Non Disruptive Road Crossings

NON DISRUPTIVE ROAD CROSSINGS MANUAL
DRAFT DOCUMENT JANUARY 2013
January 2013 Draft Edition Abu Dhabi Department of Transport Al Bateen Towers PO Box 20 Abu Dhabi, United Arab Emirates
Copyright 2012, by the Abu Dhabi Department of Transport. All Rights Reserved. This manual, or parts thereof, may not be reproduced in any form without written permission of the publisher. Page i January 2013
TABLE OF CONTENTS
List of Figures .................................................................................................................................. v List of Tables .................................................................................................................................. vi 1 Introduction .............................................................................................................................. 7 1.1 1.2 1.3 2 Overview ............................................................................................................................. 7 Purpose and scope.............................................................................................................. 7 Application of this manual .................................................................................................... 7
Non Disruptive Road Crossings Methods .............................................................................. 8 2.1 2.2 2.3 2.4 2.5 2.6 Non-steerable soil displacement methods ........................................................................... 8 Non-steerable soil removal methods.................................................................................... 9 Horizontal directional drilling (HDD) ................................................................................... 11 Micro tunnelling ................................................................................................................. 13 Pilot pipe jacking ............................................................................................................... 15 Manned pipe jacking methods ........................................................................................... 16 Open front pipe jacking techniques............................................................................. 16 Closed front (full face excavation) pipe jacking techniques ......................................... 17
2.6.1 2.6.2 2.7
New NDRC Techniques..................................................................................................... 19 Easy Pipe ................................................................................................................... 19 Direct Pipe.................................................................................................................. 20
2.7.1 2.7.2 3
General .................................................................................................................................... 22 3.1 3.2 3.3 Overview ........................................................................................................................... 22 Standards and Codes of Practice ...................................................................................... 22 Roles and responsibilities .................................................................................................. 22 Client .......................................................................................................................... 23 Consultant .................................................................................................................. 23 Contractor/Sub Contractor .......................................................................................... 23 Road Authority............................................................................................................ 23 Abu Dhabi Town Planning .......................................................................................... 23 Utility Agencies ........................................................................................................... 23
3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.4 3.5
Process Map ..................................................................................................................... 23 Health and Safety .............................................................................................................. 26 At Concept Stage ....................................................................................................... 26 Page ii January 2013
3.5.1
NON DISRUPTIVE ROAD CROSSINGS MANUAL 3.5.2 3.5.3 3.5.4 3.6 3.7 3.8 Preliminary Design Stage ........................................................................................... 26 At Pre-Construction Stage .......................................................................................... 27 During Construction Stage.......................................................................................... 27
Environmental requirements .............................................................................................. 30 Site condition survey ......................................................................................................... 31 Geotechnical Investigation................................................................................................. 32 Minimum requirements of the exploratory boreholes .................................................. 33 Borehole Positions...................................................................................................... 33
3.8.1 3.8.2 4
Procedures for undertaking non disruptive road crossings ............................................... 35 4.1 4.2 4.3 Overview ........................................................................................................................... 35 Concept Stage................................................................................................................... 35 Preliminary Design Procedures ......................................................................................... 35 Method selection ........................................................................................................ 35 Design drawings ......................................................................................................... 58 Hand excavation......................................................................................................... 59
4.3.1 4.3.2 4.3.3 4.4
Pre-construction stage ....................................................................................................... 59 Design calculations..................................................................................................... 59 Design drawings ......................................................................................................... 60 Ground Surface Movement......................................................................................... 60 Groundwater Control .................................................................................................. 77 Materials and equipment ............................................................................................ 77 Method of statements ................................................................................................. 78 Risk Assessment and Risk Register ........................................................................... 80 Procedure and logistics for obtaining No Objection Certificates .................................. 81
4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.4.8 4.5
During Construction ........................................................................................................... 81 Monitoring of Surface Movement ................................................................................ 81 Instrumentation Requirements .................................................................................... 83 Equipment Performance Requirements ...................................................................... 84
4.5.1 4.5.2 4.5.3 4.6
After Construction .............................................................................................................. 85 Inspection and testing................................................................................................. 85 Site clearance and decommissioning ......................................................................... 86 Monitoring/inspection for long term (latent) defects .................................................... 86 QA/ QC Methodology ................................................................................................. 86
4.6.1 4.6.2 4.6.3 4.6.4
Appendix A: Checklists for submittals ........................................................................................ 88 Page iii January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Appendix B: Forms and examples of letters for applying for NDRC works .............................. 92 Appendix C: Suggested minimum safe distances between utilities ........................................ 106 Appendix D: Checklists for monitoring during and after construction ................................... 107 Cited References ......................................................................................................................... 112 Other References ......................................................................................................................... 113 Glossary ....................................................................................................................................... 114
Page iv
January 2013
LIST OF FIGURES
Figure 1: Impact moling/soil displacement hammer ........................................................................... 8 Figure 2: Pipe ramming diagram (Earth Tool Company, LLC)............................................................ 8 Figure 3: Impact moling ..................................................................................................................... 9 Figure 4: Auger head ....................................................................................................................... 10 Figure 5: Auger boring ..................................................................................................................... 10 Figure 6: Process of the horizontal directional drilling (HDD) ........................................................... 12 Figure 7: Micro tunnelling ................................................................................................................ 13 Figure 8: Slurry shield micro tunnelling (Iseki Poly-Tech, Inc.-japan) ............................................... 14 Figure 9: Stages of pilot pipe jacking with auger soil removal .......................................................... 15 Figure 10: Backactor shield ............................................................................................................. 16 Figure 11: A cutter boom shield ....................................................................................................... 17 Figure 12: Open front pipe jacking ................................................................................................... 17 Figure 13: A slurry shield (full face excavation) pipe jacking machine .............................................. 18 Figure 14: Earth Pressure Balance Machine (EPBM) ...................................................................... 18 Figure 15: Easy pipe Method ........................................................................................................... 20 Figure 16: Direct Pipe Method ......................................................................................................... 21 Figure 17: Process map of NDRC.................................................................................................... 25 Figure 18: Pipe jacking worksite and shaft ....................................................................................... 26 Figure 19: The different cutting heads ............................................................................................. 39 Figure 20: Principles of a hydraulic mucking boring machine (Herrenknecht documents) ................ 40 Figure 21: Locating systems ............................................................................................................ 45 Figure 22: Basic components of rig.................................................................................................. 46 Figure 23: Slanted face Drill Bits ...................................................................................................... 49 Figure 24: Modified Slanted face Drill Bits ....................................................................................... 49 Figure 25: Modified Slanted face Drill Bits ....................................................................................... 50 Figure 26: Rock Drill Bits ................................................................................................................. 50 Figure 27: Tri-Cone Rock Bits.......................................................................................................... 51 Figure 28: Experience guidelines for the application of different NDRC methods............................. 55 Figure 29: Working shafts ................................................................................................................ 56 Figure 30: Stability Vs Volume Loss ................................................................................................ 66 Figure 31: Typical Settlement Profile for a Soft Ground Tunneling ................................................... 70 Figure 32: Assumptions for width of settlement trough (adapted from Peck, 1969) .......................... 71 Figure 33: Example of Finite Element Settlement Analysis for Twin Circular Tunnels under Pile Foundations ..................................................................................................................................... 72
Page v
January 2013
LIST OF TABLES
Table 1: Parameters to be considered in relation to each soil type .................................................. 34 Table 2: NDRC methods related to soil types .................................................................................. 37 Table 3: Different applications of NDRC .......................................................................................... 38 Table 4: NDRC methods with typical pipe size, length and accuracy ............................................... 42 Table 5: Rigs types and specification............................................................................................... 47 Table 6: Drill Bit Types and Application Guidelines (Courtesy DCCA) ............................................. 48 Table 7: Operational risks in HDD installations (Baumert and Allouche 2003) ................................. 54 Table 8: Design of working shafts in Dry ground .............................................................................. 56 Table 9: Design of working shafts in wet ground .............................................................................. 57 Table 10: Shaft Dimensions ............................................................................................................. 58 Table 11: Shaft sizes ....................................................................................................................... 58 Table 12: Relationship between Volumes Loss and Construction Practice and Ground Conditions . 68 Table 13: Risk summary for typical NDRC methods ........................................................................ 80 Table 14: Type of records for NDRC projects .................................................................................. 83
Page vi
January 2013
1
1.1
INTRODUCTION
Overview
In 2010, the Abu Dhabi Department of Transport commenced with the Unifying and Standardizing of Road Engineering Practices Project. The objective of the project was to enhance the management, planning, design, construction, maintenance and operation of all roads and related infrastructures in the Emirate and ensure a safe and uniform operational and structural capacity throughout the road network. To achieve this objective a set of standards, specifications, guidelines and manuals were developed in consultation with all relevant authorities in the Abu Dhabi Emirate including the Department of Municipal Affairs (DMA) and Urban Planning Council (UPC). In future, all authorities or agencies involved in roads and road infrastructures in the Emirate shall exercise their functions and responsibilities in accordance with these documents. The purpose, scope and applicability of each document are clearly indicated in each document. It is recognized that there are already published documents with similar objectives and contents prepared by other authorities. Such related publications are mentioned in each new document and are being superseded by the publication of the new document, except in cases where previously published documents are recognized and referenced in the new document.
1.2
Purpose and scope
The purpose of this Manual is to provide specific procedural guidance on Non Disruptive Road Crossings (NDRC) for staff of the Abu Dhabi Department of Transport and other concerned government highway agencies (Municipalities), designers, Contractors and utility agencies. However, due to the specific technical nature of this type of construction, the Manual also provides guidelines for the specialized Contractors experienced in the utilization of plant and equipment fabrication, in order to select the most appropriate method for such operations. The Manual is specifically aimed at recognizing local conditions related to the present legal framework, existing geotechnical conditions and practices presently employed by the local construction industry which perform successfully. However, global best practices are studied and improvements recommended as appropriate. The overall objective of this Manual is to provide guidelines for the construction of NDRC which do not result in either short term or long term surface movement, nor in road collapse due to drilling mistakes or obstacles.
1.3
Application of this manual
The Manual is intended for use by the Abu Dhabi Department of Transport and other road agencies of the Emirate (Municipalities) in specifying the requirements and approval procedures for NDRC work. It is however also to be used by utility agencies, designers and Contractors in selection and design of NDRCs. Page 7 January 2013
2
2.1
NON DISRUPTIVE ROAD CROSSINGS METHODS

