Pre-fabrication adopted in HA

Prof. Joseph Y.W. Mak

Overview of Public Housing in
Hong Kong
• High rise residential
construction.
• Relatively fast speed of
construction to meet
waiting list demand.
• Modest cost of
development for lower
income sector.
• Material and labour cost
are high due to high cost
of living.
Overview of Public Housing in
Hong Kong (cont’d)
• Redevelopment of old existing
housing blocks to modern
domestic living habitat.
• Committed to quality of living in
terms of environment and
sustainability.
• Quality of works is not
compromised to meet public
expectation and to sustainably
reduce future maintenance.
Characteristics of Public Housing
Construction in Hong Kong
Standardization

Prefabrication

Mechanized Construction
Standardization to Modular
Flat Designs
• Taking the benefit of mass flat
production, but bearing in mind
the impact of prototype blocks,
we target for standardization of
flat units only.
• This has replaced the standard
block designs which we have
adopted in the past three
decades.
Standardization to Modular
Flat Designs (cont’d)
• Building skeleton components
such as facades, slabs,
staircases, partition walls and
beams are standardized to form
modular flat units.
Standardization to Modular
Flat Designs (cont’d)
• Building fabric components
such as windows, bathroom
and kitchen fittings, doors,
metal gatesets are
standardized for factory
manufacture.
Standardization to Modular
Flat Designs (cont’d)
• Blocks are assembled using
these modular flat units within
layout, but outlook of blocks
can be unique and different.
Prefabrication

• Prefabrication of concrete
components is essentially
the construction method
which transfers some of the
difficult insitu reinforced
concrete construction from
working floor to factory.

• The transfer is also from

elevated construction on site
to construction on ground in
factory.
Mechanized Construction
• Mechanized construction
comprise primarily the use of
tower crane to move around
steel formwork, concrete skips
and precast components. The
transportation is between
ground and working floor and
between different wings of
working floors. The Hong
Kong Housing Authority (HA)
has adopted this approach
early in the 80’s.
Mechanized Construction
• For elevated construction
using traditional methods, it is
often difficult to construct at
locations which are difficult to
access.

• Substantial falsework and

working platforms may be
required. In case timber
formwork is used, the
workmanship may deteriorate
after repetitive construction.
Mechanized Construction
• Large panel steel wallforms
are used in HA which
replace timber formwork.

• Large panel formwork was

mandatorily introduced in
the mid 80’s.

• It was a pioneer
environmental initiative to
reduce the use of timber.
Prefabricated Systems
Prefabricated Components
Precast Facades
Purpose
• To tackle the complicated
profile by casting on
ground.
• To cast-in windows to
prevent water seepage.
Prefabricated Components
(cont’d)
Technical Considerations
• Horizontal cast (wall as slab)
• Sophisticated steel mould
with removable mechanism.
• Applying finishes in factory
and on ground.
Prefabricated Components
(cont’d)
• Design to be supported on
either side by structural
walls; not to accumulate
the loadings to lower
floors.
• Horizontal water proof
joint.
• Vertical insitu joint, to
ensure no structural
movement.
HORIZONTAL JOINT VERTICAL JOINT
BETWEEN UPPER & BETWEEN FACADE AND
LOWER FACADES WALL
Prefabricated Components
(cont’d)
Semi-precast Slab
Purpose
• To avoid using substantial
insitu formwork and
falsework, hence neater
construction.
• To provide quality surface
finish at soffit of slab.
• To house concealed
conduits within slab
thickness.
Prefabricated Components
(cont’d)
Technical considerations
• By ‘composite’
construction, i.e. precast
plus insitu.
• Formwork at slab soffit is
hence not required, only
vertical props for
supporting the semi-
precast slabs.
Prefabricated Components
(cont’d)
• Insitu portion at upper part
allows incorporation of
concealed conduit runs
before adding top
reinforcement.
• Slab width within 2.5m to
facilitate transportation by
trucks.
Prefabricated Components
(cont’d)
Precast Staircase
Purpose
• Staircase is normally confined
in a limited space within the
staircore. Insitu construction
is difficult and sometimes
dangerous due to possible
movement of falsework.
• Precast staircase is simple to
produce in factory and easy to
install on site.
Prefabricated Components
(cont’d)
Technical considerations
• Connection at supports by
dowel bars and box-outs,
to be grout filled
afterwards.
• Early completion to allow
passage during
construction period.
Prefabricated Components
(cont’d)
Precast Partitions
Purpose
• Two types of precast partitions :-
(i) Lightweight partitions
(ii) R.C. partitions
Prefabricated Components
(cont’d)
• Lightweight partitions are
either by aerated concrete or
hollow tube panel.
• Lightweight partitions are to be
erected after construction of
structural frame, to serve as
partitions but eliminate wet
trade (previously by
blockworks).
Prefabricated Components
(cont’d)
Technical considerations
• R.C. partitions are thin
partitions which is difficult
to construct vertically by
insitu method.
• R.C. partitions often for
FRP reasons or for sound
insulation, are better cast
in factory and horizontally.
Prefabricated Components
(cont’d)
• Concealed conduits could
be installed within panels
or incorporated on site.
• Panels placed into position,
jacked up and mortar filled
at bottom.
Prefabricated Components
(cont’d)
Precast Tie Beams
Purpose
• These tie beams are located
in elevated positions
unsupported by floor slabs.
Construction is difficult in
terms of erection of falsework.
• Precast tie beams are easier
to install, mainly to make the
connections at supports.
Prefabricated Components
(cont’d)
Technical considerations
• Relatively simple, since
these tie beams are
normally short span.
Prefabricated Components
(cont’d)

