Design and Construction of

Tai Po Water Treatment Works Expansion

20 March 2014

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Programme

Project Background and Procurement Strategy by Ir P. W. LAM

Design Challenges by Mr. Stephen TING

Construction Challenges by Ir Roger P. F. LEUNG

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Expansion of Tai Po Water Treatment Works

Background and Procurement Strategy

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 Tai Po Tau Raw Water
Pumping Station
Lam Tsuen

Tai Po Road
(Tai Wo Section)

Tai Wo MTR
Station

Tai Po WTW

Tolo Highway

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Birds-eye View

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 Existing Facilities

SRGF I DAF I

PBF I
TPFWPS

PAC

SPH

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CB II 3
CB III 1
CB I
CSB

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 Part 2
150 Mld
Commissioned 400 Mld
in 2011 To be commissioned 400 Mld
Part 1 No programme
in 2017
250 Mld
Commissioned
in 2003

Stream I Stream II Stream III

= Total 1,200 Mld
Purpose of Stream II works :
Facilitate in-situ re-provisioning of Sha Tin WTW
Enhance overall resilience, flexibility and reliability of water supply

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Tai Po WTW Stream I Supply Zone (Kln)

West Kowloon

Central Kowloon

Western

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Tai Po WTW Streams I & II Supply Zone (Kln)

West Kowloon

Central Kowloon

Western

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 Stream II Implementation Programme

Contract Contract Contract Scheduled

Scope of Works Contractor Start Date
No. Type Sum Completion

Design & Construct new

China State
15/WSD/10 Build Stream II 3,252 M 6/2/2013 5/2017
ATAL JV
Contract at Tai Po WTW

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Contract No. 15/WSD/10 - Scope of Works

Expanding the treatment capacity of the existing Tai Po

Water Treatment Works from 400 Mld to 800 Mld;
Increasing the pumping capacity of the existing Tai Po Tau
No. 4 Raw Water Pumping Station from 400 Mld to 800
Mld; and
Increasing the pumping capacity of the existing Tai Po Fresh
Water Pumping Station from 400 Mld to 800 Mld.

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Contract No. 15/WSD/10 - Scope of Works

SRGF II

DAF II

OGB

PBF II
SPH PCT II & III

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 To be
Design Construction
presented by
Challenges Challenges
B&V

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Design and Construction of New Stream II
Contract No. 15/WSD/10
Expansion of Tai Po Water Treatment Works
and Ancillary Raw Water and Fresh Water Transfer Facilities
Design and Build of New Stream II
Roger Leung and Stephen Ting
CONTENT
I Design Challenges
- Key Objectives
- Process Schematics
- Limited Footprint
- Selection of DAF
- Zero Discharge
II Construction Challenges
- New Buildings
- Bored Piles
- ELS
- Monitoring Plan
- Single Narrow Access Road
- Environmental Concerns
III Q&A 16
DESIGN
CHALLENGES

STEPHEN TING SENIOR RESIDENT ENGINEER (PROCESS)

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 WSD KEY OBJECTIVES FOR PART 2 EXPANSION

Minimise the use of chlorine

- Reduce the storage and transport

Increase protection against microbial

pathogens
- Provide 4-log reduction in Cryptosporidium & Giardia
CHALLENGES

Allow space for ultimate expansion

- Construct another 400 MLD (Stream III)
DESIGN

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 PROCESS DESIGN OF STREAM II

Investigation Study in 2008

Ozone for manganese oxidation
Reduction in chlorine use
Current treatment (Stream I) - 3 log C&G credit
Ozone was selected for 1 log C&G
CHALLENGES
DESIGN

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 PROCESS SCHEMATICS
EXISTING PLANT (STREAM I)

SRGF
Pretreatment DAF PBF
Disinfection
DESIGN CHALLENGES

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 PROCESS SCHEMATICS
CHANGES FROM STREAM I

GAC
DAF Filter

Intermediate Post
Ozone Ozone
DESIGN CHALLENGES

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 PROCESS SCHEMATICS
STREAM II MAIN TREATMENT PROCESS

GAC
Pretreatment DAF PBF Filter

Intermediate Post
Ozone Ozone
DESIGN CHALLENGES

Sludge Balancing Tanks

Media Traps
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 LIMITED FOOTPRINT
COMPARISON WITH OTHER TREATMENT PLANT

Approx. area
Water Treatment Works Output capacity (1)
of site
Tai Po Water Treatment Works Streams I & II: 800 MLD
10 ha(1)
(3 Stages treatment process) Ultimate: 1200 MLD

