use of readily-assemble components which are prefabricated off site and to connect them on site into a permanent structure in a convenient and structurally strong manner. Materials suitable for prefabricated construction mainly include concrete, steel and timber. Out of the three named, prefabrication using precast concrete is the most popular in Hong Kong.

Prefabricated Construction
The basic principle of using prefabrication in construction is to take the advantage of allowing some of the major building elements being produced off-site in a prefabrication yard or factory where productivity, quality and cost of works can be better controlled. The finished elements can then be transported to the site for assembly and connection.

Prefabricated Construction
The Construction using precast concrete has the following advantages. a) Precast elements produced in factory environment can be worked to a very high structural or architectural standards. b) Precast elements is more durable when compare to structure constructed in in-situ concrete. c) Elements can be stressed to produce structures of higher performance.

High quality precast elements can be produced in well-equipped casting yard/factory

Stressing work applied during the casting process

Prefabricated Construction
Continue - advantages of precast concrete d) Productivity is much higher than cast in-situ works especially when standardized design is adopted. e) Assembly & installation process carried out on site can save up significant amount of formwork & falsework especially when the structure is of very high headroom. f) Construction can normally be done in higher speed with easier supervision and reduced cost.

Falsework involved when casting a floor with high headroom

Limitation and drawback in using precast construction in Hong Kong

Though prefabricated construction exhibits much benefits over traditional construction methods, it is still not popularly received in the construction of buildings in Hong Kong. One very major reason is that prefabrication construction using precast concrete components cannot produce a very rigid structure. This drawback becomes more significant when used in high-rise buildings where huge lateral wind load has to be taken into account.

The insufficient rigidity mainly originated from the joints of the major elements, such as in joints between columns and columns, beams and columns, or beams to paneled walls etc. Sometimes, rigid joint design can be made to improve the performance, but this will, again, complicate the connection and increase the time and cost of work. Furthermore, prefabricated construction also inherits with the following drawbacks.

Provision for the forming of a rigid joint between members

Drawback:
TTighter and longer period of coordination are required to allow for structural design, construction planning, procurements and approval procedures MMore time required in advance for production of precast elements until they can be accumulated to sufficient numbers for delivery to site to start installation. Huge working space is required for the carrying out of fabrication works. This is particularly critical under Hong Kong situation. Though most of the fabrication works are recently carried out in casting yards in China, this will increase the transportation cost by sea or on land.

Precast elements required huge amount of space as handling and storage area

d) SStorage and pre-installation handling, again, requires extra working space. e) IInstallation of precast elements on site requires careful planning and extra cranage provisions. f) HHandling and assembly of heavy precast members, poses certain safety problems and increase risk both to human operatives or to the semi-completed structure itself. g) TThe structure under assembly in its semi-completed state may cause difficulties in making access into the work spot. h) DDefective connections may result to cracks and water leakage which will create further maintenance problems.

Transportation, access and lifting problems in the using of precast

Leakage problem due to defective jointing during the connection process

Connecting precast elements

1. Connecting column to foundation base (similar for connecting column to column)
Precast column usually has a cast-in steel plate at the bottom. This plate is fastened to anchor bolts set into a concrete footing or base

Connecting column to footing base using anchor bolts

Connecting column to base (similar for column to column connection)

2. Connecting beam to column Precast beam is connected to column in a variety of ways. For non-rigid jointing, corbel is usually formed on the column to support the precast beam. However, anchorage provision should be provided to secure the members from seismic or wind action. Rigid joint (moment resisting) is common for building requiring stronger performance. In this case, haunching arrangement by inserting link bars between the column and beam members and infill the joint afterward with concrete can often produce an acceptable joining result. It should be noted that suitable propping support should be provided before the final setting of the joint.

Beams rest on corbel of column (with tie bolt to secure beams from movement)

Connecting beam to column (non-moment resisting)

Haunching arrangement to connect beam to column

3. Topping to form the deck/slab Deck or slab of precast structure often appears in the form of a RC topping, placed on top of the precast beam and semi-slab (precast floor plank).