E. Volumetric precast bathroom

a) Purpose
• To precast a box-type
structure to embody
numerous pipe ducts,
fittings, tiles, waterproofing
membranes etc.
• A lot of wet trade could be
transferred to the factory
which is a better controlled
working environment.
Prefabricated Components
(cont’d)
• From past experience,
bathrooms and kitchen
areas are locations
which call for frequent
maintenance
throughout their life
spans.
Prefabricated Components
(cont’d)
• Precast bathroom placed
in storage area.

• Waterproofing is applied
on the bottom slab with
certain upstand at the
four edges.
Prefabricated Components
(cont’d)
• The floor tiles are layed
subsequently, with
attention to drain and fall.
• All precast bathroom are
water test by ponding
and the bathroom is only
accepted for delivery if
there is no leakage from
the underside of floor
slab.
Precast Roof Water Tanks
 Prefabricated components (cont’d)
F. Prefabricated Roof
Water Tank
• A semi-precast water
tank was first
prefabricated in the
factory, then delivered
to site and insitu cast
the inner portion
(yellow)
• The purpose is to
reduce the weight
for delivery and for
saving the setting
up formwork and
falsework at roof.
 F. Prefabricated Roof Water Tank
• Semi-precast tank comprise of two types, mainly
differentiated by weight. The first type is a smaller
tank capacity, which can be cast totally semi-
precast. The second type has a larger capacity ,
which cannot be fully semi-precast, but has to be
cast in two portions, then insitu connected on site.

• In addition, for both types of water tanks, the top of

the tanks will be fully precast.
 F. Prefabricated Roof Water Tank

• Reinforcement of
water tank was fixed
in factory and then
cast with concrete.
• Tank completed with
adequate concrete
strength will then be
delivered to site.
• The benefit of casting
in factory is to allow
the tank be inspected
for defects before
delivery.
 F. Prefabricated Roof Water Tank

• For larger sized water

semi-precast tank, it can
be fabricated in two
portions in factory, then in-
situ connected on site.
• Since the two semi-
precast portions has set
the framework, the
formwork can be easily
erected on site.
• In addition, the water
pipings can be installed
with better accuracy.
Prefabricated Roof Water
Tank
• Water tank top cover was
precast in the factory and
on ground, which is much
easier to cast than insitu
on site.
• In addition, the joint
between the water tank
and the top cover is
above the top water level,
hence no problem of
leakage at the joint.
Formwork Systems
Large Panel Steel Formwork

