SEHS 3284

Construction Technology
& Materials II

Prefabrication /
Precast Concrete /
Modular Construction

Edmond Wong
 Prefabrication

Manufacture of different sections or
components that can be assembled later on
the site to form part a building

Usually fabricated in the factory

On-site or off-site

E.g. steel sections, door frame, curtain wall,
plasterboard, dry wall, cladding

Precast concrete – very popular (will be
discussed in detail)
2
Steel Truss – Exhibition &
Convention Plaza
3
 Prefabricated
Curtain Wall
Panel

4
 Precast Concrete - Advantages
1)Demand on Skilled Labour

Semi-skilled labour required on site for installation
of precast elements

Lower labour cost (wage gap: HK Vs. China)

Aging skilled labour force in HK
2) Reliable Quality Control

QC in factory – accurate, reliable

Substandard quality discard the products before
installation

RFID tag embedded in building products (e.g.
precast units)
5
 Traceability of Products
(Logistic, source of defective product)
RFID – radio frequency identification

6
7
8
Defective
Precast Slab
in Public
Housing (Sep
2016) 
trace the
source and
production
batch

9
3) Consistent & Higher Quality

Indoor working environment (shielded from
heat and rain)

Use of robot / machinery (consistent
workmanship) e.g. troweling

Vertical elements cast horizontally (e.g.
façade)  better compaction

Vibration table (e.g. slab) – compaction

Curing chamber – controlled environment:
temperature, humidity, pressure
10
Vibration table - compaction

11
Curing Chamber

12
Trowelling - finishing

13
3) Consistent & Higher Quality

Window frame cast BEFORE concreting
 lower risk of water leakage

Waterproofing layer applied to floor slab
in precast toilet  lower risk of water
leakage

External finishes (e.g. tiles) fixed on the
ground level (rather than working at height
on a scaffold!)

14
Window frame fixed before concreting

15
16
Source: www.hiphing.com.hk
17
4) Reduce No. of Separate Operations

Some elements (e.g. façade, toilet) involve a lot
of trades/sub-contractors

Different companies  conflicts

E.g. Trades involved in toilet: plastering,
painting, waterproofing, stonework, joiners,
suspended ceiling, plumbing/drainage,
electricity, gas

Precast factory : under the same
management; well-planned

18
5) Better Continuity of Operation

Production line  smooth operation, not
affected by weather, not affected by delay of
a particular trade

Must guarantee steady supply of precast
components/elements (logistic)

19
6) Faster Construction

No need to erect and strike formwork on site

No need to wait for the concrete to develop
strength

Progress not affected by weather

Avoid labour shortage affecting progress

20
7) Environmentally Friendly (Lean Construction)

Factory production Vs. Site production: reduce
wastage on materials

Good quality  minimum defective works 
lower demand on future repair and maintenance
works

Noise and air pollution– away from domestic
area

Replace timber formwork

Recycling (e.g. reinforcement, formwork)

Accurate ordering of material – avoid over-
ordering causing wastage
21
7) Environmentally Friendly (cont’d)

Smooth concrete surface  reduce /
eliminate finishes (direct painting or
tiling without plastering)

Hollow units  save materials

Hollow units  reduce dead load 
saving in structural components e.g.
foundation, columns

22
Hollow Precast Floor Slab

23
8) Prestressed Concrete

Fully utilize the strength of materials
(concrete and steel rebar)

Pre-tensioning to be carried out in the factory
(more difficult in site)

Thinner slab, no/shallow beam design 
save materials  save foundation cost,
reduce building height (thus less wind load)

E.g. Cambridge House in Quarry Bay used
U-shape pre-tension beam

24
Prestressed Beam and Flat-slab Design

25
9) Safer

Minimize work at height

tidier site – housekeeping

More machine/robot to substitute workers

Minimize weather exposure (heat, rain)

10) Higher Productivity


Use of machinery, e.g. vibration table for
compaction

Reduce demand on tower crane (lifting
reinforcement, concrete, formwork)
26
 Precast Concrete - Limitations
1) Lack of Flexibility (to change layout)

Difficult and expensive to change layout
design once committed i.e. freeze design

In-situ construction  more flexible (last-
minute change) WHY CHANGE?