Semi-slab (rebar will be fixed on top)

Case Examples

Generations of Public Houses (Harmony Block) constructed using semi-prefabricated concept

First generation of Harmony Block using after-fix faade

Later version of Harmony Block using inisitu faade cast at the same time with structural walls

Precasting yard was set up to produce precast elements for public housing projects in early to mid 1990

After-fix faade system required the formation of small amount of in-situ joint and grouting that easily caused leaking problem

Detail of faade installation using in-situ jointing arrangement in the later version of Harmony Block Construction

Forming the floor slab in the Harmony Block construction using semi-slab (right) and aluminium formwork (above)

Introduction of mechanical formwork systems incorporating the standard precast elements in the construction of latest version of public houses in the late 1990

Public houses using Concord design with special emphasis on the use of mechanicalised construction system

Layout of the Concord Block showing the position of the cast-insitu core wall, shear walls and precast faade

Other pioneered projects in the early 1990 constructed using semi-prefabricated concept

The construction of the Headquarter and Members Facilities Complex for the Hong Kong Jockey Club

Forming the floor slab using precast secondary beams and semi-slab for the main building (above) and members complex (right)

Detail of the floor system with the cast in-situ main beams and the place-in precast secondary beams

Introduction of prefabricated concept to construct government quarters in 2000

Government quarters in West Kowloon

Layout of the quarter building showing typcial phasing arrangement of work

Features in the construction extensive use of precast faade and lintel beams, precast cast-in-situ internal partitions are also introduced

Detail of the faade and the lintel beam installation

Installation of the cast-in-situ precast internal partition

Construction of special buildings using high proportion of precast since 1998

Kowloon Canton Railway Station podium/deck

Construction of the Kowloon Canton Rail podium deck cargo handling bay on the ground level and on top for a large-scale residential development afterward

Forming of the castin-situ main beams

Jointing detail of the main beam and precast secondary beams

Semi-slab with RC topping to form the composite podium deck

Kowloon Motor Bus Maintenance Depot

- 3-level depot building with columns, main and secondary beams all in precast

Erecting of the building frame using precast columns and beams

Connecting the precast column to the foundation cap with a base plate

Placing the secondary beams onto the main beam

Connecting beams to columns by stitching, a means to provide an in-situ joints with rigid RC links

Detail of the beam/column and beam/beam joints

Recent Residential/Commercial Developments using prefabricated concept to construct

Residential development at Cyber Port

Faade and general installation details

Features in the construction large amount of external walls are constructed in precast faade untis, with major structural links tie back to the inner shear walls and floor slab

Incorporation of other sophisticated formwork in construction steel gang form for walls and table form for floor

Residential Development at Taikoo Valley

Construction features the use of large amount of precast units both of structural or architectural nature. This includes the balcony, faade units, loss-form for external walls and some shading fins.

Detail of the precast balcony unit

Detail of the loss-form

Residential development at Ma Tau Wai

Overview of the precast installation arrangement

Faade installation detail as seen on the floor deck

Cambridge House a 42-storey Office Building at Quarry Bay

Features in construction precast beam trough and precast sub-slab with RC topping forming the floor system

Placing of the precast beam trough to form the floor layout

Recent Achievements of Hong Kongs Prefabricated Technology

Previous defects such as leakage problems have been improved Application diversified to other forms of construction Capable to apply to rather complicate-shaped buildings Incorporation of other advanced technology in the construction (such as use with mechanical form/ tensioned elements) Generally mastering of skill and growing popular

Future Trend in the application of Prefabricated Technology in Hong Kong

1. To increase the use of prefabrication for more structural elements such as for beam, column or load bearing wall 2. Use more modulated elements or plug-in units 3. Use more for architectural or decorative elements 4. Incorporation of other composite elements in the design such as using at the same time with structural steel 5. Apply prefabrication more to medium-rise buildings with more standardized structural items 6. Improve the supply chain management to make production more efficient and economical

Practical Constraints
1. Tighter coordination to allow for structural design, construction planning, procurement & approval procedure 2. Required a critical amount of precast items before work can be economically used 3. Huge work space for handling precast elements especially in congested urban environment in Hong Kong 4. Congested site environment makes access and delivery of heavy precast units to the work spot becomes difficult 5. Quality assurance become critical especially where large amount of precast components are used as structural nature

Examples of very congested construction environment where prefabrication approach is adopted

Example of Innovative Project (Local)

The Integer

The Integer House at Admiralty

Floor plan of the experimental house

The working concept

Typical connection details

Assembly of the 3-D modules

Possible future development for high-rise structures using similar concept

Example of Innovative Project (overseas)