Non-steerable soil displacement methods
In this Chapter more detailed information is given on various methods of NDRC.
A number of soil displacement methods exist. Impact moling or sometimes called soil displacement hammer is one of the more common methods. The method involves driving a moling or hammering tool with a tapered head through the ground (see Figure 1). The hammering tool can either work with compressed air or hydraulically and it displaces the soil as it moves through the ground. The piping or cable material is either pushed directly behind the tool or, in stable soil conditions it may be pulled in afterwards through the cavity made by the tool. Pipe ramming with a closed pipe is another soil displacement method often used. Like impact moling or soil displacement hammer it uses compressed air or hydraulically activated ramming device to push a closed steel pipe through the soil (see Figure 2). Figure 1: Impact moling/soil displacement hammer
Figure 2: Pipe ramming diagram (Earth Tool Company, LLC)
Page 8
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Advantages and disadvantages of the non-steerable soil displacement technique are briefly set out below. Advantages Generally very quick and easy to use and thereby also very cost effective. Moles or hammering tools are available for many soil conditions and can penetrate soft rock. The methods require relatively small entry and exit pits. When installing the pipe or cable directly behind the hammering tool, surface settlements are minimised.
Disadvantages The methods require that the soil is displaceable and surface heave may occur if sufficient soil cover is not available above the tunnel. A minimum cover of 10 times the outer pipe or hammer diameter is recommended. Pipelines installed in this manner are necessarily straight as there is no steering mechanism. The alignment of the tunnel can be influenced by the soil conditions, especially obstructions or stratifications that may alter the direction of the tool or pipe. Installation of pipelines that require a precise alignment should not be undertaken using nonsteerable methods. The poor alignment accuracy also reduces the typical lengths for which the methods are appropriate, and safe distances to other structures or utilities must be maintained. Figure 3: Impact moling
2.2
Non-steerable soil removal methods
Pipe ramming can also be carried out with an open pipe end and thereby without soil displacement. Instead the soil is either removed during the driving of the pipe or afterwards. Soil removal is typically undertaken using water jetting, flushing, compressed air or mechanically, for example with an auger. These are some points to consider with this method: With the use of an auger, a cutting head can be attached to the head giving an improved method for application in harder soils. Examples of pipe ramming and auger boring are shown in Figures 8 and 9. Page 9 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL The pipe material is usually a steel casing or sleeve pipe inside which the product pipe or cables can be pulled or pushed after soil removal. Entry and exit pits are required for this method, where the entry pit may need to be very long in order to accommodate the pipe and auger sections along with the ramming or jacking device. Below ground water levels the methods must be used with caution or dewatering must be initiated. Pipe ramming may be achieved if the pipe can be driven completely through before soil removal and the soil "plug" inside the pipe is sufficiently stable to withstand the ground water pressure while ramming.
When auger boring, the auger may become flooded underground water levels giving way for excessive soil loss and major surface settlement. Some manufacturers have designed a sluice system for the auger to counter this effect. Figure 4: Auger head
Figure 5: Auger boring
Page 10
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Advantages These methods, like the other non-steerable methods, are generally less expensive than similar sized steerable methods due to the need for fewer and simpler equipment and machinery. The method can be used for significantly larger pipe sizes compared to displacement techniques (2000 mm diameter or larger). The larger diameter pipelines are typically stiffer and less susceptible to altering direction during installation.
Disadvantages In swelling or very plastic soils the methods may not be possible. Pipe ramming cannot be done in rock. However with the use of an auger, a cutting head can be attached to the head giving an improved method for application in harder soils. Loss of face stability when tunnelling below groundwater level can lead to construction difficulties and even failure to complete the tunnel. The same difficulties with directional control exist as for the non-steerable methods.
2.3
Horizontal directional drilling (HDD)
Horizontal direction drilling is likely to be the most widely used NDRC method, due to the extreme versatility in uses. The method can be conducted from the ground surface without the need of deep entry and exit shafts. The installation size can be anywhere from small diameter single cable crossings up to 1200 mm diameter pipes. Drilling distances can reach as much as 1500-1800 m in a single drill longer drills have been achieved using intersecting methods. The method requires a HDD rig capable of applying torque and thrust to drill a drilling pipe through the ground. A steerable drilling head, specially designed for the soil conditions, is situated at the front end of the pipes. Directly behind the drill head is a probe or transmitter sending signals through the ground. These signals can be tracked from the ground surface, thereby determining the position and depth of the drill. The direction of the drill can be altered by the asymmetrical steering face of the drill head. After completing the drill, the bore hole is expanded to the required size by attaching reamers to the drill pipe and pulling back in one or more steps. The desired pipeline is typically attached directly behind the final reamer. Drilling fluid (typically a bentonite suspension) is continuously pumped into the borehole in order to remove the spoils and support the borehole. An example of a HDD setup is shown in Figure 6. The reamer is generally larger than the pipeline being installed creating an overcut or annular space surrounding the pipeline through which the soil and drilling fluid mixture can escape. Page 11 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 6: Process of the horizontal directional drilling (HDD)
Advantages The wide size range and the ability to undertake HDD without large entry and exit pits and without groundwater lowering are very clear advantages of this method. The direction of the drill can be altered while drilling making it possible to install a curved pipeline. This can be a great advantage when manoeuvring around existing structures or other utilities.
Disadvantages The achievable alignment accuracy may be insufficient for pipelines that require high precision alignment. Maximum pipe diameters are limited to about 1200mm.
Page 12
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Sudden changes in soil type from say clay to sand can lead to loss of control of fluid pressure which in turn can lead to collapse of the soil annulus around the pipe. In certain situations, the pipe may become stuck leading to loss of the HDD string.
2.4
Micro tunnelling
Micro tunnelling is a name generally associated to unmanned pipe jacking methods for pipes smaller than 1000 mm diameter. However larger diameter machines and equipment are readily used and it would be more appropriate to use the term micro tunnelling for any unmanned pipe jacking using a steerable tunnelling machine. Figure 7: Micro tunnelling
In micro tunnelling the pipeline is installed by pushing (jacking) the pipes forward from the starting shaft as the tunnelling machine excavates the soil at the front of the pipeline. The excavated soil can be removed through the already laid pipes by various methods. Examples of this are auger soil removal or slurry shield micro tunnelling as shown in Figures 7 and 8. In the auger method the excavated soil is removed mechanically with the continuous line of augers. In the slurry shield method the excavated soil is mixed with a bentonite slurry suspension and pumped out of the pipeline. After being pumped out the soil is settled or separated from the slurry in a tank or separation unit and the slurry is reused. When working below ground water levels the auger soil removal may pose the same problems, where the auger may flood and give way for excessive soil loss. The slurry shield micro tunnelling machine is typically designed with a pressurized bulkhead, where slurry is pumped at a sufficient pressure to stabilizes any loose soil and balance ground water pressure. The tunnelling machine can be controlled by an operator outside the pipeline. The alignment is usually controlled by laser or by gyroscope and water level. The line is typically straight, but using Page 13 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL gyroscope or specialized surveying equipment and short pipe lengths, curved tunnels can be constructed. Piping materials must be designed to withstand the jacking forces acting on them under installation. Concrete is often used as piping material along with fibreglass or composites with concrete and fibreglass. Polymer materials especially polymer concretes are becoming more common due to there strength and corrosion resistance. Figure 8: Slurry shield micro tunnelling (Iseki Poly-Tech, Inc.-japan)
Advantages Micro tunnelling works in almost all soil conditions and cutting heads can be modified to deal with weak rocks. Pipes of up to 2000mm diameter can be installed and can be constructed to a high degree of accuracy which makes the technique suitable for pipelines that require precision in alignment or gradient.
Disadvantages Obstacles (large rocks/boulders or other materials) may stop machines not designed for cutting through these materials. In such cases there may be no other solution, than to excavate from the surface to remove the obstacle. If this is not possible, the tunnel and machine may have to be abandoned. Page 14 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Working in mixed face conditions can be problematic, particularly where slurry support is used below groundwater as the slurry pressure may be difficult to control. Loss of slurry/face support can lead to instability and ravelling leading to large surface settlements and, in the extreme case, abandonment of the pipe and machine. Micro tunnelling is generally more expensive than many of the other NDRC methods, requiring relatively large entry and exit shafts and more advanced equipment and materials.
2.5
Pilot pipe jacking
This method is basically a variation of the non-steerable auger boring method. In this method however a steerable pilot pipe is initially jacked or drilled through the soil. The alignment of the pilot pipe is controlled by laser and a small camera at the head of the pipe. After installing the pilot pipe an open steel pipe with an auger for soil removal is attached to the pilot pipe and pushed/jacked through. The steel pipe is usually just used as a sleeve for the product pipe which is pulled in afterwards. Variations of the method include attaching a reamer followed by a plastic pipeline and pulling these through in a similar manner as HDD. Figure 9: Stages of pilot pipe jacking with auger soil removal
Page 15
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Advantages The method is very accurate (unlike the non-steerable auger boring method). The pilot pipe can generally be installed to an accuracy of +/- 20 mm and the steel sleeve pipe will typically follow this line with little deviation. The technique is a relatively cheap method of achieving a pipeline to a high precision in alignment and gradient.
Disadvantages Large rocks or differences in soil structure surrounding the pilot pipe can give problems. Ground water may give some of the same problems described in sections on non-steerable auger boring and micro tunnelling.
2.6
Manned pipe jacking methods
Manned pipe jacking methods are very similar to the techniques given as micro tunnelling the difference is basically that the manned methods are sufficiently large in diameter to accommodate workers inside the pipeline. A wide range of tunnelling machines designed for varying types of soil and groundwater conditions exist. The machines can generally be divided into open or closed face machines the selection is dependent on the soil conditions and the required support necessary for stability of the soil.
2.6.1
Open front pipe jacking techniques
Open faced pipe jacking can be done in stable soil conditions with little or no ground water inflow. The method consists of a tunnelling machine with an open front, where soil is excavated mechanically and transported with conveyor belt and/or buckets out of the pipeline. Examples of open front pipe jacking are shown in Figure 10 and Figure 11.
Figure 10: Backactor shield
Page 16
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 11: A cutter boom shield
Figure 12: Open front pipe jacking
Working below ground water levels, pressure may be applied to the front using a chamber lock system as shown in Figure 12. The pressurized front allows excavation without losing soil stability due to ground water infiltration. This will generally only work in cohesive soils or rock - in very loose soils, an open front is very questionable.
2.6.2
Closed front (full face excavation) pipe jacking techniques
In loose soils or conditions with high ground water levels, a closed front machine may be used. Closed front machines can be of the slurry shield type as described in Section 4.5 on micro tunnelling or alternatively an earth pressure balance machine. The slurry shield tunnelling machine works as described previously with a bentonite slurry suspension that is mixed with the excavated soil and pumped out of the pipeline. An example of this type of machine is shown in Figure 16.
Page 17
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 13: A slurry shield (full face excavation) pipe jacking machine
Figure 14: Earth Pressure Balance Machine (EPBM)
Advantages Manned pipe jacking methods have the general advantage that access to the driving front is relatively easy - making it possible to remove obstacles (larger rocks/boulders etc.) with manual methods. Open front machines obviously have the most direct access, where closed front machines may need to be designed with access gates.
Disadvantages There are many health and safety issues associated with manned pipe jacking, not least the need to work in confined spaces with the dangers of face collapse and groundwater inundation. Detailed and robust health and safety procedures dealing specifically with the hazards related to this construction method need to be implemented for all manned pipe jacking operations. Page 18 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Tunnelling equipment is large and expensive and requires relatively large site areas for the launch and reception pits.
2.7
New NDRC Techniques
NDRC techniques continue to evolve and new techniques are constantly being trialled and implemented to overcome some of the disadvantages of conventional techniques or provide faster, cheaper installations. Two such techniques are the Easy Pipe and the Direct Pipe methods
2.7.1
Easy Pipe
This technique combines conventional micro tunnelling with an innovative method of using the jacking pipes to help install the permanent pipe. Once the tunnel has been bored, the micro tunnelling machine is removed and the permanent pipe is attached to the installed jacking pipes. The jacking pipe segments (which are bolted together) are pulled back through the tunnel, pulling the permanent pipe with them. In this way, the permanent pipe is installed quickly and easily and the jacking pipe segments can be re-used for the next project. Easy Pipe installation requires a micro tunnelling unit to be prepared and assembled in the launch pit. The cutter head is launched and guided in the conventional micro tunnelling way along a planned alignment. The difference between the jacking pipes used by Easy Pipe and conventional ones is that the special design allows them to be used as jacking pipes in the forward direction while allowing them to be retracted from the completed bore to pull in the product pipe. This is because the joints between the jacking pipe sections bolt together with a design that will withstand thrust and pullback forces of up to 6,300 kN (630 tons).The close proximity of the jacking pipes' outer wall to the bore wall also avoids the potential for collapse of the bore in unstable ground formations. After the cutter head has reached the target pit, it is separated from the jacking pipe string and replaced by a specially designed connection pipe that also connects to the product pipe. The jacking pipes are then pulled back using the bi-directional jacking frame, simultaneously pulling the product pipe into position. In the launch pit the individual jacking pipes are successively removed along with all other equipment until the product pipe arrives at the launch shaft. The connection pipe and jacking frame are removed from the pit leaving the product pipe in place to be finally connected to the remainder of the pipeline on either side of the obstacle(s) crossed.
Page 19
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 15: Easy pipe Method
2.7.2
Direct Pipe
The direct pipe technique is a hybrid of the HDD and micro tunnelling methods. In this technique, the micro tunnelling machine is pushed in to the ground using a jacking frame that grabs directly on to the final production pipe and uses this to push the micro tunnel machine forward. In this way, once the tunnel is bored, there is no need for a secondary production pipe installation process as the production pipe is installed directly as part of the tunnelling operation. Installation of the pipe is limited by the thrust that can be applied to the pipe without causing damage and the need for sufficient space to lay the pipe out behind the micro tunnel machine prior to commencing boring.
Page 20
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 16: Direct Pipe Method
Advantages Single-step method leads to rapid installation of product piping and pipelines No time needed for coupling pipes (Micro tunneling) or drill rods (HDD) Pipeline can be installed pre-welded and already tested Costly shaft construction unnecessary - instead, only simplified surface entry and exit pits are required One-pass work phase of operation for excavation and pipeline installation Inclines and gradients as well as curved drilling profiles can be negotiated precisely Ideal method for sea outfalls with access from one side only Pipe Thruster enables both tunneling machine and pipeline to be withdrawn, for example for cutting tool retooling operations in inaccessible, low-diameter areas Cone crusher removes obstacles as they occur
Application options Pipeline laying from construction pit to construction pit Pipeline laying from construction pit to shaft Pipeline laying from construction pit to destination point, for example water course beds
Range of application Pipeline diameter: - 28 - 36 38 - 44 46 - 52 54 - 60 Excavation diameter 805 / 990 mm 1,140 mm 1,325 mm 1,540 mm Maximum pipeline / drilling length 300 m 700 m 1,200 m 1,400 m Geology: - Clay, Silt, Sand, Gravel, Cobbles, Boulders, Rock (up to 150 Mpa = 21,750 psi) Pipe material: - Steel Coating material: - . PE, PP, GRP, FBE Page 21 January 2013
3
3.1
GENERAL
Overview
This chapter provides general information for undertaking Non Disruptive Road Crossings including an overview of the parties involved and their roles and responsibilities. The chapter further covers the general requirements for environment, health and safety along with requirements for site survey and geotechnical investigations.
3.2
Standards and Codes of Practice
A number of local and international Standards and Codes of Practice along with guidelines and specifications have been sourced during the process of creating this manual. The documents and information listed below were chosen as they are typically viewed as being best practice internationally, in the field of NDRC and trenchless technology. Particular reference can be made to the following existing key documents: Abu Dhabi Municipality Road Department - Requirements and Recommendations for Non disruptive Road Crossings Abu Dhabi Municipality Sewerage Projects Committee - General specifications for civil works, Pipeline construction by Non disruptive method (2003) The Pipe Jacking Association (UK) - "An introduction to pipe jacking and micro-tunnelling design" (1995) Horizontal Directional Drilling Good Practices Guidelines - 2008 (3rd Edition) USA Standard DWA-A 125E Pipe Jacking and Related Techniques, German Association for Water, Wastewater and Waste. (2008) Microtunneling and Horizontal Drilling Recommendations, FSTT, French Society of Trenchless Technology (2006) Euronorm EN 12889: Trenchless Construction and Testing of Drains and Sewers. There is a wealth of globally available documentation about 'trenchless' or 'no dig' technology and the list above covers some of the more important ones. Additional information on methods and equipment can be found in these or from technical associations such as: International Society of Trenchless Technology, ISTT - www.istt.com Pipe Jacking Association (UK) - www.pipejacking.org North American Society for Trenchless Technology, USA - www.nastt.org
3.3
Roles and responsibilities
This section describes typical roles and responsibilities of the parties involved in undertaking NDRC works. The specific responsibilities and authorities of the different parties involved can vary from project to project depending on the contract agreements between the parties. Road crossings and in particular NDRC works are typically contracted as part of a main project involving installation of utility lines in an area, along roads, etc.
Page 22
January 2013
3.3.1
Client
The Client is the owner of the pipeline or cable to be installed. The overall responsibility for the installation and operation of the pipeline or cable is that of the Client. The Client can delegate certain responsibilities such as design and calculations along with the responsibility for safeguarding of the road to others through contract agreements.
3.3.2
Consultant
The Consultant is typically hired by the Client to design, tender and supervise the overall project. The Consultant will typically undertake preliminary site and soil investigations to collect information on existing utilities, surface and sub-surface constructions during the design stage. The consultant will supervise the installation and NDRC work during construction.
3.3.3
Contractor/Sub Contractor
The Contractor or, if delegated, the specialist Sub Contractor is responsible for the correct installation of the pipeline or cable in accordance with the specifications. The Contractor/Sub Contractor is responsible for obtaining approval from the Road Authority prior to commencement of the NDRC work. Approval is only given after Submitting a complete and acceptable method statement including all required information in accordance with this manual.
3.3.4
Road Authority
The Road Authority (Abu Dhabi Department of Transport or any Municipality) is responsible for giving approval of any NDRC work. The Road Authority's main interest is in protecting their assets the road, footpaths, structures, etc. from any harm, settlement or heave resulting from the NDRC work which lies within the highway Right of Way.
3.3.5
Abu Dhabi Town Planning
Abu Dhabi Town Planning will give initial approval and assign a corridor that the Client may use. This is done only after checking with, and obtaining NOCs from the Road Authority, other Utility Agencies and any other relevant authorities. After giving approval and assigning a corridor Abu Dhabi Town Planning will refer to the Road Authority for final approval of the NDRC work.
3.3.6
Utility Agencies
Other utilities agencies may be affected by the NDRC if their pipelines or cables are located near the proposed NDRC. The Contractor will need to obtain No Objection Certificates (NOC's) from all the concerned utilities agencies. These may be accompanied with certain requirements or restrictions concerning the NDRC.
3.4
Process Map
When following the procedure below, it is imperative that the Consultant follow the guidance contained in this Manual, and if any of the processes are not completed to the DoTs satisfaction, then the relevant stage will not be approved.
Page 23
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL The process of undertaking NDRC work involves a five part approval process. Important points for the Consultant to consider: The stages are illustrated in Figure 17 below showing the main activities and responsibilities in each stage. Detailed information and requirements of the various activities can be found the subsequent sections of this manual. Check lists of required submittals to the Road Authority are given in Appendix A. The estimated processing times in the approval stages are based on complete and full submittals. Any missing information may result in prolonged processing times. Anywhere along the process factors may arise that will require the planned NDRC to be revised and the process to be returned to an earlier stage. All applications for approval with the DoT must be submitted using the No Objection Certificate - Right of Way (NOC-ROW) online system. Please refer to the DoT website for the latest information on this subject.
Page 24
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 17: Process map of NDRC
Responsible
PHASE 1
Client/ Consultant
Activity Concept Stage Map of intended NDRC
Details and information to be acquired Location/vicinity Size (diameter) and level
Approval process - part 1 Submit to Abu Dhabi Town Planning for approval of corridor and NOC
Expected processing time: 4-6 weeks
PHASE 2
Client/ Consultant
Preliminary design Geotechnical Geotechnical Assessment (Key stage 2) according to Manual for Geotechnical Investigation and Geotechnical Design including Ground Investigation Factual and Interpretative Reports. Surface and underground structures Location and type Line, level, diameter Work area with working shaft locations and sizes Suggested method and equipment Requirements for accuracy, material, etc.
Site investigation Other utilities Drawings Method selection
Approval process - part 2 Submit to Road Authority for preliminary approval of design Check list of submittals required is given in appendix A. Pre-construction Stage PHASE 3 Contractor/ Sub Contractor Design calculations
Expected processing time: 2-3 weeks Pipe strength Working shafts Jacking and friction forces Surface settlement/heave Plans and profiles of the intended line Working area plans showing placement of equipment and materials. Traffic diversion plans Details of working shafts De-watering system design Lists of all in use Contractor name List of personnel with qualifications Sequencing and procedure of work Ground water control and dewatering Safety procedures Environmental assessment Risk assessment From all relevant utilities and authorities From Client and Consultant
Design drawings
Materials and equipment Method statement
NOC Letters of undertaking Approval process - part 3 Submit to Road Authority for approval of construction List of submittals required is given in Appendix A Construction PHASE 4 Contractor/ Sub Contractor Site condition survey Monitoring QA/QC
Expected processing time: 3-4 weeks Surrounding surfaces and structures Pre construction photos Setup and monitoring of surface movement Documentation in accordance with QC plan
PHASE 5
After construction Monitoring Surface movement - monthly reports
Page 25
January 2013
3.5
Health and Safety
All parties involved in NDRC work have an important role in establishing safe working conditions. During planning and design all foreseeable health and safety risks likely to arise shall be identified and taken into consideration in the design. All health and safety information known to the Client, Consultant or designer must be given to the Contractor prior to undertaking the NDRC work. Figure 18: Pipe jacking worksite and shaft
The Contractor must ensure that prior to commencement of any project, a Health and Safety Plan is prepared which covers the specific requirements of the project. This plan shall be submitted prior to approval of construction along with the Method Statement, and approved by the relevant Consultant (usually the Engineer). General requirements for Environment Health and Safety must comply with the EHS Manual for Road Projects. All issues relating to EHS must be raised and addressed along all stages of the project.
3.5.1
At Concept Stage
During this phase, it is important for the design team to establish the route of the NDRC to minimise the risks to safety for any persons working on the construction. When submitting the relevant design information to Abu Dhabi Town Planning, the Consultant must take into account the safety impacts of the size and material used in the NDRC works, if they are available at this stage.
3.5.2

Preliminary Design Stage

The specification of materials The location of the crossing to minimise the safety impact on pedestrians, motorists and the general public The diameter to minimise the impact of construction works for construction personnel The ground conditions to establish the risks of stability of the surrounding soils. Page 26 January 2013
During this phase, the designer must take into account:
3.5.3
At Pre-Construction Stage
This is an important phase for safety considerations as it maps out the construction processes and methods via the Method Statement. The appointed Contractor should submit: A Method Statement which should detail all the construction methods and programme A Risk Assessment highlighting ALL risks to safety, rating each in terms of probability and severity A Site Emergency Plan to show evacuation procedures in an emergency A Traffic Management Plan to set out the specific requirements for the site.
3.5.4
During Construction Stage

