prefabricated
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Prefabricated Construction Systems for Building and Civil works
adopted in Hong Kong
Presented by
Raymond W M Wong
Division of Building Science & Technology
City University of Hong Kong
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The presentation is based on a paper prepared by Raymond Wong for the
World Congress on Housing Process & Product,
Organized by the International Association for Housing Science
and hosted by the Concordia University,
Montreal, Canada, June 2003
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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 façades of the flats were constructed in precast in a after-fixed manner
3. Improvement to public houses by introducing in-situ joined façade 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
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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 façades as a form of green elements in construction (exemption of Gross Floor Area)
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Generations of Public Houses (Harmony Block) constructed
using semi-prefabricated concept
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First generation of Harmony Block using after-fix façade
Later version of Harmony Block using inisitufaçade cast at the same time with structural walls
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Precasting yard was set up to produce precast elements for public housing projects in early to mid 1990
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After-fix façade system required the formation of small amount of in-situ joint and grouting that easily caused leaking problem
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Detail of façade installation using in-situ jointing arrangement in the later version of Harmony Block Construction
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Forming the floor slab in the Harmony Block construction using semi-slab (right) and aluminium formwork (above)
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Introduction of mechanical formwork systems incorporating the standard precast elements in the construction of latest version of public houses in the late 1990
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Public houses using Concord design with special emphasis on the use of mechanicalisedconstruction system
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Layout of the Concord Block showing the position of the cast-in-situ core wall, shear walls and precast façade
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Other pioneered projects in the early 1990 constructed using semi-prefabricated concept
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The construction of the Headquarter and Members Facilities Complex for the Hong Kong Jockey Club
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Forming the floor slab using precastsecondary beams and semi-slab for the main building (above) and members’ complex (right)
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Detail of the floor system with the cast in-situ main beams and the place-in precast secondary beams
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Introduction of prefabricated concept to construct government
quarters in 2000
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Government quarters in West Kowloon
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Layout of the quarter building showing typcial phasing arrangement of work
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Features in the construction –extensive use of precastfaçade and lintel beams, precast cast-in-situ internal partitions are also introduced
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Detail of the façade and the lintel beam installation
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Installation of the cast-in-situ precast internal partition
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Construction of special buildings using high proportion of precast
since 1998
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Kowloon Canton Railway Station podium/deck
Construction of the KowloonCanton Rail podium deck –cargo handling bay on the ground level and on top for a large-scale residential development afterward
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Forming of the cast-in-situ main beams
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Jointing detail of the main beam and precastsecondary beams
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Semi-slab with RC topping to form the composite podium deck
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Kowloon Motor Bus Maintenance Depot
- 3-level depot building with columns, main and secondary beams all in precast
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Erecting of the building frame using precast columns and beams
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Connecting the precast column to the foundation cap with a base plate
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Placing the secondary beams onto the main beam
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Connecting beams to columns by stitching, a means to provide an in-situ joints with rigid RC links
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Detail of the beam/column and beam/beam joints
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Recent Residential/Commercial Developments using prefabricated
concept to construct
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Residential development at Cyber Port
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Façade and general installation details
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Features in the construction –large amount of external walls are constructed in precastfaçade untis, with major structural links tie back to the inner shear walls and floor slab
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Incorporation of other sophisticated formwork in construction –steel gang form for walls and table form for floor
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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, façade units, loss-form for external walls and some shading fins.
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Detail of the precast balcony unit
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Detail of the loss-form
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Residential development at Ma Tau Wai
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Overview of the precastinstallation arrangement
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Façade installation detail as seen on the floor deck
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Cambridge House – a 42-storey Office Building at Quarry Bay
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Features in construction –precast beam trough and precast sub-slab with RC topping forming the floor system
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Placing of the precast beam trough to form the floor layout
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Recent Achievements of Hong Kong’s 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
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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
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Practical Constraints1. 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
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Examples of very congested construction environment where prefabrication approach is adopted
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Example of Innovative Project (Local)
The Integer
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The Integer House at Admiralty
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Floor plan of the experimental house
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The working concept
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Typical connection details
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Assembly of the 3-D modules
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Possible future development for high-rise structures using similar concept
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Example of Innovative Project (overseas)
The Habitat 67 in Montreal, Canada
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Building Section
Habitat 67 as seen along the bank of St Lawrence River
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Habitat 67 as seen along the bank of St Lawrence River
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Close up look of the modulated dwelling units
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Close up look of the modulated dwelling units and the linking structure in the form of a access corridor
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View as seen on the deck level
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Forming and Installation of the modulated units
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Installation of the modulated units and the associated structure
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Building Section
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Floor plan
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Connecting the modules
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Prefabricated Construction
Application in Civil Works
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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
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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
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Elevated pedestrian footbridge in Mong Kok
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Piers formed using precast column
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Precast girder erected on top of the piers to form the main span of the footbridge
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Extending precast plank to form the deck of the footbridge
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Structural arrangement of the footbridge
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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
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Precast box-girder for the Rambler Strait Bridge of Route 3
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Forming the elevated bridge of the West Kowloon Expressway
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West Kowloon Expressway –installing the precast box girder using balanced cantilever method with the help of track mounted gantry crane
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Forming the elevated track of the West Rail using the slung launching girder
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Forming the elevated track of the West Rail using the longitudinal steel support beam
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Forming the elevated track of the KCR Ma On Shan Line by precast girder and lifted to deck level for erection using mobile crane
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Placing the precastgirder in position
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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
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Construction of highway bridge using precast box-girder (viaduct) –Road T7 in Ma On Shan
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Early stage of the project –formation and forming the piers for the viaduct
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Overall layout of the precasting yard
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Forming the box-girder units
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Formwork to form the inner void of the box-girder units
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Overview of the launching machine
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Drawing provided by China Harbour Engg. Co. (Group)
Launching sequence of the box-girder units using launching machine
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Installation of the box-girders
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Installation of the box-girders
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Other example of application in civil engineering works
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Precast parapet unit for the highway and railway road/track way
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Precast floating slab for the laying of railway track
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Tunnel lining formed by precast segments
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Detail of the lining as seen inside the tunnel tube
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Forming the station platform using precast curb and plank (KCR Tsim Sha Tsui Station)
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Forming the cable hood
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Delivery of the precast units
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Forming the deck of the berth for the Container Terminal No. 9
Forming the deck of the Ting KauBridge using precast concrete plank
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Precast concrete plank as cover to podium deck
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Precast vertical panel forming an earth-reinforced type retaining structure
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Forming storm water discharge culvert – Tseung Kwan O Reclamation
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Delivery and storage along the temporary seawall
Prepare for the foundation to support the culvert
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Precast units to form the 4m high 5-cell culvert system in Tseung Kwan O
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Positioning the Precast units onto the culvert alignment
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Precast culvert in the form of semi-submerged tube –Tsuen Wan West Reclamation as advanced work for the West Rail Tsuen Wan Station
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Sinking of the precastculvert section
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Positioning of the culvert section onto to formed bed
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Connecting the culvert from the precast section to the in-situ section
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Precast box as footing to bridge tower – Tsing Ma Bridge tower on Ma Wan side
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Precast box as pump house for water cooling system in the Central Reclamation
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End of Presentationand
Thank you
If you require more information about the Author’s recent work on various
technology topics, you can enter his homepage at
http://personal.cityu.edu.hk/~bswmwong/