DEVELOPERS NEEDS DESIGN
FLEXIBLITY to suit change of market,
customers’ taste/affordability, Govt. policy,
esp. in volatile market

27
2) Coordination Between Design & Construction

Construction details different for in-situ and
precast construction  early decision by
developers

Contractor is normally absent during design stage
and cannot advise on buildability

Procurement procedures: early award of window
supplier/contractor

Building services and finishes need to be
confirmed at early stage (freeze design)
28
29
3) Joints (more discussion later)

Precast units have a lot of joints

Movement on building – cracks easily developed
at joints  water leakage, cracks

Error in joint design or construction will result
water leakage; for structural precast elements 
affect structural integrity, building stability!

Monolithic joint (bonding with insitu concrete)
 better structural integrity, lower risk of crack

Dry joint – performance affected by
workmanship and durability of joint materials

30
Monolithic Joints on 2 sides
and at top
31
32
4) Insufficient Time

Contractor needs sufficient lead time
(say, 4 months), to liaise with precast
factory to prepare for the production,

e.g. prepare drawings and sample
approval, the mould/formwork,
arrange trial production + testing;
speed of production

Allow approval time – architect, E&M
consultant, Buildings Department
33
34
5) On-site Or Off-Site Production

On-site  lower transportation cost,
need more space on site; lower
dimensional limits; quality
inspection; high labour cost

Off-site  cheaper labour cost in
China but additional transportation
cost; weight and dimensional limited
by road traffic; possibility of
interrupted supply

Possibility of transportation by sea?
35
On-Site Casting Yard

36
6) Repetitive Design (e.g. Public Housing)

Repetitive  economy of scale

Hotel development  identical rooms

Public housing  standard and repetitive
design

Private development

different layout design from project to project 
uniqueness of project

Different layout from flat to flat  suit customers’
need/affordability

37
Example of standard design

38
7) Powerful Hoisting Plant

Heavy duty tower crane  more
expensive

Modular construction (3D/volumetric
precast) e.g. precast toilet

39
8) Ample Storage Space Required

Storage of precast units needs a lot of space
(more feasible for public housing)

Urban site (just-in-time delivery?)

40
 Factors to be Considered

4 Stages:
1. Design and Decision Stage
2. Factory Production Stage
3. Movement and Transportation Stage
4. Site Assembly Stage

41
42
 1) Design & Decision Stage

Financial feasible (GFA exemption)?

Technical feasible (structural / non-
structural) ?

How repetitive? public housing
(Harmony block) – standard design

Symmetrical is NOT repetitive

Joining methods: dry joints (bolt & nut,
dowel or weld), monolithic concrete
43
Symmetrical (e.g. flat D vs E)

44
1,2,3 Bedroom – suit customers’ need

45
 2) Factory Production Stage

Finalise design for panel size
(dimensional, weight factors), joint (type,
location), lifting and handling method,
mould manufacturing production line, etc.

Trial production + testing (e.g. water
tightness) before mass production

Modify design (e.g. joints) if water leakage
is found

46
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48
49
 2) Factory Production Stage

Speed of construction  delivery
schedule  production rate  number
of moulds and size of workforce,
quantity of concrete

Set up quality control procedures

Products clearly marked (or with
RFID)  easy to locate if defect is
found later
50
 Location
of Panel
Clearly
Identified

51
3) Movement & Transportation Stage

Prevent damage during storage or
transportation (protection of edges/corners)

Only be hoisted at the designated lifting
inserts, with specially-designed hoisting
frames/beams

Elements stacked and stored according to the
installation sequence

52
Proper storage – avoid excessive
stress
Designated Hoisting Hooks (Lifting Inserts)

Stacked according to
53 installation sequence
Tailor-made lifting beam and frame

54
Requirements on Facade Lifting Beam

55
3) Movement & Transportation Stage

Maximize the space utilization of lorry, by
mounting frame

Supporting frames used to secure the position
of elements (prevent overturning during
transportation)

Internal access road clear for delivery

Trial drive by vehicle – limitations on road
width, height, corner turns, etc.

Avoid disruption to traffic (timing)
56
Maximize Space Utilization

57
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3) Movement & Transportation Stage

May need to apply for traffic permits

By sea / road / both?