• Large panel steel formwork is

robust and in one single piece,
without vertical joints within
the panel. As a result, no
vertical marks due to grout
leakage on wall face after
dismantled.
• Off-form wall surface are
smooth and no undulating
profile.
Large Panel Steel Formwork

• Large panel steel formwork

saves the need for carpentry
which are expensive skilled
labourers nowadays.
• It can be used when the flat
units are relatively
standardized in residential
buildings.
Aluminium Formwork

• Aluminium formwork panels

are smaller in size, normally
600 mm in width. They are
assembled into one big panel
piece by connecting with bolt
joints.
• As a result, they are more
flexible in fitting different
shapes and dimensions.
• They are transported and
assembled by manual labours
because of their smaller sizes.
Aluminium Formwork

• Aluminium formwork panels

have still the drawback of
possible vertical joint marks,
though far less significant than
those produced by timber
formwork.
• Compared with large panel
formwork, it is more expensive
because of the cost of
material, i.e. aluminium is
more costly than steel.
Construction Cycle
Construction Cycle

• HA adopts 6 days cycle, with one tower crane per block.

• Design facilitates rotation symmetry, allowing large panel

steel formwork for one half floor to be rotated such that no
formwork needs to be transferred to ground level.

• Major activities include:-

(a) Dismantling and erection of large panel formwork
(b) Installation of precast facades
(c) Laying of semi-precast slab on falsework
(d) Fixing of wall reinforcement and laying of steel fabric
on top of semi-precast slab
(e) Concreting to walls and slabs
Construction Cycle ( Day 1 )
Construction Cycle ( Day 2 )
Construction Cycle ( Day 3 )
Construction Cycle ( Day 4 )
Construction cycle ( Day 5 )
Construction cycle ( Day 6 )
Precast in High Rise Buildings
Prefabrication for High Rise
Construction
• There are several important
considerations to facilitate use of
prefabrication in high rise construction:-
• Symmetry in Layout Design
If the layout can be designed to be
symmetric, or as far as possible
symmetric, the prefabricated steel
formwork can be rotated from one
wing to another, thus avoiding the
transfer of formwork to ground level.
The no. of types of precast elements
could also be largely reduced, hence
more repetitive use of steel moulds
and simplify logistics.
Prefabrication for High Rise
Construction (cont’d)
Symmetry of layout could also greatly enhance the
tower crane capacity as the reach of the crane
can be optimized. Sometimes, if the block is
very asymmetric, two instead of one tower crane
may be required.
Prefabrication for High Rise
Construction (cont’d)
• Dimensional Accuracy of precast
elements
Precast construction calls for high
precision; otherwise it cannot
fit into and interface with
insitu construction as
formwork is also
prefabricated.
Where precast is connecting to Insitu concrete walls
precast, such as non-wind
resisting elements, accuracy Precast Façade
is also vital. (Dimensional
accuracies are very
Generally, a maximum of 4mm important as very
tolerance between each tight tolerances
connection is allowed. could be allowed)
Prefabrication for High Rise
Construction (cont’d)
• Transportation from Factory
to Site
Width of precast element
has to be limited to less
than 2.5m for truck
transportation.
Transportation is preferably
by road, and ‘just in
time’ to minimize
storage on site.
Prefabrication in Factory
 Steel Cut &
Semi-automatic Bend Yard
Production Line

Ready-
mix
Concrete
Plant

Transportati- Production
on Route Line
Factory Layout

A. Transportation Route
• Transportation route
between production
lines must have
adequate width,
allowing large trailors
to move, and
facilitating the gantry
to lift the components
onto the trailors.
Factory Layout
B. Production Line
• Production line should
as far as possible be
carried out in covered
factory, particularly for
concreting which will not
be affected by rain.
• If the works involved can
be carried out under the
sun and time is not a
constraint, such as
applying finishes,
production line can also
be not covered.
Factory Layout
C. Cut and bend and
cage fabrication yard
• If steel cut and bend
and can be carried out
in covered factory, the
working condition is
much better and
quality can be better
assured.
• For cage fabrication
like that used for
precast bathroom,
reinforcement cage
can be carried out in a
steel frame.
Factory Layout
D. Ready-mix plant
• Concrete mixing and
batching plant is set
up in factory,
supplying all precast
concrete production.
• All the raw materials
and ready mix
concrete are under
stringent quality
control.
Factory Layout