A daily checklist for inspection of the works is included in the Appendix and this is to be checked back and corroborated with the Method Statement.
During this stage there are many considerations for the Contractor to consider.
The worker should take the following general precautions: Do not take chances that may lead to injury Either use tight sheet shoring to guard against the caving in of sandy soil or loose material when the depth of the excavation exceeds 5 ft, or cut back the bank to the proper slope. Keep shoring at or near the bottom of the ditch as it is excavated and follow with bracing to ensure safety. Trench shields are also acceptable as a protective system. A trench shield does not protect the environment, only the worker. The placement of shores will depend on the type (classification) of soil encountered. Local, state or provincial, and federal laws man - date the distances and sizing of shoring support systems. Extend shoring of any type below the excavation bottom whenever possible, and brace it thoroughly using timbers, wedges, and cleats, or a pipe/screw-jack combination. Place all bracing at right angles to the sheeting or uprights and rigidly wedge, bolt, or cleat it to prevent movement. Hydraulic units are being used in many types of utility-trench construction Use only full-sized lumber that is assessed to be sound and straight. Install the upper braces or screw jacks first, and remove them last for best protection. Also consider excavation dimensions, soil stability, variable weather and moisture conditions, proximity of other structures, weight and placement of soil and equipment used on the job, and sources of vibration when choosing the type of shoring to use, if any. The decision must rest with the engineer or foreman in charge. Use hydraulic jacks temporarily only, and replace them with properly sized screw jacks or solid bracing. Personnel should not be required to do heavy lifting that may cause injury; use mechanical lifting devices to raise, lower, or suspend heavy or bulky material when working in trenches, manholes, or vaults. Use ladders where required. Do not jump into an excavation.
Page 27
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Provide an adequate means of trench exit, such as a ladder or steps. Locate it so no more than 25 ft of lateral travel is required. Extend the ladder from the bottom of the excavation to at least 3 ft above the ground surface. Do not place excavated material closer than 2 ft from the edge of an excavation. Keep all tools, working materials, and loose objects orderly and away from the excavation shoulder. Keep tools, equipment, and excavated material out of open traffic lanes. Take work breaks, rests, etc. at designated locations away from the excavation. When resuming excavation after heavy rains or freezing weather, inspect all banks for cracks. These may indicate earth movement and the probability of cave-in. Frequently inspect the sides and rim of all open excavations to guard against cave-in. Operate earth-moving equipment from a position that will not imperil personnel or property by a cave-in due to vibration, stress, or dead weight. If it is absolutely necessary to work above an overhanging bank, use a safety belt and a lifeline. Have a helper nearby to assist in an emergency. To avoid striking electric or telephone conduits, gas lines, or other sub-structures, locate other utility installations before starting work. Require workers to wear adequate eye, ear, and foot protection when using a jackhammer or when exposed to flying particles or falling objects. Workers should always be aware of locations of running machines (backhoes, trenching machines, etc.). Workers should keep clear of the sweep path and try never to turn their backs toward the working machine(s).
3.5.4.1 Pipe storage

Keep pipe yards and walkways clean and orderly. Always block pipe to prevent it from rolling or falling. Arrange and block each row of stacked pipe to prevent it from rolling from the pile. Store small pipe in racks according to length and size. Store pipes larger than 2inch diameter by stacking them with spacing strips placed between each row. Withdraw pipe from the top rows.
3.5.4.2 Shoring and bracing

Use proper shoring and bracing to prevent cave-ins while vaults or similar openings are under construction. Proper shoring cannot be reduced to a standard formula. Each job is an individual problem and must be considered under its own conditions.
3.5.4.3 Posting barricades and warning signs

Place advance warning, instructional signs, barricades, and delineators well ahead of the construction area to warn motorists and pedestrians of the area and safely take them through or past it.
Page 28
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Protect the work area with barricades, barriers, or planks to provide a safe working space. If necessary, use flaggers to direct and slow down traffic. When used, place trucks or air compressors between the work and the traffic. During periods of reduced visibility, use adequate lighting on all barricades. When no work is in progress, place adequate barriers, barricades, flashing lights, and signs to warn and divert traffic. Use reflecting tape on all barricades. All personnel should wear protective clothing including hard hats and high visibility traffic vests.
3.5.4.4 Trenching machines

The following rules apply equally to all mechanical devices used to dig trenches and/or make excavations including various types of trenchers, buckets, scoops, and similar pieces of equipment: Operators should always wear hard hats. Never attempt to oil or grease a mechanism or repair or adjust any moving part of a trenching machine while it is in operation. Only qualified personnel should operate a trenching machine. Guard all moving parts. Before starting the conveyor, make sure that no person is endangered by it. To remove obstructions from the conveyor mechanism or buckets, stop the machines. Be alert for falling material that might roll from the conveyor. When practicable, drop dirt between the excavation and the high-way to act as a barrier. Cautiously fill gasoline or diesel tanks. Keep spout in metallic contact with the machine to prevent static sparks from bridging the gap and igniting the vapours. Do not smoke. Keep proper fire extinguishers available when refuelling construction equipment. Use only approved containers when storing flammables on the job site; clearly mark and define storage areas. Use flags by day and flashing lights or flares by night to warn the public of the trenching machine and its operations. Liberally use these precautions on all highway or street work. Plan the warning system before the work is started. Operate the machine vertically to prevent undercutting the trench wells. When loading or unloading trenching machines or other heavy equipment from truck beds, lowboys, or other conveyances, provide suitable skids and ample blocking to prevent movement of the conveyance When manually lifting or lowering pipe in an excavation, use two or more rope slings looped under the pipe and handle from each side of the excavation. To prevent a heavy pipe from pulling workers into the excavation, anchor one end of each rope sling to a massive object such as a truck. When aligning pipes in the excavation, either manually or mechanically, keep hands and fingers away from ends of pipe and other substructures that could crush. Govern crane operations only by the signals of a qualified worker. Never try to catch and hold a length of pipe that slips from a crane or hoist sling. Be alert to unsafe excavation sides when measuring, testing, or inspecting pipe in place on an excavation bottom.
Page 29
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL When cutting sections of pipe, keep feet in the clear and use adequate blocking, chocks, etc to prevent pipe movement. Wear safety goggles Keep tools and appliances in good condition for handling, cutting, threading, or treating pipe. Always use the right tool for the job. Do not let tools or materials become stumbling hazards where pipe is being handled. Avoid shortcuts and makeshift methods that may increase the hazards of handling pipe. limited
Accidents and risks that may be particularly related to NDRC work will include, but are not to:
Falling accidents (deep excavations and shafts) Materials falling from a height Collapse of excavation or shaft Road collapse or failure Flooding from broken pipelines or groundwater Striking other utilities (power, gas, oil, water, etc.) Suffocation due to inadequate fresh air supply (manned pipe jacking or micro-tunnelling) Dangerous gasses Rotating and moving machinery and equipment
These along with any other risks must be assessed in the Health and Safety plan including mitigation measures. Employment of workers inside pipe jacking or micro tunnelling pipelines shall not be permitted for pipelines with an internal diameter smaller than 1.2 m. The Contractor shall develop an emergency plan that describes actions to be taken in the event of any sudden surface settlement or collapse. This plan shall be included in the Contractors method statement.
3.6
Environmental requirements
General environmental requirements for any construction works in connection with main roads, including undertaking of NDRCs, can be found in the EHS Manual for Road Projects. Prior to commencing any projects an environmental permit must be acquired from The Environment Agency - Abu Dhabi (EAD). Points that will need to be addressed for the environmental permit may include: Soil or spoil removal including slurry handling and disposal. Dewatering including discharge. Waste management. Handling and storage of any hazardous materials. Activities creating dust, air pollutants or odours. Noise or vibrations. Page 30 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL The Contractor is responsible for establishing, operation and decommissioning of the work site in an environmentally safe way and this can be controlled by using a daily checklist report which will be followed in line with the Method Statement. Such details will be included in the Contractor's Method Statement. All waste materials shall be collected and disposed of in an appropriate manner, and the site shall be cleared and void of any waste matter after the construction is completed. All materials and equipment shall be stored in accordance with manufacturer's guidelines and in a way so that spills or emissions are avoided. Drilling fluids (slurry, bentonite, etc.) shall be recovered for reuse or disposal at an approved location in accordance with the environmental permit. The environmental issues that typically concern HDD include: Access restrictions due to wetlands, streams, endangered plant or animal life, endangered habitat, and potential erosion Oil and fuel spills from construction equipment Drilling-fluid surface spills that endanger animal and plant life Drilling fluid returns in water bodies Groundwater contamination from drilling-fluid additives Drilling-fluid disposal locations (The contractor must obtain approval to dispose of the drilling fluid at an approved disposal location. Bentonite is a good product for sealing drainage ditches, irrigation reservoirs, and livestock ponds.
However, approval must be obtained from EAD permit received for the works.
3.7
Site condition survey
A site condition survey shall be conducted during both the preliminary design and construction stages of the proposed NDRC. All surface and subsurface construction within a minimum of 30 m from the proposed centreline and any shafts must be identified and the exact location determined. These will include, but are not necessarily limited to: Cables, pipelines, sewers and manholes Pavements, footpaths, etc. Buildings Foundations, retaining walls, etc. Artificial cavities Constructional systems that have remained in the area along with any other structures or systems that may have impact or be influenced by the intended NDRC.
A building and structure assessment plan documenting the condition and including photographs of any existing damage must be included in the site condition survey. This shall be submitted for approval of both the preliminary design and final design. In connection with the final design the site Page 31 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL survey must be reviewed and approved by the DoT road maintenance consultant and approved by the DoT. Immediately prior to construction the site survey shall reviewed by the Contractor and any changes in the condition of buildings, structures, roads, footpaths and other paved areas shall be recorded and photographed.
3.8
Geotechnical Investigation
The geotechnical investigation shall be conducted in accordance with the Manual for Geotechnical Investigation and Geotechnical Design including determining the projects geotechnical category and the procedures for managing geotechnical risk as described. Evaluation of soil conditions on NDRC projects is critical, but often under-emphasized. Success or failure is intricately tied to correctly matching equipment and methods to soil Conditions. It is the designer's responsibility to ensure that sufficient geotechnical information is available for the complete design and safe installation of the NDRC. For all NDRC work, a minimum requirement of a desk study shall be carried out, assessing the available literature, maps, aerial photographs, utility plans and existing site investigations. The aerial photographs must encompass as much historical information as possible, that show for example lowlands swamps which have since been backfilled. Existing geotechnical investigations may be acquired from the road department, adjacent building owners or structures and other utilities agencies. If insufficient geotechnical information is available for the area where an NDRC is proposed, then a thorough geotechnical investigation must be conducted. The soil investigation analysis is necessary for: Selecting the appropriate NDRC method, jacking technique and jacking works Selecting and designing the supports for launch and reception shafts Selecting and designing jacking pipes Planning measures for soil improvement in unstable soils Planning of soil disposal (landfill, treatment, recycling) Planning of measures for the control of groundwater
The field exploratory techniques selected should be appropriate to the type of ground and the planned depth of the NDRC. The laboratory testing programme should include tests relevant to the ground conditions and the NDRC techniques likely to be employed. Table 1 below suggests parameters to be considered in relation to each soil type. The soil conditions shall be investigated and documented in accordance with the Manual for Geotechnical Investigation and Geotechnical Design. The investigation should result in information on reliable soil parameters which are necessary for the adequate design of the drives, shoring, and dewatering details. Analysis and design (calculations for Page 32 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL jacking forces, stress analysis on the pipeline, ground surface settlement and heave analysis, etc.) should be based on such parameters.
3.8.1

Minimum requirements of the exploratory boreholes

2 exploratory holes for crossings less than 25 m (one at each end) 3 exploratory holes for crossings greater than 25 m (each end and centre) Additional holes for long crossings or in areas with difficult soil conditions (layered)
Number of boreholes:
Depth of boreholes: Down to 2 m below pipe invert in groundwater free soils Down to 3 m below pipe invert in groundwater bearing soils Down to the planned bottom edge of sheeting in the area of launch and reception shafts.
3.8.2
Borehole Positions
Exploratory borehole positions should be chosen to provide information on the nature of the ground that will be encountered by the NDRC. Under no circumstances should boreholes be sunk on the line of the NDRC. All boreholes should be properly backfilled and sealed. Piezometers should be installed where recommended. Boreholes should always extend sufficiently far below the invert level to identify changes in the strata below the NDRC that could affect both the construction and long term impact of the NDRC. Boreholes should be sunk adjacent to shaft locations. Additional boreholes should be considered, if required, to identify the location of significant changes in geology or to resolve other geotechnical uncertainties. All geotechnical investigations shall be carried out by qualified personnel and in accordance with The Manual for Geotechnical Investigation and Geotechnical Design.
Page 33
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Table 1: Parameters to be considered in relation to each soil type Test
NonCohesive Soils Cohesive Soils Mixed Soils X X X X X X X X Fill Material X X X X X X X X X Rock X
Unit weight and moisture X X content Angle of friction X Particle size distribution X X Abrasivity X X Cohesion X Types and proportions of X X minerals Standard penetration tests X X Permeability and nature of ground water level and X flows (seasonal/tidal changes) Toxic/hazardous constituents in the X X ground/groundwater Frequency and physical properties of boulders, X X cobbles or flints Pump down tests X Presence of gases Compressive strength Rock quality designation (RQD) Core logging (TCR, SCR, FI) Tensile strength Specific energy (excavatability) Slake durability Geological description X X Plasticity indices (LL, PL, X PI) Source: An Introduction to pipejacking and microtunnelling design
X X
X X
X X
X X X X X X X X
X X
X X
Page 34
January 2013
4
4.1
PROCEDURES FOR UNDERTAKING NON DISRUPTIVE ROAD CROSSINGS

Overview
This chapter contains the general procedures and requirements for undertaking any NDRC works under DOT roads. It is divided into sections relating to the process map described in Chapter 1.
4.2
Concept Stage
At this early stage, the concept of each project will be considered by the Designer, and as per the stage gateway process, the options will be considered from a financial and environmental impact point of view before progressing to the next stage. This will be in line with the requirements of Town Planning as detailed in Chapter 2. For NDRC, if applicable the impacts will be established and examined, and put forward into the report generated by the Consultant. Depending on the project, it may be the case that different routes for the NDRC are considered.
4.3
4.3.1
Preliminary Design Procedures

Method selection
In this section more detailed information about the guidelines requirements and criteria related to the two major NDRC methods are currently used in emirate of Abu Dhabi are given in order to help select a method appropriate for the given project. More information on the various methods can be found in Chapter 2. The Client/Consultant should, before tender, determine which methods may or may not be used for the NDRC works. The selection should be appropriate for the intended installation and meet the requirements of this Manual. Method and equipment should be selected to avoid ground loss and minimize settlement or heave. Also, a geotechnical section along the drive path shall be provided with the ground surface and groundwater elevations shown. This will assist in determining the method. The selection of route and method shall be based on the information gathered during the site investigation and geotechnical survey along with all other relevant information. The line and level of the route shall be selected so as to avoid driving through weak/strong soil boundaries, weathering interfaces and groundwater surfaces. The methods presently available are many and diverse and new techniques are continually being developed. Existing methods and equipment are becoming more advanced and variations or combinations of different methods are also being developed. The selection of method is also dependant on the: Cost The cost of construction can vary dramatically depending on the method, materials, and route chosen. Page 35 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Traffic Impacts Designers and Contractors need to consider the negative effects on short term traffic flow impacts Depth The depth of the crossing as a wider effect on the extent of trenching required and safety of personnel. Risk to surrounding utilities Alternative methods should be considered when there is a large impact on any surrounding apparatus. Risks should be assessed. Groundwater impact The level of ground water can affect the ability to construct in a safe and efficient manner. Required installation speed Due to construction constraints it may be required to carry out a fast installation. If so, the most appropriate method should be chosen. Settlement risks Depending on the soil type encountered, the risk of settlement of the soil may be high this should be taken into consideration. Pipe size The size of the pipe crossing effects the depth and type of construction chosen. Length of crossing The length of the pipe is a strong deciding factor in the type of construction to adopt. Required accuracy All crossings must follow the route decided, however in some cases it may be that a method is chosen where the required accuracy is not as high as others. Feasibility of open cut It may be the case that an open-cut dig is found more appropriate. This will be decided early on in the process.
Below is a Table 2 detailing NDRC methods depending on the different soil types. Below is a Table 3 shows detailing the different applications for NDRC works and the options for alternative construction methods:
Page 36
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Table 2: NDRC methods related to soil types
Parameter
Impact Molling
Pipe Ramming X X X X X X Directional Drilling
Guided HDD Systems Mini X X X Tunneling Pipe Jacking X
Guided HDD Systems Midi X X X X X X Micro-tunnelling Auger X X X X X X
Pilot Pipe Systems
Hard rock Soft rock Hard clay Soft soils Sand & gravel Sand Cobbles/boulders Obstructions Below water table Parameter
X X X X X X Auger Boring
X X X X X X Mircrotunnelling Slurry & EPB
Hard rock Soft rock Hard clay Soft soils Sand & gravel Sand Cobbles/boulders Obstructions Below water table
X X
X Not Suitable
- Suitable
- May be Suitable (depends on specific circumstances)
Page 37
January 2013
Table 3: Different applications of NDRC
Utilization
Auger Boring U U
Directional Drilling
Tunnelling Pipe Jacking U U
Micro-nnelling Auger U U
Mircro-tunnelling Slurry & EPB U U
Cables Flexible Conduits Gas lines Oil lines Potable water Force mains Gravity mains Gravity Sewers
U U U U U U
S S
U U U U
U U U U
U U U U
Suitable at appropriate diameters and lengths - Small diameter only - Small diameter only Typically for Crossings only S Siphon crossings only
Micro tunnelling and Horizontal Directional are the most used methods in Emirate of Abu Dhabi, so more discussion will be explained.
4.3.1.1 Micro tunnelling Method