The Habitat 67 in Montreal, Canada

Building Section

Habitat 67 as seen along the bank of St Lawrence River

Habitat 67 as seen along the bank of St Lawrence River

Close up look of the modulated dwelling units

Close up look of the modulated dwelling units and the linking structure in the form of a access corridor

View as seen on the deck level

Forming and Installation of the modulated units

Installation of the modulated units and the associated structure

Building Section

Floor plan

Connecting the modules

Prefabricated Construction
Application in Civil Works

Examples of application of prefabricated techniques in civil construction works

1. Used in highway projects such as cantilevered deck of elevated bridge, parapets of expressway and road curb 2. Precast girder units or beams for elevated roadway (viaduct) 3. Precast beams or decks for elevated pedestrian footbridges 4. Tunnel lining especially for tunnel formed by tunnel boring machine 5. Decks for long span bridges

Examples of application (continue)

6. Marine work such as seawall and deck of terminal berth 7. Soil retaining element such as for earth-balanced type retaining structure 8. Platform for railway station 9. Parapets and noise barrier panels 10. Overhanging ducts or services channels for underground facilities 11. Nullah section for storm water discharge

Elevated pedestrian footbridge in Mong Kok

Piers formed using precast column

Precast girder erected on top of the piers to form the main span of the footbridge

Extending precast plank to form the deck of the footbridge

Structural arrangement of the footbridge

Precast V-shape beam for the Route 3 elevated expressway at Kwai Chung

Precast V-shape beam being lifted to pier head by launching gantry

Precast box-girder for the Rambler Strait Bridge of Route 3

Forming the elevated bridge of the West Kowloon Expressway

West Kowloon Expressway installing the precast box girder using balanced cantilever method with the help of track mounted gantry crane

Forming the elevated track of the West Rail using the slung launching girder

Forming the elevated track of the West Rail using the longitudinal steel support beam

Forming the elevated track of the KCR Ma On Shan Line by precast girder and lifted to deck level for erection using mobile crane

Placing the precast girder in position

Project example Road T7 in Ma On Shan (TTD project) Technical Features

1. Total length of viaduct 2200m (approx.) 2. Span length Average 40m 3. Total nos. of segment used 790 nos. 4. No. of segment per span average 14 nos. 5. Weight of segment ranging from 50 to 98 tons 6. Weight of the launching machine 310 tons 7. Max. weight of machine with segments 1300 tons 8. Length of launching machine 85m 9. Casting of the box-girder segment match-cast

Construction of highway bridge using precast box-girder (viaduct) Road T7 in Ma On Shan

Early stage of the project formation and forming the piers for the viaduct

Overall layout of the precasting yard

Forming the box-girder units

Formwork to form the inner void of the box-girder units

Overview of the launching machine

Drawing provided by China Harbour Engg. Co. (Group)

Launching sequence of the box-girder units using launching machine

Installation of the box-girders

Installation of the box-girders

Other example of application in civil engineering works

Precast parapet unit for the highway and railway road/track way

Precast floating slab for the laying of railway track

Tunnel lining formed by precast segments

Detail of the lining as seen inside the tunnel tube

Forming the station platform using precast curb and plank (KCR Tsim Sha Tsui Station)

Forming the cable hood

Delivery of the precast units

Forming the deck of the berth for the Container Terminal No. 9

Forming the deck of the Ting Kau Bridge using precast concrete plank

Precast concrete plank as cover to podium deck

Precast vertical panel forming an earth-reinforced type retaining structure

Forming storm water discharge culvert Tseung Kwan O Reclamation

Delivery and storage along the temporary seawall

Prepare for the foundation to support the culvert

Precast units to form the 4m high 5-cell culvert system in Tseung Kwan O

Positioning the Precast units onto the culvert alignment

Precast culvert in the form of semi-submerged tube Tsuen Wan West Reclamation as advanced work for the West Rail Tsuen Wan Station

Sinking of the precast culvert section

Positioning of the culvert section onto to formed bed

Connecting the culvert from the precast section to the in-situ section

Precast box as footing to bridge tower Tsing Ma Bridge tower on Ma Wan side

Precast box as pump house for water cooling system in the Central Reclamation

End of Presentation and Thank you

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