Road Traffic (Traffic Control) Regulations

Road Traffic (Construction and Maintenance
of Vehicles) Regulations

Dimensional limitations - Max. 4.6m tall;
2.5m wide; 24-44 tonnes

Just-in-time delivery?
60
 4) Site Assembly Stage

set-up full scale Mock-up for
demonstration and necessary tests (e.g.
water tightness test)

Full-scale facade units fitted on site

Site storage (occupy large areas) – site layouts;
tower crane lifting capacity

Adequate temporary support and bracing 
precast units are very heavy

Align and plumb the units carefully before final
fixing
61
62
Mounting Frames – Site Storage

63
 Dangerous
Goods Storage Steel Moulds
Storage 6.8 ton @ Dia =
Tower Crane 40m
Dangerous Good
Storage(HH)
10.4 ton @ Dia =
28m

Electrician Storage
12 ton @ Dia =
24m

S/C BEDNING YARD

Offices

Jump Lift at Lift

Shaft

Mobile
Toilet

Chemical Waste
S/C Storage
Rest Hut
Offices
(60P)
Waste Water
Treatment Plant

Concrete Curing Facility

Wheel Wash Machine

Site Entrance

Guard House
Kitchen and Toilet Setting Out Mock Out

Site Office
Alignment

65
66
Major Precast Concrete Elements
1. Façades
2. Semi-Precast External Walls
3. Staircases
4. Sub-Slabs
5. Toilet cubicles
6. Beams
7. Balcony
8. Dry wall
9. Pile 67
 Facades

Commonly used in public housing e.g. Harmony

Old joint: infill panel (leave an opening then fit
the panel inside the opening)  water leakage

New joint: monolithic joint (in-situ concrete) +
dry joint

Monolithic joint - lower risk of water seepage

Joints on 2 sides (left & right) + top joint –
monolithic

Bottom dry joint – neoprene strip/joint filler +
non-shrinkage grout (liquid form to fill up the
gap)
68
1st generation: Infill Panel – Weak Join

69
Monolithic (2
sides + top;
Bottom – dry
joint 70
 Precast Facades

Aluminum window frame fixed before
concreting  better waterproof performance

Cast horizontally  better compaction,
economy in formwork

Autoclaving and steam curing  better quality

External finishes applied before installation 
eliminate scaffolding  cheaper and safer

Watertightness test e.g. ASTM E331-00

71
Cast Horizontally (source: www.hiphing.com.hk)

72
Source: www.hiphing.com.hk
73
Aluminum
Window
Frame
Installed

74
Semi-Precast External Wall (other side of
the panel has already been tiled)

75
76
77
 Semi-Precast External Wall

A semi-finished concrete panel with its external
face already tiled (hence, may eliminate
scaffolding)

Precast concrete panel used as external face wall
formwork (permanent formwork)

Also called ‘Lost Form’ (because the precast unit
is ‘lost’ after concrete is cast)

Construction sequence: fix precast Lost Form 
install reinforcement/conduits  fix internal face
wall formwork  concreting to wall
78
 Semi-Precast External Wall

Advantages :

monolithic joint– lower risk of water leakage
and cracks

Joints – invisible, fewer

flexible layout design – length and profile of
wall

Can act as structural wall

Lighter – smaller crane; longer panel size

concealed services conduits can be installed
in-situ: flexible to change
79
Wall Reinforcement and Concealed Conduits Fixed
Lost form temporary supported by raking strut

80
81
 Precast Staircases

Traditional timber staircase –

time consuming because irregular shape;

congested – difficult to place concrete;

easily damaged due to traffic of workers

Precast staircase – immediately available for
transportation once fixed

Bonded to structure by dowel bars or
monolithic concrete

Semi-precast staircase – permanent formwork
with reinforcement already fixed
82
Convention
al Staircase

83
Precast Stair (www.hiphing.com.hk)

84
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86
Photo – dowel bars & Slots

87
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89
90
 Semi-Precast Slab

Also known as ‘Sub-Slab’

Used as permanent formwork

Supported by falseworks

Fix concealed conduits and top layer
reinforcement on top of sub-slab

Pour top layer of concrete to form in-situ
monolithic joints (with walls/facades and beams)