All types of Micro tunnelling boring machines have the following functions in common. Mechanized ground excavation and stabilization of the face The head of the machine is equipped with a cutting wheel whose tools are used to last the soil under the combined action of rotation and thrust. A crushing cone located behind the cutting wheel and intended to reduce the size of larger elements to allow their mucking, is present on most machines. There exist different cutting heads for various types of soil. (see figure below). They can be distinguished by their cutting tools. For sandy or gravely soil, the cutting wheels are equipped with teeth (figure a). In rugged soil, these teeth dislodge the blocks, which are then crushed.
Page 38
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 19: The different cutting heads
For coherent soil (silt, clay ,marl)the cutting wheels are fitted with tools which cut out chips of soils (see figure b).on some machines ,high pressure water jets are sprayed on the wheels and in the stope to prevent sticking of clay and clogging of the mucking system. Finally for rocks (see figure c)the cutting heads are equipped with rotary cutters having small openings .with the help of the thrust ,the rotary cutters crush the rocks by means of shear and tensile stresses, which create cracks and loosen the fragements.these machines can bore through the rocky soil with a compression strenghth of 200 MPA.thi s type of cutting wheel ,also used in soil containg large b;pcks,is not suitable for clayey soil . To ensure the stability of the face ,the contact pressure of the cutting wheel and the confing pressure must be equal to the earth pressure and to the pore pressure of water if the boring is done under the ground water table.thus the total pressure thus applied on the head must be :greater than the active pressure of the earth so as to avoid over excavation leading to the settling on the surface or even subsidence .
Page 39
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL less than the passive earth pressure so as to avoid facing back the soil at the face ,leading to elevations of the surface or lateral movements likely to create disorder for already existing networks(Stein et al.,1994)
In the case of hydraulic mucking ,this pressure is ensured by the slurry injected into the chamber located at the back of the felling cone.it can be controlled more easily than the pressure exerted by the soil mixed in the stpe of the scew type boring machines(Bennett et al .1994).
Disposal of rubble (mucking) There are three types: Hydraulic mucking Removing the earth in suspension in a freely flowing fluid to the outside. That fluid can be water or pressurised bentonite slurry.(See Figure 20) Mucking with a screw conveyor The rubble is extracted from the stope using a spiral conveyor (see Figure 20) Pneumatic mucking This is a system that is rarely used and consist of mucking by suction where the rubble is extracted from the face into an airtight vacuum container.
Figure 20: Principles of a hydraulic mucking boring machine (Herrenknecht documents)
Monitoring and correction of trajectory Controlling the actual trajectory of the boring machine in relation to its theoretical position ,is done using a laser beam with the sensor located in the start shaft whose impact on a target placed in the machine helps visualize the deviations in trajectory with the help of a camera on board the boring machine When the deviation s become excessive it is possible to correct the direction of the machine whose head is articulated by moving the three cylinders placed 120 c apart. 4-installation of pipelines by jacking.
Page 40
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL This is done by successive jacking of pipes behind the boring machine ,this pipejacking is ensured by a thrust frame equipped with hydraulic cylinders and located in the starting shaft.
Pipes Materials
Many types of materials are used : Concrete pipes represent the majority of pipelines that are currently laid . Pipes made of composite materials, known as glass fibre reinforced plastic offer very good resistance to corrosion and thus are efficient in transporting corrosive fluids or for carrying chemically aggressive soil, moreover they offer a high resistance at a lower weight the external diameters available are between 400 and 2400 mm. Steel pipes have the major advantage of offering strong resistance but they are sensitive to corrosion. Clay pipes available in diameters of 150 to 1200 mm offer greater resistance than the concrete pipes at the same thickness .when their surface is vitrified ,it is extremely resistant to water absorption and chemical attacks.
In terms of corrosion resistance the jacking pipes and their joints can be subject to internal corrosion caused by the transported substances or to external corrosion caused by the surrounding soil or ground water. If the materials used are insufficient ly resistant ,measures of corrosion protection have to be taken and approved by Dot. For steel and ductile cast iron pipes the internal protection shall not be damaged during the jacking process. The methods vary in size, length and accuracy as shown in Table 4. Due to the limitations in accuracy, non-steerable methods should only be used over short distances and where suThe soil conditions and groundwater levels are of great importance in determining the most suitable method for a given NDRC. In Table 2 a number of the common methods are shown with their respective application in various soil types. Some methods can be used in almost any soil conditions as long as the equipment and tools are appropriate for the present soil types. Horizontal directional drilling (HDD) is an example, where drills and reamers are available for nearly any soil type. HDD can however have limitations in coarse noncohesive soils where the cavity created by the reamer can have a tendency to collapse. This is Page 41 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL especially the case in very uniform soil particle size efficient clear distance to other utilities can be guaranteed. Table 4: NDRC methods with typical pipe size, length and accuracy
External pipe diameters, De Non-steerable: Impact moling/soil displacement hammer, Pipe ramming with closed pipe Pipe ramming with open pipe, Auger boring Steerable: Horizontal Directional Drilling (HDD) Micro tunnelling Pilot pipe with auger spoil removal Manned steerable: Pipe jacking Hand excavation: Hand dig + Mechanical excavator Min 1500mm 125m Varies 3.0 x De Min. 3.0 m 1500 - 4500 mm 1000 m +/- 20 mm 3.0 x De Min. 3.0 m 40 - 1200 mm 400-4500 mm 100 - 1200 mm 1800 m 1000 m 100 m 2-5 % of depth +/- 20 mm +/- 20 mm 3.0 x De Min. 3,0 m 3.0 x De Min. 3.0 m Up to 200 mm 25 m 1-2 % of length 10 x De Min. 3.0 m 3.0 x De Min. 3.0 m Maximum length Accuracy Minimum ground cover
Up to 2000 mm
80 m
1-2 % of length
. Micro tunnelling or pipe jacking with closed front can also be applied in nearly any soil condition with the suitable bore heads and spoil removal systems. However, in very loose non-cohesive soils, with high groundwater levels, there is a risk of removing excessive soil in front of the bore head, which may lead to immediate or future surface settlement. In very loose soils or areas where soil investigations have indicated subsurface cavities, a decision must be made either to construct deeper in an attempt to find suitable soil conditions or to apply ground treatment methods prior to undertaking the NDRC. In Figure 2 a number of grout types are indicated for use as ground treatment methods. The final selection of an NDRC system should be developed using available factual and reliable soil data and surrounding constraints. The system should include the recommended route (line and level), boring size, NDRC method, pipeline details, equipment, and operational variables, all of which, in combination, will achieve the required tolerances. The proposed system should then be analyzed for: Jacking/pulling forces. Lubricant characteristics. Face stability. Page 42 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Thrust reaction elements. Structural design of pipe and joints. Ground surface movement (both short and long term settlement and heave).
Please refer to the Tunnelling and Pipe Jacking Guidance for Designers table which is shown in Appendix E
Drilling fluids
Functions Generally, the fluids used for boring may have several essential Functions: maintaining the cutting in suspension and ensuring its removal by hydraulic channels: this obviously is a function that is directly applicable to boring machines with hydraulic mucking; guaranteeing the stability of the bore, strengthening the walls and preventing loss of fluids by creating an external or internal cake that is as fine and as resistant as possible. This is a supporting function; lubricating and cooling the tools, drilling strings, on-board equipment and pipelines; facilitating digging by jetting. This function is sometimes necessary in clayey ground The drilling mud is essentially made up of a stable colloidal suspension in a Dispersing agent like water. Two families of colloids are mainly used: Mineral: mainly bentonite, Organic: mainly water-soluble polymers.
This suspension is rapidly altered by solids in the ground and possibly by water contained in the ground to be crossed and the minerals contained in it. The bentonites are industrial clay of the smectite group. They are characterized by a foliated structure, which is negatively charged on surfaces and positively on.
Main characteristics Main characteristics parameters of drilling fluid, which determine its behavior and which must be regularly measured and recorded as the digging work progresses: the density, which is an index of the content of solid element in the polluted sludge; it must generally be between 1.0 and 1.2; the viscosity, which characterizes the ability of forming a cake as well as the ease in transportation of the mucking; measured at the Marsch cone, it must generally be between 32 and 40 seconds in clayey ground, and greater than 50 seconds in sandy ground; the yield point, the thixotropy and the filtrate that determine the formation of the cake and its ability to reform rather rapidly; in a filtration test, clean sludge must present a cake less than 4 mm and a filtrate less than 40 cm3; in polluted sludge the cake must remain less than 3 mm, and the filtrate must be in the region of 6 cm3 in clayey ground, and 10 to 15 cm3 in sandy ground; the sand content, which results from the separation result of solid earth and which affects the permeability of the cake and therefore its stability; it must generally remain less than 4 to 5 % (measured with the elutriator); Guidelines for a Project Design 297 Page 43 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL the pH, which affects the ionic balance and thus the physico-chemical properties of the sludge; it must remain within a range of 8 to 10; the conductivity and the hardness are also indices that may be useful.
NOTE: the values indicated above are only to indicate the order of magnitude generally used in trenchless work. They must however be adjusted according to predominant performances, which are dependent on the ground. Implementation of drilling fluids requires suitable manufacturing, storage and solid treatment equipment: mixers, main and auxiliary pumps, mud tanks, vibrating screens, hydrocyclones, centrifuges, and possibly a plant for the physico-chemical treatment of waste.
The equipment as well as the quality of process water and the temperature will significantly affect the performances of the sludge. On the other hand, it is very essential to emphasis that the storage conditions (long periods, humid atmosphere, etc.) can significantly alter the characteristics of the bentonite powder. fractures. Upon contact with water, the flakes disperse, swell and possibly exchange the charge compensating cations. Beyond a certain concentration (relatively low) of the order of 4 to 6%, and depending on the quality of bentonite, a stable structure develops and has certain Rigidity under shearing. The bentonite can be combined with additives for various functions: Viscosifying, fluid-loss additive, water reducer, clay encapsulator and stabilizer, Lubricant. The most common are water-soluble polymers which, in addition to their ability In increasing the viscosity, present special physico-chemical properties. There exist several types that are natural, artificial or synthetic, which can remedy specific problems relating to certain soil materials, such as: Sticky or swelling clay, Improvement in the stability in sand and gravel, Better resistance to physical or chemical contaminations, Abrasiveness.
4.3.1.2 HDD process

All types of horizontal drilling have the following common functions: Drilling of a pilot tube A drill string is inserted into the ground applying on the bottom hole assembly a combined thrust and rotation action. This bottom hole assembly has a special feature of being asymmetrical in relation to the longitudinal axis. Mere thrust forces it to deviate, but rotation combined with the thrust gives it a straight trajectory. Page 44 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL This bottom hole assembly consists of an electronic tracking device and more or less sophisticated cutting tools. These tools are either simple drill blades or drill bits driven by hydraulic or pneumatic motors.
Monitoring and correcting the trajectory The installation of pipelines by horizontal drilling must be able to: constantly locate the position of the drilling head in the ground so as to respect the specified trajectory and avoid the already existing utilities: this is the tracking function; know the pitch of this head and its direction to guide and divert its trajectory: this is the guidance function.
It is in fact the asymmetry of the head (wearing blade and nozzles in the case of a conventional head or a bend in the case of a mud motor) which by stopping the rotations of the rods diverts the trajectory, thereby correcting it. The success of pilot drilling depends on the locating system, its accuracy and ease of use. Two types of locating systems may be distinguished:
Walk-over systems These systems are suitable at most sites. This technique is easy to implement, is safe for data transmission cables and has a low investment cost. The walk-over systems have disadvantages such as the reduction in accuracy of measurements increasing with the drilling depth, the influence of underground magnetic field interference and an operating range dependent on the life of the transmitters batteries.
Down hole systems or wire line steering systems The systems consist of three elements: a transmission probe powered by batteries placed in the drilling head, a receiver that helps vertically locate the head and its direction, display of parameters (remote) on the drill rig. Figure 21: Locating systems
Page 45
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Reaming of the drilled borehole Once the pilot hole has been made, the drill string comes out of the exit pit (most frequent case). Generally, the drill string is towed behind the reamer. The hole is enlarged by successive stages of reaming of increasing sections until the desired section is reached (generally double the section required by the pipeline). This reamer is equipped with injection jets for drilling mud. This mud washes out and disposes of the cuttings created by the reamer, lubricates and cools the cutting tools and strengthens the borehole. After the final reaming phase one end of the pipeline built earlier will be tied to the pulling head fastened to a suitable reamer. It will be pulled from one drilling end to the drill rig.
Installation of pipes or cables Used to cross obstacles such as streams or rivers, this guidance technique using data transmission cables has opposite advantages and disadvantages to the previous system with a more complex usage technique but with greater accuracy and range. The horizontal directional drilling system The horizontal directional drilling system include: Drill unit. Guidance system. Drilling fluid system. Drill pipe and down hole tools, including bits and back reamers. Drilling fluid mixing or recycling system. Figure 22: Basic components of rig
Page 46
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL HDD systems are defined by: Thrust and pullback force, stated in pounds Spindle torque, stated in foot pounds Maximum volume of drilling fluid a machine can pump per minute, and spindle Revolutions per minute. Table 5: Rigs types and specification
The composition of drilling fluid and correct/constant pressure are keys in successful installation of HDDs. Too low pressure may cause collapse of the bore cavity or clogging of soil removal. Too high pressure may result in blow out, where drilling fluid is pressed through overlying soils to the surface. Horizontal directional drilling can be undertaken in both soil and rock, and there are no specific limitations under ground water. Some restrictions may apply in very loose coarse sand or gravel. These soils will have a tendency to collapse in the borehole giving either excessive spoil removal or stopping the pipeline. Pipe materials are most often plastic (PE, PP or PVC), but steel and cast iron pipes are also manufactured for use in HDD installations. Pipe materials must be joined and have the strength necessary to withstand the pulling forces applied during installation. The accuracy of HDD is dependent on the accuracy of which the drill heads location and depth can be determined during drilling. Accuracy has typically been set at 2-5% of the depth, but more accurate transmitting/receiving equipment is continually being developed.
Drill Bits The latest bit designs are for specific types of soils, including rock, cobble, and other difficult conditions. Carbide makes todays bits more productive and last longer. Bits are designed to run smoother in difficult conditions, with less vibration transmitted to the drill unit. A truly universal bit that is effective in all soils has yet to be developed, but some of the latest bits can be productive in a much wider range of soils. Page 47 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL For much of todays short- to medium-range utility applications, slant-face bits also make it possible to change the direction of the path of the pilot bore. Many new bit products are for rock work, and drilling and steering through hard rock remain a challenge for both tool and drill-rig designers. Some drill bits are used for steering and to excavate the soil or rock at the face of the bore. The types of drill bits commonly used in HDD applications are traditional Slanted-face bits, slanted-face rock bits, and hard rock or mud motor bits.
Table 6 provides some application guidelines for the various types of drill bits. Table 6: Drill Bit Types and Application Guidelines (Courtesy DCCA)
Page 48
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 23: Slanted face Drill Bits
Figure 24: Modified Slanted face Drill Bits
Page 49
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 25: Modified Slanted face Drill Bits
Figure 26: Rock Drill Bits
Page 50
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 27: Tri-Cone Rock Bits
Guidelines on EHS and risks for HDD