Shatin Water Treatment Works 14 ha(2) 1,227 MLD

Pak Kong Water Treatment Works 10 ha(2) 800 MLD

Ngau Tam Mei Water Treatment Current: 230 MLD

12 ha(1)
Works (3 Stages treatment process) Ultimate: 400 MLD
DESIGN CHALLENGES

Ma On Shan Water Treatment

5 ha(1) 227 MLD
Works

(1)Data obtained from WSDs web site. 23

(2)Data measured from base map.
 LIMITED FOOTPRINT
DESIGN CHALLENGES
STACKED DESIGN

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 LIMITED FOOTPRINT
MASTER PLAN FOR 3 PARALLEL STREAMS

1,200 MLD
CHALLENGES

800 MLD

400 MLD
DESIGN

(installed)
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 CLARIFICATION - SELECTION OF DAF

Using a high rate DAF (17 m/h) to reduce foot-

print, to release space for an intermediate
ozone contactor

DAF particularly good when there are algae

issues
CHALLENGES

Operation follows Stream I

DESIGN

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 SELECTION OF DAF
SCHEMATIC OF CONVENTIONAL DAF
CHALLENGES

Flotation Zone or
DESIGN

Reaction Zone or Riser Clarification Zone

Riser Section wall/baffle
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 SELECTION OF DAF
LEOPOLD CLARI-DAF (CONTRACTOR PROPOSAL)
CHALLENGES

Leopold Clari-DAF Process

DESIGN

Collection laterals provide even flow distribution

and reduce velocities in flotation zone.
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 ZERO DISCHARGE

Supernatant is
Minimize water
returned to the
wastage through
Works Inlet from
the treatment
the washwater
processes
recovery tanks

Sludge press filtrate will

CHALLENGES

also be recovered and

blended with the used
washwater in the
washwater recovery
DESIGN

tanks

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 ZERO DISCHARGE
STREAM II PROCESS SCHEMATICS (DE-SLUDGE
PROCESS)
Sludge from DAF (Backwash from PBF & SRGF)
Filtrate to waste

Filtrate

Inlet Chamber
DESIGN CHALLENGES

ZERO
DISCHARGE

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CONSTRUCTION
CHALLENGES

ROGER LEUNG CHIEF RESIDENT ENGINEER

Tai Po Water Treatment Works (Proposed) Bird View

SRGF II Building Pipe Gallery

DAF II Building
Ozone Generation
Building

Washwater Recovery Tanks

Pre-Ozone
Contact
Tanks

Supernatant Tanks

PBF II Building

Sludge Thickeners

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 FOUNDATION OPTION
CHOICE OF PILING TYPES

Cause the least ground settlement and vibration

Capable to support the heavy retained water load

and seismic load

Availability of piling machines in view of the tight

programme
CONSTRUCTION CHALLENGES

Transportation of piling machines to TPWTW

1.5m and 2.0m Dia. Bored Piles

are selected
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 BORED PILE PLANT

Crawler
Crane

Oscillator
CHALLENGES

Mechanical Grab
CONSTRUCTION

Drilling Bit

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 BORED PILE PLANT

RCD
CHALLENGES

Under-reamer
CONSTRUCTION

Bell-out Bit
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 BORED PILE - CONSTRUCTION SEQUENCE
Pre-drilling should be carried out for each bored pile to
determine the rock head level and founding level of the pile
The borehole shall be extended below the founding level for
a minimum depth of 5 m
Collect rock cores for Uniaxial Compression Strength (UCS)
Pre-drilling and point load tests

Setting out of bored pile location

Temporary casing with thickened bottom and equipped with
cutting teeth
Install the temporary steel casing into the oscillator
Casing Temporary casing is driven into ground by the oscillator
Installation /rotator
CHALLENGES
CONSTRUCTION

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 CONSTRUCTION METHOD
BORED PILE Use the mechanical grab to excavate soil inside the casing
Ensure the casing toe level is 1m below the excavated level
Ensure the water level inside the casing is higher than the
GWL
Excavation Extend the casing by bolting, if necessary

Method 1: RCD and Under-reamer

Method 2: Telescopic casing method
Method 3: Concrete fill and plug method
Obstruction
CHALLENGES

Bolthole
for
Excavate down to the rock head level
exten
ding Install RCD and drilling bit
thecasing Use the drilling bit to drill through the rock stratum down
to the founding level.
If bell-out required, use the bell-out bit to form it
Rock Socket Cuttings are airlifted out of the pile shaft with water
CONSTRUCTION