Good soffit finishes but have possibility of
cracks

91
Construction Sequences

92
93
94
Fix Top Reinforcement Bar

95
96
97
 Precast Toilet Cubicles


HSBC headquarters – the 1st building in HK
used the precast toilet cubicles

Made in Japan and shipped to HK

Becomes more popular in public housing

Ready to use once the electricity, plumbing
and drainage connected

98
 Precast Toilet Cubicles

Toilet fixtures and finishes takes a lot of
time and labour

Involves a lot of trades and works: P&D,
gas supply, electricity, plastering, tiling,
screeding, marble fixing, painting

Needs to protect finished products because
involves too many trades and workers

Waterproofing in factory  better quality

99
100
101
 Precast Beams/Columns
(structural)

Used in HK Jockey Club HQ, KCR Hunghom
extension, KMB Lai Chi Kok depot, PolyU
Hunghom Bay campus etc.

Structural joints are required to ensure
continuity of rebars

Closer supervision and quality control because
affect building stability

102
103
104
105
 Precast Balcony

balcony is a green feature and promoted by the
Govt.

Cantilever structure  structural integrity  must
bond to the structure with monolithic concrete

additional top reinforcement

concrete poured with the slab to form monolithic
joint

if the final balcony wall/railing need to be fixed in-
situ (e.g. glass wall), temporary railing required for
safety consideration
106
107
108
109
 Precast Partition Wall (Dry
Wall)

Traditional – brick, block walls (wet trade –
cement/sand mortar as bond)

Wet trade – generate a lot of wastes, untidy
(unsafe)

Dry wall – fixed by metal cleats with cartridge

Electrical conduits already cast in, connected to
protruded conduits from slab

Good surface finish – no or thinner coat of
plastering

Use hollow or light weight concrete to reduce the
dead load of dry wall
110
 Placed by Tower Crane
(before overhead slab is cast)

111
112
113
Lightweight Concrete Wall Panels

114
Traditional
Block Wall

115
116
 Precast Piles

Daido piles

Used as foundation in public housing

Pre-tensioning in factory – stronger bending
strength

Cheaper than bored pile but with vibration and
noise

117
 Precast
Concrete Piles

118
Precast Refuse Chute

119
Modular Integrated Construction (MiC)
https://www.bd.gov.hk/en/resources/codes-and-references/m
odular-integrated-construction/

Idea brought out in Chief Executive’s 2018 Policy
Address

BD’s definition: “Modular Integrated Construction (MiC)
refers to a construction whereby free-standing integrated
modules (completed with finishes, fixtures and fittings) are
manufactured in a prefabrication factory and then transported
to site for installation in a building”

GFA concession – 6% of MiC floor area (PNAP APP-
161; May 2019)

A PNAP ADV-36 (2017) sets out the requirements of MiC

https://www.bd.gov.hk/doc/en/resources/codes-and-references/practice-notes-and
-circular-letters/pnap/ADV/ADV036.pdf

120
6 modules to form a 3-bedroom
apartment

121
122
Double Wall/Slab in MiC modules

123
124
125
Modular Construction –
HKU, Science Park

126
127
Usage of Precast – Public Vs. Private

128
 Prefabricated External Wall in
Private Development

Precast concrete unpopular in private
development before because (1) less repetition;
(2) lower flexibility to change; (3) takes longer
time during design stage

Prefabricated external wall ‘suddenly’ becomes
popular in 2001

Government encourages green buildings

Joint Practice Note No. 2 (Second Package of
Incentives to Promote Green and Innovative Buildings)
https://www.bd.gov.hk/doc/en/resources/codes-and-references/pra
ctice-notes-and-circular-letters/joint/JPN02.pdf
129
 Prefabricated External Wall in Private
Development

Areas of non-structural prefabricated external
wall could be exempted from Plot Ratio and
Site Coverage calculation

Developers can build more floor area for sale

Extra revenues cover additional costs and loss
of flexibility

130
131
Abstract from a Sales Brochure
: Exempted GFA > 1,500 sq ft
132
 GFA Exemption – Cap at 10%

Public concern about ‘inflated’ floor area

Public consultation document issued in 2009 “Building Design
to Foster a Quality and Sustainable Built Environment”

Govt. decided to set a cap of 10% to GFA concession
(Buildings’ Dept. Practice Note APP-151)
https://www.bd.gov.hk/doc/en/resources/codes-and-references/practice-notes-and-circular-
letters/pnap/APP/APP151.pdf