The constraints linked to the safety and protection of the environment must be considered in the study. All DoT and international rules must be followed during the work. The elements mentioned below Figure only as additional elements and can on no account substitute the current rules. Before starting the work, it is necessary for all personnel present at the site to attend an information meeting on accident and their prevention, means of rescue and emergency organizations. Taking adequate steps may prevent the following hazards linked to horizontal drilling: Work on inclines The working area used on the machines must be of non-skid material and be easy to clean. Fixed handrails must prevent the risk of falls. Work on rotating mechanical parts and tools Contact with rotating mechanical parts must be prevented in every possible way by fixed safety installations. The working clothes of the personnel operating the machines must be tight fitting and closed. During the rotation of the drilling rods, a clearance distance must be maintained. Risk of slipping increased by the presence of drilling mud During the dismantling of the drilling rods, the bentonite mixtures must be collected in salvage tanks. Clean water must be available for the cleaning of the work area near the machines and mixer Respiratory risks related to the inhalation of bentonite powder Suitable techniques to avoid working as much as possible in areas subject to contamination by bentonite powder must be employed. Work in these areas must be done only by those wearing antidust masks (half-masks that filter particles) and airtight protective eyewear. Page 51 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Handling of loads during lifting The handling of drilling rods and other loads by lifting appliances must be done with great care. The proper condition of pipe tongs, slings and straps must be frequently monitored. Staying under suspended loads must be strictly avoided. In all cases, it is necessary to maintain a safe distance from overhead lines of any type. Significant torsional moments during the tightening or loosening of drilling rod/tool unions Special attention must be paid to the proper working condition of tightening and cutting tools. In particular, spring collets must be used with great care and only by skilled personnel. Special attention must also be paid to the proper condition and safety of the workstation at the drilling exit point. Communication between the control cab, the drilling rig and the pipeline side To eliminate the dangers created by the drilling rig at the exit point by rotating tools, it is necessary to ensure continuous radio communication. With no visual contact between the machine and the pipeline sides, the use of a receiver-transmitter headset as well as walkie-talkies is recommended. In all cases, it is necessary for the operator of the drilling machine and the person in charge of the pipeline side to coordinate themselves before starting the work. Work under thoroughfares The risks are not limited to horizontal drilling except for the operator who follows the pilot hole with the receiver. Engrossed in using the receiver, he may not always be aware of his safety. It may be necessary to protect his route and/or stop the traffic temporarily while crossing the road. Risks of aggressions on underground structures The risk of sometimes coming into contact with high voltage electrical transmission lines requires a rigorous use of the drilling machine and insulation of the personnel. In the case of a damaged gas pipeline, all ignition sources must be removed: the machine and all the equipment near the leak must be stopped, as well as all electrical devices (including mobile phones). When gas pipelines are present in the drilling area, the site manager must provide the co-ordinates of the concerned gas company. Security of machines The machines used for carrying out horizontal drilling projects must meet the European recommendations as well as the national regulations applicable to them. A compliance statement as well as the issuing of the CE acronym linked to it must be provided by the manufacturers of different machines. Independent monitoring of the machines is possible. It will be done by the competent national authorities as far as safety is concerned. This is linked to the qualification and for European Tested. For protection against electrical accidents, the machines operating on electricity must be properly earthed before use. The maintenance of complex hydraulic systems of horizontal drilling machines must be done with care. The watertightness of these systems must be constantly monitored.
Page 52
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Security of drilling tools For drilling rods, tools, equipment, joints, reamers and links to be inserted inside the drilling, it will be necessary to undertake a safety check by a qualified body in MQ or by a qualified or state recognized monitoring institution (independent monitoring). This monitoring must show that the drilling rods and the tools used inside the drilling are made of suitable material. It must also show that the maximum stresses to tension, compression, torsion and internal pressure incurred by the drilling machine used do not exceed 0.8 times the elastic limit of the material (S = 1.25) according to the DIN, API bases and DS standard. For tools having rotating parts such as downhole mud motors, tricone bits or universal joints, one must ensure before every use that a detailed and documented inspection is carried out. This will guarantee that they can be used safely and without any restrictions (internal inspection).
Operational risks in HDD installations

Many risks will be associated with the HDD operations. Table 7 lists those risks must be assessed within any method of statement will be submitted to DoT to get approval for HDD operation.
Page 53
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Table 7: Operational risks in HDD installations (Baumert and Allouche 2003)
Page 54
January 2013
Figure 28: Experience guidelines for the application of different NDRC methods
Rock Dense Medium dense Loose Very stiff Non-cohesive Inter-bedding Cohesive Firm to stiff Very soft to soft
Soil classification
Method
Non-steerable methods:
With soil displacement
With soil removal
Steerable:
Directional drilling
Micro tunnelling
Pilot pipe jacking with soil removal, over GW
Pilot pipe jacking with soil removal, under GW
Manned steerable techniques:
Pipe jacking with open face, over GW
Pipe jacking with open face, under GW
Pipe jacking with closed face
Ground Treatment:
Cementitious grouts
Suspension grouts - clay filler grouts
Low viscosity grouts - resins Main area application of Application possible Application critical
Chemical grouts - silicates
GW = Ground water
Notes:
Page 55
January 2013
4.3.1.3 Working shafts, entry and exit points

Launch and reception shafts shall be designed and constructed to withstand all applicable static and dynamic loads including the maximum driving force that may be applied. The location of launch and reception shafts shall be selected to ensure safe working distances to roads, buildings and other structures (see Table 8). Figure 29: Working shafts
Table 8: Design of working shafts in Dry ground
Page 56
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Table 9: Design of working shafts in wet ground
For DOT Main Roads, a minimum distance of 5.0 m from any shaft to the edge of the embankment shall be ensured. For Municipality roads in cities or towns, this distance may be difficult to achieve due to buildings and other structures. If 5.0m cannot be achieved, then Consultant/Contractor shall present the reasons and the methods proposed to protect the asset affected by the crossing. Special care must therefore be taken in the placement, excavation and backfilling of shafts to avoid any damage. Slope stability must be examined and taken into account when submitting solutions to the DoT. For horizontal directional drilling (HDD) the entry and exit points should be at a sufficient distance to ensure the acceptable radius of the drilling equipment and piping material.
Page 57
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Table 10: Shaft Dimensions
The dimensions of launch and reception shafts shall be kept to a minimum necessary to construct the NDRC. Examples of shaft sizes for pipe jacking or micro tunnelling are shown in Table 11. Table 11: Shaft sizes
DN 200 - 300 400 - 800 800 - 1400 1500 - 3000 External Pipe Diameters (mm) Up to 406 556 - 970 1100 - 1720 1820 - 3600 Segment lengths 1.0 m 2.0 m 3.0 m 3,5 m Dimensions of launch shaft 2.0 m diameter or 2.5 m x 2.0 m 3.2 m diameter or 4.5 m x 3.0 m 5.8 m x 4.0 m or 6.0 m diameter 10.0 m x (4.5-6.0 m) or 10.0 m diameter Dimensions of reception shaft 2.0 m diameter or 2.0 m x 2.0 m 2.6 m diameter or 3.0 m x 2.5 m 4.5 m x (2.5-3.0 m) 6.0 m x (3.0-4.6 m)
Shafts beneath the water table shall be water tight and the base concrete shall be capable of withstanding external uplift pressure of groundwater in addition to other loads. Entry and exit seals or ground treatment of the soil outside the shaft will be required to ensure that there is no soil transport into the shaft when initiating the drive. When deciding entry and exit points, it is important to allow for a safe soil cover throughout the crossing length under the road.
4.3.2

Design drawings
Map of location Plan and profile showing the line, level and diameter Plans of existing utilities, buildings and structures Geotechnical profile along the drive line (showing ground water elevations) Plan of working areas showing approximate size and location of shafts, entry sties
Drawings required for approval of the preliminary design include:-
or exit
Page 58
January 2013
4.3.3
Hand excavation
If hand excavation is considered appropriate (when no other option is available), then this must be planned very carefully in line with the specific Health and Safety requirements of the project. The most appropriate tools must be used and all personnel must be adequately trained to work in confined spaces. Please refer to the Tunnelling and Pipe Jacking Guidance for Designers table which is shown in Appendix E and e consult the EHS Manual for further details.
4.4
Pre-construction stage
Prior to commencing construction the final design of the proposed NDRC must be completed and approved by all relevant authorities. This is often undertaken by the specialist Subcontractor, who has the experience and the detailed information about the method and equipment to be used. All calculations, drawings, method statement, etc. must however be approved by the Client/Consultant before submitting to the Road Authority for construction approval.
4.4.1
Design calculations
Calculations for any thrust and receptions pits/shafts which shall be designed to resist external soil and water pressure and stresses resulting from the jacking machine. Pipe calculations showing capability of pipe to resist jacking and friction forces in the axial direction along with soil, ground water and traffic loadings in the vertical direction. Calculations of friction loads, face loads, interjacks, jacking pressures etc. for the complete system including thrust walls, which demonstrate how pipes will be installed with no damage. Page 59 January 2013
Design calculations shall include:-

Calculations giving predicted settlements along and adjacent to route of pipeline. Calculations supporting maximum jacking capacity with appropriate factor or safety.
4.4.2
Design drawings
Comprehensive plan, profile, and section drawings of the proposed drive showing all necessary details (such as internal and external diameter, wall thickness, joints or connections) Working drawings showing on plan and section the method of supporting excavations (Temporary Works). Drawings showing the location of pits/shafts including those indicated as permanent works in the design drawings. Foot print plans showing the working site areas at the thrust and reception pits/shafts, control room, pipe storage area, craneage area, slurry tank, generator, etc. Plans showing proposed traffic and pedestrian diversion proposals around all pits/shafts. Details of entry and exit pipe seals and seal rings in pits/shafts. Jacking and receiving pit configurations (plus design and construction details) Ground support details Any relevant requirements for thrust blocks, backstops etc Site logistics including storage areas, excavation and backfilling procedures etc Plans for de-watering Settlement Monitoring Plan, including monitoring points, benchmarks, and survey procedures. Jacking and receiving pit working drawings, including configuration, support, storage details etc.
Drawings must include:-
4.4.3
Ground Surface Movement
The goal of any NDRC undertaking should be to avoid ground surface movement entirely. Unacceptable ground surface movement (settlement or heave) shall be defined as movement greater than 6.0 millimetres vertically anywhere in the centreline of the NDRC drive or adjacent surfaces and structures. Some important considerations include:
During pipe jacking, ground movement may occur due to the instability of the face of the bore, or from the elastic unloading of ground caused by excavation. These may be referred to as short term settlement and heave. Providing good practice is followed, the effect of such movements should not be adverse. Long term movements may occur due to closing of the overbreak. Pipe jacking has the advantage that the overbreak is minimal and may be pressurised in certain soil conditions. Page 60 January 2013
The combination of NDRC drive methods and pipeline details are the key to preventing excessive surface movement, which may be related to:
-
Diameter and depth of drive. Boring method and practice. Stiffness of pipe and joint system and structural integrity. Joint alignment. Maximum jacking/pulling forces. Lubrication and flush details. Pipe/soil interaction. Overcut and its management. Face support details. Groundwater control details Lack of post-installation annular injection Over-cutting in layers with consistency differences Inadequate rate of advancement
Obstruction collisionRegardless of drive method or details, surrounding soil may be susceptible to excessive movements when disturbed by the drive (bore). The following conditions can influence ground movements:
-
Residual or swell stresses leading to radial-elastic or time-dependent movements. Weak soils or shear failure of the face. Loose compressible soils around or above the drive leading to densification and hence ground movement upon disturbance. Internal erosion of loose, non-cohesive soil due to uncontrolled groundwater movements. Loss of soil mass due to dissolution of salts by moving water through soils with high salt content
4.4.3.1 Prediction of ground surface movement

Theoretical procedures, combined with empirical correlations may be used to assess potential ground movement above the tunnel. Since tolerances against ground surface movements are small, the Department recommends that worst credible design assumptions and methods be used in the assessment and that total, not fractional, movements be determined. For initial assessments, and where ground settlement effects are not critical, traditional settlement calculations based on an estimated volume loss during tunnelling may be sufficient. Standard empirical analyses such as those presented by) should always be undertaken where the effects of ground settlement due to tunnelling are an issue. Simple methods of calculating the extent and potential shape of the settlement trough laterally to, and axially along, the tunnel are given in numerous text books and guidance documents (i.e. CIRIA Project Report No. 30 1997). Page 61 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL O'Reilly and New (1983) presented the following formula for determining the maximum initial settlement above the tunnel axis as:
, or Smax = 0.025.Vl(r2/z0) Where:

VL is the total volume loss of ground per unit advance in m3,
Vl is the volume loss as a percentage of the tunnel volume, r = pipeline radius, z0 is depth to centre of pipeline and
i is a coefficient related to the width of the settlement trough:
When tunnelling through granular deposits such as sand however, account needs to be taken of the modified shape of the settlement trough. Jacobsz, Sanding et al suggest that the profile of the settlement trough in sands is better predicted by the formula: S = Sm.exp[-1/3.(x/i)1.5] Rather than the usual formula: S = Smax.exp (-x2/2i2) Page 62 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL based on the Gaussian distribution normally adopted. S = ground settlement at point x transverse to the tunnel axis Smax = maximum calculated settlement i = distance from tunnel centre line to point of inflection of the settlement trough. Determinations of potential damage to all structures located within the settlement trough should be carried out as described in the CIRIA documents PR 30 and SP 201 and elsewhere. Another method can be used
4.4.3.2

Analysis of subsidence trough
The analysis of subsidence trough consists of several sequential steps: Determination of the maximum settlement and dimensions of subsidence trough for individual excavations back calculation of the shape and dimensions of subsidence trough providing it is calculated at a given depth below the terrain surface. determination of the overall shape of subsidence trough for more excavations
post-processing of other variables (horizontal deformation, slope)
The analysis of maximum settlement and dimensions of subsidence trough can be carried out using either the theory of volume loss or the classical theories (Peck, Fazekas, Limanov).
4.4.3.3
Volume loss
The volume loss method is a semi-empirical method based partially on theoretical grounds. The method introduces, although indirectly, the basic parameters of excavation into the analysis (these include mechanical parameters of a medium, technological effects of excavation, excavation lining etc) using 2 comprehensive parameters (coefficient k for determination of inflection point and a percentage of volume loss VL). These parameters uniquely define the shape of subsidence trough and are determined empirically from years of experience.
Page 63
January 2013
Settlement expressed in terms volumes The maximum settlement Smax, and location of inflection point Linf are provided by the following expressions:
where: A - excavation area Z - depth of center point of excavation k - coefficient to calculate inflection point (material constant) VL - percentage of volume loss The roof deformation ua follows from:
where: r - excavation radius VL - percentage of volume loss