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 CONSTRUCTION METHOD
BORED PILE
Fabricate the reinforcement cage at levelled ground (the yard)
Install reservation pipe for post-casting tests
Cleaning of bored pile founding again and water sample will be
collected
Reinforcement Install the reinforcement cage into the shaft

Concreting by underwater tremie method with >250 dia. tremie

pipe
Ensure tremie pipe embedded within the fresh concrete at least
3m
Extracting the temporary casing during concreting, but toe of
Concreting casing maintained between 3-4m below the top of the concrete
CHALLENGES
CONSTRUCTION

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 CONSTRUCTION METHOD
BORED PILE

Sonic logging test and interface core test

after curing for every bored pile
Interface core shall be 1m, or a half of the pile dia.
whichever is the greater

Testing Full core drilling, 5% of the total no of piles, or 2

nos. whichever is the greater

Standard
Interface
CHALLENGES
CONSTRUCTION

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 EXCAVATION AND TEMPORARY WORKS DESIGN

Open Cut method

Sheet Pile Wall

CONSTRUCTION CHALLENGES

Pipe pile wall

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TEMPORARY WORK SCHEME FOR SPECIFIC
STRUCTURE
Structure Close Restricted Deep Proposed method
Proximity to Working Excavation
Existing Space
Structure

DAFII Pipe Pile wall with Strut

and Tie-back

SRGFII Combination of open cut

and Pipe pile

OGB Open cut

Pre-Ozone Contact Open cut with pipe pile

Tank wall for outlet pipe

Wash water recovery Open Cut

tank

Supernatant Tank Open cut

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CHALLENGES
CONSTRUCTION EXCAVATION AND LATERAL SUPPORT (ELS)

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ELS Layout Plan (1)
CHALLENGES
CONSTRUCTION EXCAVATION AND LATERAL SUPPORT (ELS)

ELS Layout Plan (2) 43

CHALLENGES
CONSTRUCTION EXCAVATION AND LATERAL SUPPORT (ELS)

DAF II: ELS - Plan 44

CHALLENGES
CONSTRUCTION
EXCAVATION AND LATERAL SUPPORT (ELS)

DAF II: ELS - Sections 45

CHALLENGES
CONSTRUCTION
EXCAVATION AND LATERAL SUPPORT (ELS)

DAF II: ELS - Sections 46

 ELS CONSTRUCTION SEQUENCE

STAGE 1
CONSTRUCTION

1.1 Excavate 2m below ground level for bored pile platform

CHALLENGES

1.2 Construct bored piles and install king post

1.3 Install pipe-pile wall and post-grouting
1.4 Excavate below 1st layer of strut and Install 1st layer of strut
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 ELS CONSTRUCTION SEQUENCE

STAGE 2
CONSTRUCTION

2.1 Repeat Step 1.4 for further layer of strut installation

CHALLENGES

2.2 Excavate down to level below proposed ground anchor

2.3 Install ground anchor
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 ELS CONSTRUCTION SEQUENCE

STAGE 3
CONSTRUCTION

3.1 Excavate further down and install further layer of ground anchor
CHALLENGES

3.2 Construct base slab at the middle portion

3.3 Excavate to the final formation level and install the last layer of ground anchor
3.4 Construct lower part of base slab and suction culvert
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 INTENSIVE MONITORING PLAN
Stringent and Clear Limiting Criteria (1)
Type
of Instrument Action Level Action Level (Other
Struct (Contract guidelines)
ures Requirements)
Non-Water Retaining Structure

Structure Movement Markers Vert. 12 mm 25mm (PNAP No. APP-137)

Horiz. 12 mm
Angular 1:600 1:300 (PNAP No. APP-137)
distortion

Tilt Plate Tilting 1:600 1:600 (PNAP No. APP-137)

Vibration Monitoring point (& Vib. amp. 0.2mm 0.2mm (WSD guideline)
CHALLENGES

watermain) PPV 15mm/s 25mm (WSD guideline)

Structure Movement Markers Vert. 12 mm

Horiz. 12 mm
Water Retaining Structure

Angular 1:1000
CONSTRUCTION

distortion

Tilt Plate Tilting 1:1000

Vibration Monitoring point Vib. amp. 0.1mm 0.1mm (WSD guideline)

PPV 7.5mm/s 13mm/s (WSD guideline) 50
7.5mm/s (PNAP No. APP-137)
 INTENSIVE MONITORING PLAN
Stringent and Clear Limiting Criteria (2)

