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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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 preparedby 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 PrefabricatedTechnology in Building Construction in HK
1. Had been used once in early 1970s in a pilot project toconstruct a series of 17-storey public houses
2. Used in a broader scale in the mid/late 1980s in theconstruction 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 theHong 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 stationpodium employed large amount of prefabricated elements of which some were primary structural members (1997 onward)
8. Popular use of prefabricated external wall from 2002 onwardin residential buildings due to the introduction of a newguideline encouraging the use of precast façades as a formof 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 HarmonyBlock using after-fix façade
Later version of Harmony Block using inisitu
façade cast at the same time with structural walls
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Precasting yard was set up toproduce precast elements for publichousing projects in early to mid 1990
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After-fix façade system requiredthe formation of small amount of in-situ joint and grouting thateasily caused leaking problem
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Detail of façade installationusing in-situ jointing
arrangement in the later versionof Harmony Block Construction
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Forming the floor slab in theHarmony Block constructionusing semi-slab (right) andaluminium formwork (above)
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Introduction of mechanical
formwork systems incorporatingthe standard precast elements inthe construction of latest versionof public houses in the late 1990
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Public houses using Concord
design with special emphasison the use of mechanicalisedconstruction system
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Layout of the ConcordBlock showing theposition of the cast-in-situ core wall, shear walls and precast façade
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Other pioneered projects in theearly 1990 constructed usingsemi-prefabricated concept
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The construction of the Headquarter and MembersFacilities Complex for the Hong Kong Jockey Club
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Forming the floor slab using precastsecondary beams and semi-slab for the mainbuilding (above) and members’ complex (right)
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Detail of the floor system with thecast in-situ main beams and theplace-in precast secondary beams
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Government quartersin 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 internalpartitions are also introduced
D t il f th f d d
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Detail of the façade andthe lintel beam installation
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Installation of the cast-in-situprecast internal partition
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Construction of special buildingsusing high proportion of precast
since 1998
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Kowloon Canton RailwayStation podium/deck
Construction of the KowloonCanton Rail podium deck –cargo handling bay on theground level and on top for alarge-scale residentialdevelopment afterward
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Forming of the cast-in-situ main beams
J i ti d t il f th
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Jointing detail of themain beam and precastsecondary beams
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Semi-slab with RCtopping to form thecomposite podium deck
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Kowloon Motor BusMaintenance Depot
- 3-level depot buildingwith columns, main andsecondary beams all inprecast
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Erecting of the building frameusing precast columns and beams
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Connecting the precast column to thefoundation 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 bystitching, a means to provide anin-situ joints with rigid RC links
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Detail of the beam/columnand beam/beam joints
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Recent Residential/CommercialDevelopments using prefabricated
concept to construct
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Residential developmentat Cyber Port
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Façade and general installation details
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Features in the construction –
large amount of external wallsare constructed in precastfaçade untis, with major structural links tie back to theinner shear walls and floor slab
Incorporation of other sophisticated formwork in construction –
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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 Developmentat Taikoo Valley
Construction features –the use of large amountof precast units both of structural or architecturalnature. This includes the
balcony, façade units,loss-form for externalwalls and some shadingfins.
Detail of the precast balcony unit
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Detail of the loss-form
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Residential developmentat Ma Tau Wai
Overview of the precast
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installation arrangement
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Façade installation detailas seen on the floor deck
Cambridge House – a 42-storey
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Office Building at Quarry Bay
Features in construction –
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precast beam trough andprecast sub-slab with RCtopping forming the floor system
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Placing of the precast beam troughto form the floor layout
R t A hi t f H K ’
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Recent Achievements of Hong Kong’s
Prefabricated Technology
• Previous defects such as leakage problems have beenimproved
• 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
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Future Trend in the application of
Prefabricated Technology in Hong Kong1. 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 designsuch as using at the same time with structural steel
5. Apply prefabrication more to medium-rise buildings withmore standardized structural items
6. Improve the supply chain management to makeproduction more efficient and economical
Practical Constraints
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1. Tighter coordination to allow for structural design,construction planning, procurement & approvalprocedure
2. Required a critical amount of precast items before workcan be economically used
3. Huge work space for handling precast elements
especially in congested urban environment in HongKong
4. Congested site environment makes access anddelivery of heavy precast units to the work spotbecomes difficult
5. Quality assurance become critical especially wherelarge amount of precast components are used asstructural nature
Examples of very congested
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Examples of very congestedconstruction environmentwhere prefabrication approachis adopted
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Example of Innovative Project (Local)
The Integer
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The Integer Houseat Admiralty
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Floor plan of the experimental house
The orking concept
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The working concept
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
BuildingSection
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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 themodulated dwelling units
Close up look of the modulated dwelling
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Close up look of the modulated dwelling
units and the linking structure in theform of a access corridor
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View as seen onthe 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
BuildingSection
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Floor plan
Connecting the modules
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Prefabricated Construction
Application in Civil Works
Examples of application of prefabricatedtechniques in civil construction works
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techniques in civil construction works1. Used in highway projects such as cantilevered deck
of elevated bridge, parapets of expressway and road
curb2. Precast girder units or beams for elevated roadway
(viaduct)
3. Precast beams or decks for elevated pedestrianfootbridges
4. Tunnel lining especially for tunnel formed by tunnelboring machine
5. Decks for long span bridges
Examples of application (continue)
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6. Marine work such as seawall and deck of terminalberth
7. Soil retaining element such as for earth-balancedtype retaining structure
8. Platform for railway station
9. Parapets and noise barrier panels
10. Overhanging ducts or services channels for
underground facilities11. Nullah section for storm water discharge
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Elevated pedestrianfootbridge in Mong Kok
Piers formed usingprecast column
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precast column
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Precast girder erected
on top of the piers toform the main span of the footbridge
Extending precast plank toform the deck of the footbridge
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Structural arrangementof the footbridge
Precast V-shape beamfor the Route 3elevated expresswayat Kwai Chung
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g
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 theslung 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 todeck level for erection usingmobile crane
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Placing the precastgirder in position
Project example – Road T7 in Ma On Shan (TTD project)
Technical Features
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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
Overview of the
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Overview of thelaunching 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 applicationin civil engineering works
Precast parapet unit for the highwayand railway road/track way
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Precast floating slab for the laying of railway track
Tunnel lining formedb
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g by precast segments
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Detail of the lining as
seen inside the tunnel tube
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Forming the station platformusing 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
Precast vertical panelforming an earth-reinforcedtype 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 4mhigh 5-cell culvert system inTseung Kwan O
Positioning the Precast units
onto the culvert alignment
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Precast culvert in the formof semi-submerged tube – Tsuen Wan WestReclamation as advancedwork for the West Rail
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work for the West RailTsuen Wan Station
Sinking of the precastculvert section
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Positioning of the culvertsection onto to formed bed
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Connecting the culvertfrom the precast section
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to the in-situ section
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Precast box as footing to bridgetower – Tsing Ma Bridge tower on Ma Wan side
Precast box as pump house
for water cooling system inthe Central Reclamation
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End of Presentation
andThank you