Recommended values of parameters for volume loss analysis:
Data needed for the determination of subsidence trough using the volume loss method: Coefficient to calculate inflection point k
Soil or rock
k
Page 64 January 2013
Coefficient to calculate inflection point k
Soil or rock cohesion less soil normally consolidated clay over consolidated clay clay slate quartzite
k 0,3 0,5 0,6-0,7 0,6-0,8 0,8-0,9
Percentage of volume loss VL
Technology TBM Sequential excavation method
VL 0,5-1 0,8-1,5
Several relationships were also derived to determine the value of lost volume VL based on stability ratio N defined by Broms and Bennermarkem:-
where: v - overall stress along excavation axis t - excavation lining resistance (if lining is installed) Sn - undrained stiffness of clay
For N < 2 the soil/rock in the vicinity of excavation is assumed elastic and stable. For N < 2,4 local plastic zones begin to develop in the vicinity of excavation, for N < 4,6 a large plastic zone develops around excavation and for N = 6 the loss of stability of tunnel face occurs. Figure 30 shows the dependence of stability ration and lost volume VL.
Page 65
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 30: Stability Vs Volume Loss
Ground settlement is of greater concern for soft ground tunnels than for rock for two reasons: Settlements are nearly always greater for soft ground tunnels. Typically more facilities that might be negatively impacted by settlements exist near soft ground tunnels than near rock tunnels. With modern means and methods, both the designer and the contractor are now better equipped to minimize settlements and, hence, their impact on other facilities.
Sources of Settlement
Although there are a large number of sources or causes of settlement, they can be conveniently lumped into two broad categories: those caused by ground water depression and those caused by lost ground. Groundwater Depression Groundwater depression may be caused by intentional lowering of the water during construction or by the tunnel itself (or other construction) acting as a drain. When either of these occurs the effective stress in the ground increases. Basic soils mechanics can then be applied to estimate the resulting settlement. For tunnels in granular soil the settlement due to this increase in effective stress is usually reflected as an elastic phenomenon requiring knowledge of the low stress modulus of the ground and calculation of the change in effective stress. Unless the soil contains silt or very fine sand, this elastic settlement will typically represent the majority of the total but its absolute value will also be relatively small. For fine grained soils, the situation is a bit more challenging but certainly manageable using normal soil mechanics approaches. With fine-grained soils, the conditions are reversed. In most instances, the settlement is mostly due to consolidation brought on by the changes in effective stress and hence is analysed by the usual soil mechanics consolidation theories. In some instances, primarily if lenses of sands are contained in the soil, there may also be a relatively small contribution by elastic compression. In comparison to the settlement of Page 66 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL granular soils, consolidation can lead to several inches of settlement when the consolidating soils are thick and the change in effective stress is significant. Lost Ground Lost ground has a number of root causes (at least nine) and is usually responsible for the settlements that make the headlines. By definition, lost ground refers to the act of taking (or losing) more ground into the tunneling operation than is represented by the volume of the tunnel. Thus it is highly reflective of construction means and methods. As will be discussed, modern machines can be a great help in controlling lost ground but in the end it usually comes down to quality of workmanship. For the purposes of this manual, the causes of lost ground are lumped into three groups: face losses, shield losses and tail losses. Face losses results from movement in front of and into the shield. This includes running, flowing, caving, and/or squeezing behavior of the ground itself or simply mining more ground than displaced by the tunneling machine. Shield losses occur between the cutting edge and the tail of the shield. All shields employ some degree of overcut so that they can be maneuvered. In addition, any time a shield is off alignment, the shield yaws, pitches, or plows when brought back to alignment. Mother Nature abhors a vacuum and the surrounding soils begin to fill these planned or produced voids the instant they are produced. Note that a one inch overcut plus one-eighth inch hard facing on a 20 foot shield produces lost ground of nearly two percent if not properly filled [1.125/12 (20) 3.1416 ]/ (10)2 3.1416 = 1.88%). Tail losses are similar to shield losses in that they are caused by the space being vacated by the tail itself as well as the extra space that must be provided between the tail and the support elements so those elements can be erected and so that they don't become "iron bound" and seize the tail shield. However, like the shield losses, these tail voids will rapidly fill with soil if they are not first eliminated by grouting and/or expansion of the tunnel support elements. Estimates of settlement in soft ground tunneling are just that, estimates. The vagaries of nature and of construction are such that settlements cannot be estimated in soft ground tunnels to the same level of confidence as, say, the settlement of a loaded beam. In tunneling we rely heavily on our experience with some assistance from analysis. Thus, there are two related methods to attack the problem: experience and empirical data. Experience can be used where a history of tunneling and of taking measurements exists. An example of this where soft ground tunnels have been constructed in well-defined geology for over 40 years. During that time the industry has progressed from basic Brunel shields to the most current closed-face tunneling machines. For this case it would be anticipated that an experienced contractor would achieve between 0.5 and 1.0 percent ground loss (see Table 12 ). An inexperienced contractor would attain 1.0 to 2.0 percent loss.
Page 67
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Table 12: Relationship between Volumes Loss and Construction Practice and Ground Conditions
Case Good practice in firm ground; tight control of face pressure within closed face machine in slowly raveling or squeezing ground Usual practice with closed face machine in slowly raveling or squeezing ground Poor practice with closed face in raveling ground Poor practice with closed face machine in poor (fast raveling) ground Poor practice with little face control in running ground 0.5 1.0 2 3 4.0 or more VL (%)
When there is no record to rely upon, the design would have to be based strictly on empirical data and an engineering assessment of what the contractor could be expected to achieve with no track record to rely upon. In that case the above evaluations might be bumped up one-half percentage point each as an insurance measure State-of-the-art pressurized-face tunnel boring machines (TBM) such as EPB and minimize the magnitude of ground losses. These machines control face stability by applying active pressure to the tunnel face, minimizing the amount of overcut, and utilizing automatic tail void grouting to reduce shield losses. Typically, ground loss during soft ground tunnel excavation using this technology limits ground loss to 1.0 percent or less assuming excellent tunnelling practice (adequate pressure applied to the face and effective and timely tail void grouting). The volume of ground loss experienced during tunnelling can be related to the volume of settlement expected at the ground surface (Peck, 1969). For a single tunnel in soft ground conditions, it is typically assumed the volume of surface settlement is equal to the volume of lost ground. However, the relationship between volume of lost ground and volume of surface settlement is complex. Volume change due to bulking or compression is typically not estimated or included in the calculations. Ground loss will produce a settlement trough at the ground surface where it can potentially impact the settlement behaviour of any overlying or adjacent bridge foundations, building structures, or buried utilities transverse or parallel to the alignment of the proposed tunnel excavation. Empirical data suggests the shape of the settlement trough typically approximates the shape of an inverse Gaussian curve (Figure 31). The shape and magnitude of the settlement trough is a function of excavation techniques, tunnel depth, tunnel diameter, and soil conditions. In the case of parallel adjacent tunnels, surface settlement is generally assumed to be additive. The shape of the curve can be expressed by the following mathematical relationships (Schmidt, 1974).
Page 68
January 2013
Where: w i = Settlement, x is distance from tunnel or pipeline centerline = Distance to point of inflection on the settlement trough
The settlement trough distance, i is defined as: i = KZ Where: K Z = Settlement trough parameter (function of soil type) = The depth from ground surface to tunnel springline
The maximum settlement, wmax is defined as:
Where: VL D = Volume of ground loss during excavation of tunnel = A diameter of tunnel.
Table 13 summarizes likely volumes of lost ground as a percentage of the excavated volume and a function of combined construction practice and ground conditions.
Page 69
January 2013
Figure 31: Typical Settlement Profile for a Soft Ground Tunneling
For geometrics other than a single tunnel, adjustments of the types given below should be made to obtain settlement estimates: For parallel tunnels three or more diameters apart (center to center), surface settlements are usually reasonably well predicted by adding the individual bell curves of the two tunnels. In good ground and with good practice, this will often give workable approximations up to the point where the tunnels are two diameters apart. On the other extreme, when the tunnels are less than one and one-half diameters apart, the volume of lost ground assumed for the second tunnel should be increased approximately one level in severity in Table 13 before the bell curves are added. Intermediate conditions may be estimated by interpolation. For over-and-under tunnels, it is usually recommended that the lower tunnel be driven first so that it does not undermine the upper tunnel. However, driving the lower tunnel will disturb the ground conditions for the upper. This effect may be approximated by increasing the lost ground severity of the second (upper) tunnel by approximately one level in Table 13 before adding the resulting two settlement estimates to approximate the total at the surface. (Monsees, 1996) As shown in Figure 31 the width of the settlement trough is measured by an i value, which is theoretically the horizontal distance from the location of maximum settlement to the point of inflection of the settlement curve. The maximum value of the surface settlement is theoretically equal to the volume of surface settlement divided by 2.5 i. Figure 32 illustrates assumptions for i values (over tunnel radius R) for calculating settlement trough width in various ground conditions.
Page 70
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 32: Assumptions for width of settlement trough (adapted from Peck, 1969)
The ground settlement also can be predicted by numerical methods. The numerical method is extremely useful when the tunnel geometry is not a circular or horse-shoe shape since analytical/empirical method is not directly applicable. A sample finite ement settlement analysis is shown in Figure 33.
Page 71
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Figure 33: Example of Finite Element Settlement Analysis for Twin Circular Tunnels under Pile Foundations
Evaluation of Structure Tolerance to Settlement

Evaluation of structural tolerance to settlement requires definition of the possible damage that a structure might experience. Boscardin and Cording (1989) introduced three damage definitions for surface structures due to tunnelling induced settlement (where settlement is calculated per Section 7.5):
Architectural Damage: Damage affecting the appearance but not the function of structures, usually related to cracks or separations in panel walls, floors, and finishes. Cracks in plaster walls greater than 1/64-in. wide and cracks in masonry or rough concrete walls greater than 1/32-in. wide are representative of a threshold where damage is noticed and reported by building occupants. Functional Damage: Damage affecting the use of the structure, or safety to its occupants, usually related to jammed doors and windows, cracking and falling plaster, tilting of walls and floors, and other damage that would require nonstructural repair to return the building to its full service capacity. Structural Damage: Damage affecting the stability of the structure, usually related to cracks or distortions in primary support elements such as beams, columns, and loadbearing walls.
Where determination of the surface settlement trough is critical, for instance where settlement sensitive structures are located within the settlement trough, more sophisticated methods of modelling should be used, such as finite element or finite difference numerical models. In some cases, 3D numerical modelling techniques may be appropriate. Where numerical modelling is adopted, use of small-strain stiffnesss can be used if appropriate. However it should be noted that numerical models using small strain stiffnesss often Page 72 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL overestimate the width of the settlement trough which can lead to an under prediction of the settlement and the associated curvature of the trough profile. Settlement analysis, whether using empirical formulae or numerical modelling should consider the effects of all elements affecting the settlement and settlement profile, which may include, but may not be limited to:

Elastic, elastoplastic, and viscoplastic deformational behaviour. Immediate, short-term, and long-term movements. Consolidation, collapse, and swell. Volumetric compression and expansion. Volume loss, soil piping, internal erosion, and hydro-compaction. Fractional and total ground movements Surface conditions including surcharge and topography Groundwater conditions, temporary and permanent including the effects of dewatering. 3D effects
A discussion of some of the various elements influencing settlement and damage relating to tunnelling can be found in CIRIA Special Publication SP 201 (2003) For purposes of monitoring ground surface movement on the roadway, the Contractor shall install flush-head pins (35.0 millimetres to 50.0 millimetres in length) in the road pavement. The pins shall be installed in a grid pattern at approximately 2.0m centres. The location of monitoring points and reference benchmarks are to be submitted before approval to construct can be provided. The grid of monitoring points shall cover the entire width of the roadway along the drive and shall extend outwards in each direction from the centreline of the drive to a distance of the drive centreline depth below the road surface. Measurements shall be replicable to a level of 0.5 mm and shall be done on a daily basis during construction. Ground surface movement outside the acceptable limit shall be immediately reported to the Road Authority and remedial actions taken. Ground surface movement limits in the specified area shall remain in effect for 2 years from date of completion of the NDRC and shall be monitored on a monthly basis. All surface monitoring shall be referenced back to stable benchmarks located well away from the influence of the tunnelling works. If no existing permanent stable benchmarks are available within 500m of the tunnel centreline, then a temporary deep benchmark shall be installed. Depending on the requirements of the design, additional monitoring may be required. Such monitoring may include but may not be limited to the following:

Vertical and/or horizontal inclinometers Vertical and/or horizontal borehole extensometers Page 73
January 2013

Movement monitoring pins attached to sensitive structures Standpipe, pneumatic and/or vibrating wire piezometers Strain gauges Electrolevels Portable seismographs
A construction monitoring report shall be prepared prior to start of construction works, setting out the methods of monitoring to be used. The report shall detail:

Types and locations of all monitoring instruments Method of monitoring, including details of measuring and recording equipment, calibration certificates and frequency of calibration etc. Frequency of monitoring including:-
Frequency and period of baseline monitoring prior to tunnelling works Frequency of monitoring for each instrument during tunnelling works Frequency and period of monitoring for each instrument after completion of tunnelling works
Trigger levels for each instrument, to include

-
Alert levels (when readings reach 80% of the expected design values) Action levels (when readings reach 105% of the expected design values). Alarm values (when readings reach or exceed values beyond the design values and deemed to be excessive). Alarm values shall be determined on a case by case basis for each instrument.
A detailed action plan describing the procedures to be adopted at each trigger level.
4.4.3.4 Railways
Special considerations may apply when crossing under or nearby railways. The railway authority must be consulted for further specifications or requirements. The requirements are not therefore available because it is under preparation till that time, the following are proposed guidelines from the international practice used in USA.(9). All utility crossings railroad trackage should have a minimum depth of cover of three (3) feet below the flow line of the ditch or ground surface and five and one-half (5-1/2) feet from base of rail. In fill sections, the natural ground line at the toe of slope will be considered as ditch grade. For all boring and jacking installations under main and passing tracks, greater than 26 inches in diameter, and at a depth of between 5.5 and 10.0 feet below top of tie, a geotechnical study will need to be performed to determine the presence of granular material and/or high water table elevation. The use of plastic carrier pipe for sewer, water, natural gas and other liquids is acceptable under specific circumstances. The use of plastic pipe is satisfactory if the pipe is designed to meet all applicable federal and state codes, and if the carrier pipe is properly encased within Page 74 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL a steel casing pipe. This casing must extend the full width of the right of way. Casing may be omitted only for gaseous products if the carrier pipe is steel and is placed ten (10) feet minimum below the base of rail . If the minimum depth is not attainable because of existing utilities, water table, ordinances, or similar reasons, the line shall be rerouted. Locations that are considered unsuitable or undesirable are to be avoided. These include deep cuts and in wet or rocky terrain or where it will be difficult to obtain minimum depth. Underground installations may be made by open-trenching from the property line to the toe of the fill slope in fill sections and to the toe of the shoulder slope in cut sections but to no closer than thirty (30) feet of the centerline of track. The remainder will be tunnelled, augured, jacked or directional-bored through the roadbed. Refer to the following sections for required encasement of utilities and boring requirements. Manholes should be located outside railroad property, when possible. No manhole will be located in the shoulder, shoulder slope, ditch or back slope, or within twenty-five (25) feet of the centreline of track, and shall not protrude above the surrounding ground.. Jacking/boring pits shall be located a minimum of thirty (30) feet from the centreline of track, and kept to the minimum size necessary. Under-track bores shall be located greater than 150 feet from the nearest,Track switch or other major structure.
4.4.3.5 Buildings/ Sensitive Structures

All NDRC works shall hold a minimum clear distance of 5.0 m to any buildings, foundations, bridges, retaining walls or other sensitive structures. No NDRC work shall pass under bridges or retaining walls. If 5.0m cannot be achieved, then Consultant/Contractor shall present the reasons and the methods proposed to protect the asset affected by the crossing. Generally, when dealing with adjacent structures, a full structural assessment must be produced to establish the potential impact of the crossing. Precautions that can be adopted to prevent, control or minimise settlement of overlying structures include: Development of accurate baseline conditions A good understanding of the geology to be tunnelled is key to predicting and avoiding or controlling settlements due to tunnelling. Proper and sufficient site investigation is key to developing appropriate mitigation methods for controlling or minimising settlements. A pre-condition survey of all potentially affected structures should be undertaken prior to commencement of tunnelling works Structural methods such as Page 75 January 2013

Underpinning Jacking Jet Grouting Compensation Grouting (during and/or after tunnelling) Curtain walling (Sheet piles, diaphragm walls, contiguous bored piles, mini piles) Strengthening of affected structures
Ground improvement methods such as

Consolidation grouting Vibro compaction/replacement of soils before tunnelling Ground Freezing
Tunnelling methods such as

Use of support fluids during tunnelling Use of tunnel shield Re-alignment of tunnel (horizontal or vertical) to avoid/minimise impacts on sensitive structures
Planning methods such as

Property purchase Demolition Relocation
Protection of existing services

In situ re-lining old/brittle service pipes Excavation and replacement Underpinning
Contract specifications should clearly state the settlement limits to be adopted for the tunnelling works and should require contractors to provide detailed method statements describing the method of tunnelling and precautions and procedures to be adopted to control surface settlements.
4.4.3.6
Remedial actions
Unacceptable ground surface movement or any damage to adjacent structures will necessitate full reinstatement of the affected surfaces or structures in accordance with the Road Authorities specifications. Before undertaking any reinstatement a full report shall be submitted documenting the surface movement and providing an explanation of its cause. This shall include a geophysical testing of the affected area. A complete method statement of the planned reinstatement must be submitted and approved before reinstatement work progresses. Page 76 January 2013
4.4.4
Groundwater Control
Due to the risk involved in possible soil displacement, dewatering shall always be kept to an absolute minimum necessary for satisfactory installation. Dewatering for NDRC work will generally not be permitted, however localized dewatering for construction of shafts or for the launch or reception of the tunnelling machine may be permitted for a limited time. Dewatering systems, including an appropriate filter around riser pipes, should be carefully considered and designed properly. The dewatering solutions/design shall be submitted for approval. The filter design should ensure against the possibility of any internal soil erosion that might cause ground settlement and collapse. Filters can be either conventional soil filters or geotextile filters. The use of geo-textile filters are preferred and recommended. Once shafts are constructed these shall be water tight. It is highly recommended that the pits be fully sealed using either concrete slabs or an injection plug. Any pumping of inflowing water from the shaft will be considered dewatering. All water removed from any dewatering system must be disposed of in accordance with the environmental permit. A detailed description of the required dewatering along with the estimated amounts of water and their disposal must be submitted for approval along with the Method Statement.
4.4.5
Materials and equipment
Pipe materials shall be selected in accordance with the specifications given by the Client. All materials shall have the capability of withstanding the pulling or pushing forces exerted during installation along with the long term loads of soil, groundwater and traffic. Piping and cable materials shall be chosen to withstand corrosion and other chemical reactions from both the intended media and groundwater. All joints and connections must be water tight and be designed to withstand the forces exerted upon them during installation. The following information must be supplied for all pipe materials:

Manufacturer Grade/strength Outside diameter Thickness Material composition including any coating Page 77 January 2013
Connection or joint details
For any drilling fluids or grouts:

Ingredients, including material safety data sheets Design mixes, viscosity, density, etc.
Equipment and machinery:

Manufacturer Manufactured date Model or type Thrust and/or pulling capacities Calibration certificates
4.4.6
Method of statements
The Method Statement shall include all requirements regarding the Contractor's method for undertaking the works in compliance with relevant designs, specifications, site controls and restrictions, inspection plans, programme, equipment resources, staff etc.) A complete Method Statement shall be submitted and approved prior to commencement of construction, including:
4.4.6.1 Contractor experience

Documentation detailing the training and relevant experience of the Contractors personnel shall be submitted which includes all personnel that would be undertaking the work. All personnel are required to be fully trained in their respective duties and in the safety of operating any equipment that will be utilised during the course of the works. The following shall be submitted:

Micro tunnelling Qualifications for Contractor Performing Micro tunnelling Work: Cover sheet: Date, company name, address, telephone and fax numbers, email address, and contact person. Resumes of managerial, supervisory and operational key personnel: Experience in a minimum of 3 previous Micro tunnelling projects of similar size and scope. Detailed descriptions of their Micro tunnelling Projects. Summary sheet of previous projects performed using Micro tunnelling that demonstrates expertise and experience. Named projects may be used more than once under separate paragraphs if their criteria apply. Minimum of 3 years experience performing Micro tunnelling of similar size and scope. List 3 separate projects completed using either a Slurry or Earth Pressure Balance based system. Submit for each named project above, and in same order, the following detailed information:
-
Date, full name of project, and location. Page 78 January 2013

-
Owner's name, address, telephone and fax numbers, email address, and contact person Client's name, address, telephone and fax numbers, and contact person. Employees in charge of work at both head office and site. Description of relevant work successfully completed, including ground conditions. Features under which pipe passed, depth below the water table, photos, and published articles if available. Additional information as necessary.
4.4.6.2 Working Drawings

Submit specific Working Drawings to include but not limited to:

Jacking and receiving pit configurations. Design and construction of jacking and receiving pits Details for ground support system. Special requirements for jacking and receiving pit penetrations, thrust blocks, backstops or other reactions required for Micro tunnelling, casing pipe jacking or any other jacking. Full calculations supporting maximum jacking capacity that jacking pit will withstand without movement exceeding 0.5 inches with an appropriate factor of safety. Areas for storage, material and spoil handling, dewatering, ground stabilization if required, excavation procedures, and backfilling. Dewatering and ground water control plans for all jacking and receiving pits.
4.4.6.3 Construction Works

The Contractor shall deliver a detailed time schedule for construction sequencing and programming, clearly showing the planned activities and the work areas involved. Supply full details of Micro tunnelling System to be employed.