Precast facade and other features (e.g. utility platform, club
house facilities, etc.) are included

The building design also need to be assessed by HK-BEAM;
pass accreditation  entitle the GFA exemption

Green Building Certification Label
https://www.hkgbc.org.hk/eng/beamplus-certlabel.aspx

133
134
Joints in Precast Concrete
Construction
 Functional Requirements of Joints

exclude wind and rain

allow for structural, thermal and moisture
movement

durable

easily maintained

maintain thermal and sound insulation
properties of the surrounding cladding

easily assembled

136
 Types of Joints
1. WET JOINT

Monolithic joint (in-situ concrete to bond
precast element with structure)

2. DRY JOINT

Single-Stage Joint

Filled Joint

Gasket Joint

Multi-Stage Joint

Drained Joint

137
 Monolithic joint – washed
surface to expose aggregate

138
Wet Joint in Lost Form

139
Wet Joint in Lost Form

140
 Filled Joint
– Z shaped
between
facades of
upper and
141
lower floors
142
Bottom Dry Joint
143
 n -si t u s la b
o n d with i
t – b
Top Join

Monolithic Joint – in-situ wall

bonded with precast facades
Non
-shr
ink
g rou
t to
fill
t he
Bot
t om
join
t

144
145
146
 Joints – Precast Concrete
Filled Joint Gasket Joint Drained Joint Monolithic Joint

Mechanism Adhesion (of Pressure exerted on 1) Physical barrier In-situ concrete

sealant) gasket (baffle) bonding
2) Cavity
Constructio Dry joint Dry joint Dry joint Wet joint
n method
Complexity Simple, single- Simple, single- More complex; 2 Simple but need
/ Easiness stage stage stages rebar fixing +
formworking +
concreting

Speed Fast Fast Fairly fast Slow

Possible Adhesion failure Movement / poor Workmanship – Poor
defects (unclean surface, dimensional control installing workmanship
excess / deformation will components (baffle,
movement) affect pressure flashing, air seal)
weather attack
Reliability Low Low 147 Higher Highest
Filled Joint

148
Filled
Joint

149
 Filled Joint

Adhesion of sealant to seal off joints

Easy to apply but not very reliable

Common failure – poor adhesion (remove dirt,
grease, oil before apply sealant)

Vulnerable to movement and weather attack

Applied flush or set-back (avoid weathering)

Failed if under excessive compression or
elongation
150
Gasket Joint

151
 Gasket
Joint

152
 Gasket Joint

Working mechanism : pressure exerted on the
gaskets to provide a weathertight seal

Rubber gaskets: compressible, high elastic
recovery, good resistance to weather attack,
impermeable to water and moisture

Accurate dimensional control  affect
pressure

Minor deformation or unevenness  joint
failed because insufficient pressure

Excessive pressure may also damage the
joint material
153
Drained
Joint

154
155
 Drained Joint

Neoprene baffle to divide the joint into 2 parts

Outer part: baffle to stop water to pass through
and drain the water away with the aid of
flashing

Inner part: air barrier to reduce the wind
pressure difference (pressure equalization)

Additional compressive joint material may be
added to enhance the waterproof performance of
the joint
156
Metazeal – Air Seal (Compressive Joint Material)

157
Air
Seal

Flashing

158
 Air
Seal

159
 Air
Seal

Baffle
(U-shaped)

160
Horizontal & Vertical Joints of
4 facade units

161
 Joints in Structural Precast Elements

Major concern for structural elements: integrity
and continuity of structural elements like rebars

Splice sleeves are used to connect the rebars

Air space inside the sleeves will then be filled
up by cement grout

Structural precast elements are not popular in
HK because of concern of quality control and
there is no GFA exemption

162
 Joints in Structural Precast Elements

the HK Housing Dept. had
a pioneer projects, Kwai
Chung Flatted Factory
Redevelopment, where up
to 60% of the concrete
elements were precast,
including structural
elements

They named it as
‘Enhanced Precast and
Prefabrication System Volumetric (3D)
(EPPS)’ bathroom-cum-kitchen
unit
163
Ove
rflo
w
Gro
ut i
n

164
165