Far East Façade Overcomes Impossibilities - Achieving Low-carbon Construction through Technology

Modern buildings not only serve practical purposes but also contribute to the aesthetic value of cities and highlight cities features. In recent years, buildings’ façade has played a crucial role in shaping the appearance of buildings, and production of glass façade has gained rapid technological development. Ir Thomas HO, Chairman of the Construction Industry Council (CIC) led industry representatives in a visit to Far East Façade (Hong Kong) Limited (Far East Façade), a subsidiary of China State Construction Development Holdings Limited (CSCD), to observe the company's achievements in industrialising curtain wall products and promoting low-carbon construction, which has greatly accelerated the development of curtain walls in China.

Embracing the Extensive Use of Digital Technology

With its visions and application of advanced technologies, Far East Façade has successfully achieved full automation and digitalisation in the production process. During the design phase, Building Information Modelling (BIM) and Design for Manufacture and Assembly (DfMA) technologies are integrated, streamlined production and enhanced installation efficiency.

Extended from BIM, the design team also establishes a Fabrication Information Model (FIM), a type of data which could be communicated with digitalised machinery and robots. By incorporating parametric design, Far East Façade connects design concepts with manufacturing processes, realising digital fabrication and automated production.

Advantages in Automated Production and Quality Management

To industrialise façade production, Far East Façade recognizes the necessity of increasing production capacity, making automation an indispensable element in the manufacturing process. At its production base in Zhuhai, Far East Façade has introduced the most advanced roll bender in the country while at the same time mastering the complex roll bending and twisting techniques for various materials.

One notable project is the 3D-curved, all glass building façade of The Henderson, a new landmark in Hong Kong, where more than 60% of the curtain wall panels are curved, with 30% are double curved or conical curved panels. With its exquisite craftsmanship, Far East Façade successfully produced the modules for the façade area of 25,000 square meters. Additionally, with automated production for cutting and drilling of framing members and brackets etc., Far East Façade possesses the most advanced automated production line in the mainland, with an annual production capacity exceeding 500,000 square meters.

The team also focuses on quality management and has introduced advanced automated equipment, such as 3D Scanner with Robotic Arm and an automated flood test system. Regarding the latter, Mr. ZHU Min-feng, Assistant President of CSCD and Chairman and General Manager of Far East Façade, stated that the equipment improves efficiency and accuracy. "The prefabricated modules of curtain walls are often large in size, and it can be challenging for workers to handle and flip them. Moreover, manual inspection may not be 100% accurate. Therefore, the factory has established several automated flood test systems, which can perform automated test and evaluation on the modules after production."

BIPV for Sustainable Construction Development

In recent years, Far East Façade has also demonstrated its commitment to low-carbon and environmentally friendly construction to support the Chinese government's "30/60 dual carbon goals" of peaking carbon dioxide emissions before 2030 and achieving carbon neutrality by 2060. The team actively researches and develops Building Integrated Photovoltaics (BIPV) technology, which incorporates power generation functions into buildings, saving energy costs and exploring new solutions for renewable energy development.

Mr. ZHU Min-feng mentioned that the development of buildings is driven by reforms in construction techniques and materials. MiC belongs to the former, while BIPV corresponds to the latter. Far East Façade offers a variety of photovoltaic materials, catering different needs such as aesthetics value and power generation efficiency. They also provide two operating schemes: "Solar photovoltaic, Energy storage, Direct current and Flexibility" (PEDF), which refers to 4 stages of photovoltaics, direct-current distribution, bidirectional charging and flexible control. It is expected that PEDF can reduced building carbon emission by 25%. The second scheme is Grid Connection System, which connects the photovoltaic power generation system with the electrical system, and can transform direct current generated.

Apart from applying this technology to its curtain wall products, Far East Façade has also transformed its production base in Zhuhai. BIPV modules have been installed in the factory, laboratory, staff dormitories, and even the restaurant, endorsing a large-scale photovoltaic power generation project. In terms of the low-carbon development of façade, Mr. ZHU Min-feng believes that Far East Façade is capable of providing research equipment, personnel and application opportunities, he welcomes collaborations with Hong Kong’s construction industry. Ir Thomas HO, Chairman of the CIC, considers low-carbon construction is indeed a global trend. He appreciates the rapid progress made by Far East Façade in terms of ideas, decisions, and actions. He also applauses their efforts and achievements in industrialising the production of curtain walls, which is something the Hong Kong industry should be learning.