Manufacturer and date(s) of manufacture. Type and model number for whole system if from single source or separate details for each element of system. Confirmation from manufacturer that machine set up is suitable to limit annular space, as specified, for external diameter of casing pipe proposed. System of alignment monitoring and steering control and activation. Hydraulic jacking system maximum capacity and method of limiting jacking capacity to that of maximum capacity of specified casing.
Supply full details of procedures and resources that will be employed to carry out work including method and sequence of:

Establishment of drive line of MTBM and elevation at base of shaft. Casing Pipe handling and connections. Maintaining line and grade, and re-establishment of line and grade as required. Spoil separation and disposal. Page 79 January 2013

Spoil and slurry containment during Micro tunnelling work. Installation of carrier pipe, including placement of grout between carrier pipe and casing pipe, and procedures to prevent floatation during grouting.
Supply full details of following materials:
Design mixes for all concrete, grout, or flowable fills. Casing pipe including manufacturer, grade, and specification, outside diameter, thickness, and any coatings, if required.
Calculations that clearly state:

Maximum calculated jacking resistance for installing complete casing. Maximum allowable face pressure or slurry pressure that can be exerted at tunnel face without fluid loss to surface, other structures or features or heave of ground. Relationship between hydraulic jacking pressure and force applied to casing pipe during jacking.
4.4.7
Risk Assessment and Risk Register
A risk assessment shall be conducted in accordance with the Risk Management Manual. The main risks involved in undertaking NDRCs are surface settlement or heave. Other risks that may be encountered are road user safety that may be derived from surface movement and risk of damage to existing utilities or structures. The Contractor must undertake a risk assessment listing all the possible occurrences in a risk register and evaluated the likelihood and consequences of these occurrences. The risk assessment shall include analysis and procedures for mitigating risks along with emergency procedures for dealing with specific incidents. The various methods of NDRC will have different risks associated with them. A summary of the level of risk associated with each method is shown in Table 13. This table shall be used as a guide, and the particular conditions of the specific site shall be taken into consideration. Table 13: Risk summary for typical NDRC methods
Method Surface settlement Negligible Negligible Moderate Minor Minor Minor Principal risk Road user Surface heave safety High Moderate Moderate Negligible Moderate Minor Minor Minor Minor Negligible Negligible Negligible Damage to existing utilities Moderate Moderate Moderate Minor Negligible Negligible
Impact moling Pipe ramming (open end) Auger boring Horizontal directional drilling Micro tunnelling Pipe jacking
Page 80
January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL Please see Appendix A for a list of potential H&S risks for NDRC work. In addition to highlighting the possible risks, the Contractor must also establish contingency plans for correction of potential conditions. They include:

Inability to complete the pilot hole Excessive fluid loss/hydraulic fracturing Inability to pull the pipe
4.4.8
Procedure and logistics for obtaining No Objection Certificates
No Objection Certificates (NOCs) must be obtained from all concerned utilities agencies or stakeholders that may be affected by the NDRC. A list of the Authorities as a guide but not limited to those are contained within Appendix A . Note: Some of the utilities or other authorities may require 2-4 weeks to give NOCs or even longer, if insufficient information is supplied. The Contractor must make sure that the Town Planning approval is valid.
4.4.8.1 Conflict with other Utilities

The Contractor/Sub Contractor is required to obtain information on all existing utility lines in the vicinity of the work area prior to commencing of any excavation. If there is uncertainty as to the exact location of any utility it may be necessary for trial pits to be excavated. Such details are to be included in the approved Method Statement Suggested minimum safe distances between the different utilities are shown in Appendix C. The relevant Authorities should be contacted for approval to dig near their utilities. The most up-to-date codes and standards are to be adopted. It is always the Contractor/Sub Contractors' responsibility to ensure that he has obtained all information on other utilities in the work area and that he has assessed the safe distances to these. Any damage to any utility during the undertaking of the NDRC is the sole responsibility of the Contractor/Sub Contractor. The minimum distances away from existing utilities must be followed. These are detailed in Appendix C. However the Contractor must approach the relevant Authorities for details on the latest standards for the particular crossing implemented.
4.5
During Construction
The Contractor/Sub Contractor shall keep updated records at the work site for the duration of the work. A checklist of minimum daily routines for monitoring and record keeping is given in Appendix D. The records shall be checked and signed by the supervising Consultant. A Project Board must be generated and installed detailing the specific project details and contact details of the relevant stakeholders.
4.5.1
Monitoring of Surface Movement
For purposes of monitoring ground surface movement on the roadway, the Contractor shall install flush-head pins (35.0 millimetres to 50.0 millimetres in length) in the road pavement. Page 81 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL These pins shall be the monitoring points. The pins shall be installed in a grid pattern at approximately 2.0m centres. The location of monitoring points and reference benchmarks are to be submitted before construction. Approval shall be sought from a Road Maintenance Consultant nominated by the DoT. The grid of monitoring points shall cover the entire width of the roadway along the drive and shall extend outwards in each direction from the centreline of the drive to a distance of the drive centreline depth below the road surface. Measurements shall be replicable to a level of 0.5 mm and shall be done on a daily basis during construction. Ground surface movement outside the acceptable limit shall be immediately reported to the Road Authority and remedial actions taken. Ground surface movement limits in the specified area shall remain in effect for 2 years from date of completion of the NDRC and shall be monitored on a monthly basis. The records to be kept by the Contractor and supplied to the Overseeing Organisation should be established prior to any construction works. The type of records will vary for each method and project but the following information should be recorded where applicable, is listed in Table 14.
Page 82
January 2013
Table 14: Type of records for NDRC projects

Micro Tunnelling & Pipe Eating Pipe Jacking Directional Drilling Auger Boring Pipe Ramming Impact Moling
Contract Reference of pipe run Date of work Start time Finish time Details of any stoppages Diameter of bore Pipe material Pipe diameter Joint packing Length installed Main survey checks Soil conditions Ground water level Line and level achieved Lubrication Support Fluid Jacking & winch loads, w.r.t. progress Slurry pressures, viscosity, discharge, flow rate Shield role, pitching, steering adjustment Thrust rate, cutting torque, soil discharge Interval at which measurements should be taken Grout materials and volumes
* * * * * * * * * * * * * * * *
* * * * * * * * * * * * * * * *
* * * * * * * * * * * *
* * * * * * * * * * * * * *
* * * * * * * * *
* * * * * * * * *
* *
* *
* * *
4.5.2
Instrumentation Requirements
The following data shall be recorded, if possible automatically, during installation:

For micro tunnelling:
Line and level Maximum jacking forces of the main, and if used, intermediate thrust stations Jacking speed/distance Page 83 January 2013

Quantity of slurry and if possible of excavated soil Rolling Steering correction Maximum interval of recordings should be every 0.2 m of excavation.
The following should be confirmed before and during construction:

Closed face capable of providing adequate supporting pressure to excavated area Use slurry pressure and/or auger earth pressure to achieve the balance of earth and ground water Make sure of the ability to control axial rotation and steer to correct vertical and horizontal deviation from alignment by remote activation Means to inject lubricant over lead pipe, if required The spoil transportation system has capacity for removal and balancing of spoil. The slurry system operates so that excess fluid can be discharged safely Control system enables remote control of all main functions of the system from one location
For manned techniques:
Line and level Maximum jacking forces of the main and if used intermediate thrust stations Jacking speed/distance Quantity of slurry and if possible of excavated soil Rolling
Maximum interval of recordings should be once per pipe section installed.

For horizontal directional drilling:
Line, level and length Quantity and characteristics of drilling fluid Maximum pulling forces
Maximum interval of recordings should be once per drilling rod.
4.5.3
Equipment Performance Requirements
Closed face capable of providing positive supporting pressure to full excavated area (face) at all times and capability of controlling and measuring pressure at face. Achieve balancing of earth and ground water pressures by use of slurry pressure, auger earth pressure balance or a combination of the two. System capable of any adjustment required to maintain face stability for anticipated ground conditions. Control slurry pressure systems, using slurry spoil transportation, earth and groundwater pressure at the face by use of variable flow slurry pumps, pressure control valves and minimum of 2 flow meters, one on feed side and side, and one on return side. Page 84 January 2013
NON DISRUPTIVE ROAD CROSSINGS MANUAL For earth pressure balance systems using a screw auger spoil transportation from the face, control excavated material by maintaining an earth pressure balancing plug of material at the plug of material at the face with advance of system being matched with excavation removal through auger. Control soil through auger by use of pitch spacing and/or an auger gate or throttle. Sufficient power and ability in normal operation to cut or crush hard material of sizes up to 1/3 internal diameter of pipe and up to 30,000 psi compressive strength. Ability to control axial rotation to within 3-degrees of normal operating datum. Ability to articulate and steer to correct vertical and horizontal deviation from alignment datum by remote activation. Means to inject lubricant over lead pipe, if required. Spoil transportation system that has capacity for removal of spoil in balance with excavation and advance. Slurry system:

Spoil separation system sufficient capacity to remove solids from flow while system is excavating spoil. Operates in such a manner that re-circulated or excess fluid can be discharged safely and with negligible remaining fines.
Overall control system that enables remote control of all main operating functions of system from one location, either at surface or within jacking shaft. Main jacking pit capable of exerting uniform load to casing pipe at a speed commensurate with speed of excavation advance. Set jacking hydraulics to relieve pressure at maximum safe working capacity of casing pipe.
4.6
After Construction
After construction, all details of the completed NDRC work shall be collected and submitted to the Road Authority including test certificates and relevant Contractors notes/reports. A checklist of required information and documentation is given in Appendix D.
4.6.1
Inspection and testing
Pipe inspection and testing shall be carried out according to the Clients specifications. An infiltration test of the permanent construction should be carried out to verify that the pipeline, joints/connections are water tight. The infiltration test shall first be carried out after any dewatering is stopped and the groundwater has attained normal levels. If requested by the DoT, CCTV inspections should be carried out to ensure that the inside of the pipeline is structurally sound. Man entry pipes shall be visually inspected only. The inspection should include: Page 85 January 2013

Line and level Joints Damage Deformation Connections Linings and coatings
Any leaks shall be recorded, and repaired as appropriate. All records should be submitted to the DoT. The grouting will also need to be checked and certified as applicable to the ground conditions.
4.6.2
Site clearance and decommissioning
After completion, the working areas shall be cleared and reinstated to their previous condition. All equipment, materials shall be removed and excess spoils and waste shall be disposed of in an approved and environmentally suitable way. Working shafts shall be backfilled with suitable compacted materials in accordance with the Specifications. Shoring or other temporary shaft materials shall be removed or cut to a level minimum 1.5 m under surface level. A checklist should be developed by the Contractor and submitted to the DoT. suggested points are contained within a checklist in Appendix A Some
4.6.3
Monitoring/inspection for long term (latent) defects
The Contractor shall carry out monitoring of ground surface movement, as described in Section 3.4.1, two years after completion and report monthly any changes to the Road Authority. A visual inspection of the working area and surrounding structures shall be done at the same time and any defects that may have been a consequence of the NDRC work shall be included in the report.
4.6.4
QA/ QC Methodology
Quality Assurance and Quality Control are key factors in a successful NDRC undertaking. The Contractor shall implement a Quality Assurance Plan (QAP) outlining proposed points where quality controls will be performed. These shall include but not necessarily be limited to:

Check and approval of all working drawings and method statement. Location of any other utilities or structures have been correctly identified and marked. Pipe/cable materials conform to specifications and quality documentation from manufacturer has been acquired. Line and level of proposed NDRC have been checked including guidance system. Check of machinery and other equipment. During installation; check of rate of advancement, drilling pressure, torque, pulling forces, etc. Page 86 January 2013

Check of flow and pressure of any drilling fluids or lubrication. Amount of soil excavated is registered and checked in conjunction with theoretical values. Any dewatering installations are checked and flow registered. Any deviations or unexpected developments are registered and investigated. Surface movements are monitored in accordance with this manual. After completion the line and level are surveyed and registered and documented.
A minimum requirements checklist to be followed before commencement of works is included in Appendix A All controls and information are to be gathered/documented and kept at the work site for any inspections. Please refer to the DoTs QAQC Requirements document for further information.
Page 87
January 2013
APPENDIX A: CHECKLISTS FOR SUBMITTALS

