Installation of integral prefabricated bridge abutment and pier with flexible water stop curtain

Construction of the abutment, pier, and pier cap of long cross-sea bridges are challenging in complex marine environments. In the Hong Kong-Zhuhai-Macao Bridge (HZMB) project, an installation process characterized by concrete integral prefabricated abutment and pier (IPAP) with a flexible water stop curtain was invented. Studies showed that the underwater connection of IPAP and foundation piles can be achieved by adopting the steel cover box (SCB) scheme and separate flexible tray water stop technology. Compression bimodal GINA water stops are valid to seal the gap between SCB and IPAP. The horizontal water stops between trays and IPAP underside are achieved by jacking and compressing GINA water stops, whereas the vertical water stops between trays and steel piles casing (SPC) within 20 m deep underwater are achieved by a rubber capsule with 0.4 MPa pressure. After achieving the water stop between reserved holes and SPC, rapidly hardening concrete is cast into reserved holes. This reliable, efficient, and ecologically friendly innovative construction process, especially the water stop method, ensures that HZMB was constructed more safely and efficiently the China White Dolphin habitat.