Type
of Instrument Action Level Action Level (Other
Struct (Contract guidelines)
ures Requirements)
Tell-tale gauge across movement Resultant +/- 12 mm
Any

joint

Ground movement markers at Vert. 12mm 25mm (PNAP No. APP-137)

Road

edge of excavation or on road Horiz. 12mm

CHALLENGES

paving
CONSTRUCTION

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 INTENSIVE MONITORING PLAN
Intensive Monitoring (1)
CHALLENGES
CONSTRUCTION

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 INTENSIVE MONITORING PLAN

Intensive Monitoring (2)

CONSTRUCTION CHALLENGES

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 INTENSIVE MONITORING PLAN
Monitoring Instruments

Tilting of building
CHALLENGES
CONSTRUCTION

Structure movement marker

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 INTENSIVE MONITORING PLAN
Monitoring Instruments

Tell-tale at MJ
Tell-tales at MJ
CHALLENGES
CONSTRUCTION

Tailor made strain gauge at flexible

joint of large dia. water main 55
 INTENSIVE MONITORING PLAN
Monitoring Instruments

Vibration monitoring at
pavement

Vibration monitoring
inside building
CHALLENGES
CONSTRUCTION

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 INTENSIVE MONITORING PLAN
Monitoring Instruments
CHALLENGES

Ground Settlement monitoring

CONSTRUCTION

Settlement plate

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 ACCESS ROAD CONTROL
DELIVERY OF LARGE ITEMS
Route 1
Existing
Construction challenges
CS-ATAL JV Site Office
Existing Guard House
Site Access to TPWTW
CONSTRUCTION CHALLENGES

Route 1 -
Bridge over Lam Tsuen River
(<40tons)

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 ACCESS ROAD CONTROL
DELIVERY OF LARGE ITEMS

Route 2

Route 2 -
Pass through adjacent gate
from Tolo Highway)
CONSTRUCTION CHALLENGES

Site Access to TPWTW

Existing Guard House

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 ACCESS ROAD CONTROL
TRIAL RUN FOR
DELIVERY

Scaffolding to model Trailer stopped to check

CHALLENGES

the piling machine there is sufficient space

CONSTRUCTION

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 ACCESS ROAD CONTROL
DELIVERY OF P
ILING MACHINE
CHALLENGES

Delivery and Setup

Bored Pile Machines
CONSTRUCTION

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 ACCESS ROAD CONTROL
CONTROL AT THE SINGLE NARROW ACCESS ROAD
Peak construction
20 dump trucks per hour
5 concrete trucks per hour
Materials and plant delivery
Construction and E&M installation
Operation and maintenance of TPWTW and TPT RW PS
Treatment chemicals and chlorine delivery
Operators entering and leaving the WTW and PS
CONSTRUCTION CHALLENGES

Control traffic to maintain safety

Control one direction traffic flow in some narrow section of access
road by traffic lights or manual traffic control
Priority given to O&M requirement of TPWTW and TPT RW PS

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 ACCESS ROAD CONTROL
TRAFFIC LIGHT CONTROL

Denote One-way Traffic

Location 2

Location 3
CONSTRUCTION CHALLENGES

Location 1

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 ACCESS ROAD CONTROL
CHECKLIST / ESCORT SYSTEM

Construction challenges Escort car to accompany

the truck.
CONSTRUCTION CHALLENGES

Checklist, for checking the

security of the load.

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 ENVIRONMENTAL CONCERNS
SITE DRAINAGE
Waste water treatment tank

Sump pit

Sedimentation tank

Water discharge route

PBFII

DAFII

Waste water treatment tank

CONSTRUCTION CHALLENGES

WWRTII

OGB

SRGFII

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 ENVIRONMENTAL CONCERNS
COVER TO EXISTING OPEN TANKS
CONSTRUCTION CHALLENGES

SRGF I 66
 ENVIRONMENTAL CONCERNS
COVER TO EXISTING OPEN TANKS
CONSTRUCTION CHALLENGES

Chemical Building 67
 ENVIRONMENTAL CONCERNS
COVER TO EXISTING OPEN TANKS
CONSTRUCTION CHALLENGES

Washwater Recovery Tank 68

 ENVIRONMENTAL CONCERNS
DUST CONTROL

Dust Screen for Pipe Piling Works

CONSTRUCTION CHALLENGES

Hydroseeding on temporarily
excavated slopes

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