A.1. Checklist of submittals for approval of preliminary design
The following information or documents shall as a minimum be submitted for preliminary approval (pre-tender) of NDRC design.
Nr
1 2
Requirement
NDRC Application form Approval letter from Abu Dhabi Town Planning
Drawings:
3 4 5 6 7
Map of site location Plan of line, level and diameter Profile section of proposed drive Plan of work site area showing working shaft locations and sizes Plans showing other utilities
Geotechnical:
8 9 10
Preliminary sources study Ground investigation factual and interpretative reports Profile section showing soil conditions along the proposed drive
Page 88
January 2013
A.2.
Checklist of submittals for approval of construction
The following information or documents shall as a minimum be submitted for final approval of design and approval of construction:
Nr
1 2 3 4 5
Requirement
NDRC Application form Approval letter from Abu Dhabi Town Planning Approval request letter from design consultant for design and supervision addressed to highway section (Arabic) Approval request from Contractor with confirmation of the Sub Contractor name Undertaking letters from the Client, main Contractor and NDRC Sub Contractor as per DoT forms Method statement including detailed description of method, sequencing and program of work, key qualifications and references, list of equipment and materials, ground water control, safety procedures and risk assessment
Drawings:
Map of site location Plan of line, level and diameter Profile section of proposed drive Plan of work site area showing working shaft locations and sizes Plans showing other utilities Details of shafts including entry and exit seals
Calculations:
8 9 10 11 12
13 14 15
Design calculations of pipe materials with max. permissible forces Design calculations of shafts Surface movement calculations
Geotechnical:
16 17 18
Preliminary sources study Ground investigation factual and interpretative reports Profile section showing soil conditions along the proposed drive No Objection Certificates (NOC) from utility agencies, property owners, police and other relevant authorities Bank guarantee (6000 AED per m length ) Page 89 January 2013
19 20
A.3.
Checklist of Potential H&S Hazards & Risks
The following are considered potential Health and Safety risks for NDRC work to be considered by the Contractor. This list is not exhaustive and is to be expended depending on site conditions/location
Nr
1 2 3 4 5 6 7 8 9 10 11 12 13
Potential Risk
Road User/Public Awareness of Works Site Workers Training/Ability Confined Spaces Damage to Existing Utilities Damage to Equipment Unexpected Ground Conditions Failure of Traffic Management System Surface Heave Surface Settlement Excavation collapse Poor maintained equipment Adjacent structures Adjacent works
A.4.
Checklist of Authorities for NOCs
The following is a list of Authorities who will need approaching for approval to dig. This list is not exhaustive.
Nr
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Items
Abu Dhabi Municipality, Town Planning & Survey Directorate Abu Dhabi Municipality, Roads Section Abu Dhabi Municipality Public Gardens Directorate Al Ain Municipality Western Region Municipality TRANSCO (Water and Electric) Abu Dhabi Distribution Company, ADDC (Water & Electricity Authority) Abu Dhabi Sewage Services Company, ADSSC (Sewer) Etisalat (Telephone Authority) DU (Telephone) GASCO (Gas Authority) Dolphin Energy (Gas Authority) ADNOC (Oil) TAKREER (Oil) GHQ Armed Forces (Fibre optic cables) Critical National Infrastructure Authority, CNIA
Page 90
January 2013
A.5.
Checklist of QAQC Issues
The following is a list of potential QAQC issues to be checked and signed off before construction commences.
Nr
1 2 3 4 5 6 7 8
Items
The supervisor has previous experience with the specific construction method being used The personnel performing the operations have the relevant expertise/prior knowledge The manufacturers instructions are being followed Set up procedures are complete The materials are ready and to hand before commencement The supervisor has previous experience with the specific construction method being used The personnel performing the operations have the relevant expertise/prior knowledge The manufacturers instructions are being followed
A.6.
Checklist of Post-Construction Checks
The following is a list of potential issues to be checked and signed off following construction. This list is not exhaustive and is to be expended depending on site conditions/location.
Nr
1 2 3 4 5 6 7
Items
Have all excavations been backfilled? Have all materials been removed from the site area? Has all machinery been removed from the site area? Has all traffic management signage and protection been removed? Is the surface in a clean state and as per the commencement of the works? Has all vegetation been replaced/reinstated? Have all excavations been backfilled?
Page 91
January 2013
APPENDIX B: FORMS AND EXAMPLES OF LETTERS FOR APPLYING FOR NDRC WORKS
B.1. Required forms and examples of letters
The following forms and letters must accompany all applications for undertaking NDRC work. 1. DoT Road Crossing Application Form 2. Approval request letter from design consultant for design and supervision addressed to the highway section (Arabic) 3. Approval request from Contractor with confirmation of the SubContractor name 4. Undertaking letters from the client, main Contractor and NDRC SubContractor as per DOT forms (Arabic) 5. Bank Guarantee (Example)
Page 92
January 2013
Page 93
January 2013
Page 94
January 2013
Page 95
January 2013
Page 96
January 2013
Page 97
January 2013
Page 98
January 2013
Page 99
January 2013
Conditions for NOC for Micro-tunnelling Works
Project: Owner Authority: Consultant: Contractor: Micro-tunnelling Works Contractor: Excavation Details:
No. of crossings
Crossing Location
Maximum Tunnel Diameter
Minimum Depth (From Asphalt Surface to the Top of the Pipe)
Tunnel Length Under the Road
Conditions:
1-
Obtain approval of all concerned service authorities prior to proceed with any works in the site. It is strictly forbidden to carry out or delegate any works subject of approval to any other Contractor other than the above approved Contractor for carrying out microtunneling excavation, even if he is the main Contractor, without DoT approval, where bank guarantee will be seized in case you fail to commitment to the above mentioned. The (NOC) is limited only for the above indicated excavation areas, and in accordance to the details shown next to them.
2-
3-
Page 100
January 2013
4-
If the site geotechnical report shows a layer of weak soil at the excavation level, the Contractor should do stabilization to the soil prior to commence excavation works. The microtunneling Contractor and Sub-Contractor, should commit to the submitted working method without prejudice its steps. The submitted bank guarantee does not represent the cost of repair of land subsidence in case of occurrence, it is a guarantee until the end of the period of supervising the excavation area by microturnelling and the real cost will be determined at the time, no matter how much. The control period of microturnelling excavation area is (two years) starting from date of the Consultant confirmation on completion of maintenance works on site according to the specifications and the submitted and approved working method. Works should not be commenced unless an official site handing over record is made (including the sites, the control points levels at the time, and colored photos for the excavation location) in presence of the project Consultant/ ., DoT road maintenance Consultant in the area/ , the main Contractor and the excavation Contractor. The undersigned project Consultant staff should make sure of the Contractor and the Sub-Contractor commitment to the submitted work method, and retain photos for the work phases and record of full data and reads of the excavation machine starting from commencement date to completion date, a copy of which is to be submitted to DoT after completion of work. Under the supervision of the Consultant, the Contractor and microtunneling excavation Sub-Contractor shall make arrangements required to maintain asphalt surface subsidence level within the limit allowed (6mm). In case that allowed limit is being exceeded; the Consultant should inform Road Department directly and without any delay. The depth between asphalt surface and the top of the tunnel should not be less than what is stated in the submitted work method (shown above). The tunnel diameter should not exceed what is stated in the submitted work method.
5-
6-
7-
8-
9-
10-
11-
12-
Page 101
January 2013
13-
The distance between the edge of the push pit and the receiving pit and the road (sub-grade) edge should not be less than 5m minimum. The asphalt surface subsidence control points should be fixed at a shape of net with dimensions of 2m. This net should cover the road full width along the tunnel at both sides at a distance not less than the distance between the tunnel center and the asphalt surface. Also readings should be taken (under the Consultant/Owner Authority supervision) prior to commence and during carrying out these works (at rate of 3 times for each work shift), and after execution (as shown in the submitted working method), provided that the benchmark should not be less than 50m from the tunnel location. The supervision staff (Consultant/Owner Authority) should submit all the records related to the road surface control points readings, officially and regularly every month to the Technical Support Section in the Main Roads Department. All security and safety precautions should be taken at the push pit and the receiving pit, and also the suitable warning signs to ensure the safety of the pedestrians and vehicles day and night according to the necessary conditions of Abu Dhabi Police and DoT. The two pits should be re-filled after work completion on layers and to remove all the debris and reinstate the site.
14-
15-
16-
17-
18-
If it is necessary to process a dewatering, it should be carried out by the approved way and without affecting the soil characteristics. To coordinate with the Maintenance Consultant in Roads and Technical Services Department who is supervising the maintenance of the area in which the excavation will take place. To submit to DoT two copies of the As Built Drawings for the works already implemented approved by the project Consultant after work completion, along with an official letter from the project Consultant.
19-
20-
We recognize that we have learned all the conditions (1-20) and confirm our agreement and our commitment to them, and we accordingly sign:
Consultant:
Page 102 January 2013
Name: Position:
Contractor: Name: Position:
Microtunneling Sub-Contractor: Name: Position:
Page 103
January 2013
Declaration and Undertaking
We, Company/Department of ., acknowledge that in the event of any subsidence or damages to roads or road facilities, other than what is permitted according to DoT regulations, at .. area in which the main contractor/ company ..and micro-tunnelling works Contractor, M/s .. . .type approved by the us M/s .. .is undertaking excavation works, we will immediately inform DOT and undertake to make necessary repairs according to DOT specifications or deduct the cost of repairs from the main contractor in favour of DOT immediately when the subsidence takes place, at request of DOT without delay or review and shall pay compensation for any accident caused by this subsidence. I hereby agree and accept the above. For the Company .. Name: Designation: Signature & Seal:Date:.. ..
To be signed by Authorised person, letter of authorization shall be enclosed.
Page 104
January 2013
Template for Bank Guarantee
Department of Transport P.O.Box 20 Abu Dhabi United Arab Emirates
Dear Sir RE: PERFORMANCE GUARANTEE NO. ________ FOR AED________ FOR NONDISRUPTIVE ROAD CROSSING OF ___________________ ROAD We, (insert name and address of bank) hereby guarantee to pay to the Depertment of Transport, P.O.Box 20, Abu Dhabi, UAE, the sum of AED___________ (UAE Dirhams ____________________________) on account of (insert company name and address) as a guarantee for the due and propert performance of the subject work. 1. This Guarantee shall be paid to the Department of Transport on first demand without any proof of condition. 2. This Guarantee shall be valid for 1 (one) year from ________ until ________ and shall before expiry, be automatically renewed until the Final Acceptance Certificate has been issued by the Department of Tranport. This Guarantee is issued under the official seal of the bank and signed by the required authorized signatories. Yours faithfully
________________
Page 105
January 2013
APPENDIX C: SUGGESTED MINIMUM SAFE DISTANCES

BETWEEN UTILITIES
Page 106
January 2013
APPENDIX D: CHECKLISTS FOR MONITORING DURING AND

AFTER CONSTRUCTION
D.1.
Daily requirements
The following checklist contains the minimum requirements of monitoring and data collection on a daily basis during construction. This shall comprise of, but not necessarily be limited to: Nr 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Requirement Numbers of personnel and equipment on site (names, positions, etc) Inspection of work site fencing, traffic barriers, signs, safety checks, etc Installed length of pipe (types, times etc) Line and level measurements Any vertical or horizontal deviations from planned line Instrumentation readings of jacking, drilling or pulling forces Slurry or bentonite usage and pressure readings Amount of excavated soil or spoils removed Monitoring reports of surface movement Check and inspection of delivered materials Check of machinery and other equipment Any accidents or unexpected events - their cause and actions taken
All reports shall be approved and signed by the supervising Consultant.
Page 107
January 2013
D.2.
After construction
The following checklist contains the minimum requirements of monitoring and data collection on a daily basis during construction. This should be collated and submitted by the Contractor or Sub-Contractor and shall comprise of, but not necessarily be limited to: Nr 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Requirement Line and level measurements updated on As Built drawings Infiltration test documenting the pipeline is water tight, including details on the testing analysis and techniques CCTV or other report of internal inspection, highlighting any deformation or irregularities (in DVD format) Documentation of installed pipe materials (manufacturer, type, etc.) Any vertical or horizontal deviations from planned line (to be shown in profile sections) Instrumentation readings of jacking, drilling or pulling forces (report format) Slurry or bentonite use and pressure readings (report format) Quantities of excavated soil or spoils removed Monitoring reports of surface movement, including details on the methods used for calculation Reports of accidents or unexpected events - their cause and actions taken Post-construction site survey, including electronic copy Construction photographs and/or video as appropriate Documentation of correct backfilling and compaction of shafts including compaction test results Report showing that work site has been cleared and all waste removed
All reports shall be approved and signed by the supervising Consultant.
Page 108
January 2013
Appendix E
Internal dimensions for pipejacks and tunnels below 3.m diameter and indicative drive lengths
Page 109
January 2013
Page 110
January 2013
Page 111
January 2013
CITED REFERENCES
Page 112
January 2013
OTHER REFERENCES
Page 113
January 2013
GLOSSARY
Specialized terms, abbreviations and acronyms frequently used in this manual are listed and defined below. Where a term, abbreviation or acronym is defined in another Department of Transport Manual, that definition is applied to this manual by reference.
Auger Boring: Method for forming a bore, usually from a drive pit, by means of a rotating cutting head. Spoil is removed back to the drive pit by helically wound auger flights rotating in a steel casing. The equipment may have limited steering capability. See also Guided Auger Boring. Back Reamer: Cutting head attached to the leading end of a drill string to enlarge the pilot bore during a pull-back operation to enable the product pipe to be installed. Bore: Void which is created to receive a pipe, conduit or cable. Cased Bore: Bore in which a pipe, usually a steel sleeve, is inserted simultaneously with the boring operation. Usually associated with auger boring or pipe jacking. Casing: Pipe to support a bore. Usually not a product pipe. Cutting/Cutter Head: Tool or system of tools on a common support that excavates at the face of a bore. Usually applies to mechanical methods of excavation. Directional Drilling: Steerable method for the installation of pipes, conduits and cables in a shallow arc using a surface launched drilling rig. In particular, the term applies to large scale crossings in which a fluid filled pilot bore is drilled without rotating the drill string, and this is then enlarged by a washover pipe and back reamer to the size required for the product pipe. The required deviation during pilot boring is provided by the positioning of a bent sub. Drill Bit/Head: Tool which cuts the ground at the head of a drill string, usually by mechanical means. Drilling Fluid/Mud: Mixture of water and usually bentonite or polymer continuously pumped to the cutting head or drill bit to facilitate the removal of cuttings, stabilise the bore, cool the head and lubricate the passage of the product pipe. In suitable ground conditions water alone may be used. Drill String/Stem: The total length of drill rods/pipe, bit, swivel joint, etc. in a bore. Drive/Entry Shaft/Pit: Excavation from which trenchless technology equipment is launched for the installation or renovation of a pipeline, conduit or cable. It may incorporate a thrust wall to spread reaction loads to the ground. Earth Pressure Balance (EPB) Machine: Type of microtunnelling machine in which mechanical pressure is applied to the material at the face and controlled to provide the correct counter-balance to earth pressure in order to prevent heave or subsidence. The term is usually employed where the pressure originates from the main jacking station in the drive Page 114 January 2013
shaft or to systems in which the primary counter-balance to the earth pressures is supplied by pressurised drilling fluid or slurry. Face Stability: Stability of the excavated face of a tunnel or pipe jack. Grouting: Method of filling voids, usually with cementitious grout. Guided Auger Bore: Method of auger boring in which the guidance mechanism actuator is sited in the drive shaft. The term may also be applied to those auger boring systems with rudimentary articulation of the casing near the cutting head activated by rods from the drive shaft. Guided Boring: See Guided Drilling. Guided Drilling: Method for the installation of pipes, conduits: and cables using a surfacelaunched drilling rig. A pilot bore is drilled using a rotating drill string and is then enlarged by a back reamer to the size required for the product pipe. The necessary deviation during the pilot boring is provided by a slanted face to the drill head, an asymmetric drill head, eccentric fluid jets or a combination of these, usually in conjunction with a locator. Guide Rail: Device used to support or guide, first the shield and then the pipe within the drive shaft during a pipe jacking operation. Heaving: Process in which the ground may be displaced causing a lifting of the ground surface. Horizontal Directional Drilling (HDD): See Directional Drilling. Impact Moling: Method of creating a bore using a pneumatic or hydraulic hammer within a casing, generally of torpedo shape. The term is usually associated with non-steered or limited steering devices without rigid attachment to the launch pit, relying upon the resistance of the ground for forward movement. During the operation the soil is displaced, not removed. An unsupported bore may be formed in suitable ground, or a pipe drawn in, or pushed in, behind the impact moling tool. Cables may also be drawn in. Impact Ramming: See Pipe Ramming. Jacking Force: Force applied to pipes in a pipe jacking operation. Jacking Pipes: Pipes designed for use in a pipe jacking operation. Jacking Shield: Fabricated steel cylinder from within which excavation is carried out, either manually or by mechanical means. Incorporated within the shield are facilities for controlling line and level. Launch Pit: As for drive pit but more usually associated with launching an impact moling or similar tool. Locator: An electronic instrument used to determine the position and strength of electromagnetic signals emitted from a transmitter sonde in the pilot head of a boring system, in an impact moling tool or from existing underground services that have been energised. Sometimes referred to as a Walkover System. Page 115 January 2013
Microtunnelling: Method of steerable remote control pipe jacking to install pipes of internal diameter less than that permissible for man-entry. In North America the term is used to describe remote control continuous pipe jacking in all diameters. Pilot Bore: First, usually steerable, pass of any boring operation that later requires backreaming or other enlargement. Most commonly applied to guided drilling, directional drilling and 2-pass microtunnelling systems. Pipe Jacking: Method for directly installing pipes behind a shield machine by hydraulic or other jacking from a drive shaft such that the pipes form a continuous string in the ground. Pipe Ramming: Non-steerable method of forming a bore by driving a steel casing, usually openended, with a percussive hammer from a drive pit. The soil may be removed by augering, jetting or compressed air. In appropriate ground conditions a closed casing may be used. Product Pipe: Permanent pipeline for operational use. Pull-Back: That part of a guided drilling or directional drilling operation in which the drill string is pulled back through the bore to the entry pit or surface rig, usually installing the product pipe at the same time. Reception/Exit Shaft/Pit: Excavation into which trenchless technology equipment is driven and may be recovered during the installation or renovation of a product pipe, conduit or cable. Rod Pushing: Method of forming a pilot bore by driving a closed pipe head with rigid attachment from a launch pit into the soil that is displaced. Limited steering and monitoring capability may be provided, usually in conjunction with a locator. Subsidence: Process in which the ground may be displaced causing a settlement at the surface. Target Shaft/Pit: See Reception/Exit Shaft/Pit. Thrust Pit: See Drive Pit. Trenchless Technology: Methods for utility and other line installation, rehabilitation, replacement, renovation, repair, inspection, location and leak detection, with minimum excavation from the ground surface. Uncased Bore: Self-supporting bore without a lining or inserted pipe, whether temporary or permanent. Walkover System: See Locator.
(Reference: International Society of Trenchless Technology, ISTT)
Page 116
January 2013

Non Disruptive Road Crossings

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Non Disruptive Road Crossings

Caricato da

Copyright:

Formati disponibili

NON DISRUPTIVE ROAD CROSSINGS MANUAL

DRAFT DOCUMENT JANUARY 2013