D. Ready-mix plant
• The transportation of
ready-mix concrete
within the factory is
by way of ready-mix
trucks. Upon arrival
to the covered factory,
the concrete is
delivered to the
casting point using
concrete skip.
Factory Layout
E. Lifting Gantry
• Lifting gantry is essential
for both covered or
uncovered production lines.
It runs on rails either on
ground or overhead, to lift
up heavy precast
components, steel moulds
and raw materials.
• At the same time, it can
trasfer materials from
covered factory to external
yard and then in turn to the
trailors and trucks for
delivery.
Factory Layout
F. Factory Storage
• Stacking and storage
of precast units need
to be done
systematically in
order to protect the
components from
damage. At the same
time, the units after
off-formed needs to
be regularly sprayed
with water and/or
covered with plastic
sheet to ensure
proper curing.
Factory Layout
G. Semi-automatic
production line
• For semi-precast slab
production, it can be done
semi-automatically.
• The steel mould together
with the fixed reinforcement
can be transfered via rollers
to the concreting room for
concreting, as different from
the conventional method of
casting each individual piece
on spot.
• It saves the procedure of
delivering concrete and
moving labourers to every
spots for concreting.
Factory Layout
G. Semi-automatic
production line
• Semi-precast slabs
can be cast in the
same concreting
room, with the
workers and
vibrating table all
stationed at the
same point.
• It saves both
labours and
equipment.
Factory Layout
G. Semi-automatic
production line
• Ready mix concrete
can be transferred
directly from the
batching plant via
conveyor belt to the
concreting room,
without the use of
ready mix trucks.
• If necessary in
winter or for
meeting tight
schedule, the slab
can be put into
enclosed tank for
steam curing.
Factory Layout
H. Steel moulds
• Steel mould in precasting is
a significant investment.
For the case of facades, if
the design of facades can
be standardized as far as
possible, the steel mould
can be reused many times.
• One type of facade moulds
is the lift up type whereby
the vertical returns are
made to be inclined to
facilitate the lifting
operation.
Factory Layout
H. Steel moulds
• Another type of facade
mould is the rotating steel
mould, turning 90o from
horizontal to vertical.
• When the mould is
vertical, it can be
demoulded like a wall
formwork.
Factory Layout
H. Steel moulds
• The advantage of the lifting
type of facade mould is
that it saves the rotating
frame, thus reducing the
cost of the mould system.
However, it has to wait for
the concrete to gain
strength before the
concrete can be lifted and
demoulded.
• For the rotating mould, the
facade can be demoulded
earlier, allowing the mould
to be reused, hence
speeding up the production
cycle.
How should young professionals
prepare for DfMA
Training

Whilst the MIC are now undergoing in various pilot projects in

Hong Kong, pushing the construction methodology to a new era, it
is considered necessary to educate and train up majority of
engineers at the professional and working level who have not the
opportunity to participate in prefabrication construction. In the
building construction industry in Hong Kong, except those who
have been involved in public housing, those working in other
government building projects and in the private sector may not
have the chance to experience the prefabrication technology.
Training

CIC would like to organize a series of training seminars on same

targeted to :
(a) design and project engineers of consultants
(b) design and site engineers of contractors and
(c) project and construction managers of clients and
contractors.
It is hoped that after these working level training, the industry can
pick up the technology and practice when the MIC is widely
adopted both in public and private sector.
Training

Day 1

AM Session 1 - Design of Precast Concrete Components

Session 2 – Manufacture in Factory

PM Session 3 - Delivery and Erection on Site

Session 4 – Quality Assurance

Day 2
Training

Day 2

AM Session 1 - Precast Construction in Japan

Session 2 – Precast Construction in Singapore

The End